AZ Checklists
Preventive Maintenance Checklist for Safety & Compliance

Preventive Maintenance Checklist for Safety & Compliance

Maintenance Checklists
100 Items
Comprehensive preventive maintenance checklist covering safety, inspection, cleaning, lubrication, and system performance for equipment and facilities.

Equipment Preventive Maintenance Guide

This comprehensive preventive maintenance checklist provides a systematic approach to maintaining equipment and facilities through proactive care and regular inspections. The maintenance process covers safety and compliance requirements, visual inspections, cleaning procedures, lubrication and fluid management, electrical and control systems, mechanical components, HVAC and ventilation systems, plumbing and fluid systems, calibration and performance testing, and documentation. Use this checklist to prevent equipment failures, extend asset life, ensure operational efficiency, and maintain safety standards for industrial equipment, manufacturing facilities, commercial buildings, or any critical infrastructure requiring regular maintenance.

1. Safety & Compliance

1Ensure lockout / tagout procedures are in place and used
2Verify all required PPE (personal protective equipment) is available and in good condition
3Check emergency exits, lighting, and signage for visibility and operation
4Test fire alarms, smoke detectors, and sprinkler systems
5Inspect fire extinguishers (pressure, accessibility, tags)
6Confirm safety guards and barriers are intact and secure
7Check first aid kits and emergency supplies (stock, expiration)
8Review and update safety procedures, permits, and licenses
9Perform hazard assessments for areas under maintenance
10Record and report any safety incidents or near-misses

2. Visual & General Inspection

1Walk around and look for signs of wear, damage, corrosion, or leaks
2Inspect structural parts (frames, supports, guards)
3Check paint, coatings, and surfaces for peeling, rust, or degradation
4Look for loose bolts, nuts, or fasteners
5Assess alignment of parts, belts, pulleys, shafts
6Inspect wiring, cables, and insulation for cracks or abrasions
7Check for unusual vibration, noise, or movement
8Inspect access panels or doors for secure closure
9Examine seals, gaskets, and joints for deterioration
10Record anomalies or deviations from baseline

3. Cleaning & Housekeeping

1Remove dust, debris, dirt from critical surfaces and openings
2Clean filters, vents, grilles, and air intakes
3Blow out or vacuum cooling fins, heat sinks, coils
4Wipe down control panels, switches, displays
5Flush drain lines, pans, and traps to prevent clogging
6Clean lubricated parts before re-lubrication
7Remove obstructions, tools, waste from work areas
8Check for and eliminate sources of contamination (oil, water, dust)
9Clean windows, sight glasses for clarity
10Ensure proper disposal of waste, used fluids, and filters

4. Lubrication & Fluids

1Check lubricant levels (oil, grease, hydraulic fluid, coolant)
2Lubricate bearings, joints, gears, chains per specs
3Replace or top up lubricants if degraded or contaminated
4Inspect oil filters and replace if needed
5Check hydraulic lines, hoses for leaks, cracks
6Ensure fluid reservoirs are sealed and vented properly
7Monitor and record fluid temperature and viscosity
8Bleed air from hydraulic or pneumatic circuits
9Confirm proper flow and pressure in fluid circuits
10Dispose or recycle used fluids per regulations

5. Electrical / Control Systems

1Inspect connection points, terminals for tightness and corrosion
2Check fuses, circuit breakers, and protective devices
3Measure insulation resistance and continuity of cables
4Test control relays, contactors, switches for proper operation
5Verify sensor calibrations and readings
6Examine wiring looms, conduits, cable trays
7Test backup power systems or UPS (if applicable)
8Confirm grounding and bonding systems are intact
9Inspect control panels for signs of overheating or burning
10Test alarms, indicators, and warning lights

6. Mechanical Components

1Check belts, pulleys, and tensioners for wear and alignment
2Inspect couplings, shafts, and bearings for play or noise
3Confirm gearboxes are properly lubricated
4Examine drive chain or belts for correct tension
5Inspect hydraulic cylinders, pistons, seals
6Check pumps, motors, and their mounting bolts
7Look for mechanical bindings, friction points
8Measure vibration levels and compare to baseline
9Inspect mechanical linkages, cams, levers for free movement
10Test actuators, valves, and mechanical controls

7. HVAC, Ventilation & Cooling Systems

1Replace or clean air filters
2Check blower fans, motors, belts, and bearings
3Inspect condenser and evaporator coils for dirt or blockages
4Verify refrigerant levels and check for leaks
5Confirm ductwork is clean, sealed, and intact
6Check drain lines and pans for clogging or standing water
7Test temperature control system, thermostats
8Inspect belts, pulleys, and couplings on HVAC drives
9Measure airflow and static pressure in ventilation lines
10Confirm system startup, shutdown, and safety controls

8. Plumbing & Fluid Systems

1Inspect piping for leaks, corrosion, or damage
2Test shutoff valves and control valves for proper function
3Ensure pressure relief valves are functional
4Check pump seals, bearings, and mounting
5Drain and flush expansion tanks or reservoirs
6Monitor fluid pressures and flows
7Test water quality, cleanliness, and additives
8Inspect hoses, connections, and fittings
9Clean strainers, filters, and screens in fluid circuits
10Confirm backflow prevention and check valves

9. Calibration, Testing & Performance

1Calibrate sensors, gauges, and meters
2Run performance tests under normal operating loads
3Compare measured output to design or baseline values
4Monitor temperature, pressure, flow, speed as applicable
5Test safety trips, interlocks, and emergency stops
6Conduct functional tests of system components
7Validate system stability over extended run periods
8Log performance data and trends
9Adjust setpoints, offsets, or configurations as needed
10Verify system response times and tolerances

10. Documentation, Reporting & Review

1Record results of each checklist item (OK, needs repair, replaced)
2Note date, technician name, and shift / time
3Log anomalies, observations, and corrective actions
4Update maintenance history or asset records
5Review previous maintenance records or trends
6Plan and schedule follow-up work orders as required
7Update spare parts / consumables inventory list
8Report critical failures or risks to management
9Review and revise the checklist based on findings
10Conduct periodic audit of checklist compliance and effectiveness
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