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Generator Testing and Maintenance
Specification List of Services

A. Engine Lubrication System
  • Check for leaks.
  • Replace filters.
  • Inspect strainers clean if required.
  • Change oil.
  • Clean crank case breather.
  • Take oil sample, submit for analysis, and submit copy of analysis to the City along with invoice.

B. Engine Fuel System

  • Check for leaks and damage.
  • Change fuel filter.
  • Clean fuel strainers and screens.
  • Drain water from filters and separators.
  • Drain sediment from fuel day and sub-base tanks.
  • Check flexible fuel hoses.
  • Check overflow line for blockage, unclog if necessary.
  • Check operation of float switches in day task.

C. Ignition System

  • Inspect all spark ignition system components for wear and proper adjustment.
  • Adjust timing

D. Air Intake System

  • Check and tighten all hoses and connections.
  • Clean and oil all wet type air cleaners.
  • Clean and/or inspect all dry type air cleaners.

E. Governor

  • Check and adjust engine speed.
  • Check and adjust governor sensitivity and droop.
  • Check oil level, drive belt, linkage and general operation.

F. Cooling System

  • Check for Coolant level, fill as necessary.
  • Hydrometer check coolant and report freeze protection limit.
  • Pressure test system.
  • Check radiator for leaks and general condition.
  • Check and lube water pumps as necessary.
  • Check engine fan and fan drive. Lube as necessary.
  • Check ducts and louvers for proper operation.
  • Check engine heater for proper operation.
  • Check belts, hoses, and connections for wear and leaks.

G. Exhuast System

  • Check for leaks .
  • Drain exhaust condensate from exhaust lines and mufflers.
  • Check general condition of mufflers, connections, lines, and supports.

H. Engine Electrical System

  • Check battery electrolyte level and specific gravity.
  • Float charge battery at a high charge for 30 minutes or until battery is at full charge and reconditioned.
  • Clean and coat battery post and cable connections.
  • Check starter motor, pinion, and ring gear for damages and proper operation.
  • Check battery charager operation and adjust as necessary.
  • Check Gen set battery charging system for proper operation.

I. AC Generator

  • Check appearance and clean generator windings.
  • Check and clean air screens.
  • Check appearance and clean slip rings and commutator if applicable.
  • Check brushes for wear and brush tension if applicable.
  • Manually check generator tail bearing temperature.

J. Controls and Instruments

  • Check for all instruments for proper operation.
  • Check instrument panel and control box.
  • Check operation of all safeties and system alarms.

K. Load Transfer Control and Inter-Connection Devices

  • Operate all circuit breakers manually.
  • Inspect load transfer control power contacts, electrical connections, and bus bars for cleanliness and overheating.
  • Check time delays for proper operation. Reset to customer specifications if necessary.

L. Final Inspection Test

  • Operate genetor set without load until it achieves operationg temperature.
  • Shut system down and wait 10 minutes for fluid level to stabilize.
  • Re-check lube oil, coolant, battery electrolyte, and fuel levels. Fill as necessary.
  • Clean all service areas leaving the site in a condition of good order and cleanliness.

M. Final Power Outage Test

  • Notify responsible on site city representative of your intentions to cut utility power on those circuits protected by the stand-by generator system. Advise the city representative that there will be at least a 10 second power outage on those circuits.

  • After notification to the city, Use the test switches on the generator switchgear panel to simulate a power outage. Observe the stand-by generator set system to make sure if functions properly. Return the test switch to the normal power position. Observe that the stand-by generator shuts down properly. Make any adjustments necessary.

N. Site Wrap-Up

  • Check to insure that all control switches are left in the proper position for automatic stand-by power protection.
  • Complete all routine maintenance check lists and summary reports.
  • Discuss the system condition with on-site personnel leaving with them copies of the maintenance check list. Insure a copy of the summary report is attached to the generator set.

O. Full Power Load Bank Test

A full power load bank test, using vendor supplied external test equipment and cables, will be conducted once per year.
  • Connect the vendor supplied load bank to the system. Do not disconnect the generator set from the stand-by system to accomplish this hook-up.
  • Exercise the generator set under load for no less than two hours. No less than one hour of this test should be at 100% of the generator set's name plate rating.
  • Record the following areas of generator set performance:

    • Load expressed as a percentage of maximum generator set rating
    • Voltage
    • Amps (all 3 legs if 3 phase)
    • Frequency
    • Oil Pressure
    • Coolant Temperature

  • Note both time and effect of any adjuestments attempted on the generator set during this test.
  • At the conclusion of this test, disconnect the load bank and allow the generator set to run for ten minutes to cool down.
  • Disconnect all external load test equipment and cables from the stand-by system leaving the system ready to respond automatically to a power outage.
  • Leave the site in a state of good order and cleanliness.
  • Write a load bank test report.

P.Coolant Change

  • Replace coolant with 50% 50% water and new (not recycled) antifreeze mixture.

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