OPERATOR MAINTENANCE Operator maintenance generally includes whatever you have to do to start the generator set and keep it running smoothly and safely. Equipment must be inspected systematically so that defects can be discovered before a serious failure occurs. Operator maintenance includes both prestart checks and operating checks. 

Prestart Checks When starting the generator set and preparing to put it on line, you expect everything to go well. A systematic inspection before start-up will help ensure that the generator will operate properly. To do a prestart checkonthe generator, make the following inspections:

1. Ground cable. See that the cable is intact and that the connections are tight.

2. Engine. Compare the actual lube oil level to the appropriate markings (running level or stopped level) on the dipstick. The stopped level is, of course, appropriate for prestart checks. Add oil as required. Check the engine for loose connections; free action of all moving parts, such as the throttle linkage and the emergency shut-off lever; and for leaking oil, fuel, or coolant.

3. Coolant system. Check that the coolant is at the required level. Add coolant as required. Using an antifreeze solution tester, check that the antifreeze content is sufficient for the existing ambient temperature. (Refer to the manufacturer's manual for the type and quantity of antifreeze. Add antifreeze as required.) Check the hoses and clamps for security.

4. Batteries. Check the batteries for the required electrolyte level; add distilled water or, if distilled water is not available, clean tap water as required to raise the electrolyte level to the slots in the filler wells.

5. Air intake system. Check the air intake system cleaner for excessive dirt (see AIR CLEANER PANEL FILTER, fig. 3-15); remove and clean the air cleaner panels as required. Check the air intake louvers and radiator grille for freedom of motion, and ensure that they are not clogged.

6. Exhaust extension. Inspect the exhaust extension (where extended through the roof or wall) for condition and tightness at the seams and at the point of coupling near the housing.

7. Alternator (fig. 3-16) and belts. Inspect the alternator for signs of overheating, frayed or loose wiring, and corrosion. Inspect the alternator drive belts and fan belts for proper tension and for cracks, fraying, and other signs of deterioration.

8. Breather. Inspect the breather extension for tightness, general condition, and leakage. Check that the breather coupling is not restricting the flow of air and that the breather exit port is clear.

9. Fuel system. Inspect the electric fuel transfer pumps for secureness, tight fittings, signs of damage, corrosion, leaks, and loose electrical connections. Look over the fuel filters and strainers for leaks and tight fittings. Drain water and sediment from the

Figure 3-15.- Generator set, left rear, three-quarters view.

Figure 3-16.- Generator set, right front, three-quarters view. primary filter and strainer and from the secondary filter, using rags to catch the waste.

WARNING

Check the day tank for leakage or signs of obvious damage. Remove the cap from the day tank drain valve and open the valve. Drain the water and sediment into a suitable container, close the valve, and replace the cap.

Always maintain constant metal-to-metal contact between the fuel tank filler neck and the spout of the fuel supply. That will prevent the possibility of sparking caused by static electricity. Inspect the fuel lines, valves, and fittings for bent, leaky, or loose connections and signs of obvious damage. Inspect the fuel tank for leakage or obvious damage.

Service the fuel tank as follows:

Remove the fuel tank filler cap and fill the tank with the proper fuel. Replace the filler cap and wipe up any spilled fuel. Remove the cap from the fuel tank drain valve and open the valve. Permit water and sediment to drain into an approved nonflammable container. Close the drain valve when clear fuel runs out of the tank. Reinstall the cap on the valve. Remove the fuel filler cap and strainer, as shown in figure 3-17. Check the cap vent valve for proper opening and closing. Inspect the strainer for holes, breaks, and tears. Also, inspect the parts for cracks, breaks, and other damage. Install the cap and strainer, as shown in figure 3-17.

NOTE: The fuel tank filler cap vent valve must be in the open position during operation of the generator set. 10. Ether system. Inspect the ether system (used to aid cold-weather starting). The ether cylinder is strapped to the day tank. Look for broken wires, loose connections, corrosion, and any other signs of obvious damage. 11. Set controls and instrumentation. Inspect meters and gauges at the control cubicle (fig. 3-15) for bent pointers, broken glass, unreadable dial faces, and restricted movement of pointers. Clean gauges and meter faces with a lint-free cloth.

Check for broken indicator lenses and for unreadable lettering. Set the panel light to ON; the panel lights should light. Check all switches for positive action; each switch should snap from one position to the next.