Ajax Preventative Maintenance Manual

 

Preventative Maintenance Manual

 

PREVENTATIVE MAINTENANCE MANUAL The following maintenance schedule is to be used as a guideline in setting up a maintenance schedule on your machine. We feel the best maintenance program is a  preventative type, which will help detect the beginning of problems before failure, occurs. This schedule is similar to the one some of our customers use in their preventative maintenance program and appears to have given them good results in preventing costly  breakdowns. We are in no way saying the Ajax package will not give long trouble free continuous service without such maintenance program, but common sense rules that the more preventative maintenance is done the less chance of an unexpected failure to occur  and the longer the unit will run trouble free.

 

PREVENTATIVE MAINTENANCE MANUAL SCHEDULE "A" 1.  Check lubricator oil level.

(weekly)

2.  Check crankcase oil level. 3.  Check each lubricator pump to make sure each pump is functioning. 4.  Check for water in lubricator. 5.  Check fuel gas pressure normally 7-12 PSI PS I records GI 4-6 oz. LP. 6.  Check EJW temperature (record) 180 degrees de grees F. maximum forced system, 206 degrees F. thermosyphon. 7.  Check sight level in separator gauge glasses. 8.  Check discharge gas temperature maximum 350 degrees F. (record). 9.  Check RPM of machine (record). 10. Check exhaust temperature (record). 11. Check fluid level in CJW/EJW system. 12. Check operating gas pressures (record). 13. Check for any abnormal vibration or sounds. 14. Check oil reservoir oil level. 15. If suction or discharge line pressure change check che ck to see if compressor cylinder is clearanced properly (record). 16. Check to see if belts are tight and not excessively loose. 17. Check for any loose bolts unit to skid and skid to skid, skid to foundation guide to  bed cylinder to guide power, cylinder to bed. 18. Check to see if cylinder c ylinder support is tight, not over tight. 19. Check fluid level in gas injection tanks (record any amount added). 20. If interstage pressures change from normal or if capacity capacit y drops, inspect compressor  valves and replace or repair. 21. Drain any oil from power end scavenging chamber (shutdown mode) record quantity. 22. Check for any hot compressor valves and remove and replace.

 

PREVENTATIVE MAINTENANCE MANUAL SCHEDULE "B" (700 HOURS)

1.  Do schedule "A" maintenance if not done weekly. 2.  If you have oil bath air cleaners, replace oil in air cleaner with 10 wt. oil (shutdown mode). 3.  If dry type air cleaner, check manometer reading maximum 3" water column, clean filters. 4.  Check for any rod packing blow by. 5.  Drain oil from compressor end distance piece and record quantity and observe for  any metal flaking. 6.  Open drain on fuel bottle and drain any liquid. 7.  Open condensate drain to oil reservoir and drain off any liquid condensate this may have formed in tank. SEE ESS-D-761. 8.  Grease water pump with one shot of grease. 9.  Lubricate each cooler bearing with one shot of grease. 10. Lubricate idler bearing with one shot of grease. 11. Inspect lubricator check valves for leakage. 12. Lubricate injector valve with one shot Whitmores anti-friction compound #2. 13. Inspect belts for tightness, wear, etc. Replace if necessary.

 

PREVENTATIVE MAINTENANCE MANUAL SCHEDULE "C" (5000 HOURS)

1.  Inspect spark plugs for proper gap and carbon build-up, change if necessary. 2.  Remove, inspect, and clean compressor valves. Replace worn or damaged parts. 3.  Lubricate engine radiator radiator fan. See instruction manual. 4.  Lubricate cooler bearings (one pump with grease gun). 5.  Lubricate idler bearings (one pump with grease gun). 6.  Check and replace any broken reed valves in mixer manifold. 7.  Check shutdowns for proper operation. 8.  Check spark plugs wires for spark leakage. 9.  Check for debris build-up on radiator and/or cooler c ooler fins. 10. Units that have Partlow switches, remove front cover and lubricate internal linkage with WD-40 and check switch pointer for freedom of movement.

NOTE:  If above switch does not have two (2) 1/8" drain holes in the bottom of the switches please add for drainage.

 

PREVENTATIVE MAINTENANCE MANUAL SCHEDULE "D" (10,000 HOURS)

1.  Change crankcase oil and inspect for any metal, water, etc. 2.  Pull power pistons and inspect: a.  Check for carbon build-up, stuck and a nd broken rings, scuff marks.  b.  Remove old rings and replace. c.  Check power cylinder for any wear. 3.  Clean crankcase breather. 4.  Inspect spark plugs and replace, if necessary. n ecessary. 5.  Replace power cylinder head gaskets. 6.  Drain and flush out lubricator. 7.  Inspect intake filter screen on lubricator pump for dirt build-up. 8.  Check injector valve seat area and replace if worn. 9.  Work shop test alternator, coils. 10. Check water scale built up on power cylinder jackets and cooler tubes. Remove scale if any present. 11. Check running clearances on crossheads, crosshead pin bushing and replace if  clearances are excessive. 12. Check power piston rod for any wear or scuff scuff marks (max. .002/inch of rod  diameter undersize). 13. Check fuel injection cams for any an y excessive wear compressor end (sch. "D"). 14. Check crosshead piston rod nut for tightness 15. Change oil wiper packing, if necessary. 16. Change compressor stuffing box rings, if necessary and inspect compressor cylinder  condition. 17. Change compressor piston rings, if necessary. 18. Check compressor cylinder bore for any an y scuff marks. 19. Check cooler bearings for excessive wear. 20. Change mechanical seal in water pump if leakage occurs.

 

PREVENTATIVE MAINTENANCE MANUAL Major Overhaul Approximately 130,000 hours 1.  Re-ring power & compressor cylinders. 2.  Replace reed valves & springs. 3.  Overhaul gas injection valve & plunger plun ger assemblies. 4.  Test or replace alternator, capacitor and coils. 5.  Replace oil wiper packing on power & compressor rods. 6.  Replace pressure packing. 7.  Overhaul compressor cylinder suction & discharge valves. 8.  Replace water pump seal. 9.  Check water pump bearings. 10. Replace or re-chrome power cylinder c ylinder if worn. 11. Replace power piston & rod assembly. 12. Replace crosshead pins & bushings in power & compressor end  13. Replace bearing in connecting rods 14. Replace cooler & water pump belts 15. Re-build radiator fan hub assembly 16. Inspect & replace cooler bearings 17. Inspect & replace idler bearings 18. Test & re-work control panel