Preventive Maintenance Checklist: GENERATOR, EMERGENCY (CATERPILLAR) Annual

• Site conducted

• Conducted on

  Date

• Prepared by

• Location

• Work Order Number

(T)ools, (S)afety Equipment and (M)aterials

• Mechanics/Electricians tool set

  Yes

  No

  N/A

• Battery tester and distilled water

  Yes

  No

  N/A

• Coolant sampling collection bottles

  Yes

  No

  N/A

• Replacement zincs

  Yes

  No

  N/A

• Oil sampling collection bottle

  Yes

  No

  N/A

• Engine oil

  Yes

  No

  N/A

• Oil filters

  Yes

  No

  N/A

• Air filters

  Yes

  No

  N/A

• Fuel filters

  Yes

  No

  N/A

• Collection container for used oil

  Yes

  No

  N/A

• Plastic bags for used oil filters

  Yes

  No

  N/A

• Ladder

  Yes

  No

  N/A

• Insulation Tester

  Yes

  No

  N/A

• Infrared Measurement Meter

  Yes

  No

  N/A

• Cleaning materials

  Yes

  No

  N/A

• Vibration measuring equipment

  Yes

  No

  N/A

Safety Guidelines

• Schedule equipment downtime with operating personnel

  Yes

  No

  N/A

• De-energize, tag, and lock out circuits and machinery. Disable automatic starting circuits. DANGER-CHECK THAT CIRCUITS ARE DEAD BEFORE STARTING WORK.

  Yes

  No

  N/A

• Have approved type fire extinguishers readily available

  Yes

  No

  N/A

• Allow no open flame or smoking in area

  Yes

  No

  N/A

• Use safety type fuel cans only

  Yes

  No

  N/A

• Use extreme caution when removing the radiator pressure relief cap. Steam may spray outward under high pressure

  Yes

  No

  N/A

• Follow site safety procedures and your supervisor instructions

  Yes

  No

  N/A

• Record and report equipment damage or deficiencies

  Yes

  No

  N/A

• Record all test results in the component maintenance log

  Yes

  No

  N/A

• Obtain and review manufacturer maintenance instructions

  Yes

  No

  N/A

• Tests to conform with manufacturer test procedures and values

  Yes

  No

  N/A

• Use proper personnel protective equipment when handling hazardous materials, fuels, and lubricants

  Yes

  No

  N/A

• Complete RCM procedures CM-0002 (Qualitative Infrared Thermography) and CM-0003 (Insulation Test, Motor).

  Yes

  No

  N/A

Maintenance Procedures

• Perform a walk around inspection

  Yes

  No

  N/A

• Inspect and wipe down the generator

  Yes

  No

  N/A

• Check electrical connections for evidence of looseness or overheating

  Yes

  No

  N/A

• Rotating Rectifer - Check

  Yes

  No

  N/A

• Speed Sensor - Clean / Inspect

  Yes

  No

  N/A

• Starting Motor - Inspect

  Yes

  No

  N/A

• Stator Lead - Check

  Yes

  No

  N/A

• Perform CM-0003 (Insulation Test, Motor)

  Yes

  No

  N/A

• Check coolant level

  Yes

  No

  N/A

• Cooling System Coolant Sample (Level 2) - Obtain

  Yes

  No

  N/A

• Belts - Inspect / Adjust / Replace

  Yes

  No

  N/A

• Check the jacket water heater for proper operation

  Yes

  No

  N/A

• Check radiator hoses for wear and cracks. Plan for replacement if necessary

  Yes

  No

  N/A

• Inspect zinc rods. Change if necessary

  Yes

  No

  N/A

• Radiator - Clean

  Yes

  No

  N/A

• Water Pump - Inspect

  Yes

  No

  N/A

• Engine Air Precleaner – Clean

  Yes

  No

  N/A

• Engine Air Cleaner Service Indicator – Inspect

  Yes

  No

  N/A

• Engine Air Cleaner Element (Dual Element) - Clean / Replace

  Yes

  No

  N/A

• Engine Air Cleaner Element (Single Element) - Clean / Replace

  Yes

  No

  N/A

• Check fuel level

  Yes

  No

  N/A

• Drain water and sediment from the day tank. Clean fuel strainer

  Yes

  No

  N/A

• Check space heater

  Yes

  No

  N/A

• Bearing (Ball)-Lubricate

  Yes

  No

  N/A

• Bearing (Spherical Roller) - Lubricate

  Yes

  No

  N/A

• Crankshaft Vibration Damper - Inspect

  Yes

  No

  N/A

• Engine - Clean

  Yes

  No

  N/A

• Engine Crankcase Breather - Clean

  Yes

  No

  N/A

• Engine Mounts - Check

  Yes

  No

  N/A

• Engine Oil Sample - Obtain

  Yes

  No

  N/A

• Check engine oil level for excessive usage. Change oil and filter

  Yes

  No

  N/A

• Prelube Pump - Inspect

  Yes

  No

  N/A

• Engine Protective Devices - Check

  Yes

  No

  N/A

• Engine Valve Lash - Inspect / Adjust

  Yes

  No

  N/A

• Fan Drive Bearing - Lubricate

  Yes

  No

  N/A

• Fuel Control Linkage - Check / Lubricate

  Yes

  No

  N/A

• Fuel Injector - Inspect / Adjust

  Yes

  No

  N/A

• Fuel System Primary Filter - Clean / Inspect / Replace

  Yes

  No

  N/A

• Fuel System Secondary Filter - Replace

  Yes

  No

  N/A

• Perform a one hour system operational test under full load conditions

  Yes

  No

  N/A

• Operation for indication of defects of possible malfunctions

  Yes

  No

  N/A

• Inspect the annuanciator panel for proper operation

  Yes

  No

  N/A

• After unit has operated for 50 minutes, log the operation to show at least the following information: engine and generator speed in R.P.M., voltage, amperes, frequency, power factor, engine temperatures, engine oil pressure, hour meter readings.

  Yes

  No

  N/A

• Inspect safety devices

  Yes

  No

  N/A

• Test safety shut-off controls

  Yes

  No

  N/A

• Measure and record stator winding temperature

  Yes

  No

  N/A

• Measure and record bearing temperature

  Yes

  No

  N/A

• Test for vibration at various loads on the load bank

  Yes

  No

  N/A

• Open covers and complete CM-0002 (infrared testing) on all conductors and connections. Note: For the deficiencies while unit is de-energized. (Perform with unit running.)

  Yes

  No

  N/A

• Check charging system for proper operation

  Yes

  No

  N/A

• Check battery electrolyte level

  Yes

  No

  N/A

• Determine specific gravity of starting batteries. Add distilled water if necessary. Clean terminals. Set charge rate after generator has been operated

  Yes

  No

  N/A

• Note any exhaust, oil, coolant, or fuel leakage. Plan for correction

  Yes

  No

  N/A

• Cool down and stop the unit

  Yes

  No

  N/A

• Drain the exhaust condensate trap

  Yes

  No

  N/A

• Re-accomplish CM-0002 on any problem areas

  Yes

  No

  N/A

Maintenance Hours

• Estimated Time spent on work order?