A detailed Crawler Crane SEMI ANNUAL preventive maintenance checklists
1. General Inspection
2. Engine and Powertrain
3. Hydraulic System
4. Electrical System
- Examine insulation for cracks or fraying.
- Look for any exposed wires or connections.
- Check for signs of corrosion at junctions.
- Ensure that the wiring is not pinched or chafed.
- Turn on all lights to verify operation.
- Replace any burned-out bulbs with appropriate types.
- Check for foggy or cracked lenses.
- Ensure all light covers are secured properly.
- Test each alarm for audible and visual signals.
- Verify gauge readings against known values.
- Inspect any warning lights for proper function.
- Ensure all displays are clear and legible.
- Check tightness of all electrical connections.
- Look for any signs of oxidation on terminals.
- Use a wire brush to clean corroded connections.
- Ensure no loose or frayed wires are present.
- Activate the emergency stop to ensure it functions.
- Check for immediate shutdown of all systems.
- Inspect the emergency stop button for damage.
- Reset the system and verify normal operation.
- Check if any circuit breakers are in the 'off' position.
- Inspect fuses for blown elements or discoloration.
- Ensure all breakers and fuses are properly rated.
- Test each circuit breaker for functionality.
- Disconnect battery terminals before cleaning.
- Use a mixture of baking soda and water to clean terminals.
- Rinse with water and dry thoroughly.
- Reconnect terminals securely, ensuring no movement.
- Use a multimeter to measure battery voltage.
- Perform a load test using a battery tester.
- Check for voltage drop under load.
- Replace the battery if it fails to hold charge.
- Inspect panel for any visible damage or burn marks.
- Ensure all circuit indicators are functioning.
- Check for secure mounting of all components.
- Test voltage output at various terminals.
- Check for smooth operation of each switch.
- Test joystick movements in all directions.
- Look for any signs of wear or damage.
- Ensure all switches return to neutral position.
- Inspect grounding wires for secure connections.
- Check for corrosion at grounding points.
- Test grounding resistance using a multimeter.
- Ensure all components are bonded to a common ground.
- Inspect harness routing to avoid sharp edges.
- Ensure all clips and ties are intact and secure.
- Look for areas where harnesses may be pinched.
- Check for any signs of wear on the harness.
- Test each interlock for proper operation.
- Verify that interlocks prevent operation when necessary.
- Inspect for any signs of wear or damage.
- Document any failures for immediate attention.
- Check the operation of all auxiliary lights.
- Inspect wiring and connections for integrity.
- Test functionality of any additional electrical systems.
- Ensure all auxiliary systems are properly mounted.
- Check clarity and volume of communication devices.
- Test all channels for proper operation.
- Inspect microphones and speakers for functionality.
- Ensure batteries are charged and connections secure.
- Record all findings in the maintenance log.
- Note any parts that require replacement.
- Detail the steps taken during inspection.
- Sign and date the log for accountability.
5. Boom and Jib Inspection
6. Winch and Rigging
- Check for unusual noises during operation.
- Listen for grinding, squeaking, or clicking sounds.
- Inspect for excessive vibration or instability.
- Ensure the winch engages and disengages smoothly.
- Examine the entire length of the wire rope.
- Look for broken strands or excessive wear.
- Check for rust or other signs of corrosion.
- Ensure the rope is free of kinks and twists.
- Inspect hooks for deformation or cracks.
- Check shackles for wear and proper locking mechanisms.
- Ensure all hardware is free of corrosion.
- Confirm that all components are rated for the load.
- Ensure charts are visible and accessible.
- Check that the information reflects current load capacities.
- Update charts if any changes in equipment or loads occur.
- Store charts in a designated location for easy reference.
- Engage the winch with a test load.
- Verify that the load limit switch activates correctly.
- Check other safety features like emergency stops.
- Ensure that all safety features are functioning properly.
- Check for cracks, dents, or deformations on the drum.
- Ensure the drum rotates freely without obstruction.
- Inspect alignment with other components for proper function.
- Look for signs of uneven wear on the drum surface.
- Inspect lubrication points for adequate grease or oil.
- Ensure that no excess lubricant is present.
- Follow manufacturer recommendations for lubrication intervals.
- Check for signs of leakage around seals.
- Observe the spooling pattern during operation.
- Adjust the rope if any overlaps or twists are present.
- Ensure even distribution of the rope on the drum.
- Check for proper tension while spooling.
- Examine the entire length of each sling.
- Look for any frayed edges or excessive wear.
- Check for discoloration that may indicate damage.
- Ensure slings meet safety standards and ratings.
- Check manufacturer specifications for WLL ratings.
- Ensure compatibility with the load being lifted.
- Inspect labels and markings for legibility.
- Replace any components that do not meet requirements.
- Review manufacturer guidelines for lifting accessories.
- Ensure all accessories are marked and rated appropriately.
- Look for certification tags and compliance documentation.
- Replace any non-compliant items immediately.
- Test the brake system under various loads.
- Listen for unusual sounds during braking.
- Ensure brakes engage and release smoothly.
- Inspect brake pads for wear and replace if necessary.
- Test all controls for responsiveness.
- Check for any obstructions around control areas.
- Ensure labels are clear and legible.
- Confirm that emergency stop controls are operational.
- Check for signs of movement or instability.
- Inspect for corrosion or physical damage.
- Ensure anchor points are rated for the intended load.
- Verify that all connections are tight and secure.
- Document all inspections and tests performed.
- Note any repairs or replacements required.
- Include dates and personnel involved.
- Ensure logs are updated immediately following maintenance.
7. Tires and Undercarriage
- Check tread depth using a gauge.
- Look for uneven wear patterns.
- Measure tire pressure with a gauge.
- Inflate tires to manufacturer's specifications.
- Visually inspect the undercarriage area.
- Remove any visible debris manually.
- Use a pressure washer if necessary.
- Ensure no debris obstructs moving parts.
- Check track tension according to specifications.
- Look for signs of wear on the track links.
- Ensure tracks are aligned correctly.
- Adjust tension if needed using the adjustment system.
- Inspect rollers for cracks or damage.
- Check for proper lubrication levels.
- Look for unusual wear patterns.
- Replace any damaged rollers or idlers.
- Check bolts and fasteners for tightness.
- Inspect for any loose components.
- Tighten any loose fittings.
- Verify integrity of all connections.
- Examine sidewalls under good lighting.
- Look for signs of punctures or damage.
- Check for bulges or deformities.
- Replace tires showing significant damage.
- Use alignment tools for precision.
- Check that tires and tracks are parallel.
- Adjust alignment as needed.
- Consult manual for specific alignment procedures.
- Inspect all tires for consistent wear.
- Note any tires with irregular patterns.
- Rotate tires if necessary.
- Consult a professional for severe cases.
- Remove wheel covers if applicable.
- Check for any unusual noises while rotating.
- Ensure proper lubrication is applied.
- Replace bearings showing excessive wear.
- Inspect metal surfaces for rust.
- Use a wire brush to remove minor corrosion.
- Apply rust inhibitor if needed.
- Schedule replacement for heavily corroded parts.
- Refer to manufacturer’s torque specifications.
- Use a torque wrench for accurate measurements.
- Check all lug nuts for proper tightness.
- Re-torque after initial use if necessary.
- Inspect teeth for wear and deformation.
- Check alignment with tracks.
- Replace sprockets showing excessive wear.
- Lubricate as per manufacturer's instructions.
- Inspect hydraulic lines for leaks.
- Ensure tensioning cylinders are functioning.
- Adjust tension as required.
- Check for any signs of malfunction.
- Examine springs and joints for integrity.
- Look for cracks or signs of fatigue.
- Lubricate moving parts as needed.
- Replace damaged components promptly.
- Use a brush to remove loose dirt.
- Employ a vacuum for hard-to-reach areas.
- Pressure wash if necessary for thorough cleaning.
- Ensure all areas are free from obstruction.
Use in Manifestly