U.S.

DEPARTMENT OF STATE
OVERSEAS BUILDINGS OPERATIONS
FACILITIES MAINTENANCE DIVISION
PREVENTIVE MAINTENANCE CHECKLIST

E61H - Generator, Onan/Cummins (or other)

SAFETY & SPECIAL INSTRUCTIONS:

1. Have approved type fire extinguisher readily available.
2. Allow no open flame or smoking in area.
3. Use safety type fuel cans only.
4. Follow instructions in manufacturer's operation & maintenance manuals.
5. Turn engine switch off and tag out.
6. Wear eye protection when testing and filling batteries.
7. If the answer to a PM task is NO, briefly explain WHY NOT.
Notes: This checklist is intended as a Reminder and a Record. Some tasks may not apply to the unit you are maintaining.
Replaceable or refillable items were not replaced or refilled unless noted in the Comment Column.
Data Entry: Tab to the next field. Shift Tab to the previous field. Enter or Space to check a box. Use semicolon, not comma.
1. IMAP Equipment Identifier Number: 2. Checklist Completed By: 3. Date (m/d/yy):
                 
4. Post: 5. Manufacturer: 6. Leave Blank
                 

7. Model Number: 8. Serial Number:

           

9. Location Installed CAA or (Building/Area/Room 10. Area Served CAA or (Building/Area/Room Number):
Number):      
     
11. Date Manufactured:       12. Leave Blank
unknown date known date estimated      

13. General Assessment of Condition listing anything out of the

ordinary including broken, worn, missing, or newly replaced
components):       Excellent Good Fair Poor Failed / Broken

14. DOCUMENTATION: Manufacturer’s operation and maintenance manuals available at Post: YES. NO.
15. Total Run Time (hours): 16. Estimated Annual Run Time (hours):
           

THE ENGINE
17. The Engine Manufacturer: 18. Governor Type:
           
19. The Engine Model Number: 20. The Engine Serial Number: 21. The Engine Arrangement
            Number:
     
22. Governor Manufacturer: 23. Starting Battery Voltage:
      12 Volt 24 Volt 32 Volt
24. Fuel Type: 25. Fuel Tank Construction:
Gasoline Diesel Steel Fiberglass Other      
26. Day Tank Size:       27. Fuel Tank Size:      
Gallons Liters Gallons Liters

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E61H Updated from version F
 THE GENERATOR
28. Generator Manufacturer: 29. Generator Model Number:
           

30. Generator Serial Number: 31. Generator Arrangement Number:

           

32. Number of Phases: 33. Frequency (50 / 60 Hz):

           

34. Prime Continuous Rating:

      KVa      
KW

35. Standby Rating:

      KVa      
KW

36. Output Voltage:

      Phase – Phase      Phase – Neutral

TRANSFER SWITCH
37. Transfer Switch Type: 38. IMAP Equipment Identifier Number for Transfer
Automatic Manual Switch:
     

 Preventive Maintenance Procedures: Onan/Allis Chalmers Checked Record Readings/ Comments

or Done?
Y/N/NA
A. Check battery specific gravity and water level, add distilled water            
as required.
B. Inspect engine and generator wiring harness for wear and damage.            
C. Inspect engine and generator wiring and terminals for loose and            
broken connection.
D. Clean battery terminals and lugs. (Apply grease on            
terminal/connections.
E. Inspect starter motor and alternator. Clean and lubricate as            
required
F. Check and tighten circuit breaker lugs and connections with            
torque wrench.
G . Clean generator interior, starter, rotor, and exciter windings with            
compressed air or vacuum cleaner.
H. Automatically start unit and run under load for 1 hour. (add load            
test data to Box #40[below])
I. Observe auto-start Delay and transfer time and record *#.            
J. Read and record all gauges/meters (adjust/calibrate as required).            
K. Inspect trickle-charger voltage/amps.            

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 39. Preventive Maintenance Procedures: Onan/Allis Chalmers CHECK RECORD READINGS/
(continued) Y/N COMMENTS

L. Reset test switch. Observe and record retransfer/cool down time.*#            
(Use Additonal Comments block if more space is needed.)
M. Test start unit. Read and record all gauges/meters(5 Minutes No            
Load).
NOTE: *#. Time delay engine start (TDES) 10-12 seconds. 2.Time delay transfer to emergency (TDNE) 2-3 seconds.
3.Time delay emergency to normal (TDEN) 3-5 minutes. 4. Time delay engine cooldown (TDEC) 5 minutes.
N. Inspect all fuel, oil water piping for secure mounting.            
O. Check fuel level in storage and day tank. Add as required            
P. Open fuel day tank drain valve, Drain off water and sediment            
Q. Drain water and sediment from fuel line and filters. Reprime            
R. Drain water and sediment from water separator.            
S. Check exhaust for excessive black or white smoke. (See            
manufacturer’s manual)
T. Check all hoses for wear, leaks and flexibility, change if necessary.            
U. Check fuel pressure gauge. If green, OK. If Red, Change fuel            
filter. Green
Red Red Green Red Check air filter service
indicator. If Green it is OK. If Red, replace the air filter. Green
Red Check air filter service indicator. If Green it is OK. If
Red, replace the air filter. Green Red
V. Lubricate fan shaft bearings. (Non shielded bearing only)            
W If applicable, check operation of engine block water heater.            
X. Clean radiator air Passages and duct work with pressure washer.            
Y. Check cooling system anti-freeze mixture freeze-protection level.            
Record the reading in o F.
Z. Inspect tension and condition of Vee-belts. Replace if cracked.            
(adjust tension to 1/2” movement when pressed inward).
AA. Check water level in radiator tank. Add antifreeze as required.            
AB. Add 0.5 liters of Caterpillar coolant conditioner. See manufacturer            
's operation and maintenance manual.
AC. If applicable, check operation of oil heater.            
AD. Check engine, lube oil level with dip stick. Add as required.            
Change engine oil. (if over200 hrs since last oil change or 1 year)
AE. Replace engine oil filter ( if over 200 hrs. or 1 year since last filter            
change. Note eng hrs on filter).
AG. While Engine is operating, check for water, fuel, and oil leaks.            
AH. Clean air filter element. Replace after three cleaning or 200 hrs. or            
1 year (note eng hrs on filter)

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 AI. Inspect exhaust muffler and piping insulation.            
AJ. Inspect unit thoroughly for loose fasteners.            
AK. Check turbocharge for vibration, check for any abnormal noise            
during operation.
AL. Check exhaust manifold, muffler, and piping for leaks and secure            
mountings.
AM. Check air filter service indicator. If Green it is OK. If Red,            
replace the air filter. Green Red
AN. Inspect unit for corrosion. Remove any corrosion, prime and paint.            
AO. Shut down engine. (Non-Emergency)            
AP. Clean mechanical room and remove unnecessary materials and            
parts.
AQ. Test engine auto-shutdown components. *            

AR. Additional Comments

     

NOTE * AUTO SHUTDOWN COMPONENTS:

1. Test not applicable for transducer type shutdown system.
2.With engine running (in manual mode) and generator circuit breaker open and no load on the generator perform the
following:
A. Jumper water temperature switch.(engine should stop and temp failure light should light) reset the control panel.
B. Jumper oil pressure switch. (engine should stop and oil press. failure light should light). reset the control panel.
C. Press test button on the overspeed module.(engine should stop and overspeed failure light should light). Reset the
control panel.
TOOLS & MATERIALS: 1. Standard mechanic's tool set. 2. Distilled water. 3. Grease gun. 4. Hydrometer. 5.
engine oil. 6. air & fuel filters. 7. Antifreeze/coolant inhibitor. 8. Oiler can. 9. Cleaning Rags. 10. Oil filters. 11.
Vacuum cleaner. 12. Compressed air. 13. Radiator hoses. 14. torque wrench, 1/2" drive x 250 lbs. 15.Pressure sprayer.

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E61H Updated from version F
 E40H - Load Test Data: Date of Test     

Time A phase amp reading B phase amp reading C phase amp reading

                       

                       
                       
                       
                       
A to B phase volts B to C phase volts C to A phase volts

                       

                       
                       
                       
                       
A phase to neutral B phase to neutral C phase to neutral volts
volts volts
                       
                       
                       
                       
                       

Time delay to start      

Time delay to emergency power      
Time delay to normal power      
Engine cool down time      

41. ADDITIONAL FINDINGS OR COMMENTS:

     

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E61H Updated from version F