Service details
From batching computer or hour meter — tracks 200hr and 500hr service intervals
Compliance status
Daily lubrication — confirm current at this service
These must be done daily per Vince Hagan manual. Confirm they are current and in good condition.
Gate quadrant grease fittings
All gate quadrant bolt fittings — grease fitting at each bolt
Lithium base grease. Should show slight weep at fitting.
Air supply lubricator — 10W oil
At cylinders on cement section and aggregate section
Fill with 10W non-detergent oil. Set to 1 drop per valve cycle after warm-up.
Air cylinder rod oil film — all cylinders
Aggregate bin gates, aggregate batcher gates, cement batcher, silo bottoms
All rods must show oil film. Dry rod = apply oil immediately.
Piston vibrator lubricators
Bin feed hopper, aggregate batcher, cement batcher, silo bottoms
Fill all lubricator reservoirs.
Motor bearings — monthly · CAUTION: at standstill only
⚠ ALL motor bearings must be lubricated at standstill only. Wipe fitting clean first. Grease slowly until fresh grease appears at both seals.
Radial stacker conveyor motor bearings
Unit 2 — drive motor at base of stacker
At standstill. Flush until fresh grease at both seals.
Inclined raw conveyor motor bearings
Unit 5 — conveyor drive motor
At standstill. Flush until fresh grease at both seals.
Baghouse blower motor bearings
Unit 6 — dust collector blower motor
Baghouse discharge fan motor bearings
Unit 6 — discharge fan motor
Baghouse rotary airlock motor bearings
Unit 6 — rotary airlock drive motor
Turn head motor bearings
Bin feed conveyors — top of aggregate bin
Pillow block & flange bearings — monthly
Grease slowly at operating speeds until fresh grease appears at both seals. 200-series ball bearings — Vince Hagan 500hr minimum. Monthly is NRMCA best practice for this environment.
Stacker head pulley pillow block bearings
Unit 2 — head pulley, both sides
Stacker tail pulley pillow block bearings
Unit 2 — tail pulley, both sides
Raw conveyor head pulley pillow block bearings
Unit 5 — head pulley
Raw conveyor tail pulley pillow block bearings
Unit 5 — tail/drive end
Flip-flop tray / door flange bearings
Conveyors, top of aggregate bin, batch belt conveyor
Continuous motion during operation — check for wear
Turn head flange bearings
Top of aggregate bin — radial stacker pivot
Live bottom cement batcher flange bearings
Unit 7 — cement weigh hopper batcher
Check for cement contamination in bearing seals
Conveyor idlers — quarterly (every 3 months)
Many idlers are sealed-for-life — NO lubrication needed. Only service idlers with grease fittings. Max 200 PSI. ~1 tablespoon per roller.
Confirm idler type on this plant
Inspect Units 2 and 5 — re-greasable or sealed-for-life?
If sealed-for-life: document here, no lubrication. If re-greasable: service below.
Stacker re-greasable idlers (if applicable)
Unit 2 — grease while running, 1 tbsp per roller
Raw conveyor re-greasable idlers (if applicable)
Unit 5 — grease while running, 1 tbsp per roller
Return idler rolls — inspect all
All conveyors — check for free rotation, no seized bearings
Seized idler = friction = fire risk. Replace immediately.
Shaft mounted reducers & gear drives — oil check monthly
Stacker conveyor shaft mounted reducer — oil level
Unit 2 — check at level plug, face input shaft side
Oil should be at center of sight glass. Note any metal particles on drain plug magnet.
Raw conveyor shaft mounted reducer — oil level
Unit 5 — check at level plug
Same procedure. Metal particles on drain plug = internal wear.
Baghouse rotary airlock gear reducer — oil level
Unit 6 — rotary airlock drive
Chain drives — fluid level
Bin feed conveyors, mixers — check chain case
Check for sludge or metal contamination.
Hour-based service items
Service based on cumulative operating hours. Verify against current hours entered above.
Rotary cement valve shaft bearings — every 200 hrs
Cement section — shaft bearings on rotary cement valve. High-contamination area.
200hr interval reached — service rotary cement valve bearings this visit.
General 200-series ball bearings — every 500 hrs
All pillow block, flange, and ball bearings plant-wide. Vince Hagan minimum baseline.
Approaching 500hr interval — perform full bearing flush this visit.
Gear couplings — first million revolutions then as needed
Bin feed conveyors, batch belt conveyor, mixers. Critical on new or rebuilt equipment.
Wheel hubs — annual (pack with grease once per year)
Bin feed conveyors, turn heads.
Air compressor service
Compressor case oil — level and condition
Tail end of plant — check dipstick or sight glass
Clear to amber = good. Dark or milky = contamination. Change annually or per manufacturer.
Air intake filter — inspect and service
Compressor intake — inspect element condition
Heavy dust environment — inspect monthly. Replace when restriction shows. Clean if washable type.
Compressor drive belt — tension and condition
Compressor drive — V-belt condition
Glazed, cracked, or frayed = replace. Incorrect tension causes premature bearing failure.
Compressor tank — drain moisture
Tank petcock — drain fully before service
Open petcock until all moisture discharges. Verify auto-drain cycling if equipped.
Baghouse cartridge service — Unit 6 (7 cartridges each)
Unit 6A (cement) and Unit 6B (flyash) — VH245JP pulse jet baghouses. Permit opacity limit: 20% (Cond. 2d). Replace if torn, plugged, or hopper 2/3 full.
Unit 6A — inspect all 7 cartridges
Cement silo baghouse — remove access panel
Check for tears, blowouts, blinded media. Tap lightly — heavy fallout = plugged. Replace if hopper 2/3 full.
Unit 6B — inspect all 7 cartridges
Flyash silo baghouse — same procedure
Flyash is finer — may blind faster. Check differential pressure.
Cartridges replaced this service?
Pulse cleaning system — solenoids and timer
Unit 6 pulse controller — listen during operation
Each solenoid must fire cleanly. Timer must cycle all rows. Missing pulses = stuck solenoid.
Differential pressure — check reading
Unit 6 — manometer or pressure gauge
Normal: 2-6 inches WC. High ΔP = plugged cartridges. Low ΔP = cartridge failure or bypass.
Belt & conveyor inspection
Belt condition — full length both conveyors
Units 2 and 5 — run belt, inspect full surface
Cuts, fraying, edge wear, splice condition. Note location of any damage.
Belt tracking — centered on all idlers
Both conveyors at head, tail, and all idlers
Misaligned belt = edge wear, spillage, structural damage. Trougher idlers for loaded tracking, return idlers for empty.
Belt splice — fasteners and condition
Head end of each conveyor
Check tightness — too loose or tight both cause damage. Mechanical: check each clip. Vulcanized: check edges.
Belt tension — adjust take-up if needed
Tail end of each conveyor
Just enough to prevent slip at head pulley. Over-tension damages belt, splice, and bearings.
Skirt board rubber — all load points
Loading zones on both conveyors
Rubber must fold flat on belt. Any gap allows material on return belt.
All conveyor frame bolts — check and tighten
Full frame both units
Vibration loosens all bolts.
Scales & weigh systems
Scale zero check — all hoppers empty
Units 4 and 7 — aggregate batcher and cement weigh hopper
Zero with hopper empty only. Drift beyond tolerance = calibrate.
Scale float — all hoppers
All weigh hoppers — push gently, must spring back
Nothing touching hopper sides. Check all boots, cables, conduit — none pulling on hopper.
Load cells — visual inspection
All weigh hoppers — cable condition, physical protection
Damaged cable insulation, moisture, physical impact = replace. Cannot be field repaired.
Scale pivots — clean and check
Discharge gates and scale pivots
Must move freely and be clean. Cement/aggregate buildup causes scale error.
Scale calibration status
Structural integrity & safety systems
Weld inspection — entire plant
All welded connections on structural steel, hoppers, conveyors
Cracked welds or deformed metal = notify plant manager immediately. Do not operate until repaired.
All plant bolts — check and tighten
Full plant — all structural and mechanical bolts
High vibration environment. Loose bolts cause progressive damage.
Emergency stop systems — test all
All e-stop buttons and conveyor pull cords
Press/pull each one. All must stop equipment immediately.
Safety pull cords — full length test
Units 2 and 5 conveyor pull cords
Pull from multiple points — must stop conveyor from anywhere along conveyor length.
Guards and safety devices — all in place
All rotating equipment, nip points, belt conveyors
No missing or bypassed guards.
Fire extinguishers — inspect all
All plant locations
Charged, pin in place, tag current, unobstructed.
Semi-annual bearing inspection — every 6 months
Vince Hagan requires bearing inspection at minimum every 6 months. Any unusual noise or vibration must be investigated immediately.
Is this a 6-month bearing inspection service?
Water system — monthly inspection
Water spray nozzles — clean and inspect all
All spray nozzles on aggregate loading points — Units 1-5
Clogged nozzles = incomplete coverage = Condition 1f.iii violation. Flush or replace.
Water pump — pressure and operation
Plant water pump — check pressure gauge
Low pressure = clogged strainer or pump wear.
All water lines and fittings — check for leaks
Full plant water system
Any active leaks must be repaired same day.
Water butterfly valve — operation check
Main water supply valve
Must move freely — not sticky in either direction.
Additional items & follow-up
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