MAINTENANCE ROUTINE PREVIEWED

Acronyms maintenance (abbreviations)

As the word and the concept, many maintenance acronyms are Anglo-Saxon. A
neologism emerged, including the most spectacular is the plethora of acronyms starting with
"MT" (initials of "mean time", literally "average weather" (Anglicism), it is time to say average
mean time interval, and consequently, time average). Some acronyms as examples, together
with their more or less literal translation;

 MTBF: mean time between failures,

 MTTR: mean time to recovery or mean tome to restart or mean time to repair or mean
time to return to service;

 µ is the repairing rate;

 𝝀is the failure rate,
 MTTFF: mean time to first failure,
 MUT: make up time,
 MDT: production stoppage time

The Availability, Reliability and Maintainability time of equipment

This schematic diagram shows steps in which a system can be repairable.

Fig: FMD diagram

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 MAINTENANCE ROUTINE PREVIEWED
And the below graph indicates the life span of any equipment:

Graphical form of failure rate 𝝀

ZONE 1: This is the beginning of the life of an equipment which is still young, the
component can have failure due to the manufacturing (fabrication).

ZONE 2: This is the Failure period where 𝝀is constant. It is the natural zone, zone of
full productivity of the equipment. Here every failure is possible and non-predictable.

ZONE 3: This is the period due to ageing of equipment, 𝝀 increase here with time. The
fatigue of components is obvious.

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DIFFERENT LEVELS OF MAINTENANCE

Since we will be walking on a production line where by availability will be our highest target,
it will be good to talk about some bases in different maintenance levels as follows

According to NF X 60-010 defines an indicative five "levels of service" (include

"interventions"):

MAINTENANCE LEVELS
LEVEL WORK LOCATION PERSONNEL EXAMPLE
1 simple adjustments - On site Operator resetting after
no disassembly or an automatic
opening shutdown

2 Troubleshooting on site qualified changing a

exchange standard technician relay
minor operations - control fuse
preventive -reset circuit
maintenance breaker
_greasing

3 Identification and on site or in technician identification

troubleshooting - maintenance of the faulty
repair exchange workshop component,
standard - minor finding the
mechanical repairs - cause,
preventive eliminating
maintenance (e.g. the cause,
Adjustment or replacement
realignment of
measuring devices)
4 important work specialized coaching team work on
except corrective or workshop with material for
preventive tools with specialized return to
maintenance general technical service is
renovation and testers, subject to
reconstruction - documentation qualification
setting measuring
devices - control
standards

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5 Renovation - rebuild - manufacturer means close to compliance

the by regulation
major repairs or rebuilder
manufacturing of heavy
equipment

CYCLE OF A CORRECTIVE MAINTENANCE

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Proposed intervention report form

INTERVENTION REPORT

Intervener: NATURE OF INTERVENTION

Date: Mec Elec Pneu Hyd

Time of intervention: Intervention required

Call time: Cleaning adjustments

Start: Replacement welding

Modification Reconfiguration
Finish:
Reprogramming scrap

Mode of failure:

(Mode de défaillance)

Cause of failure:

Cause de la

Maintenance operation:
(Opération de maintenance)

Replaced part:

(Piéce détachées)

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BUILDERMAT FACTORY ROUTINE MAINTENANCE PREVIEWED PROGRAM

A- CUBER & TRAY BIN

The following aspect to be follow up and understood accurately in the following technologies are:

Mechanic Electric hydraulic Pneumatic

* identify all orifice * identify all sensors * Visit for leakages * control and visit on the FLG
on the section to be with nomenclatures on and cleaning, systems
lubrified/greased ( in them;
number form) if * once oil leakages are
possible with *control the position found on the jacks,
nomenclatures on of lifting limit valve blocks valve
them; switches on the Cuber part, tubing or other
tray (up and down); hydraulic parts,
* Control and visit will methods such as
be carried out on the corrective maintenance
pinions on cuber ( for will be applied on
necessary greasing) seals rings or whole
part replacement ( to
* avoid machine
malfunctioning)

*During operation, verify whether the level, lifting and rotation of cuber main engine and its double
clamping switch run reliable and stop at a correct position with any collision.

* All power shall be cut off when repairing, filling up lubrication oil and cleaning the machines

* -Fastening of *regular listening and

bolts,- Filling up and visit are required
lubrication oil and during the operation of
cleaning shall be done the oil motor and oil
repeatedly every two pump.
shifts (note during full
production) * filter the hydraulic
oil once a year.

* check actual oil level

to make up

* Attention need to be paid to whether the limit of each process is normal and whether the screws are loose
at any time. so therefore if any, the machines needs to be stop in time for adjustment to eliminate hidden
dangers

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B- Fully Automatic conveyor system

it consist of pallet feeder, block conveyor, mobile type stacker, block unloader, block unloading
conveyor, pitch type conveyor pallet turnover, horizontal conveyor, chain-type conveyor,
oil/non-oil brush machine and pedestrian bridge

B-1. SB1100H Pallet feeder (inlet into the mould)

Mechanic Electric hydraulic Pneumatic

* verify (period still to * ensure whether the *Visit to the pipes, *Control and visit on the FLG
be determine) whether all electrical devices valves, jacks systems
are reliable; distributor and its units
the bolts are fastened
and the moving parts *examine whether the
stroke and the
are flexible and
photoelectric switch
reliable before are in accurate
production positions and the
connections are
commences(for now
fastened without
daily) loosening;

*clean up the trickle * identify all sensors

material and sundries with nomenclatures on
or dust particles on the them;
moving parts and fill
up lubrication on every
oil site

B-2. SZ605 BLOCK CONVEYOR (green blocks)

Mechanic Electric hydraulic Pneumatic

*Ensure that there are * examine whether the No hydraulic No pneumatic

no dirt and barriers electrical devices are
inside the guide rails reliable and whether
of the belts and always the stroke
lubricate the chains photoelectric switch
and test to see if the are in accurate
running is smooth positions and the
connections are
* examine whether the fastened without
bolts are fastened and loosening;
the moving parts are
flexible and reliable * identify all sensors
with nomenclatures on
them;

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B-3. GP1100 PITCH-TYPE CONVEYOR (cured blocks and pallet transporter)

Mechanic Electric hydraulic Pneumatic

*Before its first running, please examine the height of whole machine to make sure the position connecting
with the front and rear equipment is accurate.

* Please ensure that there are no dirt and barriers inside the machine and keep the guide rail clean
with no sundries.

*Make sure the * Please examine * visit * Check the fuel consumption
lubrication of each whether the in pneumatic FRL
bearing and moving electric devices are
parts are in good reliable and
condition and rotate
whether the stroke
flexibly.
and photoelectric
*Please examine switch are in
whether the bolts are accurate positions
fastened, the moving and the
parts are flexible and connections are
reliable and each fastened without
claw is in correct loosening.
position.

B-4. FB1100B Pallet Turnover (90°)

Mechanic Electric hydraulic Pneumatic

*Please ensure that * Please examine NON NON

there are no dirt and whether the electric
barriers inside the devices are reliable
machine and keep and whether the
the guide rail clean stroke and
with no sundries. photoelectric switch
are in accurate
*Please examine positions and the
whether the bolts are connections are
fastened and the fastened without
moving parts are loosening;
flexible and reliable.

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B-5. HSB950 Horizontal Pallet Conveyor ( where by pallets are being oiled during the process)

Mechanic Electric hydraulic Pneumatic

*Make sure the * identify all sensors *control the hydraulic * Check the fuel consumption
lubrication of each with nomenclatures on units in pneumatic FRL
bearing and moving them;
parts are in good
condition and rotate
flexibly;

Please ensure that there are no dirt and barriers inside the machine and keep the guide rail clean
with no sundries.

*Please examine *Please examine

whether the bolts are whether the electric
fastened and the devices are reliable
moving parts are
and whether the
flexible and reliable
stroke and
photoelectric switch
are in accurate
positions and the
connections are
fastened without
loosening.

B-6. QFT10.26.2B Chain-type Conveyor (transfer of finish block stacking for forklift)

Mechanic Electric hydraulic Pneumatic

*Clean up the * Please examine NON

trickled material and whether the electric
sundries of the
devices are reliable
machine after every
shift and fill up and whether the
lubrication on every stroke and
oil site
photoelectric switch
*Please examine are in accurate
whether the bolts are
positions and the
fastened, the moving
parts are flexible and connections are
reliable,

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fastened without
loosening.

B-7. MZJ10D Block Stacker

*Before its first running, please check whether the oil in the reducer is sufficient and make sure the
lubrication of each bearing and moving parts are in good condition and rotate flexibly.

*Clean up the trickled material and sundries of the machine after every shift and fill up lubrication
on every oil site.

Mechanic Electric hydraulic Pneumatic

*Please ensure that *Please examine * Check the fuel consumption

there are no dirt and whether the electric in pneumatic FRL
barriers inside the devices are reliable
machine and keep and whether the
the guide rail clean stroke and
photoelectric switch
* Please examine are in accurate
whether the bolts are positions and the
fastened, the moving connections are
parts are flexible and fastened without
reliable, and each loosening.
claw is in correct
position.

* Clean up the
trickled material and
sundries of the
machine after every
shift and fill up
lubrication on every
oil site (if necessary)

B-8. XZJ10F1 Destacker

Mechanic Electric hydraulic Pneumatic

Same action carried out on B-7

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QFT10-300 Block Making Machine

Mechanic Electric hydraulic Pneumatic // Operators

*Lubricate every * the approximation *checking the * Operators /Concrete in the

part as required, and sensors need to be hydraulic parts and mixtures in mixing machine
the lubricant oil level followed up during the assembly joints and hoppers gets
should not be higher this period of for leakage coagulating easily. So
operation and adjust
than the down face concrete should be used as
later;
of the soon as possible, do not
synchronization * identify all sensors store it for long time. The
gear. And adding the with nomenclatures on concrete remains left on the
grease to the nipples them; machine should be removed
daily. after every shift

*The users should *There cannot be aggregate

replace the seal parts particles or other materials
or totally change with diameter＞10mm in
when the cylinder, the mixtures, especially
valve, pipe or any steel and other hard things
kind of hydraulic when mixing and feeding
parts leak. The material to avoid damages
machine cannot run to the parts. Check the shift
with problems. You daily
can look over by * Set the parameters of
hearing, seeing and material feeding, vibration,
touching when the the pressing time according
hydraulic pump and to the size and shape of the
motor working. As products. To improve
anything is out of the productivity based on the
way, stop and check high quality and adjust the
the machine, then fix amount and frequency of
it. feeding when needed.

*Clean the filter core *Do not use unqualified

on time, and filtrate pallets which may damage
the oil one time at the machine. Make sure
least annually pallets are clean and remove
the binding material on the
pallets before sending them
into the pallets feeder. The
number of the pallets in the

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pallets feeder should not be
over the plain top

*make sure that the *Remove the residual

temperature of the concrete aggregate on the
hydraulic oil is lower molding box, press head and
than 60°C the other parts every shift.
(cleaning)

*The limit switches should work well and the bolts and others for fixed should not be loose. If find
any abnormal, stop the machine at once to remove the malfunction.

*Adjust the altitude of the leading track and the bottom board of coarse concrete cart when
changing the moulds. After the adjustment, fasten the bolts one by one and check the dimensions
and the locations of the parts, fix the proximity switch, etc. Then test the machine in this process”
manual-auto-trial produce” to check the dimensions and eliminate errors.

MP1000 PLANETARY CONCRETE MIXER

Mechanic Electric hydraulic Pneumatic / operators

*Cut off the power before maintenance and set warning signs;

*Ensure no people inside the trough before starting the mixer;

*verify daily if the *make sure the * water pressure for *operators/ check if all the
gearbox oil is at the supplied voltage mixing should be 2- initial security devices are
marked position for should agree with 3bar; ready before starting the
production; rated voltage of mixer
motor and other *check hydraulic oil
*check whether all electrical level; and pressure * operators/ the
the bolts are tight, if components; should not be more temperature of the gear box
not do so ( weekly) than 90bar should not exceed 70-75°C,
*check if the the highest should be 85°C;
*check the position approach switch is *verify if the
of mixing arms; sensitive or not ( all hydraulic unit * operators/ use 50-60bar
the captors) before pipeline are fixed of water gun/pressure to
*check if the gear firmly to reduce clean them after every shift
box runs steady and production;
noise;
no abnormal noise; * operators /after each shift,
* faults and
*the working clean the discharging door,
*check if the space diagnosis if the
pressure for the check the maintenance door,
between the blade mixer fails and it not mixing trough and mixing tool,
caused by motor or discharge door is 60-
and the liners is not 80bars, repeat to the
and open and close the
more than 10mm, relative switch,
inspect the electrical opening and closing
adjust it to be 10mm

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to ensure the mixing component and cable of the discharging discharging door several times
arm can scrape and replace the door and check if its to ensure the smooth actions;
materials on the damage component; flexible or not;
*clean the surface of the
sides. But if the hydraulic component;
clearance more than *to ensure normal
10mm and cannot working pressure, *clean the cement and grease
more be adjusted, verify whether the on the mixing trough with
replace the blades, cylinder and valve gun water of 50-80bar after
when the mixing leaked in the each working shift of 8 hours
arms are badly worn, temperature and
*clear all the blocked cement
replace them; pressure if yes,
on the k after every 50hours
replace the leakage of work (weekly);
*the space between component;
the mixing arms and
the side tiles should * replacement of
hydraulic oil and *operators: corrective/ if the
not be more than
filter should be machine stop due to electrical
5mm (test instantly
done in the first 100 failure or over load, discharge
to check if the some materials before starting
mixing blades and running hours, 2nd
again while the discharging
liners interfered or replacement at its
door is operated manually;
not); 1000hours then
from there every *operators: corrective/ if the
*make sure the 2000hours machine stop due to fusing and
clearance between thermal protection, keep the
the liners and tiles or *take some system cool then re-start, in
not more than 4mm hydraulic oil to test this situation, discharge all the
and are parallel to the chemical; materials once with discharge
door operated manually;
each other; *over haul the
*after each shift, hydraulic system
check inside the once a year;
mixer after it has * faults and
been clean whether diagnosis if the
the bolts are loose or discharging door did
not not act when press
*recommended gear OPEN / CLOSE
oil (MOBIL button, but acted
when press manually
ELGRE CO220 or
the left and right bolt
SHELL SHC630;
of the solenoid
valve, it’s a circuit
faults, inspect the
*do not mix different contactor and coil of
types of gear oil; the solenoid valve

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avoid filling too
much or too less for
it may affect gear
running or gear wear
respectively;
*check the gear oil
height level monthly
and fill oil in time;
*Gear box oil should
be replaced after the
first 100 running
hours then every
1500hours
and ensure good
power supply. If not
possible, check
whether the oil level
and pressure of the
hydraulic oil is
correct if not inspect
the entire system.
*change the cylinder
if the discharge door
did not act due to oil
leakage of cylinder;

*Manual oil nipple

greasing (3 lithium
grease) should be
done weekly on the
mixer arms bearings.
See manual to see
the filling points

*clean the air vent of

the gear oil filling
blockage 2-3
months ( due to
dirty parts, dirty
lubricant or dusty
working
environment the air
vent of the filling
blockage is easily
blocked causing the
oil temperature too
high and destroys the
seals;

* check all the wear

situation of wearing
parts on the mixing
trough (200hours)

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*check the *check weekly the

lubrication on the isolations of all the
cement screw motors then prevent
bearings after 400hrs them from water
of functioning penetration each day

*check the blade and *verify whether the

tiles weekly, replace screws tightening the
them if necessary cables are not loose

*grease the railways

of all the moving
bodies;

*lubricates the all

the motors as
specified;

*verify the
discharging
conveyor belt during
functioning to adjust
it center position

Mechanic: The assign preventives operation on the aggregate skip system consisted of skip hopper,
orbit and the hoisting system will be greased frequently once full production commences,

Mechanic: The preventive to be carried out now on the cement screw are grease the bearings after every
400hours of functioning

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