Three-Level Equipment Maintenance System

　　The Three-Level Maintenance System originated in China during the mid-1960s. It evolved through the refinement and development of the Soviet planned preventive maintenance system based on practical experience in China. This system reflects the shift in China's equipment maintenance management focus from repair to maintenance, signifying progress in maintenance practices and a clearer emphasis on a preventive maintenance management approach. The Three-Level Maintenance System encompasses: daily equipment upkeep, Level One maintenance, and Level Two maintenance. The three-tier maintenance system is a mandatory maintenance framework centered on operators, prioritizing preventive maintenance while balancing corrective repairs. It relies on the collective participation of workers, fully leveraging their initiative to implement group-based management and repairs. This approach combines specialized expertise with collective efforts to effectively ensure equipment upkeep.

　　(1) Daily Equipment Maintenance

　　Daily equipment maintenance typically comprises daily upkeep and weekly upkeep, also known as daily routine maintenance and weekly routine maintenance.

　　1. Daily Routine Maintenance

　　Daily routine maintenance is performed by equipment operators during their shift, diligently executing the four pre-shift tasks, five in-shift precautions, and four post-shift tasks.

　　(1) Four Pre-Shift Tasks: Review technical drawings and documentation, inspect shift handover logs. Wipe down equipment and lubricate/refuel as specified. Verify correct and flexible positioning of handles and manually operated components, and confirm reliability of safety devices. Conduct low-speed operation to verify transmission functionality and ensure lubrication/cooling systems are unobstructed.

　　(2) Five Key Observations During Operation Monitor operational sounds, equipment temperature, pressure, fluid levels, electrical/hydraulic/pneumatic systems, instrument signals, and safety interlocks for normal operation.

　　(3) Four Post-Shift Tasks Switch off power and return all handles to neutral position. Remove metal shavings and debris. Wipe oil residue from equipment guideways and sliding surfaces, then lubricate. Clean the work area and organize accessories and tools. Complete shift handover logs and operating hour records, then process shift handover procedures.

　　2. Weekly Maintenance

　　Weekly maintenance is performed by equipment operators at the end of each week. Maintenance duration: 2 hours for general equipment; 4 hours for precision, large, or rare equipment.

　　(1) Appearance

　　Wipe clean equipment guideways, all transmission components, and exposed parts. Clean the work area. Achieve thorough internal and external cleanliness with no blind spots or rust, and maintain an orderly surrounding environment.

　　(2) Control & Transmission

　　Inspect technical condition of all components. Tighten loose parts and adjust clearance fits. Check interlocks and safety devices. Ensure normal transmission sounds and reliable safety.

　　(3) Hydraulic Lubrication

　　Clean oil lines, dust felts, and oil filters. Refill or replace oil in the tank. Inspect the hydraulic system to ensure clean oil, unobstructed oil passages, no leaks, and no wear damage.

　　(4) Electrical System

　　Wipe down motor surfaces and flexible hoses. Inspect insulation and grounding to ensure integrity, cleanliness, and reliability.

　　(II) Level I Maintenance

　　Level I maintenance is primarily performed by operators with maintenance personnel assistance. It involves scheduled partial disassembly and inspection of equipment, cleaning specified areas, clearing oil passages and pipelines, replacing or cleaning oil lines, felt, and oil filters, adjusting clearance fits throughout the equipment, and tightening all components. Level I maintenance takes 4-8 hours. Upon completion, a record must be made noting any unresolved defects, with workshop mechanics organizing the acceptance inspection. The scope of Level 1 maintenance covers all operational equipment within the enterprise, with strict implementation required for critical equipment. Its primary objectives are to reduce equipment wear, eliminate potential hazards, extend service life, and ensure equipment readiness to fulfill production tasks until the next Level 1 maintenance cycle.

　　(3) Level 2 Maintenance

　　Level 2 maintenance is primarily performed by maintenance personnel with participation from operating personnel. Included in the equipment maintenance schedule, it involves partial disassembly inspection and repair, replacement or restoration of worn parts, cleaning, oil changes, and inspection/repair of electrical components to ensure the equipment's technical condition fully meets the specified operational standards. Secondary maintenance typically takes approximately 7 days.

　　Upon completion, maintenance workers must fill out detailed inspection records. These are verified by the workshop mechanic and operator, with the acceptance form submitted to the Equipment and Power Department for archiving. The primary purpose of Level 2 maintenance is to restore equipment to operational standards, enhance and maintain equipment reliability rates, and extend major overhaul intervals.

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