PM Maintenance Checklist

Detailed checklist to plan and execute preventive maintenance tasks for machinery and infrastructure. Ensure optimal equipment performance and prevent unexpected failures.

Pre-Maintenance Planning & Safety Setup

  • Review equipment maintenance history and service records for baseline assessment.
  • Verify work order details and required maintenance tasks in CMMS system.
  • Gather all required tools, parts, and materials for efficient workflow execution.
  • Implement lockout/tagout procedures for all energy sources before starting work.
  • Ensure proper personal protective equipment is available and worn by all personnel.
  • Verify work permits and safety briefings are completed for hazardous operations.
  • Check work area for adequate lighting and ventilation requirements.
  • Establish clear communication protocols with production and operations teams.
  • Document equipment condition and operating parameters before maintenance begins.
  • Prepare emergency contacts and procedures for unexpected situations or findings.

Mechanical Component Inspection

  • Inspect all drive belts for proper tension, alignment, and wear patterns.
  • Check coupling alignment and condition for signs of wear or damage.
  • Lubricate all grease points according to manufacturer specifications and schedule.
  • Measure vibration levels at key monitoring points using calibrated instruments.
  • Inspect bearing condition through temperature, noise, and vibration analysis.
  • Check all seals and gaskets for leakage and replace as needed.
  • Verify proper operation of all moving parts and mechanisms.
  • Inspect guards and safety devices for proper installation and condition.
  • Check foundation bolts and mounting hardware for tightness specifications.
  • Document any abnormal wear patterns or component deterioration findings.

Electrical System Maintenance

  • Inspect all electrical connections for tightness and signs of corrosion or overheating.
  • Test motor insulation resistance using megohmmeter and record values.
  • Clean control panels and inspect components for damage or deterioration.
  • Verify grounding connections and test for continuity throughout the system.
  • Test all emergency stops and safety interlocks for proper operation.
  • Check and calibrate protective devices including breakers, fuses, and relays.
  • Inspect cable condition and support systems for wear or damage.
  • Test backup power systems and emergency lighting if applicable.
  • Verify proper labeling and documentation of electrical components.
  • Record electrical measurements and compare to baseline values for trend analysis.

Fluid System Maintenance

  • Check all fluid levels and top off as required using specified fluids.
  • Sample hydraulic and lubricating fluids for laboratory analysis and contamination testing.
  • Replace filters according to maintenance schedule or condition indicators.
  • Test system pressures and calibrate relief valves to proper settings.
  • Inspect all hoses, fittings, and connections for leaks and wear.
  • Check cooling system operation and coolant condition for optimal performance.
  • Verify proper operation of pumps and fluid handling equipment.
  • Inspect reservoirs and tanks for cleanliness and structural integrity.
  • Test air dryers and filtration systems in pneumatic applications.
  • Document fluid changes and disposal according to environmental regulations.

Performance Testing & Verification

  • Complete equipment startup procedure following manufacturer guidelines.
  • Measure and record key performance parameters against baseline specifications.
  • Test all safety systems and verify proper operation before returning to service.
  • Conduct functional testing of all control systems and automation features.
  • Verify proper operation of instrumentation and monitoring devices.
  • Check alarm systems and notification functions for proper operation.
  • Perform load testing if applicable to verify equipment capacity.
  • Document any performance deviations or abnormal operating conditions.
  • Adjust and calibrate equipment settings to optimal operating parameters.
  • Obtain operations approval before releasing equipment back to production service.

Documentation & Maintenance Records

  • Complete all work order documentation with accurate dates and descriptions.
  • Update CMMS system with parts used, labor hours, and findings.
  • Record all measurements and test results for trending and analysis.
  • Document any defects found and corrective actions taken during maintenance.
  • Update preventive maintenance schedules based on equipment condition and usage.
  • File completed inspection forms and test reports in equipment history records.
  • Schedule follow-up maintenance if required based on inspection findings.
  • Report any safety concerns or recommended improvements to management.
  • Clean and properly store all tools and test equipment after use.
  • Provide handover documentation to operations team with any special instructions.
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