FRM-GEN-1702-200 Service Audit Checklist

• Document No.

• Depot

• Conducted on

  Date

• Prepared by

• Attendees

• Location
  Address

Unit Information

• Unit Number

• Unit Description

• Workplace being audited

Scoring 3 - Zero Errors 2 - Minor Errors 1 - Significant Errors NA - Not Applicable - Not Verified

• Audit Title

Supply Cabling

• Route, damaged insulation and protection

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Plugs and Sockets

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Position of Main Power Cable

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Condition of gantry (if fitted)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Unit displays current and valid tags

  Yes

  No

  N/A

• Next test due?

• Test Tag Serial # - RCD:

• Test Tag Serial # - Packer (Inlet Socket):

• Test Tag Serial # - Supply Lead:

ELECTRICAL EQUIPMENT

Control Box: CAUTION: Isolate power before opening control box.

• Condition, rust and weatherproof

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Boxes locked and secured via a key lock

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• RCD trips when test button pressed

  Yes

  No

  N/A

• Condition of conduit/cable entries

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Emergency stops at all control boxes

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Emergency stop "latch in when operated"

  Yes

  No

  N/A

• Condition of controls/lights on control box

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Key start switch spring returns (if fitted)

  Yes

  No

  N/A

• Key required to start machine (minimum standard - must prevent unauthorised access)

  Yes

  No

  N/A

• Equipment labelled (as per current stanard)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• PLC error light is not illuminated - if fitted - (contact Electrical Dept if illuminated

  Yes

  No

  N/A

Internal Equipment of Control Box

• Absence of vermin / moisture / dust

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Connections properly terminated (n unterminated or uninsulated wires)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Components securely fastened

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Box penetration/cable entries

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Wiring contained in duct or fastener

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

Compactor Wiring and Equipment (external and internal)

• Insulation protection

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Junction boxes externally sealed

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Conduit entries sealed

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Limit / proximity switches general condition

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Machine stops when cage door opened a maximum of 200 mm

  Yes

  No

  N/A

• Hopper doors switches shut down packer/lifter

  Yes

  No

  N/A

MECHANICAL

Compactor Tank

• Lift pin diameter (Check both A and B where applicable)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Weld Integrity

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Levels of rust

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Rear door seals

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Do turnbuckles meet current upgrade (applicable to all doors with compaction pressure against it)

  Yes

  No

  N/A

• Does the tank show signs of leakage

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

Compactor Unit

• Unit # present on machine

  Yes

  No

  N/A

• Secured to floor (if appliable)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Blade area has no holes

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Oil tank secure + oil level adequte

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• All panels secured

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• "Hopper" door barrel bolt servicable

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Positive locking for hopper door when in open position (door latches open)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Service access doors locked

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Bottom of compactor caged off to prevent access

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Unit sealed and shows no signs of leakage

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Levels of rust

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Lower edge of hopper 1.2m above operators walking surface

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

Compactor Cages/Lifter

• Secured to floor

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Barrel bolt serviceable

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Gap between Cage and Packer (max 50mm)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Door hinges in good condition

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Mesh in good condition

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Check for damage to cage (Dents, sharp edges, etc)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Lifter bush condition

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• General lifter condition

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Cage door switch shuts down machine

  Yes

  No

  N/A

Compactor Enclosure

• Access available to turn buckles

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Access to power lead

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Condition of floor

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Possibility of slips/trips/falls

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Items stored in compactor enclosure

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Lighting adequate for tasks

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

HYDRAULIC EQUIPMENT

Hydraulic Oil Sample #

• Check for obvious leaks

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Check condition of hose and fittings

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Check hose routing

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Check pack ram change over (Fwd to Rev)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Lifter operation is smooth

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Inspect condition of oil (visual)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• If oil is visibly cloudy or suspicious - take sampling and take remedial action as suggested by the lab

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

Access - Via ramps, walkways, platforms, and railing heights (If railing height is outside the designated range contact Fleet Management to assist in assessing Railing Requirements).

• Ramp Incline within acceptable limits (Max gradient 1 in 8 Non-Slip Surface)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• If platform is above 300mm railings must be fitted. Railing height must be between 900mm and 1100mm

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Condition of all equipment acceptable

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Possibility of slips/trips/falls (nil smooth walkways, unexpected rises in platform, unexpected variations in ramp and decks)

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

SIGNAGE

Safety Stickers - check stickers are present (if applicable) - Sticker Kit Conversion

• C9v2 Electrical Equipment Sticker fitted to control boxes

  Yes

  No

  N/A

• C1v1 Safety Instruction

  Yes

  No

  N/A

• C11v1 Operational instruction

  Yes

  No

  N/A

• Switches/light labels

  Yes

  No

  N/A

• C2v1 Do not tamper with safety equipment

  Yes

  No

  N/A

• C6v1 Warning stand clear of bin lifter

  Yes

  No

  N/A

• C10v1 Do not enter cage

  Yes

  No

  N/A

• C3v1 Machine starts automatically

  Yes

  No

  N/A

• C8v1 Disconnect Power sticker (Unipak)

  Yes

  No

  N/A

• C7v1 Release stored energy sticker

  Yes

  No

  N/A

• C5v1 Isolate before servicing

  Yes

  No

  N/A

• C13v1 Transport from 'A' Frame End

  Yes

  No

  N/A

• Stickers are not covered / faded

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

• Condition of other stickers as per Compactor Intranet Site

  3 - Zero Errors

  2 - Minimal Errors

  1 - Considerable Errors

  0 - Not in Place

  N/A - N/V

LUBRICANT - Lubricate Machine

• Lifter if fitted

  Yes

  No

  N/A

• Packing mechanism where applicable

  Yes

  No

  N/A

• Turn buckles where applicable

  Yes

  No

  N/A

• All hinges and latches including tank if appliable

  Yes

  No

  N/A

• Wiper

  Yes

  No

  N/A

• Pad locks

  Yes

  No

  N/A

Comments

• Add media

  Media

• Service Technicians Comments:

• Remedial Action

• Defects arising from Service

• Service Technicians Name:

  Sign

• Auditor's Name:

  Sign