1️⃣ Visual & Physical Inspection

🔍 Check for dust, dirt, and debris

• Dirt and dust can accumulate on the motor’s surface and cooling vents, causing overheating. Regular cleaning prevents efficiency loss.

🔍 Inspect motor casing for cracks or overheating marks

• Overheating can cause discoloration or burnt marks on the motor housing. Cracks may indicate structural issues.

🔍 Ensure proper alignment between the motor and its load

• Misalignment between the motor and connected equipment can lead to excessive wear, vibration, and energy loss.

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2️⃣ Electrical Inspection

⚡ Measure voltage and current draw to ensure proper load balance

• Using a multimeter or clamp meter, check if the voltage and current draw are within the manufacturer’s specifications. Imbalances can damage the motor over time.

⚡ Check for loose or corroded electrical connections

• Loose connections cause resistance, leading to overheating and potential failure. Corroded terminals should be cleaned or replaced.

⚡ Inspect motor terminals for overheating or burn marks

• Overheated terminals can indicate excessive current flow or loose connections. These should be addressed immediately to prevent damage.

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3️⃣ Mechanical Inspection

⚙ Check motor bearings for wear and apply lubrication as needed

• Bearings reduce friction and allow smooth rotation. Lack of lubrication can cause friction, noise, and failure.

⚙ Ensure motor shaft alignment with connected machinery

• A misaligned shaft can cause uneven wear and excessive vibration, reducing the motor’s lifespan.

⚙ Test the motor for unusual noise or excessive vibration

• A well-maintained motor should run smoothly. Any unusual noise (grinding, humming, or rattling) may indicate internal damage.

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4️⃣ Insulation & Cooling System

🌡 Measure insulation resistance using a Megger test

• A megger test measures the insulation resistance between motor windings and ground. Low resistance indicates deteriorated insulation, leading to short circuits.

🌡 Clean cooling fans and ventilation openings

• Overheating is a common cause of motor failure. Ensure cooling fans and air vents are free from dust and debris to maintain airflow.

🌡 Check the motor’s temperature during operation

• Use an infrared thermometer or temperature gun to check the operating temperature. If it exceeds the rated value, there might be overloading or ventilation issues.

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5️⃣ Operational Testing

✅ Start the motor and monitor smooth operation

• The motor should start without delay or excessive current draw. A slow start may indicate capacitor or starter relay issues.

✅ Verify correct rotation direction

• Some motors have a designated rotation direction. Running in the wrong direction can affect equipment performance.

✅ Test motor under load conditions and ensure efficiency

• The motor should operate smoothly under its normal workload. Monitor any overheating, vibrations, or unusual noises.

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6️⃣ Safety Checks

⚠ Inspect emergency stop functions

• The emergency stop button must function properly to immediately shut down the motor in case of an emergency.

⚠ Test overload protection devices

• Overload relays protect the motor from excessive current. Test these devices to ensure they trip correctly when needed.

⚠ Ensure proper earthing and grounding

• A well-grounded motor prevents electric shock hazards and protects against electrical surges.

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7️⃣ Documentation & Reporting

📋 Log all maintenance activities and findings

• Record the date, time, and details of maintenance performed. This helps in tracking trends and identifying recurring issues.

📋 Record any unusual vibrations, noise, or overheating

• Keeping a detailed log helps diagnose problems before they lead to failures.

📋 Recommend necessary repairs or replacements

• If any component shows signs of wear or failure, recommend corrective actions such as part replacement or realignment.

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🔹 Additional PPM for Other Systems

8️⃣ CCTV System Maintenance

📹 Physical Inspection – Ensure cameras are free from dust and aligned properly.

📹 Functionality Testing – Check video clarity, night vision, and motion detection.

📹 Storage & Recording – Ensure footage is being recorded and saved properly.

📹 Power & Connectivity – Verify cables, power sources, and network connectivity.

📹 Software & Security – Update firmware and check access permissions.

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9️⃣ Home Automation System Maintenance

🏠 Smart Lighting & Switches – Test response time and automation schedules.

🏠 Sensors & Security – Ensure motion sensors and alarms work correctly.

🏠 Integration & Network – Check cloud sync and mobile app control.

🏠 Power Backup & Firmware – Test battery backups and update firmware.

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🔟 Gate Automation & Boom Barrier Maintenance

🚪 Mechanical Inspection – Lubricate hinges, rollers, and check structural integrity.

🚪 Motor & Control System – Inspect motor wiring, power levels, and emergency stop.

🚪 Access Control System – Test remote controls, RFID, and biometric scanners.

🚪 Power & Backup – Ensure UPS and battery backup systems are working.

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🔹 Electrical Systems & LED Lighting

💡 Wiring & Connections – Inspect for loose, burned, or corroded wiring.

💡 Load Management – Verify balanced voltage and test circuit breakers.

💡 Lighting Inspection – Ensure LEDs are functioning properly and not flickering.

💡 Surge Protection & Backup – Check surge protectors and UPS for reliability.