A detailed Crawler Crane QUARTERLY preventive maintenance checklists
1. Safety Precautions
2. Visual Inspection
- Look for any visible dents, scratches, or other surface damage.
- Check for any loose or missing bolts and fasteners.
- Assess the paint condition for signs of rust or corrosion.
- Ensure all components are securely attached and in place.
- Inspect hydraulic hoses for cracks or signs of wear.
- Look for wet spots or puddles under the crane.
- Verify fluid levels in the hydraulic reservoir.
- Ensure all seals are intact and functioning properly.
- Inspect the entire length of the wire rope for damage.
- Check for any signs of rust or corrosion on the wire.
- Look for kinks or twists that could affect performance.
- Ensure end fittings are secure and not damaged.
- Look for any visible cracks or deformities on the boom.
- Check for signs of excessive wear in load-bearing areas.
- Inspect welds for integrity and signs of failure.
- Ensure all structural components are clean and undamaged.
- Check that all required safety decals are present.
- Inspect labels for fading or damage that affects readability.
- Ensure that warning signs are properly placed and visible.
- Replace any damaged or missing decals as necessary.
- Check for cracks or deformation in the undercarriage.
- Look for excessive buildup of dirt or debris.
- Inspect components for signs of wear or damage.
- Ensure all parts are free from obstruction for functionality.
- Inspect tracks for cracks or deformities.
- Check for wear indicators showing excessive wear.
- Look for missing links or components in the track system.
- Ensure tracks are properly tensioned and aligned.
- Check that counterweights are properly secured.
- Inspect for cracks or signs of wear on the weights.
- Ensure there is no excessive rust or corrosion.
- Verify that the counterweights are appropriate for the load.
- Check for any visible damage to the cab structure.
- Ensure controls are clean and free of obstructions.
- Test all controls for proper functionality.
- Inspect the seating and ergonomics for comfort.
- Inspect mirrors for cracks and cleanliness.
- Ensure windows are clear and unobstructed.
- Check that all visibility aids are functioning correctly.
- Replace any damaged mirrors or windows as needed.
- Inspect outriggers for bends or deformation.
- Check for wear on pads and securing mechanisms.
- Ensure stabilizers deploy and retract smoothly.
- Look for any signs of hydraulic leaks in the system.
- Check wiring insulation for fraying or damage.
- Inspect connections for corrosion or looseness.
- Ensure all electrical components are secure and functioning.
- Look for any signs of overheating or burning.
- Test all lights for functionality and brightness.
- Inspect lenses for cracks or dirt buildup.
- Ensure signals are clear and visible from all angles.
- Replace any non-functioning lights immediately.
- Check for signs of fuel leaks around the tank.
- Ensure the tank is properly secured to the crane.
- Inspect the fuel cap for tightness and integrity.
- Look for any rust or corrosion on the tank surface.
- Inspect the ladder for stability and secure attachment.
- Check for any signs of wear or damage on rungs.
- Ensure access points are clear and unobstructed.
- Verify that handrails are secure and intact.
- Ensure fire extinguishers are easily accessible.
- Check the expiration date and service tags.
- Inspect for any visible damage or corrosion.
- Verify that extinguishers are properly mounted and secured.
- Ensure the operator's manual is present and up-to-date.
- Check that maintenance records are complete and organized.
- Verify that all previous inspections are documented.
- Ensure the manual is easily accessible in the cab.
3. Mechanical Systems
- Locate the engine oil dipstick.
- Remove and wipe clean the dipstick.
- Reinsert and remove the dipstick to check the level.
- Inspect oil color and consistency.
- Change oil if it’s low or dirty.
- Locate air filter housing.
- Remove the air filter carefully.
- Inspect for dirt and damage.
- Clean with compressed air or replace if necessary.
- Reinstall the air filter securely.
- Inspect hoses and connections for leaks.
- Check coolant reservoir for appropriate levels.
- Look for signs of corrosion or damage.
- Tighten loose connections if needed.
- Top off coolant if levels are low.
- Identify all moving parts and pivot points.
- Clean surfaces to remove debris.
- Apply appropriate lubricant to each point.
- Wipe off excess lubricant.
- Ensure parts move freely after lubrication.
- Check brake fluid levels.
- Test foot brake and emergency brake functionality.
- Listen for unusual noises during operation.
- Inspect brake pads for wear.
- Ensure braking response is smooth and consistent.
- Inspect each bolt and fastener visually.
- Use a torque wrench to check tightness.
- Tighten any loose bolts to specifications.
- Look for signs of fatigue or damage.
- Replace any compromised fasteners.
- Examine all hydraulic hoses for cracks.
- Check connections for leaks or wear.
- Ensure clamps are tight and secure.
- Replace any damaged hoses immediately.
- Test hydraulic system after replacements.
- Visually inspect tracks for damage or wear.
- Check sprocket teeth for signs of wear.
- Measure track tension against specifications.
- Adjust tension if necessary.
- Clean debris from tracks and sprockets.
- Extend and retract boom and jib.
- Listen for unusual noises during operation.
- Check for smooth movement and response.
- Inspect cables and pulleys for wear.
- Lubricate moving parts if necessary.
- Locate the slew ring assembly.
- Check for signs of wear or damage.
- Inspect lubrication points for accessibility.
- Apply suitable lubricant to the slew ring.
- Ensure smooth operation after lubrication.
- Inspect winch for operational issues.
- Check rope for fraying or kinks.
- Ensure rope is properly wound on the winch.
- Replace any damaged sections of the rope.
- Test winch operation under load.
- Inspect counterweights for structural integrity.
- Ensure all securing mechanisms are tight.
- Check for signs of corrosion or damage.
- Test counterweight functionality during operation.
- Document any issues found.
- Examine each hydraulic cylinder for leaks.
- Check seals and fittings for damage.
- Test cylinder operation by extending and retracting.
- Listen for unusual sounds during operation.
- Replace or repair any faulty cylinders.
- Inspect drive belts for wear or damage.
- Check alignment of pulleys and gears.
- Tighten any loose components.
- Look for signs of excessive wear.
- Ensure smooth operation of the drive system.
- Inspect controls for functionality.
- Check for any obstructions in the cab.
- Look for signs of wear on seats and controls.
- Ensure visibility is unobstructed.
- Clean the cab area thoroughly.
- Locate the hydraulic fluid reservoir.
- Check fluid level against the dipstick or gauge.
- Inspect fluid condition for color and debris.
- Top off or change fluid if necessary.
- Ensure all caps are securely fastened afterward.
- Inspect each safety interlock visually.
- Test functionality of limit switches.
- Ensure all switches engage and disengage properly.
- Look for signs of wear or damage.
- Replace any faulty components immediately.
- Locate the radiator and remove debris.
- Check for bent fins or damage.
- Clean using compressed air or a soft brush.
- Ensure airflow paths are clear.
- Inspect hoses for leaks or wear.
4. Hydraulic Systems
- Locate the hydraulic fluid reservoir.
- Use a dipstick or gauge to check fluid levels.
- Add the appropriate hydraulic fluid if levels are low.
- Ensure the reservoir cap is securely closed after topping off.
- Examine hoses for cracks, bulges, or abrasions.
- Check fittings for signs of leakage or corrosion.
- Ensure all connections are tight and not damaged.
- Replace any worn or leaking hoses and fittings immediately.
- Extend and retract each cylinder fully.
- Listen for unusual noises or observe for leaks.
- Check seals for wear or damage.
- Document any issues and perform necessary repairs.
- Drain the hydraulic reservoir carefully.
- Remove and clean filters according to manufacturer guidelines.
- Inspect for debris or contamination.
- Replace filters if they show excessive wear.
- Locate the hydraulic fluid reservoir.
- Use a dipstick or gauge to check fluid levels.
- Add the appropriate hydraulic fluid if levels are low.
- Ensure the reservoir cap is securely closed after topping off.
- Examine hoses for cracks, bulges, or abrasions.
- Check fittings for signs of leakage or corrosion.
- Ensure all connections are tight and not damaged.
- Replace any worn or leaking hoses and fittings immediately.
- Extend and retract each cylinder fully.
- Listen for unusual noises or observe for leaks.
- Check seals for wear or damage.
- Document any issues and perform necessary repairs.
- Drain the hydraulic reservoir carefully.
- Remove and clean filters according to manufacturer guidelines.
- Inspect for debris or contamination.
- Replace filters if they show excessive wear.
- Listen for abnormal sounds while the pump is operating.
- Check for vibrations or overheating.
- Inspect for fluid leaks around the pump.
- Document any irregularities and schedule repairs.
- Inspect all hydraulic line connections.
- Ensure there is no dirt or debris around fittings.
- Check for signs of wear on connection points.
- Tighten loose connections as necessary.
- Operate control valves to observe functionality.
- Check for smooth operation without sticking.
- Inspect actuators for responsiveness.
- Document any malfunctions for further evaluation.
- Examine all metal surfaces for rust or corrosion.
- Check hydraulic lines for signs of deterioration.
- Inspect the reservoir and components for physical damage.
- Replace any corroded or damaged parts immediately.
- Monitor fluid temperature using a gauge.
- Ensure it remains within the manufacturer's specified range.
- Allow cooling if temperatures exceed limits.
- Document temperature readings during operation.
- Activate the system to engage the relief valves.
- Observe for proper pressure release and operation.
- Check for leaks around the valve seals.
- Replace any valves that do not operate correctly.
- Inspect the fluid for air bubbles during operation.
- Bleed the hydraulic system if air is present.
- Ensure all connections are sealed to prevent air ingress.
- Document any findings related to air in the system.
- Test each safety device to confirm functionality.
- Inspect for damage or wear on sensors.
- Ensure all safety features engage as intended.
- Document any issues found during inspection.
- Create a detailed report of the inspection.
- Include all findings, repairs, and parts replaced.
- Ensure records are stored in a maintenance log.
- Review documentation with relevant personnel.
5. Electrical Systems
- Check battery terminals for signs of corrosion.
- Clean terminals with a wire brush if corrosion is found.
- Ensure battery is securely mounted and connections are tight.
- Test battery voltage with a multimeter.
- Inspect wiring for frays, cuts, or abrasions.
- Check connectors for signs of corrosion or looseness.
- Use a multimeter to test continuity in wires.
- Replace any damaged wiring or connections.
- Turn on all lights to ensure they are operational.
- Test alarms by activating them to confirm sound.
- Check gauge readings against manufacturer specifications.
- Replace any non-functional lights or gauges.
- Operate controls to test responsiveness and feel.
- Verify accuracy of control readings against benchmarks.
- Inspect wiring to control systems for damage.
- Lubricate any moving parts if necessary.
- Check each fuse for continuity and replace if blown.
- Inspect circuit breakers for tripping or wear.
- Ensure all fuses and breakers are correctly rated.
- Document any replacements or issues found.
- Test the emergency stop button for functionality.
- Check that the crane stops immediately when activated.
- Inspect wiring connected to the emergency stop.
- Ensure the system resets properly after testing.
- Inspect all harnesses for signs of wear or damage.
- Secure any loose wiring harnesses to prevent movement.
- Replace any frayed or damaged harness sections.
- Document any repairs made.
- Inspect ground connections for corrosion or looseness.
- Verify grounding continuity with a multimeter.
- Ensure all components are grounded to the correct points.
- Correct any grounding issues found.
- Activate remote controls to ensure they function properly.
- Check battery levels in remote devices.
- Inspect receiver units for damage or obstructions.
- Document any issues or repairs needed.
- Check for discoloration or burn marks on panels.
- Inspect internal components for corrosion or wear.
- Ensure all connections are tight and secure.
- Document any findings and corrective actions.
- Inspect seals on enclosures for integrity.
- Check for signs of moisture or contamination inside.
- Replace any damaged seals or gaskets.
- Document the condition of each enclosure.
- Test charging system output with a multimeter.
- Check for proper voltage and current levels.
- Inspect charging cables for wear or damage.
- Document any findings and maintenance performed.
- Check all connectors for tight fit and no play.
- Clean connectors using an appropriate cleaner.
- Inspect for corrosion or oxidation on contact points.
- Replace any damaged connectors as necessary.
- Access diagnostic systems to check for logged codes.
- Document any error codes and their meanings.
- Perform troubleshooting based on diagnostic results.
- Clear codes after resolving issues.
- Test each safety interlock to ensure operation.
- Check for proper activation and deactivation.
- Inspect wiring and connections related to interlocks.
- Document any failures and corrective actions taken.
- Record details of repairs, including parts replaced.
- Include dates and technician names in documentation.
- Maintain records for future reference.
- Ensure all documentation is filed appropriately.
6. Operational Checks
- Use calibrated weights to perform the load test.
- Ensure that the crane is on stable ground.
- Record the maximum weight lifted successfully.
- Check for any abnormal sounds or movements during lifting.
- Operate each control individually to verify functionality.
- Observe the boom movement for smooth transitions.
- Check for any unusual vibrations or noises.
- Ensure all movements are within specified limits.
- Manually test each limit switch.
- Verify that switches activate at correct positions.
- Check for any damage or wear on safety features.
- Document any faults found during testing.
- Inspect leveling jacks for wear and damage.
- Ensure that the crane is level before operation.
- Test the stability system by applying load.
- Record any discrepancies in stability readings.
- Extend and retract all outriggers fully.
- Check for any leaks in hydraulic lines.
- Ensure that stabilizers lock into place securely.
- Look for signs of wear or damage.
- Activate emergency stop from each control point.
- Confirm that all operations cease immediately.
- Check the reset function for proper operation.
- Document any issues with emergency stops.
- Test LMI under various load conditions.
- Ensure readings are accurate and within limits.
- Check calibration of the LMI system.
- Replace any faulty components as needed.
- Engage the winch and hoist under no load.
- Listen for unusual noises during operation.
- Inspect cables for fraying or damage.
- Ensure proper alignment of all moving parts.
- Check that all controls are within easy reach.
- Inspect for any obstructions in the cabin.
- Verify that safety equipment is accessible.
- Ensure that visibility is clear from the cabin.
- Check the functionality of all communication devices.
- Test for clear audio transmission and reception.
- Inspect for any physical damage to equipment.
- Ensure backup communication methods are available.
- Test each alarm individually for activation.
- Check for volume and clarity of alarm sounds.
- Inspect alarm indicators for proper lighting.
- Replace any malfunctioning alarms immediately.
- Test movement in both forward and reverse directions.
- Inspect tracks for wear and debris.
- Ensure smooth operation without hesitation.
- Document any irregularities in movement.
- Provide copies of manuals and safety protocols.
- Ensure documentation is up-to-date and legible.
- Check for easy accessibility within the cabin.
- Review any new regulations or updates with the operator.
- Observe engine sound and vibration during operation.
- Check engine gauges for normal readings.
- Test throttle response at various levels.
- Document any performance issues encountered.
- Attach each auxiliary equipment and test functionality.
- Check for proper fit and secure attachment.
- Assess compatibility with crane specifications.
- Record any issues with auxiliary equipment.
- Examine logs for patterns or recurring issues.
- Identify any unresolved problems from last quarter.
- Discuss findings with the maintenance team.
- Plan necessary corrective actions.
Use in Manifestly