Preventive Maintenance Standby Engine Checklist

Customer: POWERSAFE ENERGY SERVICES Customer No: CASH20

Site Contact: JOE VAUGHN Work Order No: CV85133-88
Contact Number: 440-477-6856 PM Date: 3412
Technician: ROSS ERBACHER/R184 Voltage: 600
Site Address: 37611 EUCLID AVE kW Rating: 550
WILLOUGHBY, OH 44094 Unit Number:
Unit Hours: 527

Make: Model: Serial #:

Package: CAT 3412 AFH00335
Engine: Click here to enter text. BCW00832
Service Type: Annual PM Service
Optional Services†:  Coolant Sample  Fuel Sample  Loadbank Test
†Optional Services are included at the customer's request

Monthly PM Service
# Cooling System: N/A: OK: Monitor: Action: Comments:

  
Visually Inspect Radiator/Heat Exchanger for Enter Comment
1 I necessary
Leaks, Damage and Obstruction

  
Add Coolant to Bring the Coolant to the Added coolant during service
2
Correct Level ____ Gal.

  
Inspect Condition of Radiator Cap, Gasket Enter Comment
3 I necessary
and Sealing Surface

  
Visually Inspect Water Pump and Cooling Enter Comment
4 I necessary
System Gaskets for Leaks

  
Inspect Flexible Water Connections for Enter Comment
5 I necessary
Cracking, Leaks and Pliability

  
Enter Comment
6 Inspect Pulleys for Excessive Wear I necessary

  
Enter Comment
7 Inspect Belts for Cracking and Fraying I necessary

  
Enter Comment
8 Check Belt Tension I necessary

   
Check Jacket Water Heater(s) for Proper Was unable to check funtion of jwh. Recommend replacing jwh
9 hoses
Operation and Adjust Thermostat Setting
# Lubrication System: N/A: OK: Monitor: Action: Comments:

  
Add Crankcase Oil to Bring to the Correct Enter Comment
10 I necessary
Level (Change Oil and Filters for Annual PM)

  
Inspect the Oil Heater for Proper Operation Enter Comment
11 I necessary
and Check Thermostat Seals

  
Visually Inspect Front and Rear of Enter Comment
12 I necessary
Crankshaft Seals and Lubrication System

   
Check Governor Oil Level and Add Oil as Enter Comment
13 I necessary
Needed ____ Qts.
# Fuel System: N/A: OK: Monitor: Action: Comments:

  
Test Day Tank Pump for Proper Operation Enter Comment
14 I necessary
and Level

  
Enter Comment
15 Drain Water from Water Separator I necessary

  
Operate Fuel Priming Pump and Check for Enter Comment
16 I necessary
Proper Operation and Leaks

  
Enter Comment
17 Check the Engine's Fuel System for Leaks I necessary
   
Inspect Flexible Fuel Lines for Cracking, Enter Comment
18 I necessary
Leaks and Pliability

   
Record Fuel Level in Main Fuel Tank Enter Comment
19 I necessary
______ Gal. ______ Inches
# Starting System: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
20 Top Off Electrolyte Level I necessary
Check and Record Battery Charger Amp Enter Comment
21 Equ.. Rate: ______ Amps
Float Rate: ______ Amps
   I
necessary
Enter Comment
Check Battery Charger and Adjust Float Rate I
22
for Optimum Battery Performance and Life:
Equ. Volts: _______ VDC
Float Volts: _______ VDC
   necessary

# Air Intake System: N/A: OK: Monitor: Action: Comments:

   
Inspect Air Filters for Plugging and Enter Comment
23 I necessary
Deterioration
# Exhaust System: N/A: OK: Monitor: Action: Comments:

  
Inspect Flexible Exhaust Coupling for Enter Comment
24 I necessary
Cracks and Excessive Leakage

  
Inspect Exterior of Exhaust Manifolds for Oil or Enter Comment
25 I necessary
Fuel Slobbering (signs of wet stacking)

   
Inspect Exhaust Rain Protection and/or Enter Comment
26 I necessary
Exhaust Outlet Screening
# Miscellaneous: N/A: OK: Monitor: Action: Comments:

  
Inspect Generator Set Vibration Isolators Enter Comment
27 I necessary
and Adjust as Needed

   
Make a Walk Around Inspection of Complete Enter Comment
28 I necessary
Installation
# Electrical Control System: N/A: OK: Monitor: Action: Comments:

  
Perform an Operational Check of Enter Comment
29 I necessary
Illumination and Safety Lamps

  
Check for Unit On-Line Capability in Less Enter Comment
30 I necessary
Than Ten Seconds

  
Check for Proper Cranking Termination Enter Comment
31 I necessary
Upon Starting

  
Check for Proper Operation of Engine and Enter Comment
32 I necessary
Gen. Instruments with Generator Running

  
Adjust Governor Control for Optimum Enter Comment
33 I necessary
Performance and Frequency ____60__

  
HZ
Adjust Voltage Regulator for Proper Enter Comment
34 I necessary
Voltage ____600__ VAC

   
Check and Record Alternator Voltage with Enter Comment
35 I necessary
Engine Running ____27__ VDC
# Operational Checks: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
36 Check for Abnormal Noise or Vibration I necessary
Check for Abnormal Exhaust Enter Comment
37 Characteristics with Engine Running (signs of
wet stacking)
   I

necessary
Check for Proper Operation of Remote Fan Enter Comment
38 Motors, Thermostats, Circulating Pumps, and
Solenoid Valves
   I

necessary

  
Check Inlet and Discharge Louvers with Engine Enter Comment
39 I necessary
running and stopped

  
Check for Excessive Crankcase Blow-by Enter Comment
40 I necessary
with Engine Running

  
Enter Comment
41 Re-Check Oil Level with Engine Running I necessary

  
Enter Comment
42 Re-Check for Leaks with Engine Running I necessary
Quarterly PM Service
# Fuel System: N/A: OK: Monitor: Action: Comments:

  
Stick Main Tank for Water ______ Gal. Enter Comment
43 I necessary
______ Inches

   
Inspect Steel Fuel Lines for Cracks, Leaks Enter Comment
44 I necessary
and Proper Line Bracket Support
# Starting System: N/A: OK: Monitor: Action: Comments:

  
Tighten Battery Cable Connections as Recommend replacing battery connections
45
Needed
Clean and Apply Corrosion Inhibitor to Enter Comment
46 Terminals of Only Lead Acid Batteries as
needed
   I
necessary

   
Inspect and Tighten Starter Motor Enter Comment
47 I necessary
Connections and Wiring
# Air Intake System: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
48 Test Air Cleaner Indicator I necessary

Semi-Annual PM Service
# Cooling System: N/A: OK: Monitor: Action: Comments:

  
Analyze Coolant for Proper Antifreeze Enter Comment
49 I necessary
Protection ______ Deg.F
Analyze Conditioner SCA Level and Add Enter Comment

  
Additional SCA as Needed ______ PPM I
50
LLC Yes/No: ______
necessary
LLC Extender: ______ Qts.

   
Enter Comment
51 Re-Torque Hose Clamps I necessary
# Lubrication System: N/A: OK: Monitor: Action: Comments:

  
Clean Crankcase Breather, Inspect Hose and Enter Comment
52 I necessary
Connections

  
Lubricate Fan Drive with Caterpillar Bearing Enter Comment
53 I necessary
Lubricant

  
Lubricate Governor Linkage with Caterpillar Enter Comment
54 I necessary
Bearing Lubricant

   
Lubricate Generator Bearing with Caterpillar Enter Comment
55 I necessary
Bearing Lubricant
# Fuel System: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
56 Test Day Tank Alarms I necessary

  
Drain Water and Sediment From Day Tank (if Enter Comment
57 I necessary
accessible)

  
Enter Comment
58 Clean or Replace Inlet Filters for Day Tank I necessary

   
Enter Comment
59 Clean Primary Fuel Filter (if screen type) I necessary
# Starting System: N/A: OK: Monitor: Action: Comments:

   
Check and Record Battery Cells Electrolyte Enter Comment
60 I necessary
Specific Gravity
# Air Intake System: N/A: OK: Monitor: Action: Comments:

  
Inspect Air Cleaner Seal for Pliability and Enter Comment
61 I necessary
Sealing

  
Check All Air Intake Piping for Damage and Enter Comment
62 I necessary
Loose Connections

   
Inspect Turbocharger for Seal Leakage and Enter Comment
63 I necessary
Excessive End Play Clearance (if accessible)
# Exhaust System: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
64 Drain Water in Exhaust Moisture Traps I necessary

  
Inspect Exhaust Manifold(s) for Broken or Enter Comment
65 I necessary
Missing Hardware
# Generator: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
66 Check Rotor Air Gap for Correct Clearances I necessary

  
Check Tightness of Generator Leads and Enter Comment
67 I necessary
Voltage Regulator Control Wiring

  
Strap and Tape any Wiring or Generator Enter Comment
68 I necessary
Leads that Have Rubbing or Worn Insulation

  
Inspect Brushes and Slip Rings or Rotating Enter Comment
69 I necessary
Rectifiers

  
Clean and Adjust Voltage Droop Enter Comment
70 I necessary
Potentiometer

   
Inspect Rotor and Stator for Damage and Enter Comment
71 I necessary
Excessive Oil and/or Dirt Build Up
# Miscellaneous: N/A: OK: Monitor: Action: Comments:

   
Inspect Coupling and Guards for Loose or Enter Comment
72 I necessary
Missing Parts
# Electrical Control System: N/A: OK: Monitor: Action: Comments:

  
Check for and Tighten Loose Terminals on Enter Comment
73 I necessary
the Generator Set and Generator Control

  
Check Tightness of Relays in the Generator Enter Comment
74 I necessary
Control Panel

  
Inspect for Excessive Dirt Accumulation in Enter Comment
75 I necessary
the Control Panel and Clean as Needed

  
Enter Comment
76 Test Auto-Start System I necessary

  
Test Safeties and Pre-alarms on Control Enter Comment
77 I necessary
and Annunciator Panels
Check and Record Battery Voltage Dip Enter Comment

  
Level During Overcrank Test for Minimum I
78 Ne
Voltage Required to Maintain
cessary
Controls During Starting ______ VDC

   
Record Field Voltage During Generator No- Enter Comment
79 I necessary
Load Run for Base Line ______ VDC
# Operational Checks: N/A: OK: Monitor: Action: Comments:

  
Take Oil Sample (after operational checks) Enter Comment
80 I necessary
for Caterpillar S.O.S. Program

Annual PM Service
# Filter Replacement: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
91 Oil Filter Replacement I necessary

  
Enter Comment
92 Fuel Filter Replacement I necessary

  
Enter Comment
93 Oil Drain and Replacement I necessary
 # Back In Service Checks: N/A: OK: Monitor: Action: Comments:

  
Enter Comment
S0 Reset All Controls to Automatic I necessary

  
Enter Comment
S1 Set Circuit Breaker to Correct Position I necessary

  
Enter Comment
S2 Check Fuel Valves for Correct Position I necessary

  
Check Voltage Regulator is ON and NOT Enter Comment
S3 I necessary
Tripped

  
Enter Comment
S4 Check Battery Charger is ON I necessary

  
Enter Comment
S5 Check Day Tank Controls are ON I necessary

  
Enter Comment
S6 Check Remote Radiator Fan Controls are ON I necessary

  
Enter Comment
S7 Check Auxiliary Water Pump Controls are ON I necessary

  
Enter Comment
S8 Check Jacket Water Heater(s) are ON I necessary

  
Enter Comment
S9 Check Louver Controls are ON I necessary

Battery Installation Date: 3/21 Battery Qty: 2 Maintenance Free? 

Battery Mfg: Cat Group No: 4d Part No: 153-5710
Battery / String
Cells
A B C D E
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Additional Notes:
Recommend replacing battery connections. Recommend replacing jacket water heater hoses.

Ohio CAT Power Systems Division Location

Cleveland (Main Office) Columbus Cincinnati
900 Ken-Mar Industrial Pkwy. 5232 Walcutt Court 11330 Mosteller Road
Broadview Heights, OH 44147 Columbus, OH 43228 Sharonville, OH 45241
800.637.5000 tel 888.443.4658 tel 888.332.4658 tel

Canton Dayton Toledo Youngstown

4731 Corporate St. NW 1281 Brukner Dr. 25970 State Route 25 1 Ohio Machinery Blvd.
Canton, OH 44706 Troy, OH 45373 Perrysburg, OH 43551 Youngstown, OH 44420
800.837.6207 tel 888.330.4658 tel 888.339.4658 tel 800.837.6203 tel