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An emergency generator requires a unique set of maintenance services to retain
its' maximum reliability. The best way to ensure dependable emergency power is
with a Fabick CAT planned maintenance program. From fueling services to a Total
Maintenance and Repair agreement, Fabick CAT Power Systems can be your single
source for generator services. Need something tailored to your particular needs?
We can build a maintenance plan to meet your specific requirements.
Level I - Quarterly Visit
Our technicians will perform the following:
Electrical Systems
- Check battery electrolyte level and top off
- Check and record battery voltage
- Check and record battery charger amperage
- Check battery connection terminals and clean as necessary
- Clean battery posts and terminals
- Check battery charger and adjust float rate (if necessary)
Lubrication System
- Check crankcase oil level and add up to 2 gallons of Caterpillar DEO API CG4 engine oil
- Visually inspect oil for contamination by fuel water or glycol
- Visual inspection of front & rear crankshaft seals and lubrication system gaskets for leaks
- Check for excessive crankcase blowby with engine running
Cooling System
- Check coolant level and correct level if necessary
- Visual inspection of radiator/heat exchanger for leaks, damage and obstructions
- Inspect condition of radiator cap, gaskets and sealing surfaces
- Visually inspect engine coolant for contamination
- Visually inspect water pump and cooling system gaskets for leaks
- Inspect engine belts for fraying and cracking
- Check jacket water heater(s) for proper operation and adjust thermostat settings as needed
- Check and adjust belt tension if necessary
- Inspect hoses for cracking, leaking, and pliability
- Check and record engine coolant antifreeze protection
Fuel System
- Check level of main storage tank
- Test day tank pump for proper operation and level
- Inspect fuel lines for leaks or cracking
- Drain water from fuel separator
- Check fuel injection and transfer pumps for proper operation and leaks
- Drain water from water separator and fuel tank
- Check governor linkages, and oil level if applicable
- Check and record level in main fuel tank
Air Induction and Exhaust System
- Inspect air filter for deterioration and plugging
- Check inlet and discharge louvers for proper operation with engine running and stopped
- Inspect air intake piping for leaks and possible dirt entry
- Inspect flexible exhaust couplings for cracks & excessive leakage
- Inspect exterior of exhaust manifolds for oil/fuel slobbering (signs of wet stacking)
- Inspect exhaust silencer for deterioration
Engine Mounts
- Inspect generator set vibration isolators and adjust as needed
Control Panel
- Operational check of warning and fault lamps
- Check proper operation of engine and generator monitoring displays with engine running
- Adjust governor control for optimum performance and frequency
- Adjust voltage regulator for proper voltage
- Check remote annunciator for proper operation (if applicable)
Generator and Voltage Regulator
- Inspect rotor & stator for damage and excessive oil or dirt buildup
- Inspect couplings and guards for loose or missing parts
- Check fastening of generator leads and voltage regulator control wiring
- Strap and tape any leads that are rubbing or have worn insulation
Automatic Transfer Switch
- Check Operation of Transfer Switch
- Transfer Building Load to Generator, Check Operation of Transfer Switch
Operational Checks
- Check Over-crank safety
- Check Over-speed safety
- Check engine low oil pressure safety
- Check engine high water temp safety
- Check alternator output (if applicable)
- Check for unusual noises or vibrations
- Check for proper operation of remote fan motors, thermostats, circulating pumps and solenoids
- Check for oil, fuel and coolant leaks
- Check and record engine oil pressure
- Check and record engine coolant temperature
- Check and record engine rpm
- Check and record generator frequency
- Check and record generator voltage
- Check and record amperage under building load
Upon Completion of Service
- Set all controls to automatic
- Set circuit breaker to correct position
- Return area to condition it was in upon our arrival
Level II Annual Visit
Our technicians will perform all listed in Level I as well as the following:
Lubrication System
- Obtain engine oil sample for analysis
- Change oil filters
- Change engine oil
- Dispose of engine waste oil and filters in a legal and environmentally safe way
Fuel System
- Clean primary fuel filter (if screen type)
- Drain water and sediment from day tank (if accessible)
- Replace primary and secondary fuel filter elements
- Inspect and lubricate governor linkages
Cooling System
- Replace coolant filter (if applicable)
- Check concentration level of coolant conditioner to prevent cylinder liner pitting or solder bloom
Electrical System
- Clean & apply corrosion inhibitors to lead acid battery terminals
- Inspect and tighten starter motor(s) connections and wiring
Generator
- Inspect generator strip heater (if applicable)
- Lubricate generator bearing with Caterpillar bearing lubricant for high speed applications
Turbocharger
- Inspect turbocharger compressor and turbine wheel (if accessible)
- Check turbocharger shaft end play (if accessible)
Automatic Transfer Switch
- Replace Nine Volt Battery in Transfer Switch
- Inspect Transfer Switch for proper operation
- Inspect for burnt contacts and loose connections
Level III - Triennial Visit
Our technicians will perform all listed in Level I & II as well as the following:
Cooling System
- Drain engine coolant system and flush. Install Caterpillar Extended Life coolant, Dispose of old coolant in a legal and environmentally safe manner
- Replace all engine coolant hoses
- Replace engine thermostats and seals
- Replace engine belts
Valve Adjustment
- Inspect valve guides for excessive carbon buildup
- Check and adjust engine valve lash
- Check and adjust fuel injector settings (if applicable)
- Check internal fuel lines for leakage (if applicable)
Electrical System
- Replace Batteries
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