Preventive Maintenance Checklist

Open the scheduled PM in Fiix, eMaint, Limble, or whichever CMMS the plant runs. Confirm the asset tag matches the equipment in front of you, the PM frequency is current, and the task list reflects the most recent PFMEA / OEM revision. Capture the asset tag below — closeout entries roll up to this asset.

Follow the machine-specific LOTO procedure (29 CFR 1910.147) — never a generic one. Isolate every energy source: electrical disconnect, pneumatic shutoff with bleed, hydraulic block, stored mechanical (springs, raised platens). Sign the lock with your name and date.

Try-out step before any hands go in: press the start button, verify the machine does not energize. Meter electrical leads to confirm de-energized. Bleed residual pneumatic and hydraulic pressure to zero at the gauge.

Pull replacement filters, belts, lubricants, and seals per the PM kit list. Confirm calibration stickers on torque wrenches and gauges are current — a past-due gauge invalidates the PM.

Walk the machine looking for cracked welds, deformed guards, missing fasteners on the cabinet, and any guard interlock that has been bypassed or zip-tied closed. Bypassed interlocks are an OSHA 1910.212 finding and a top cause of amputations.

Use a tension gauge — thumb-pressure feel is not a measurement. Inspect belts for cracking, glazing, and cord exposure; chains for stretch beyond 3% and stiff links. Replace as a matched set, never one belt of a multi-belt drive.

Use the lubricant grade called out on the lube chart — mixing greases (lithium vs. polyurea) breaks down both. Hit every zerk on the diagram; over-greasing seals is as damaging as under-greasing bearings. Attach a photo of completed lube points for the audit trail.

Check torque on the fasteners flagged in the PM spec — typically motor mounts, coupling bolts, and bearing housings. Use a calibrated torque wrench. Mark each fastener with a paint pen after verification.

Open the control cabinet. Look for chafed insulation, discolored terminals, loose lugs, and corrosion at terminal blocks. A discolored or pitted contactor terminal is a classic precursor to an arc-flash event.

Confirm fuses match the spec on the panel schedule (no upsized fuses bypassing a real fault). Look for contactor pitting on motor starters; pitting beyond 1/16" warrants replacement.

Use a calibrated ground bond tester. Ground continuity should be under 0.1 ohm to the equipment frame. A high reading on a VFD-driven motor commonly indicates a damaged ground brush or shaft grounding ring.

Look for weeping at JIC and ORFS fittings, blistered hose covers, and abrasion against the frame. Never run a hand along a pressurized hydraulic line — pinhole leaks at 2,000+ psi inject through skin.

Sight-glass level at operating temp, not cold. Milky fluid indicates water ingress; black or burnt smell indicates thermal breakdown — both warrant a sample to the oil lab before topping off.

Compare the pressure-gauge reading at the test port to the value on the hydraulic schematic. Adjust the relief valve only with an isolated pump and a calibrated test gauge — the panel-mounted gauges drift.

Drain the FRL bowl, refill the lubricator to the line, verify regulator setpoint matches the spec on the cabinet door. Listen for hiss at solenoid manifolds — internal leakage shows up as elevated air consumption on the compressor monitor.

Walk the machine, confirm all guards reinstalled, no tools left in the work envelope, no personnel in line of fire. Each lock is removed by the person who applied it — never cut another tech's lock.

Cycle the machine at the slowest jog speed first, then ramp to full speed. Listen for bearing whine, slap, or chatter. Use a vibration pen on motor end-bells if available — baseline against last PM's reading in the CMMS.

Don't run the machine through the anomaly — shut down, re-LOTO, and trace the source (bearing, coupling alignment, hydraulic cavitation, loose mount). Capture readings: vibration ips, surface temp, audible signature. Photographs and measurements feed the corrective work order.

Hit every e-stop button in turn, open every guard interlock, trip the light curtain. Each must drop the machine to a safe state within the spec response time. A failed e-stop is an immediate red-tag — do not return the asset to production.

Pass = all checks within spec, no findings. Pass with notes = all functional, minor issues logged for next PM. Fail = asset cannot return to production until corrective work is complete. Sign off — the signature is the audit-trail entry that satisfies ISO 9001 / TPM evidence requirements.

Create the CM work order in the CMMS, link it to this PM record, and red-tag the asset. Notify the production scheduler so the machine is removed from the run schedule until the CM closes. Maintenance manager owns the CM priority decision.

Notify the shift lead the asset is back online, update the CMMS status to Available, and post next PM due date. Confirm OEE monitoring (MachineMetrics, Plex, Tulip) is logging again before walking away.