Maintenance Schedule2.pdf
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- Solicitation number
- ITN 591 260000000037 1
- Issued by
- Michigan
About this file
This file is an Owner's Manual Maintenance Schedule for Stationary Industrial Generators applicable to the State of Michigan's Intermediate Warranty Services for Permanent Generators contract opportunity. The document outlines comprehensive maintenance protocols for industrial generators, establishing a tiered maintenance schedule based on operating hours and time intervals. The maintenance program is divided into five levels: Extended Run-Time Maintenance (every 24 continuous operating hours), Maintenance Level 1A (one-time at 50 hours/3 months), Maintenance Level 1 (monthly or every 24 hours), Maintenance Level 2 (semi-annual or every 125 hours), Maintenance Level 3 (annual or every 250 hours), and Maintenance Level 4 (bi-annual or every 500 hours). Tasks range from basic visual inspections and fluid level checks that can be performed by Authorized Operators to more complex procedures requiring certified Industrial Authorized Service Dealers (IASD), including oil and filter changes, belt replacement, cooling system flushing, and load testing.
The maintenance schedule specifies detailed procedures for monitoring engine condition, fuel systems, battery electrolyte levels, hose integrity, and electrical connections, with particular provisions for both gaseous and diesel units. Annual maintenance includes 60-minute load exercises, while bi-annual maintenance requires 120-minute load exercises using load banks to achieve full rated capacity. All maintenance activities require documentation on completion checklists, including date, hour-meter readings, technician signatures, and records of fluids added and discrepancies identified. The document provides standardized data collection fields for recording unit voltage, frequency, kilowatt, and kilovolt-ampere measurements during operational tests, establishing a systematic framework for warranty service delivery and equipment performance tracking throughout the generator's operational life.
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Text version
Owner’s Manual for Stationary Industrial Generators 25
Maintenance
Extended Run-Time Maintenance Checks These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices contained in the owner’s manual.
IASD/Authorized Operator Maintenance Tasks.
Perform steps 1 through 8 and 11 every 24 continuous operating hours.
Task Completed Date/Initials
1. Before shutting the unit down, perform a thorough visual inspection for leaks, loose components or connections, excessive apparent wear or damage. Any discrepancies noted should be further inspected and corrected while the unit is shut down.
2. Shut the unit down per the procedure in the owner’s manual.
3. Check the engine oil level. The level should be between the low and full markings on the dipstick. Adjust as necessary.
4. Check the engine coolant level. Make sure the level in the coolant catch tank is between the cold and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate coolant.
5. Visually inspect the engine accessory drive belts and fan coupling device (if equipped) for correct tension and any signs of abrasion, wear, deterioration or damage. Correct as necessary.
6. Visually inspect all hoses and connections (exhaust, intake, coolant, block heater, fuel lines and filters, oil filters, etc) for leaks, tightness, signs of deterioration, wear, or damage. Correct as necessary.
7. Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as necessary.
8. Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.
9. Gearbox Equipped Only: Check the gearbox oil level every 100 operating hours. Adjust as necessary.
10. Weekly When Operating: Check the battery electrolyte level (if accessible). Adjust as necessary (add only distilled or deionized water to replenish battery cells).
11. Return the unit to operational condition and restart. Check unit voltage and frequency. Visually inspect the unit for leaks, loose connections or components. Place the unit back in service.
Date inspection Completed: Unit Hour-Meter Reading:
IASD/Authorized Operator signature signifying inspection complete:
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.
26 Owner’s Manual for Stationary Industrial Generators
Maintenance Level 1A One Time at 50 Hours / 3 Months. These maintenance tasks must be performed by an IASD. Comply with all safety notices contained in the owner’s manual. Some of these tasks require the use of the applicable engine service manual.
IASD Tasks.
Perform these tasks in addition to the regularly scheduled Monthly maintenance tasks
Task Completed Date/Initials
1. Disable the unit from operating per the procedure found in the owner’s manual.
2. Check engine valve clearance (valve lash) as specified in the engine service manual.
NOTE: This is NOT required for engines with hydraulic lifters. Check the engine service manual.
3. Change the engine oil.
4. Change the oil filter(s).
5. Check the engine accessory drive belts and fan coupling device (if equipped) for correct tension, wear or abrasion, deterioration, or damage. Correct as necessary.
6. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.
7. Check wiring connections (at MLCB, customer connections, control terminal strips, battery, etc) for loose connections, corrosion or damage. Correct as necessary.
8. Return the unit to operational condition and test. Place the unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Exercise the unit against the load for 15 minutes, visually inspecting for leaks, loose connections or components, and any abnormal operating conditions. Record the unit voltage, frequency, kW and kVA while running. Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.
Voltage: Frequency: kW: kVA:
9. If the control has alarm and/or event or run logs, record the alarm and event logs to a history file for the unit.
10. Return the unit to operational condition.
Date inspection Completed: Unit hour Meter Reading:
IASD signature signifying inspection complete:
Owner’s Manual for Stationary Industrial Generators 27
Maintenance Level 1 - Monthly or Every 24 Hours These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices contained in the owner’s manual.
IASD/Authorized Operator Maintenance Tasks Task Completed Date/Initials
1. Disable the unit from operating per the instructions in the owner’s manual.
2. Check the engine oil level. The level should be between the low and full markings on the dipstick. Adjust as necessary.
3. Gearbox Equipped Only: Check the gearbox oil level. Adjust as necessary.
4. Check the engine coolant level. Verify the level in the coolant catch tank is between the cold and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate coolant.
5. Check the battery electrolyte level (if accessible). Adjust as necessary (add only distilled or deionized water to replenish battery cells).
6. Check the battery terminal posts, connections, cables and charger connections, and battery hold-downs for signs of corrosion, looseness, etc. Remove, clean and tighten connections as necessary.
7. Check operation and condition of the battery charger. Check operation and condition of optional block heater, oil sump heater, and battery warmer (if equipped). Correct discrepancies as necessary.
8. Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as necessary.
9. Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.
10. Perform a 5 minute, no-load operational test of the unit. Check unit voltage and frequency.
Visually inspect the unit for leaks, wear, damage, loose connections or components, and corrosion. Correct as necessary.
Voltage: Frequency:
11. If the control has alarm and/or event or run logs, record the alarm and event logs to a history file for the unit.
12. Return the unit to operational condition.
Date inspection Completed: Unit hour Meter Reading:
IASD/Authorized Operator signature signifying inspection complete:
28 Owner’s Manual for Stationary Industrial Generators
Maintenance Level 2 - Semi-Annual or Every 125 Hours These maintenance tasks must be performed by an IASD. Perform these tasks every six months or every 125 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly maintenance tasks. Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable engine service manual.
IASD Tasks Task Completed Date/Initials
1. Disable the unit from operating per the procedure found in the owner’s manual.
2. Check the engine accessory drive belts and fan coupling device (if equipped) for correct tension, wear, abrasion, deterioration, or damage. Correct as necessary.
3. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.
4. Load test the battery or test electrolyte levels (specific gravity) with a hydrometer.
5. Return the unit to operational condition and test. Place the unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Exercise the unit against the load for 15 minutes, visually inspecting for leaks, loose connections or components, and any abnormal operating conditions. Record the unit voltage and frequency while running.
Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.
Voltage: Frequency: kW: kVA:
6. If the control has alarm and/or event or run logs, record the alarm and event logs to a history file for the unit.
7. Return the unit to operational condition.
Date inspection Completed: Unit hour Meter Reading:
Owner’s Manual for Stationary Industrial Generators 29
Maintenance Level 3 - Annual or Every 250 Hours These maintenance tasks must be performed by an IASD. Perform these tasks every 12 months or every 250 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly and Semi-Annual maintenance tasks.
Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable engine service manual.
IASD Tasks Task Completed Date/Initials
1. Disable the unit from operating per the procedure found in the owner’s manual. Some of the following tasks will require the use of the applicable engine service manual.
2. Change the engine oil (or change the engine oil at the interval defined in the engine service manual).
3. Change the engine oil filter(s) (or change the engine oil filter at the interval defined in the engine service manual).
4. Inspect the air filter. Replace as necessary (or inspect and replace the air filter at the interval defined in the engine service manual).
5. Gaseous Units Only: Inspect, clean, and gap the spark plugs. Replace as necessary.
6. Gaseous Units Only: Inspect ignition wires for damage, deterioration and tightness. Replace as neces-sary.
7. Diesel Units Only: Test the fuel quality. If required, strip any water/sediment from the tank.
Filter or polish the fuel and add any additional additives required to maintain fuel quality.
8. Diesel Units Only: Change the primary and secondary fuel filters (if equipped). Clean any water separa-tor or mechanical strainer (if equipped). Prime and bleed the fuel system per the engine service manual procedures.
9. Check the engine accessory drive belts and fan coupling device (if equipped) for correct tension, wear or abrasion, deterioration, or damage. Correct as necessary.
10. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.
11. Visually inspect the radiator and charge air core (if equipped) unit enclosure drains for any build up of dirt, debris, or oil contamination (external). Clean, correct as necessary.
12. Check the coolant thermal protection level. Correct as necessary.
13. Check all wiring connections in the high voltage and low voltage connection panels. Check for loose connections, corrosion, arcing or damage. Check torque on all main load lugs at generator connections (MLCB) and transfer switch connections (refer to applicable transfer switch man-ual). Correct as necessary.
14. Return unit to operational condition and test. Place unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Exercise unit against the load for 1 hour (60 minutes).
Visually inspect for leaks, loose connections or components, and any abnormal operating conditions.
Record unit voltage, frequency and kW while running. Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.
Voltage: Frequency: kW: kVA:
15. If control has alarm and/or event or run logs, record the alarm and event logs to a history file.
16. Return the unit to operational condition and place back in automatic operation.
Date inspection Completed: Unit hour Meter Reading:
30 Owner’s Manual for Stationary Industrial Generators
Maintenance Level 4 - Bi-Annual or Every 500 Hours These maintenance tasks must be performed by an IASD. Perform these tasks every 24 months or every 500 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly, Semi-Annual and Annual maintenance tasks. Comply with all safety notices contained in the owner’s manual. Some of the tasks will require the use of the applicable engine service manual.
IASD Tasks Task Completed Date/Initials
1. Disable the unit from operating per the procedure found in the owner’s manual. Some of the following tasks will require the use of the applicable engine service manual.
2. Check engine valve clearance (valve lash) as specified in the engine service manual.
NOTE: This is NOT required for engines with hydraulic lifters. Check the engine service manual.
3. Gearbox Equipped Only: Change the gearbox oil. Can be extended to 600 hours.
4. Replace the engine air filter(s).
5. Gaseous Units Only: Replace the spark plugs. Gap per the engine specifications.
6. Replace the engine accessory drive belts. Inspect and lubricate (if required) the belt tensioning device (if equipped) and replace if necessary.
7. Drain and flush the cooling system. Refill with fresh coolant of appropriate type (50/50 mixture).
8. Replace all flexible hoses: Coolant hoses including the block heater hoses and vaporizer hoses (if equipped); charge air system connection hoses/joints/couplings, and any flexible fuel or oil lines.
9. Replace fuel filter. Verify the fuel system is bled and primed before running unit (diesel only).
10. Remove, clean, inspect, reinstall and reset to correct voltage level the flywheel magnetic pickup(s) (if equipped).
11. Return the unit to operational condition and test. Place the unit in automatic and open the service disconnect to force the unit to start and transfer to the load. Use an appropriate load bank to supplement load to full rated load (100% kW at rated kVA) if possible. Exercise the unit against the load for 2 hours (120 minutes). Visually inspect for leaks, loose connections or components, and any abnormal operating conditions. Record the unit voltage, frequency, kW and kVA while running. Remove the load bank load, restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.
Voltage: Frequency: kW: kVA:
12. If control has alarm and/or event or run logs, record the alarm and event logs to a history file.
13. Return the unit to operational condition and place back in automatic operation.
Date inspection Completed: Unit hour Meter Reading:
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