PM Checklist Template
Routine maintenance checklist to prevent equipment failures and improve longevity. Standardized preventive maintenance procedures for all equipment types.
PREVENTIVE MAINTENANCE PRIORITY
Regular preventive maintenance reduces equipment failures by 70% and extends asset life by 20-40%. Follow manufacturer recommendations and safety protocols.
Pre-Maintenance Planning & Safety
- Review equipment maintenance history and manufacturer service recommendations for proper scheduling.
- Gather all required tools, replacement parts, and consumables before starting maintenance work.
- Implement proper lockout/tagout procedures for all energy sources including electrical and mechanical.
- Verify all maintenance personnel are wearing appropriate personal protective equipment for tasks.
- Document equipment running hours, cycles, or operational time since last maintenance service.
- Check for any outstanding work orders or pending repairs before starting routine maintenance.
- Ensure adequate workspace lighting and ventilation for safe maintenance operations.
- Review safety data sheets for all lubricants and chemicals to be used during maintenance.
- Photograph equipment condition before maintenance for documentation and comparison purposes.
- Verify maintenance schedule compliance and update CMMS system with current status.
Visual Inspection & Performance Assessment
- Conduct comprehensive visual inspection for leaks, cracks, corrosion, or unusual wear patterns.
- Check all guards, covers, and safety devices are properly installed and functioning correctly.
- Inspect electrical connections for looseness, corrosion, overheating, or damaged insulation.
- Listen for unusual noises, vibrations, or operational sounds that indicate potential problems.
- Check equipment mounting, foundation, and structural support for stability and integrity.
- Verify control panel displays, indicators, and alarms are functioning within normal parameters.
- Inspect belts, chains, and drive components for proper tension and alignment specifications.
- Check for proper clearances and alignment of moving parts according to manufacturer specifications.
- Document any defects, wear patterns, or abnormal conditions found during visual inspection.
- Record operating parameters such as temperature, pressure, flow rates, and power consumption.
Lubrication & Fluid System Maintenance
- Check oil levels in all reservoirs and top off with manufacturer-specified lubricants as needed.
- Inspect oil condition for contamination, discoloration, or degradation requiring fluid replacement.
- Lubricate all grease points according to manufacturer schedule using correct grease type and quantity.
- Check hydraulic fluid levels and condition including particle count and moisture content analysis.
- Replace hydraulic and lubrication filters according to manufacturer intervals or condition monitoring.
- Inspect coolant level and concentration for proper freeze protection and corrosion inhibition.
- Check all fluid lines, hoses, and connections for leaks, wear, or deterioration.
- Verify pressure relief valves and safety devices are set to proper operating pressures.
- Sample and analyze critical fluids for wear metals, contamination, and degradation indicators.
- Document all fluid changes, filter replacements, and lubrication activities in maintenance records.
Electrical System Inspection & Testing
- Test motor insulation resistance and record values for trending and comparison purposes.
- Check electrical connections for proper torque specification and signs of overheating or arcing.
- Inspect control panels and electrical enclosures for cleanliness and proper ventilation.
- Test emergency stops, safety interlocks, and protective devices for proper operation.
- Verify proper grounding and bonding of all electrical equipment and conductive surfaces.
- Check power quality including voltage, current, and power factor measurements at motor terminals.
- Inspect cables and conduits for damage, wear, or environmental degradation.
- Test protective devices including circuit breakers, fuses, and overload relays for proper operation.
- Clean electrical components and enclosures to prevent dust accumulation and overheating.
- Update electrical system documentation and maintain current electrical drawings and schematics.
Mechanical Component Service & Adjustment
- Check bearing condition through temperature monitoring, vibration analysis, and acoustic inspection.
- Inspect and adjust belt tension to manufacturer specifications using proper tension gauge tools.
- Verify shaft alignment using precision alignment tools and correct any misalignment conditions.
- Check coupling condition and inspect for wear, cracking, or deterioration of elastomeric elements.
- Lubricate and exercise all valves, actuators, and control devices for proper operation.
- Inspect seals and gaskets for leakage and replace worn or damaged sealing components.
- Check wear parts including impellers, cutting tools, and contact surfaces for replacement needs.
- Calibrate instrumentation and control devices including sensors, transmitters, and indicators.
- Perform functional testing of all automated systems and control sequences for proper operation.
- Document all adjustments, replacements, and calibration activities in equipment maintenance log.
Performance Testing & Documentation
- Conduct equipment startup procedures and verify all systems operate within design parameters.
- Record operating data including temperatures, pressures, flow rates, and power consumption.
- Compare current performance data with baseline values and historical trends for analysis.
- Test all safety systems and emergency shutdown procedures for proper response and timing.
- Verify equipment meets production requirements and quality specifications for output products.
- Update equipment history records with maintenance activities, parts used, and labor hours.
- Schedule next preventive maintenance based on operating hours, calendar time, or condition indicators.
- Generate work orders for any deficiencies or repairs identified during maintenance inspection.
- Photograph equipment condition after maintenance for before and after comparison documentation.
- Submit completed maintenance reports to management and update CMMS database with findings.
