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The Benefits/Need of Preventive Maintenance

Only with preventive maintenance we can ensure the machines will work hour
by hour, day after day, and continue to operate to their full life expectancy.
1. Avoiding Downtime
One of the foremost benefits of preventive maintenance is that it makes the
equipment run smoothly and more efficiently and decreases occurrences of
system downtime. As we understand the downtime can be a very costly
problem because when the machines fail to function, it halts production.
A company that fails to enact timely maintenance protocols runs the risk of
encountering performance issues with greater frequency. Such occurrences
are hard to predict, but can arise at the worst moments, such as when a high-
cost production is underway with a set deadline. To be on the safe side, we
need to perform maintenance as scheduled without skipping a date, even on
days when everything seems to be running flawlessly with no conceivable
problems in sight.
2. Saving Money by Avoiding Costly Emergency Repairs
With reduced occurrences of downtime and parts failure in the system, we
save money. As such, we profit both ways — through increased productivity
and reduced overhead.
Without maintenance, the costs involved in the repair of an equipment and its
peripheral parts can take a huge chunk from a company’s annual earnings.
When we conduct timely maintenance, we’ll reap savings we can pass on to
the company through higher wages and less expensive products.
3. Increase Equipment Life and Efficiency
Of course, the greatest benefit of preventive maintenance is that it increases
the life and efficiency of the machine itself and the system as a whole. When
we compare the profits of companies that implement responsible system
maintenance with those that do not, we are liable to see major differences in
productivity.
4. Safety and Compliance
Preventive maintenance through a qualified expert, ensures that all safety
hazards are identified and eliminated. This keeps us, our equipment, and our
employees safe from harm. It can ensure that our equipment complies with all
relevant safety and environmental regulations. This can save us from costly
fines or penalties.

Degreasing
The objective for a degreasing is to remove the offending soil quickly, avoiding
as much wiping and scrubbing as possible. A degreaser is a cleaner designed
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to remove grease, oils, cutting fluids, corrosion inhibitors, handling soils,

fingerprints, and other contamination common in assembly, stamping and
other metal fabrication in refineries, motor repair shops, airplane hangars,
and factories, etc. Degreasers go by a number of different names including
precision cleaner, maintenance cleaner, as well as several specific for
automotive repair such as carb cleaner or brake cleaner.

Degreasing solvents are commonly packaged as an aerosol for convenience.

Aerosols have the added advantage of providing a forceful spray that creates
agitation and which penetrate small crevices. Water-based degreasers are
common in a trigger sprayer, or in gallon or drum containers for immersion or
batch system cleaning. Specialized equipment like ultrasonic or vapor
degreasers are available for more automated cleaning. These processes are
repeatable, so better suited for more critical cleaning applications, like
aerospace or medical appliance maintenance.

Factors to consider when selecting a degreaser

There are several factors that can have a big impact on performance and safety
in choosing the proper degreaser for a given application in an environment:

Flammability – Degreasers often contain very flammable alcohols and

hydrocarbon solvents. They can be cheap and effective, but can be dangerous
without proper ventilation, or around open flames, sparks (e.g., from welding),
or hot surfaces. Non-flammable degreasers avoid these safety issues but are
generally more expensive. In addition, some non-flammable cleaners can be
very toxic, containing hazardous solvents like Perchloroethylene,
trichloroethylene or n-propyl bromide. High flashpoint (often called “high
flash”) solvents have vapours that are less likely to combust in normal ambient
temperatures (say below 140°F/60°C).

Dielectric strength – If you plan to work on powered equipment, or need to

switch it on before the solvent has flashed off, consider a degreaser with a high
dielectric strength. Make sure you know the amperage and voltage of the
circuits you are trying to clean before spraying anything onto the circuits, and
evaluate the suitability of any cleaner in your application. Dielectric strength
is the maximum electric field that the material can withstand before its
insulating properties break down. The lower the dielectric strength, the more
likely it will breakdown and allow electricity to flow through and short out.

Plastic / rubber compatibility – Care needs to be taken when cleaning plastic

or components, rubber gaskets and seals. If the degreaser is incompatible with
the plastic, it can craze (create small cracks), embrittle, or soften the material.
Rubber seals may swell, shrink, or dissolve. A new degreaser should always
be tested before being used broadly.
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Toxicity – N-Propyl Bromide (nPB), Trichloroethylene (TCE) and

Perchloroethylene (Perc) are highly toxic chemicals commonly used in
degreasers to provide cleaning performance in a non-flammable formula.
There are documented court cases where workers suffered major health effects
when exposed to high levels of these chemicals. Workers reported headaches,
dizziness, and even loss of full body control. There are also possible links to
reproductive problems and cancer. All of this has caused maintenance
facilities to reconsider their solvent choices, especially with manual cleaning
when exposure tends to be higher.

Environmental issues – Volatile organic compounds (VOCs), solvents that

add to smog, or solvents with high global warming potential (GWP) have been
a focus of regulators. Some state (e.g. CARB, the California Air Review Board),
municipal, and even industry-specific regulations restrict the use of high VOC
or high GWP materials.

Degreasing Methods

Manual Degreasing Methods

It is common to clean grease and oil off of parts at a benchtop, work station,
or in the field, which generally requires a manual cleaning method. Manual
cleaning methods are more labour-intensive and less repeatable, so results
vary from operator to operator.

Aerosol – Aerosol packaging is a sealed system, which ensures fresh solvent.

The spray pressure and application pattern add agitation, like a scrubbing
action. A straw attachment is generally included to spray into tight areas or
for focused application.

Trigger spray – Spray bottles are common for water-based cleaners and
isopropyl alcohol (IPA), but not for aggressive solvent cleaners.

Liquid immersion – The part can be immersed in a tray or bucket of solvent

cleaner, and then wipes, swabs and brushes scrub off tough soils. Heating the
solvent can improve the cleaning performance, but for safety’s sake, should
only be done with non-flammable degreasers.

Pre-saturated wipes and swabs – For added convenience, wipes are

available pre-saturated with a mild solvent like isopropyl alcohol.

Automated or Semi-Automated Degreasing Methods

For higher-volume manufacturing or if minimal variability is required, like in

critical applications like aerospace and medical, more automated cleaning
methods are available.
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Ultrasonic – Ultrasonic cleaning equipment use sound waves to break apart

grease and lift it off the part. Ultrasonic equipment usually has the option of
heating the cleaning material to increase cleaning performance. Cross-
contamination can be a concern, so change the solvent regularly. Also
consider that ultrasonic cleaning might be too rough on sensitive parts or
materials.

Vapour degreaser – Vapor degreasing is the best cleaning process for critical
cleaning, like in aerospace and medical applications. Parts are submerged in
a sump of boiling solvent or in a rinse sump with ultrasonics and rinsed in
solvent vapours. Specialized azeotropes or near-azeotrope solvents are
required to avoid problems as the solvent is boiled and reconstituted
repeatedly.

Batch washer – Parts are either stationary in a rack or run on a conveyor,

and the degreasing agent (often water-based and highly caustic) is sprayed
over the parts.

Overhauling of Electrical Motor

(Reference: IKM Elektro, Norway)

In the workshop the standard method of overhauling of electrical motor will

be as follows:

1. Inspection/diagnosis:

• Disassembly, cleaning, evaluation and diagnosis.

• Finally, an inspection report is produced.

Based on the findings and recommendations from the inspection report, and
with agreement from the customer to rectify nonconformity, the following
elements may apply:

2. Standard overhaul:

• Replacement of bearings and seals, cleaning of junction boxes, and

standard surface treatment.

3. Rewinding:

• New winding, vacuum pressure impregnation (VPI) and drying.

4. Ex d / Ex D repair:

• Repair of ‘Ex d’ or ‘Ex D’ flameproof/dustproof joint on motor.

5. Ex e junction box:
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• Renewal of ‘Ex e’ junction box on motor, including new gaskets and

necessary accessories.

6. Fan and fan cover:

• Repair or replacement of the corresponding fan and fan cover.

7. NORSOK surface treatment:

• Perform additional surface treatment in accordance with NORSOK M-

501(developed by Norwegian petroleum industry)

8. Recertification:

• Recertification, documentation and new rating plate

9. Additional mechanical repair:

• Varying degrees of necessary machining, repair of bearing housing, etc.

• When overhaul and repair work is completed, the machine is assembled
and verified in the last phase;

10. Assembly and completion test:

• Assembly, inspection and test, repair report and documentation, and

preparation for transport.

Steps/procedure for periodic and preventive maintenance of

Machine tools (CNC Machine)
(Reference: Machine Tool Technologies, UK)
1. Daily care
• Check hydraulic pressure and ensure it remains at 4.5 MPa
• Check hydraulic fluids
• Check grease and chuck pressure
• Check lube level and ensure it’s at the right operating level
• Clean out chips
• Clean the window of the door
• Wipe down stainless-steel covers and lubricate using hydraulic oil
2. 3-months or 500 hours
• Check the chain on the chip conveyor and grease it
• Check, clean or replace the filters on the coolant tank
3. 6-months or 1000 hours
• Clean the coolant tank
• Remove and clean chuck and jaws
• Drain and clean the hydraulic tank and replace the hydraulic oil
• Change the line and suction filters
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• Clean the radiator and straighten radiator fins

• Drain and clean lubrication unit and add fresh lube
• Drain, clean, refill cooling unit
• Check and adjust your machine levelling
• Inspect, clean, and replace wipers
4. Yearly check or 2000 hours
• Check headstock for taper
• Check spindle for radial and end play
• Check chuck cylinder for run out
• Check tailstock for taper
• Check the turret parallelism and inclination
• Run backlash program to check the backlash in the X and Z axis
• Check and adjust the X and Z axis gibs

Steps/procedure for periodic and preventive maintenance of

Air compressors
(Reference: Quincy Compressor, Alabama, USA)

On an industrial air compressor, preventive maintenance is crucial to ensure

the functionality of the system and its various attachments. The key parts to
check include the filters, vents, belts and bearings, all of which could become
troublesome to the system if dirt and grime build up. Moreover, you must
apply and reapply lubricant at timely intervals on all applicable parts of an air
compressor. The following components are the most important to inspect and
clean and/or lubricate according to schedule:

1. Air Filter

The purpose of an air compressor is to produce clean, pure, compressed air

that will ultimately power numerous functions. To ensure the quality of air
that comes out at the end, the ambient air that goes into the compressor must
be filtered of impurities before it leaves the machines. None of that could be
possible without a clean air filter.

If the air filter is dirty, impurities and particulates could corrupt the
compressed air and degrade the quality of end-point applications. Therefore,
clean the air filter regularly. Change it out at regular intervals, which vary
based on the environment.

2. Oil Filter

Oil can degrade the quality of compressed air if it passes through the system
and gets carried to the end of an application. Some of the worst-affected
processes would include pneumatic spray painters, air cleaners and anything
else where oil could corrupt the surface in question. Therefore, it is crucial to
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ensure oil, when present in the system, is removed from the compressed air
before the air leaves the machine.

Check oil filters weekly, regardless of whether the compressor is lubricated or

non-lubricated. Moreover, replace the oil filter entirely at recommended
intervals, which can range from 4,000 to 8,000 hours of use depending on
your unit. If the oil filter gets heavily covered in oily residue before that time,
replace it sooner.

3. Lubricant

Lubricant is one of the most vital elements in the function of an air

compressor. On all the internal metal parts and joints, lubricant allows for
smooth, non-corrosive movement. Without lubrication, tension occurs
between the touching metal surfaces, which leads to the corrosion of parts
and joints. Once corrosion takes hold, rust is liable to spread and eat through
certain mechanical parts.

However, even when lubricant is present, it can lose its viscosity and become
corrosive if it gets too old. Check the lubricant level daily to ensure the health
of your air compressor. Every three to six months, wipe off old lubricant and
reapply a fresh coat. Each time you replace the lubricant, be sure you also
change out the separator element.

4. Motor Bearings

For a motor to run, the bearings must have proper lubrication. The tiny metal
balls are constantly rolling against each other, as well as against the interior
walls of the round encasement. Consequently, rust could form on the bearings
without proper lubrication. If rust forms, the bearings will gradually slow and
ultimately become stuck in place. When this happens, the motor fails.

To protect the health and performance of the air compressor motor, grease the
bearings every 4,000 hours. Be sure to inspect the bearings at quarterly
intervals between each greasing to ensure they remain sufficiently lubricated.

5. Belts

For an air compressor to go about its internal motions, it is crucial for the
belts to have proper tension. The rubber of each belt must also remain firm,
yet flexible, to ensure balanced movement between the pulleys of connected
parts. Over time, however, the rubber on a belt will inevitably wear down and
crack in certain places. Therefore, it is crucial to replace the belts before they
lose their tension or, even worse, snap in the middle of an operation.

Inspect each belt once per week to verify they are free of wear. Adjust the
tension if necessary and replace each belt once wear takes hold.
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6. Intake Vents

An air compressor performs the magic feat of transforming ambient air into
something that can power heavy-duty machinery and effectively serve as a
replacement for electrical power. That said, the compressor itself can only do
so much to turn mundane air into something powerful. While internal
components do their job to purify the air for end-point use, that job is harder
for the machine to perform if the intake vents become lined with dirt and
grime.

To ensure the incoming air remains as clean as possible and to prevent dirt
from getting sucked into the system, inspect the intake vents weekly and clean
them when necessary.

7. Other Parts and Things to Check

In addition to the periodic cleaning, lubrication and replacement of parts,

check various points along the air compressor and its attachments at regular
intervals. Inspect the following on a weekly basis:

• Air dryer performance

• Amps
• Oil level
• Temperatures
• Vibration
• Voltage

Inspect the air compressor for signs of oil or air leaks. Also check the
pneumatic hoses for air leaks, as leakage severely reduces the efficiency of an
air compressor. Furthermore, make sure the coolers are free of dirt.

Maintenance Schedule

When we make an air compressor preventive maintenance checklist, we need

to first take into account the type of compressor in question. Most
compressors need preventive maintenance on various system parts at
intervals that range from daily to annually.

1. Air-Cooled Reciprocating Compressor

Daily: Perform the following steps every day, or after every eight hours of use.

• Check the lubricant level to verify it never drops below the mid-range of
the bayonet gauge. If the lubricant becomes discoloured, empty and
refill it.
• Empty water out of the receiver tank.
• Visually inspect the compressor and verify the safeguards are in place.
• Check for leaks and vibrations.
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Weekly: Perform the following steps every week, or after every 40 hours of use.

• Check the pressure relief valves.

• Clean the surfaces of the compressor and intercooler.
• Inspect the compressor and hoses for air leaks.
• Clean out the air intake filter.
• When the weather is humid or the environment is dusty, perform the
preceding steps twice weekly, or every 20 hours.

Monthly: Every month, or after every 160 hours of use, inspect the belt
tension inside the air compressor.

Quarterly: Every three months, or after every 500 hours of use, perform the
following steps.

• Change out the lubricant.

• Inspect the lubricant filter, and change the oil filter if applicable.
• Inspect the torque on the pulley nuts and screws.

Biannually: Every six months, or after every 1,000 hours of use, perform the
following steps:

• Change out lubricant — this step also applies if the lubricant is

synthetic, which lasts twice as long as regular.
• Check valves for signs of leaks or carbon prints.
• Clean the crankcase.
• Clean the strainer screen of the crankcase.
• Examine the motor-area contact points and pressure switch diaphragm.

2. Lubricant-Injected Rotary Compressor

Daily: Each day, or after every eight hours of use, do the following tasks.

• Monitor all gauges and indicators for normal operation.

• Check fluid level.
• Observe for fluid leaks.
• Observe for unusual noise or vibration.
• Drain water from air/fluid reservoir.

Monthly: Every four weeks, perform the following.

• Service air filter as needed. This should be a daily or weekly task if

extremely dirty conditions exist.
• Clean aftercooler and fluid cooler fins, for air-cooled units only.
• Wipe entire unit down to maintain appearance.

Biannually: Every six months, or after every 1,000 hours of use, perform
these tasks.
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• Take fluid sample.

• Change fluid filter.
• Check pressure relief valve.

Periodically/Yearly: Complete these tasks each year.

• Go over unit and check all bolts for tightness.

• Change air/fluid separator.
• Change air filter.
• Lubricate motors.
• Test pressure relief valve for proper operation.
• Check safety (HAT) shutdown system.

3. Lubricant-Free Rotary Screw Compressor

Daily: Each day, or after every eight hours of use, do the following tasks.

• Check readings on display.

• Check if condensate is discharged during operation.
• Drain condensate manually (when applicable).
• On compressors with integrated dryer, check the dew point

Every Three Months: Every three months, or after 500 hours of running use,
do the following.

• Check the pressure drop over the (optional) filters.

• Inspect the air inlet filters: check for cleanness and damage. Replace a
dirty or damaged filter with a new one.
• Check the coolers. Clean by air jet if necessary.

Biannually: Every six months, or 1,000 hours, perform these tasks.

• Operate the safety valve.

• Clean the compressor.
• On compressors with an integrated dryer, brush or blow of the finned
surface of the condenser. Inspect and clean the electronic drain.

Periodically/Yearly: Perform these tasks every year.

• Replace the air inlet filters.

• Test the safety valves.
• Have temperature protection and motor overload tested.
• Check tension and condition of the V-belts.

Every Two Years: Every two years, complete the following tasks:

• Replace V-belt(s).
• Replace the check valves.
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Steps/procedure for periodic and preventive maintenance of

Pumps
(Reference: JEE Pumps, Ahmedabad)
The strength and effectiveness of your pump preventive maintenance plan
depending on how robust your checklist is. While you would want to include
all possible checks in the plan, it is impractical and inadvisable for all routine
checks. Therefore, the checklist is divided based on the frequency of checks
making it more sustainable and effective:

Daily Check:

• Check pump exterior for any leaks

• Clean pump and nearby region to remove any debris
• Check for excessive pump vibration or unusual noises
• Check for foaming or oil discolouration
• Check bearing temperature for overheating
• Inspect all gaskets to ensure there are no oil leaks
• Inspect self-flush pumps is applicable
• Clean bearing covers if needed
• Check pump cooling system

Monthly Check:

• Top up oil to bearing reservoirs if needed

• Clean oil bulbs and level windows
• Check the pump guards and replace them if needed
• Clear out dirt and debris from bearings and grease them
• If applicable, check that the hydraulic governors are working properly
• Check overall pump systems for leaks and clean the pumping system
surroundings

Quarterly Check:

• Check pump and motor for any vibration damage

• Grease bearings as per need
• Change the oil in bearing systems
• Check suction, discharge and head pressure
• Check all hold down bolts for tightness to reduce vibration
• If needed, inspect shaft pump alignment
• Apply rust preventive coat to prevent corrosion

Annual Check:

• Check axial float of the pump along with the driver shaft
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• Remove mechanical cover and inspect the entire pump arrangement

• Check disc couplings for damage
• Inspect coupling alignment
• Perform the Overspeed test for the pump
• Inspect seal chamber for scoring and pitting
• Check oil levels and refill as per need
• Inspect impeller for erosion and replace if needed

Please note that the pump preventive maintenance schedule for each pump
would depend on its design and application, and hence you should always
consult the pump manufacturer for the same. However, the above checklist is
a general checklist that can guide the process of pump preventive
maintenance. A well-maintained pump will last longer and perform better than
one not correctly cared for.

Steps/procedure for periodic and preventive maintenance of

Diesel Generator
(Reference: Mahindra, Chennai)

Every business needs a standby diesel generator for backup power and the
generator gives more power to the whole unit. Also considered to withstand
heavy loads for long hours and start off the power supply on the full load
within minutes and must be regularly maintained to ensure they provide
quality power throughout their service life.

The engine is the core component of the generator. If you want to run your
generator well without any mechanical issues or electrical issues must
maintain the generators carefully. Once you start running the diesel
generator, the exhaust system, fuel system, DC electrical system, and engine
require close monitoring for any leaks that can cause hazardous occurrences.
The very essential one is to maintain the internal combustion engine. A
backup generator is mandatory in the industry and also proper maintenance
of diesel generators is important so take a look at these steps.

1. Lubrication Service

• The Engine oil must be checked while powering off the

generator at regular intervals using a dipstick.
• Allow the oil in the upper portion of the engine to drain back
into the crankcase and follow the engine manufacturer’s
recommendations for API oil classification and oil viscosity.
• Keep watching the oil level as near as possible to the full mark
on the dipstick by adding the same quality and brand of oil.
The oil and filter must also be changed at particular time
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intervals. Check regularly with the engine manufacturer for

procedures for draining the oil and replacing the oil filter and
their disposal is to be done appropriately to avoid
environmental damage or liability.

2. Cooling System

• Check the coolant oil level during shutdown periods at the specified
interval.
• Must be noted these points “remove the radiator cap after allowing the
engine to cool, and, if necessary, add coolant until the level is about 3/4
in” And a More critical role in balancing diesel engines require a
balanced coolant mixture of water, antifreeze, and coolant additives.
• Examine the exterior of the radiator for obstructions, and remove all
dirt, grimy or foreign material with a soft brush or cloth with caution to
avoid damaging the fins.
• If available means, use the low-pressure compressed air or a stream of
water in the opposite direction of normal airflow to clean the radiator.

3. Fuel System

• This is the important point when it comes to the maintenance of diesel

generators. Diesel is subject to contamination and corrosion within a
period of time is one year, and therefore regular generator set exercise
is highly recommended to use up stored fuel before it degrades.
• The fuel filters should be drained at the designated intervals due to the
water vapor that accumulates and condenses in the fuel tank.
• Better check regularly testing and fuel polishing may be required if the
fuel is not used and replaced in three to six months.

4. Testing Batteries

• If the battery’s charges reach the dead-end level is a common cause of

standby power system failures.
• The battery must be kept fully charged and well-maintained at an all-
time 40% to 100% to avoid regular testing and inspection to know the
current status of the battery and avoid low battery levels.
• Testing batteries: Merely checking the output voltage of the batteries is
not indicative of their ability to deliver adequate starting power. As
batteries age, their internal resistance to current flow goes up, and the
only accurate measure of terminal voltage must be done under load. On
some generators, this indicative test is performed automatically each
time the generator is started. On other generator sets, use a manual
battery load tester to attest the condition of each starting battery.
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• Cleaning batteries: Keep the batteries clean by wiping them with a damp
cloth whenever dirt appears excessive. If corrosion is present around
the terminals, remove the battery cables and wash the terminals with a
solution of baking soda and water (¼ lb baking soda to 1 quart of water).
Be careful to prevent the solution from entering the battery cells, and
flush the batteries with clean water when finished. After replacing the
connections, coat the terminals with a light application of petroleum
jelly.
• Checking specific gravity: In open-cell lead-acid batteries, use a battery
hydrometer to check the specific gravity of the electrolyte in each battery
cell. A fully charged battery will have a specific gravity of 1.260. Charge
the battery if the specific gravity reading is below 1.215.
• Checking electrolyte level: In open-cell lead-acid batteries, verify the level
of the electrolyte at least every 200 hr of operation. If low, fill the battery
cells to the bottom of the filler neck with distilled water.
5. Routine Engine Exercise
• Regular exercising keeps the engine parts lubricated and thwarts
oxidation of electrical contacts, uses up the fuel before it deteriorates,
and helps to provide diesel generator maintenance to reliable engine
starting.
• Engine exercise is recommended to be executed 15 days once or 25 days
once for a minimum of 30 min

6. Keep your Diesel Generator Clean

• Maintain your engine all-time nice and clean because it will be taken
care of Oil drips and other issues. Check day-by-day hoses and belts
that are in good condition or not.
• Frequent checks can keep better conditions and other nuisances from
nesting in your equipment. However, the generator users thought is a
generator set that is rarely used and might not need a lot of care. So,
please avoid this kind of thought and keeps regular maintenance of
diesel generators based on manufacturer guidelines.
6. Exhaust system inspection
• In case of any leaks along the exhaust line which usually occur at the
connection points, the welds, and the gaskets. Find the place of
leakages and repair them immediately by a technician.

Maintenance Schedule

Here are a few tasks you’ll want to consider for a preventive diesel generator
maintenance checklist.

Maintenance with each use

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• General inspection
• Test batteries
• Check intake and exhaust
• Manual start
• Engine exercise
• Adjustments

Weekly:

During weekly maintenance, we should;

• Do a visual inspection
• Run the generator
• Check fluid levels
• Check for leaks
• Check auto mode
• To exercise the generator, check the fuel level and start the motor, then
leave it running for 30 minutes or so to make sure it’s working properly.
• Once you’ve started the generator, check the exhaust system. Examine
the muffler, manifold, and exhaust pipe for leaks, and be sure the pipes
aren’t overheating any nearby components. Be sure the engine is
purring; look and listen for signs of a misfire, such as vibrations, smoke,
or power fluctuations.

Monthly

• Inspect battery cables and electrolyte levels monthly. Remove the plastic
tops from the cell ports and use a toothbrush and baking soda to clean
away corrosion or dirt.
• Check engine coolant and oil levels (the oil should be close to full
without overflowing), and look for signs of leaks in the oil or coolant
lines. Also check the coolant concentration: It should be roughly half
purified water and half antifreeze. If you live where freezing is a risk, the
antifreeze level can be as high as 60% (but no higher).
• Use a load bank to conduct a load test monthly for at least 1 hour to
make sure everything is in running order. You should also do an
electrolyte specific gravity test or electrical conductance test at this time.
• Clean generator
• Clean surrounding area
• Check engine coolant levels
• Check battery charger
• Check engine oil levels
• You should change the oil after 100 hours of use, and sooner the first
time. It’s recommended that you do the first oil change after 30 hours.
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Annual

• Once a year, focus on the generator’s electrical system. Turn off all
power sources to conduct an internal inspection. Examine the AC wiring
and alternator, making sure it’s free of dirt.
• Inspect the air intake system and replace the air filter. Check the air
induction piping while you’re at it. You’ll also want to make sure the
crankcase breather is in good shape: that’s the generator’s source of
fresh air, which allows it to sweep fumes out of the crankcase.
• Change oil
• Change oil filter, fuel filter, and air filter
• Flush cooling system
• Inspect wiring/electrical system
• Change spark plugs
• Test transfer switch
• Also, check the transfer switch to make sure it’s functioning to transfer
your home’s power source from the grid to the generator during an
outage. Finally, to simulate operation during a power outage, perform a
functional test.

Repair Complexities
In maintenance systems, complexity can be defined based on technical and
managerial aspects of a maintenance project. Because relative complexity
between two projects can be used as a standard/measuring scale for resource
allocation between them, quantifying the complexity becomes important.

In uncertain situations, a fuzzy graph-based models are used that determines

relative complexities of maintenance projects based on experts’ opinions with
respect to technical and managerial aspects.

The complexity of a maintenance project can be investigated through time to

repair (TTR). Performing statistical analysis shows that human cognition and
project complexity have significant influence on TTR. These influential factors
can be studied by a learning curve. A project complexity can be derived from
the learning curve at the breakpoint time. Taking into account human
cognitive abilities, the breakpoint indicates the required number of trials in
order to reach mastery level for performing certain tasks unsupervised.
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Figure: Learning curve with breakpoint

Repair Cycle
Repair cycle refers to the stages through which a repairable item passes from
the time of its removal or replacement until it is reinstalled or placed in stock
in a serviceable condition.