GENERATOR INSPECTION

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​ALARMS, CONTROL PANEL AND INSTRUMENTATION

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1. Alarms/Pre-Alarms – Prior to completing any services, note presence of any alarms and notify appropriate personnel if alarms are present.  Verify proper annunciation of pre-alarms.  Note any indication of non-functional alarms.

2. Analog Gauges/Digital Meters – Check for proper operation.  Measure and record the following readings while equipment is operating with no building load:

   1. Oil Pressure – Measure and record engine oil pressure (PSI).

   2. Water Temperature - Measure and record engine water temperature (F).

   3. Voltage – Measure and record unloaded AC voltage (V).

   4. Frequency – Measure and record unloaded frequency (A).

   5. Amperage – Measure and record unloaded amperage (Hz).

3. Auto Start/Stop – Check for proper operation of automatic stop. 

4. Controls Panel - Visually inspect for wiring deterioration, loose connections, or presence of foreign material.  Verify proper operation of shutdowns.

5. Remote Annunciator (where applicable) – Inspect for proper communications and alarms.  If equipped, test for remote start functionality. 

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ALTERNATOR (A/C) 

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1. Bearings – Inspect bearings for proper lubrication.  If equipped with grease fittings, lubricate as needed if specialty grease is not required.

2. Brushes/Diodes – Visually inspect for wear.

3. Leads/Connections – Visually inspect for wear or deterioration of insulation.  Inspect for wear or broken terminal lugs.

4. Output breaker – Test for proper operation by actuating output breaker.

5. Operational function – Under operating conditions, note any operational noise or indicators of mechanical malfunction.

6. Vibration Isolators/Mounts – Visually inspect for wear and/or damage. 

7. Windings – Visually inspect windings.

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COOLING SYSTEM

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1. Coolant – Check coolant/antifreeze level to ensure proper volume.  Top off as necessary (maximum of 2 gallons).  Measure and record freeze point and PH levels.

2. Coolant Filter (where applicable) – Record last date of filter change.

3. Engine Thermostats – Check for proper operation under equipment operation.  Recommend repairs or replacement as necessary.

4. Fan/Fan Belt Assembly – Visually inspect fan belts for indications of wear and check for proper tension. Inspect fan and fan shroud for indications of impact or contact damage.  Inspect fan bearing where equipped for proper operation and note any auditory indication of wear under operation.  Lubricate fan bearing if equipped with grease fittings (when specialty lubricant is not required).

5. Hoses/Couplings – Visually inspect couplings, gaskets, clamps and hoses for indications of coolant leakage or signs of wear.  Note any presence of cracking or wear on hoses and recommend repairs or replacement as needed.  

6. Jacket Water Heater – Measure and record block heater temperature prior to equipment operation to ensure jacket water heater functionality.  Visually inspect jacket water heater for indications of wear on heater, hoses and clamps.  Check for presence and proper operation of ball valves on jacket water heater lines.  Record any recommendations for repairs or replacement.

7. Radiator – Visually inspect radiator core, upper and lower tanks and tank seals.  Note any indication of coolant leakage, impact damage or airflow obstruction or blockage due to debris or foreign material.

8. Radiator cap – Check for indications of wear.

9. Water Pump/Seals – Visually inspect for proper operation and presence of leaks from seals or water pump weep hole.  Note any auditory indications of wear under operation.

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ELECTRICAL SYSTEM (D/C)

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1. Batteries – Check battery water level, age and specific gravity.  Perform battery load test.  Clean exterior of batteries.  Clean battery cables and posts of corrosion and apply battery saver.  Record any deterioration of battery cables and age of batteries.  Recommend replacement as needed.

2. Battery Charger - Visually inspect battery charger, replace failed fuses when required.  Measure and record DC voltage and amperage output. 

3. DC Alternator – Visually inspect alternator for indications of wear or failure.  Measure and record alternator output.  Visually inspect alternator belt and recommend replacement where applicable.

4. Ignition system (where applicable) – Check spark plugs and spark plug wire conditions.  Inspect distributor cap and rotor for indications of wear or failure.  Note recommendations for replacement or repair as needed. 

5. Starting Motor - Visually inspect for proper operation and note any indications of wear or failure.  Test for proper operation by performing engine start.

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FUEL SYSTEM (DIESEL AND NATURAL GAS)

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1. Fuel Cell/Day Tank (diesel only) – Visually inspect for leaks and check for proper operation of any transfer pumps if equipped.  Make note of presence of water or visible contaminants in fuel.  Record fuel level and recommend top off if less than ninety percent (90%).

2. Fuel Cell/Day Tank Supply and Return Lines (diesel only) – Visually inspect for proper operation and indications of wear or deterioration.  Tighten connections as needed.  Recommend repair or replacement as needed.

3. Fuel Lines and Connections – Visually inspect for proper operation and indications of wear or deterioration.  Tighten connections as needed.  Recommend repair or replacement as needed.

4. Fuel-Water Separators/Water Trap (diesel only) – Record last date of filter change.  Visually inspect for proper operation, leaks or damage.  Recommend repairs or replacement as needed.

5. Fuel Filters – Record last date of filter change.  Visually inspect for damage, leaks and proper operation

6. Governor, Actuator, Linkage and Controls – Check for proper operation. Check linkage for proper tightness or indications of binding.  Check governor oil level where applicable and top off as needed. 

7. Natural Gas Engine Carburetor/Mixer – Visually inspect and verify proper operation.

8. Priming Pump (diesel only, if equipped) – Verify proper operation.  Inspect for seal damage or deterioration. 

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INDUCTION AND EXHAUST SYSTEMS

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1. Air Filter and Service Indicator – Record last date of filter change.  Inspect and clean air filter and pre-cleaner when necessary.  Note condition of filter housing, connections and mounting hardware.  Reset and record air filter service indicator if equipped. Recommend filter replacement when necessary.

2. Exhaust Piping and Silencer – Visually inspect for leaks.  Check rain cap (when present) for proper operation.  Checking mounting brackets and hardware for tightness or vibration wear.  Note any visual indicators or abnormalities in exhaust smoke.

3. Intake Manifold and Tubes – Visually inspect and note condition of intake piping/tubing and connections.  Note any presence of foreign material or indication of wear or vibration damage.  Note any auditory indicator of leaks.

4. Turbocharger – Visually inspect turbocharger for physical condition and presence of oil, exhaust or air leaks.  Check for proper operation and note any presence of auditory indicators of wear.

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LUBRICATION SYSTEM

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1. Crankcase Ventilation Tube or Breather – Inspect for indicators of wear or vibration damage.  Note any excessive blow by.  Clean breather (where applicable). 

2. Engine Oil – Check for proper oil level.  Top off oil level where required (maximum 2 gallons).

3. Engine Oil Filters - Record last date of filter change.

4. Tubes, Lines, Seals and Gaskets – Visually inspect for deterioration or indicators of wear.

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AUTOMATIC TRANSFER SWITCH (ATS)

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1. Cabinet/Enclosure – Wipe interior of enclosure and remove accumulated dust and/or dirt.  If excessive dust or debris is present, recommend more extensive ATS service.

2. Cabinet Door and Seals – Check door closure, seals, hinges, locking bar and lock mechanism for signs of wear and proper operation.

3. Contacts and Connections – Visually inspect emergency contacts for indications of wear.  Check temperature of building and normal (utility) source lugs and contactors with infrared thermometer.

4. Control Wiring and Connections – Visually inspect all control wiring for indications of wear, insulation deterioration, tracking, overheating or loose connections.  

5. Load Cabling – Visually inspect building, normal source and emergency source for indications of deterioration. 

6. Transfer Switch Controls – Visually inspect for proper operation of digital or analog controls.  Note any non-operational indicator bulbs, meters, switches or digital user interface controls.

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Optional Services

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The following services are included in a minor inspection but are considered optional as not all facilities choose to utilize these services.  Completion of services are based on functionality of the automatic transfer switch, on-site personnel being present and the authorization to perform a simulated power failure.  While utility source will remain present for all other building circuits, all circuits fed from automatic transfer switch will transfer from utility source to emergency (generator) power.  The duration of this test is the maximum time required to record all measurements below (typically <10 minutes, not including engine cool-down cycle).

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ALARMS, CONTROL PANEL AND INSTRUMENTATION

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1. Analog Gauges/Digital Meters – Check for proper operation.  Measure and record the following readings while equipment is operating with no building load:

   1. Oil Pressure – Measure and record engine oil pressure (PSI).

   2. Water Temperature - Measure and record engine water temperature (F).

   3. Voltage – Measure and record unloaded AC voltage (V).

   4. Frequency – Measure and record unloaded frequency (A).

   5. Amperage – Measure and record unloaded amperage (Hz).

2. Auto Start/Stop – Check for proper operation of automatic start.

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AUTOMATIC TRANSFER SWITCH

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1. Actuators – If possible, observe actuators and control arms and note any indications of mechanical binding or inhibitors.

2. Contacts and Connections – Visually inspect normal contacts for indications of wear.  Check temperature of emergency source lugs and contactors with infrared thermometer. 

3. Time Delays and Controls – Observe all time delays during simulated test.  Ensure time delays are set within manufacturer recommendations or are concurrent with or building or generator application requirements.

   1. Time Delay to Start – Delay to prevent engine start during momentary losses or “brown-outs”.  Recommended to be set to between zero and one (0-1) second. 

   2. Time Delay to Transfer – Delay between when equipment has stabilized at operating frequency and voltage and switch actuating to emergency source.  Recommended to be set between zero to five seconds (0-5).  See note below.

   3. Time Delay to Re-Transfer – Delay between utility being restored and switch actuating from emergency to utility source.  This prevents re-transfer before a stable utility source is deemed present. Recommended at a minimum of five (5) minutes. 

   4. Time Delay for Cool-down – Delay to allow generator to operate in an unloaded condition to allow equipment to cool down for safe shut down.  Recommended in accordance with manufacturer’s recommendations or for a minimum of 15 minutes.

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GENERATOR SERVICE

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A generator service consists of all inspections listed above in a Generator Inspection, but also includes the following items:

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1. Coolant Filter (where applicable) – Remove and replace engine coolant filters.  Mark filters to indicate date of change.  Check for proper seal and operation.  Retain used coolant filters and dispose of off-site in an environmentally safe manner.

2.  Fuel Filters-Primary/Secondary (diesel only) – Remove and replace primary and secondary (if equipped) fuel filters.  Mark filters or filter housing to indicate date of change.  Check for proper seal and operation. Retain used fuel filters and dispose of off-site in an environmentally safe manner.

3.  Fuel Filters-Water Separators/Water Trap (diesel only - if equipped) – Remove and replace fuel water separate/water trap filters.  Mark filters or filter housing to indicate date of change.  Check for proper seal and operation.  Retain used fuel-water separator filters and dispose of off-site in an environmentally safe manner.

4. Engine Oil – Obtain oil sample and retain for submission to outside laboratory.  Remove and replace engine oil.  Retain used engine oil waste and dispose of off-site in an environmentally safe manner.

5. Engine Oil Filters - Remove and replace primary and secondary (if equipped) oil filters.  Mark filters or filter housing to indicate date of change.  Check for proper seal and operation. Retain used engine oil filters and dispose of off-site in an environmentally safe manner. 

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