EN MJ_ 400 ÷ 900 – Marelli Motori

Chapter 5 : Maintenance

5.1. Preventive maintenance

A rotating electric machine is often an important part of a huge plant and its correct supervision and maintenance ensure
its reliable operation and standard lifecycle.
The purpose of maintenance operations is:
To ensure machine reliable operation without unforeseen actions or interventions
To evaluate and plan maintenance actions with the purpose to minimize downtimes.
The difference between supervision and maintenance is quite complex. Standard supervision of operation and
maintenance includes the recording of operative data such as load, temperatures and vibrations, as well as lubrication
control and insulation strength measurement.
After commissioning or maintenance, supervision should be carried out extensively. We recommend a frequent check of
bearings and windings temperature, load, current, cooling system, lubrication and vibrations
This chapter provides recommendations about the maintenance program and operating instructions on how to perform
common maintenance interventions. Carefully read these instructions and recommendations, using them as starting
point to plan the maintenance schedule. The maintenance recommendations in this chapter constitute the minimum
maintenance level. Increasing maintenance and monitoring activities, machine reliability and long term usability increase.
The data obtained from monitoring and maintenance operations are useful to evaluate and plan additional interventions
and if some of those indicate something out of ordinary, the troubleshooting guides provided in Chapter 6 Alarms and
interventions for malfunctions or troubles will be an useful aid to find the cause.
MarelliMotori recommends as well to use experts to prepare a maintenance plan, to implement maintenance and for
troubleshooting: in any case, the customers can rely on the Post-Sale organization of MarelliMotori, whose contacts are
indicated in Chapter 7-1.5 Post-Sales service contacts.
An essential aspect of preventive maintenance is to be provided with suitable spare parts and the best way to access
critical spare parts is to keep them in stock. Packages with ready to use spare parts can be bought from MarelliMotori
Post-Sales.

5.2. Safety cautions

Before operating on any electric equipment, we recommend to take the due general cautions for electric safety and
respect the local standards in order to avoid accidents to the personnel, operating in compliance with the provisions of
the personnel in charge of safety.
The persons who perform the maintenance on electric equipment and installations must be highly qualified, besides
being duly trained about the specific maintenance procedures and required tests for electric rotating machines.
The standards concerning connection and use of electric equipment in dangerous areas must be considered, in
particular the national standards concerning installation (see standard IEC 60079-14, IEC 6000-17 and IEC 6007-19).
Only trained personnel, knowing such standards must handle this type of equipment.
Disconnect and lock before operating on the machine or on the driven equipment.
For the general safety cautions, see the Safety Instructions at the beginning of the manual.

963857267_A 70
EN MJ_ 400 ÷ 900 – Marelli Motori

5.3. General features

This chapter provides a general maintenance program recommended for the MarelliMotori machines, to be considered
as minimum level. Maintenance interventions are to be intensified when the environmental conditions are quite difficult.
Even if you follow a maintenance program, it is always necessary to monitor the conditions of the machine.
Even if the maintenance program has been customized to satisfy the needs of the machine, it could refer to accessories
not provided on all the machines.
The maintenance program is based on four maintenance levels based on the operating hours. The amount of work
performed and the downtime vary. Maintenance level 1 includes quick visual checks, while maintenance level 4
envisages heavier provisions and replacements. The recommended maintenance interval is indicated in Table 5-1
Maintenance Interval.
Maintenance level 1 (LM1)
The Maintenance Level 1 includes visual checks and light maintenance interventions. The purpose of this maintenance is
a quick check for developing issues before they may cause failures and downtime due to unplanned maintenance
interventions, suggesting as well which maintenance provisions must be executed during the next general overhaul.
The first maintenance of LM1 is to be executed after 2,000 hours of operation or four months after commissioning, and
with half year interval, see Table 5-1 Maintenance Intervals.
Maintenance level 2 (LM2)
The Maintenance Level 2 includes inspection and checks, as well as light maintenance interventions. Its purpose is to
check for machine operating issues and to perform small repairs to ensure operating continuity.
The first maintenance of LM2 is to be executed after 4.000 hours of operation or one year after commissioning, and with
yearly interval or every 8,000 hours of operation after first maintenance, see Table 5-1 Maintenance Intervals.

Maintenance level 3 (LM3)

The Maintenance Level 3 includes inspections and in depth tests, as well as important maintenance interventions
necessary during the works at levels LM1 and LM2 and its purpose is to solve the issues occurred and replace the parts
subject to wear.
Level 3 maintenance is to be carried out every 24,000 hours of operation or at 3-year intervals. Level 3 maintenance
replaces level 1 and 2 maintenance, see Table 5-1 Maintenance Intervals.

Maintenance level 4 (LM4)

Maintenance Level 4 includes in depth inspections and maintenance interventions and its purpose is to restore reliable
operating conditions of the machine.
LM4 maintenance is to be executed every 80,000 hours of operation. Level 4 maintenance replaces level 1, 2 and 3
maintenance, see Table 5-1 Maintenance Intervals.

Maintenance interval

LM1 LM2 LM3 LM4

After commissioning 2,000 h 4,000 h - -

4,000 h 8,000 h 24,000 h

Interval 80.000 h
Half year Year 3 years

Table 5-1 Maintenance Intervals

963857267_A 71
EN MJ_ 400 ÷ 900 – Marelli Motori

5.4. Recommended maintenance program

Abbreviations used in the maintenance program

V = visual check
P = cleaning
S = disassembly and assembly
R = revision or replacement
T = tests and measurements

5.4.1 General structure

Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests
Start, stop, measurement of vibrations, point without
Operation V/T V/T V/T V/T
load
Assembly and Basement V V/T V/T V/T/S Cracks, rust, alignment
Fastenings V V V V Tightening of all fastenings
Anchoring bolts V V/T V/T V/T Fastening, conditions
External V V V/T V/T Rust, leaks, conditions
Wiring and Connections V V/T V/T V/T/S Wear, oxidation, fastening
Transformers and
V V V V General conditions
regulation boards
Condition of the entering cables and of the cables inside
Connection cables V V V V
the machine

5.4.2 Stator and rotor

Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests

Stator windings V V/T V/T/P V/T/P conditions, cleaning state, insulation strength
Insulator V V V V Damages to the insulator
Coil V V V V Damages to the coil
Stator connection cables V V V V Fastening and general conditions
Rotor connections V V V/T V/T Fastening and general conditions
Rotor balance weights V V V V Fastening

5.4.3 Accessories
Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests

Elements Pt-100 V V/T V/T V/T Resistance

Anti-condensation heaters V V/T V/T V/T Operation, resistance

963857267_A 72
EN MJ_ 400 ÷ 900 – Marelli Motori

5.4.4 Lubrication system and bearings

Rolling bearing:

Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests

Bearing T T T T General conditions, noise, vibrations

Excess grease V V/P V/P V/P Condition, bleeding
Seals V V V/S V/S Leaks
Bearing insulation V/T/S V/T/S Insulation strength

Sliding bearing:

Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests

Assembly V/T V/T V/T V/T General conditions, fastening

Brasses V V V/T/S V/T/S General conditions, wear
Seals V V V/S V/S Leaks
Bearing insulation V/T/S V/T/S Insulation strength
Lubrication tubes V V V/T V/T Leaks, operation
Lubricating oil V V V/R V/R Quantity, quality, flow
Oil flow regulator V/T V/T V/T V/T operation
Oil tank V V/P V/P V/P Cleaning state, leaks
Cooling T T T T Oil temperature

5.4.5 Cooling system

Open heat exchanger:

Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests

Fan V V V V Operation, conditions

Filters V/P V/P V/P/R V/P/R Cleaning state, operation
Air ducts V V/P V/P V/P Cleaning state, operation

Air-air heat exchanger:

Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests

Fans V V V V Operation, conditions

Tubes V V/P V/P V/P Cleaning state, operation
Ducts V V/P V/P V/P Cleaning state, operation
Dampers V V V V Operation, conditions

963857267_A 73
EN MJ_ 400 ÷ 900 – Marelli Motori

Air-water heat exchanger:

Subject of maintenance LM1 LM2 LM3 LM4 Control / Checks or Tests

Heat exchanger V V V V Operation, leaks, conditions, pressure test

Fan V V V V Operation, conditions
Tubes V V/P V/P V/P Cleaning state, corrosion
Ducts V V/P V/P V/P Cleaning state, operation
Seals V V/S V/S V/S Conditions, leaks
Anodes V/S V/S Conditions, activities
Dampers V V V V Operation, conditions
Water flow regulator V/T V/T V/T V/T Operation

5.5. Vibrations

5.5.1 Measurement procedures and operating conditions

Measurement instruments
The measurement instruments must be able to measure r.m.s. wide band vibrations - with flat frequency response on a
frequency range between 10 Hz and 1 000 Hz, in compliance with the ISO 2954 requirements. However, for machines
whose speed reaches or is below 600 r/min, the lower threshold of the flat frequency response range must not exceed
2Hz.
The equipment to measure the vibrations of the shaft must comply with the ISO 10817-1 requirements.
Positions of the measurements
The measurements usually will be executed on the usually accessible exposed parts of the machine. Take care that the
vibrations represent in a reasonable manner the vibration from the bearing seat and do not include local resonances or
amplifications. The positions and the directions of the vibration measurements must be such as to provide suitable
sensibility to the dynamic forces of the machine. Usually two ortho-radial measurement positions are required on all the
hoods or the bearing supports, as illustrated in Figure 5-2 Measurement Points.

Figure 5-2 Measurement Points

963857267_A 74