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Book 10 · Maintenance plan

One route round the plant. Every check, every grease point.

The checklists bring the check tables of all the books together, so the plant team walks the plant in a fixed order instead of opening thirteen books. Tick them on a phone, or print them and post them in the control cabin.

Daily walk-round

OPERATOR · before the first batch, in the order of material flow

0 / 16 done

	#	Area	Check	Stop if…	Book
	1	Whole plant	Guards in place; walkways clear; nobody inside equipment	Guard missing	1 · 5 · 8
	2	Control cabin	Alarms read; supply voltage normal; PC and air conditioning working	Phase missing	8
	3	Compressor	Running; oil level; no alarm; condensate drained	Alarm, oil low	7
	4	Air system	Main pressure normal; dryer in the green; FRL bowls dry	Pressure below minimum	7
	5	Water	Tank level; pump normal; booster not short-cycling	No water	6
	6	Aggregate bins	Levels; no mixing between bins; grids in place; gates close fully	Gate not closing; grid missing	4
	7	Conveyors	Pull-cords; start warning; belt centred; no spillage at the tail; cleaners working	Pull-cord broken; belt rubbing the frame	5
	8	Skip (if fitted)	Area under the track clear; stops at its marks; brake holds; rope looks normal	Creep; overrun; damaged rope	9
	9	Silos	Levels; filter air on; no dust at the safety valve; screws running quietly	Powder at the safety valve (investigate)	2
	10	Scales	Zero all scales; no material stuck; nothing touching the hoppers	Zero will not hold	3
	11	Admixture	Tank levels; no leaks; agitation running		3 · 11
	12	Mixer	Clean; lids and interlocks closed; grease reservoir level; grease at shaft ends; door opens, closes and signals	Interlock fault; no grease at the seals	1
	13	Hydraulic pack	Oil level; no new leaks	Hose leaking	6
	14	Loading points	Ground hopper grids intact; wheel stops in place; fill pipes capped and locked; truck bay clear and lit	Grid damaged	12
	15	E-stops	Not damaged; reset normally		8
	16	First batch	Watch the full cycle; listen for new noises	Any abnormal noise or overload	—

Date ______________ Signed ______________

Weekly

TECHNICIAN · locked out where hands go near moving parts

0 / 13 done

	#	Area	Check	Stop if…	Book
	1	Mixer	Paddle-to-liner gap (3–5 mm); arm and paddle bolts; liner wear; door seal; wash heads clear; weekly grease points		1
	2	Silo filters	Cartridges, pulse valves, filter air pressure		2
	3	Screws	Noise, motor current, seals at inlet and outlet; grease		2
	4	Scales	Reference-weight check; cleaning		3
	5	Bins	Gate seals, cylinders, position sensors; vibrator mountings		4
	6	Conveyors	Cleaner blades and tension; V-plough; skirts; idlers turning; take-up position		5
	7	Water	Strainers clean; booster cut-in and cut-out		6
	8	Hydraulics	Hoses (with cardboard, never hands); cylinder rods; filter indicator		6
	9	Air	Line filter drains; cylinder rods; silencers; sensors tight		7
	10	Electrical	Sensors tight and clean; motor fins clean; junction boxes closed		8
	11	Skip	Wheels, rails, switch mountings, rope terminations, sheaves		9
	12	Recycling and dust	Reclaimer screw flights and tail bearing; screen mesh; dust collector pulse valves and discharge		11
	13	Whole plant	Spillage removed under conveyors and around bins; housekeeping		—

Date ______________ Signed ______________

Monthly

TECHNICIAN · ELECTRICIAN where needed

0 / 11 done

	#	Area	Check	Stop if…	Book
	1	Safety functions	Test every E-stop, pull-cord (both directions), mixer lid interlock, sway switch, skip over-run and slack-rope switch; record the results		5 · 8 · 9
	2	Mixer	Gearbox oil level; breather; V-belt tension; mounting bolts; door hydraulics or pneumatics		1
	3	Silos	Level sensors; safety valve free; pressure sensor test; butterfly valves		2
	4	Scales	Zero drift trend; junction boxes dry; load cell cables		3
	5	Conveyors	Splices; covers and edges; lagging; pulley bearing temperature; backstop; chevron profiles; gearbox oil		5
	6	Pumps and hydraulics	Bearing noise; motor current; wash nozzles; oil condition (milky, dark)		6
	7	Air	Leak walk with the plant quiet; test automatic drains; regulator settings		7
	8	Electrical	Main motor currents; voltage and unbalance; panel AC and fans; cables; PLC and batching data backup		8
	9	Skip	Full-length rope inspection and diameter; brake gap and holding test; drum spooling		9
	10	Lubrication	All monthly points of the chart; grease record reviewed for missed points		10
	11	Structure	Handrails, gratings, ladders; loose bolts; corrosion spots; vibrating supports		13

Date ______________ Signed ______________

Every 3 months

TECHNICIAN

0 / 7 done

	#	Area	Check	Stop if…	Book
	1	Mixer	Measure liner and paddle thickness; plan the wear-part order		1
	2	Scales	Partial verification at selected points		3
	3	Moisture probes	Calibration check		3 · 4
	4	Conveyors	Pulley alignment; frame; take-up travel remaining		5
	5	HP wash pump and slurry pumps	Oil change per maker; impeller and liner wear		6
	6	Compressor	Air filter inspection; dryer condenser cleaned		7
	7	Mobile chassis (standing)	Tyre pressure and condition; corrosion; cylinder rods protected		13

Date ______________ Signed ______________

Every 6 months

TECHNICIAN · ELECTRICIAN

0 / 5 done

	#	Area	Check	Stop if…	Book
	1	Scales	Full calibration with test weights; records and labels		3
	2	Silos	Screw flight thickness; filter cartridges by differential pressure		2
	3	Booster tank and accumulators	Pre-charge pressure		6
	4	Electrical	Re-torque MCC terminals (isolated); earthing; surge protection; UPS test		8
	5	Skip	Rail gauge and alignment; sheave grooves; structure		9

Date ______________ Signed ______________

Every year

TECHNICIAN · ELECTRICIAN · COMPETENT PERSON

0 / 8 done

	#	Area	Check	Stop if…	Book
	1	Electrical	Infrared scan of panels under load; insulation resistance of main motors; drive service		8
	2	Hydraulics	Oil and filter change (or 2,000 h); hose register review		6
	3	Compressor and air	Service per maker hours; receiver safety valve and legal inspection; line filter elements; drain service		7
	4	Silos	Safety valve springs and gaskets (about every 24 months); full silo protection service		2
	5	Skip	Thorough examination by a competent person (lifting equipment law)		9
	6	Structure	Full structural inspection: bolts, welds, corrosion, anchors, silo legs; plumb and level		13
	7	Mobile chassis	Bearings, brakes, suspension, lights — full running gear service		13
	8	Documents and backups	Wiring diagrams, lubrication chart, spare parts list updated; restore the PLC and batching backup on a spare PC		8 · 10

Date ______________ Signed ______________

Ticks are saved on this device for today only.

CAUTIONLock out before greasing any point near moving parts. Never remove a guard to grease, never point a grease gun at skin, and never feel for a leak by hand.

The equipment maker’s lubricant and interval always win. Write your own product and interval in for each point, and number every grease point on the plant (G1, G2…) to match the chart.

Lubricants used on the plant

Code	Type	Typical use	Your product
L1	Mixer seal grease — adhesive, water-resistant (calcium or lithium-complex EP, NLGI 0–2 as the mixer maker says)	Mixer shaft-end seals and bearings, central lube pump
L2	General EP lithium grease, NLGI 2	Bearings: conveyor pulleys, screw end bearings, skip wheels and sheaves, pins
L3	Open-gear grease	Open gear drives on some mixers
L4	Industrial gear oil ISO VG 220 (VG 150 in cold climates)	Mixer, conveyor and screw gearboxes
L5	Anti-wear hydraulic oil ISO VG 46	Mixer door and gate hydraulic packs
L6	Compressor oil (maker’s product)	Screw or piston compressor
L7	Plunger pump crankcase oil (e.g. ISO 68)	High-pressure wash pump
L8	Wire rope lubricant	Skip hoist ropes
L9	Pneumatic lubricator oil (only if lubricators are already fitted)	FRL lubricators
L10	Seal grease for pneumatic cylinders (silicone or paraffin type)	Resealing air cylinders

Book 1Mixer

Point	Lubricant	Method	Interval
Shaft-end seals and bearings (central system)	L1	Central pump; check reservoir and test nipple at each shaft end	Reservoir daily
Shaft ends by hand (if the pump fails)	L1	Grease gun until grease shows at all shaft ends	Every 2 h until the pump is repaired
Gearbox oil level	L4	Dipstick or sight glass	Monthly
Gearbox oil change	L4	Drain warm, flush, refill; never mix grades	As the gearbox maker says
Open gear ring (where fitted)	L3	Brush or spray	Weekly
Gearbox breathers	—	Clean	Monthly
Door hydraulic pack	L5	Level; change through a filter	Level daily; change 2,000 h or yearly

Book 2Silos and screw conveyors

Point	Lubricant	Method	Interval
Screw end and hanger bearings	L2	Grease gun	As the screw maker says
Screw gearmotor oil	L4	Level; change	Level monthly; change per maker
Butterfly valve actuator	—	Check operation	Weekly

Book 3Weighing

No routine lubrication. Never grease anything touching a load cell mounting; greasing belt-scale idlers changes the zero. Weigh-belt gearmotor: oil level monthly.

Book 4Aggregate bins

Point	Lubricant	Method	Interval
Gate hinge pins and shafts	L2	Grease gun	As the gate maker says
Gate cylinder clevis pins	L2	Grease gun	Monthly

Book 5Belt conveyors

Point	Lubricant	Method	Interval
Head, tail, snub and bend pulley bearings	L2	Grease gun — do not over-grease	Per bearing maker (often monthly–quarterly)
Gearbox or drum motor	L4	Level; change	Level monthly; change per maker
Idlers	—	Usually sealed for life	—
Screw take-up threads	L2	Light coat	Monthly

Book 6Pumps and hydraulics

Point	Lubricant	Method	Interval
Water pump bearings (bearing-frame pumps)	L2	Grease gun	Per pump maker; sealed bearings need none
High-pressure wash pump crankcase	L7	Level; change	Level daily; change per maker hours
Hydraulic power pack	L5	Level; change through a filter	Level daily; change 2,000 h or yearly

Book 7Pneumatics and compressor

Point	Lubricant	Method	Interval
Compressor oil level	L6	Sight glass	Daily
Compressor oil, filter and separator	L6	Change	Per maker hours
FRL lubricators (only if already fitted)	L9	Fill	Weekly; never let run dry

Book 8Electrical

No lubrication. Motor bearings with grease nipples: grease to the interval and quantity on the motor nameplate; most small motors are sealed.

Book 9Skip hoist

Point	Lubricant	Method	Interval
Wire rope	L8	Brush or spray on	Per rope maker; more often when wet and dusty
Skip wheels, top sheave and drum bearings	L2	Grease gun	Per maker
Winch gearbox	L4	Level; change	Level monthly; change per maker