I. General Provisions
1.1 Purpose
To standardize industrial production equipment maintenance behavior, ensure safe and stable equipment operation, extend equipment service life, reduce failure downtime rates, and establish procedures based on the Production Safety Law of the People's Republic of China and relevant national standards.
1.2 Scope
This manual applies to maintenance management of industrial production equipment within enterprises, including but not limited to power equipment (air compressors, boilers), transmission equipment (gearboxes, belt conveyors), processing equipment (lathes, milling machines), heat exchange equipment (heat exchangers, cooling towers), and special equipment.
II. Maintenance Classification and Standards
2.1 Daily Maintenance
Daily maintenance should be combined with equipment operation data and historical records, using data analysis to predict potential failures and realizing the concept of predictive maintenance. Daily maintenance should be incorporated into equipment lifecycle management, forming closed-loop management with equipment procurement, use, and disposal to improve overall equipment comprehensive efficiency.
2.2 Daily Care Tasks
- Equipment Cleaning: Remove dust, oil stains, and debris from equipment surfaces and surroundings. Clean critical areas such as guide rails, lead screws, and sliding surfaces.
- Lubrication: Check oil levels at all lubrication points and replenish or replace as needed. Follow equipment lubrication charts strictly.
- Fastener Inspection: Check all bolts, nuts, and fasteners for looseness. Tighten to specified torque values where needed.
- Operational Check: Verify equipment starts, runs, and stops normally. Check for abnormal sounds, vibrations, or temperature rises.
2.3 Periodic Maintenance
Periodic maintenance includes weekly, monthly, quarterly, and annual maintenance cycles. Prevention-first maintenance strategies should be implemented.
Weekly Maintenance
- Check all safety protection devices for integrity and functionality
- Inspect belt tensions and chain tensions
- Clean filters and air intake vents
- Verify emergency stop functions
Monthly Maintenance
- Comprehensive inspection of electrical systems including wiring and connections
- Calibrate pressure gauges, temperature gauges, and flow meters
- Check gear meshing and replace lubricant as needed
- Inspect hydraulic system oil quality and filter condition
Quarterly Maintenance
- Replace hydraulic oil and filters
- Inspect and adjust all transmission clearances
- Check bearing conditions and replace if necessary
- Test all safety interlocks comprehensively
Annual Overhaul
- Complete equipment disassembly and inspection
- Replace all wear parts including seals, bearings, and belts
- Restore equipment precision to factory specifications
- Update control system software and backup parameters
III. Lubrication Management Standards
3.1 Lubrication Principles
- All equipment lubrication points must use specified lubricants — mixing or use of unclean lubricants is prohibited
- Lubrication intervals and quantities must follow equipment manuals and lubrication charts
- Lubricant storage must be in clean, sealed containers in designated areas
- Record all lubrication activities including date, lubricant type, quantity, and responsible person
3.2 Five-Determination Lubrication Management
- Fixed Personnel: Assign specific personnel responsible for lubrication of each equipment unit
- Fixed Points: Clearly mark all lubrication points on equipment
- Fixed Quality: Specify exact lubricant grades and types for each point
- Fixed Quantity: Define exact lubricant quantities for each application
- Fixed Time: Establish precise lubrication schedules and intervals
IV. Special Equipment Management
4.1 Boilers and Pressure Vessels
- Strictly follow periodic inspection requirements as mandated by national regulations
- Check safety valves, pressure gauges, and water level indicators regularly
- Inspect pressure components for corrosion, deformation, or leakage
- Maintain complete inspection and maintenance documentation
4.2 Lifting Equipment
- Focus on inspecting wire ropes, hooks, slings, brakes, limiters, and safety interlocks
- Conduct periodic load testing as required
- Verify all safety devices function correctly before each use
V. Equipment Maintenance Records
5.1 Record Types
- Equipment Daily Point Inspection Form
- Equipment Periodic Maintenance Record
- Equipment Lubrication Record
- Equipment Fault Repair Record
- Spare Parts Replacement Record
5.2 Problem Reporting Process
Minor Hazards: Issues that can be addressed on-site by maintenance personnel — document in maintenance records after resolution.
General Problems: Issues requiring coordination or additional resources — promptly report to team leader or equipment management department.
Major Hazards/Faults: Emergency situations that may cause equipment damage or personal injury — immediately stop machine and report, while taking emergency measures to prevent escalation. Report content should include equipment name/model, fault phenomenon, occurrence time, measures taken, and preliminary cause assessment.
VI. Safety Compliance
6.1 Pre-Maintenance Safety Briefing
Before maintenance work begins, conduct safety briefing for operators covering maintenance content, steps, precautions, and ensuring operators possess corresponding skills and safety awareness. Tools and spare parts should be placed in order according to specified requirements.
6.2 Equipment Lifecycle Management
Daily maintenance should be incorporated into comprehensive equipment lifecycle management, forming closed-loop management with procurement, use, and disposal processes to improve overall equipment comprehensive efficiency and achieve systematic equipment management throughout the entire lifecycle.
