ROUTINE MAINTENANCE

Routine maintenance is a type of maintenance process carried out in generating set in order that such generating set can meet its performance standard and also to prevent the plant from frequent break-down.

Routine maintenance is usually on time schedule of a particular maintenance operating function required to be accomplished in a given time in order that such electric generating plant can operate at 100% performance standard.

In order to obtain the above mentioned performance standard of the generating set plant, a scheduled routine maintenance is necessary.

In the scheduled routine maintenance, it is of vital important to record the maintenance operation and the time that such maintenance was carried out in a logbook or in the record book.

The use of the maintenance log record book is to act as a guide to the maintenance supervisor engineer in carrying out maintenance operations.

MANUFACTURER’S ROUTINE MAINTENANCE MANUAL

Normally, the manufacturer during purchase usually gives scheduled routine maintenance manual handbook.

Read the routine maintenance manual carefully and strictly adhere to it.

When you have problems in interpreting the manual’s instruction, write for simple clarification from the manufacturer.

However, where there is no maintenance manual handbook, the under-listed schedule routine maintenance mentioned below will be of useful purpose.

SCHEDULED ROUTINE MAINTENANCE

The scheduled routine maintenance could be carried out as follows:

DAILY: - Top-up water in the reservoir/radiator – water coolant

* Check and top-up engine oil

* Clean battery’s terminals

* Check oil-diesel - level

* Manually primes the fuel system to fill the fuel filters to eliminate air from the fuel system.

* Note any oil leakage run before and while the machine runs.

WEEKLY: - Apply Grease oils to all joints and bearing housings.

* Re-adjust belts, coupling belts and nuts.

* Top-up battery’s electrolyte and grease its terminals.

* Measure voltage across cables terminals.

* Check radiator waters temperature and compare with thermostat opening temperature.

MONTHLY: - Change engine oil after running engine for 12 hours per

day or 800hrs.

* Top-up radiator/reservoir adds coolant as recommended by the maintenance engineer or specialist.

* Adjust/change contact breaker point in case of petrol engine.

* Clean change spark plugs

* De-grease and grease alternator’s shaft bearings

* Clean/change fuel and oil filters after running engine for 12 hours per day.

* Adjust top-cylinder and valves

Change belt at every 2000 hrs.

3 – 6 MONTHLY:

* Clean injector nozzles and re-calibrate

* Clean flush fuel tank

* Clean flush water radiator/reservoir

* Clean/change carbon brushes

* Clean/change bushing

* Adjust timing chain

* Test AVR performance standard

* Clean radiator’s fins and fan blades and change fan belts

* Change spark plug

* Change contact breaker point

* Fasten/tighten all bolts and nuts

* Clean/change pitted cable joints and connections

* Change any week insulators

* Use compressed air to clean alternators and couplings housing.

Note: 1. Service in engine 300HRS after overhauling-to aid “Bedding-in” of changed parts.

2. Do not use Electrolyte to top-up Batteries instead use distilled water.

3. Top-up batteries only when machine is running