A detailed Crawler Crane SEMI ANNUAL preventive maintenance checklists
1. General Inspection
- Confirm registration details are current and valid.
- Check for any expired permits or certifications.
- Ensure compliance documentation is accessible and organized.
- Review any specific regulatory requirements for the crane type.
- Examine the frame for cracks, dents, or deformation.
- Look for signs of rust or corrosion on metal surfaces.
- Check welds and joints for integrity.
- Assess the overall structural stability of the crane.
- Ensure all safety labels are legible and intact.
- Verify that operational guidelines are clearly displayed.
- Check for load capacity signs and operational limits.
- Confirm that hazard warnings are present and visible.
- Inspect for chips, peeling, or faded areas.
- Look for areas where protective coatings are compromised.
- Assess for corrosion beneath paint layers.
- Evaluate the need for touch-ups or complete repainting.
- Check ladders for stability and secure attachments.
- Inspect handrails for integrity and grip.
- Verify that access points are free of obstructions.
- Ensure non-slip surfaces are intact and effective.
- Test all lights to confirm they function correctly.
- Inspect lenses for cracks or dirt that may hinder visibility.
- Ensure warning lights are operational and visible.
- Check indicator lights for accuracy in signaling.
- Verify safety covers are intact without gaps.
- Check that guards are firmly attached and not loose.
- Inspect for any signs of wear or damage.
- Confirm that safety features are operational.
- Ensure all tools are accounted for and organized.
- Inspect equipment for signs of damage or wear.
- Confirm that tools are calibrated and functional.
- Check for any missing items that are essential.
- Look for oil, hydraulic, or coolant leaks.
- Check seals and gaskets for signs of failure.
- Inspect hoses and connections for wear.
- Assess any pooled fluids for potential issues.
- Inspect controls for wear and proper operation.
- Check the seat for comfort and secure mounting.
- Evaluate visibility from the operator's position.
- Ensure that all cab features are clean and functional.
- Test emergency stops to ensure they activate correctly.
- Inspect wiring and connections for any damage.
- Confirm that emergency procedures are posted.
- Ensure operators are trained on their use.
- Inspect all connections for tightness and security.
- Check for signs of corrosion or wear on connectors.
- Ensure hoses are properly routed and protected.
- Verify that electrical systems are functioning without issues.
- Check logs for all maintenance performed.
- Ensure entries are timely and accurate.
- Look for any missed scheduled maintenance.
- Confirm that recommended actions have been addressed.
- Check for any outstanding manufacturer recalls.
- Verify that all updates have been completed.
- Ensure documentation of updates is maintained.
- Consult manufacturer guidelines for compliance.
- Check battery charge level and condition.
- Inspect terminals for corrosion and tightness.
- Verify that cables are free from fraying or damage.
- Ensure battery hold-downs are secure and intact.
- Check the location and accessibility of extinguishers.
- Inspect gauges to ensure they are in the green zone.
- Verify that extinguishers are not obstructed.
- Ensure that inspection tags are up to date.
- Test operator aids for functionality.
- Inspect wiring and connections for damage.
- Verify calibration of load moment indicators.
- Ensure limit switches engage as intended.
2. Engine and Powertrain
- Locate the dipstick and remove it.
- Wipe clean, reinsert, and remove again.
- Check the oil level against the markers.
- Inspect oil for color and consistency.
- Add oil if necessary, ensuring proper type.
- Examine fuel lines for signs of leaks.
- Check connections at the fuel tank and engine.
- Inspect fuel filters for clogs or damage.
- Test fuel pump operation and pressure.
- Look for any unusual odors or dripping.
- Check coolant reservoir for proper level.
- Inspect hoses for cracks and wear.
- Look for leaks around the radiator.
- Ensure radiator cap is in good condition.
- Test the thermostat operation if accessible.
- Check battery terminals for corrosion.
- Ensure all connections are tight and secure.
- Inspect battery case for cracks or leaks.
- Test battery voltage with a multimeter.
- Clean terminals if corrosion is present.
- Remove the air filter cover.
- Inspect the filter for dirt and debris.
- Clean or replace the filter as needed.
- Ensure proper seating of the new or cleaned filter.
- Reattach the air filter cover securely.
- Examine exhaust pipes and joints visually.
- Listen for unusual sounds or hissing.
- Check for rust spots or corrosion.
- Inspect mounting brackets and hangers.
- Ensure that emissions components are intact.
- Start the engine and observe dashboard.
- Check each gauge for proper readings.
- Test all warning lights for functionality.
- Note any discrepancies or malfunctions.
- Report any issues for further inspection.
- Inspect the front of the radiator for debris.
- Use compressed air to clean if necessary.
- Check the oil cooler for any obstructions.
- Ensure airflow is unobstructed around coolers.
- Replace any damaged cooling components.
- Examine belts for fraying or cracks.
- Check hoses for bulges or leaks.
- Test the tension of each belt.
- Replace any defective belts or hoses.
- Ensure all connections are secure.
- Start the engine and listen for starter function.
- Measure voltage output from the alternator.
- Check for any unusual noises during operation.
- Ensure battery charge remains stable.
- Replace faulty components as necessary.
- Inspect driveshaft for bends or cracks.
- Look at universal joints for play or wear.
- Examine any visible gears or couplings.
- Check for leaks around seals and bearings.
- Document any signs of wear for repair.
- Locate the transmission dipstick and remove it.
- Wipe clean, reinsert, and check fluid level.
- Inspect fluid color and smell for burning.
- Add fluid as needed, using the correct type.
- Document fluid condition and any changes.
- Check hydraulic fluid reservoir level.
- Inspect fluid for clarity and color.
- Top off with the appropriate hydraulic fluid.
- Look for signs of leaks in hoses and fittings.
- Document any changes in fluid condition.
- Listen for noises when the engine is running.
- Check for vibrations during operation.
- Inspect drive components for physical damage.
- Test torque converter operation if accessible.
- Document any irregularities for further investigation.
- Inspect all safety guards for proper installation.
- Check for any missing or damaged guards.
- Ensure bolts and fasteners are tightened.
- Verify that shields are free of obstructions.
- Document any safety concerns for corrective action.
- Engage the crane under controlled conditions.
- Monitor engine performance for stability.
- Check for any unusual sounds or vibrations.
- Test powertrain responsiveness during operation.
- Evaluate performance and document findings.
3. Hydraulic System
- Check the fluid level against the gauge.
- Look for any discoloration or debris.
- Ensure fluid is at the recommended level.
- Replace fluid if it appears contaminated.
- Inspect hoses for cracks or bulges.
- Check fittings for tightness and leaks.
- Look for signs of fluid seepage.
- Replace any damaged components immediately.
- Extend and retract each cylinder fully.
- Monitor for smooth movement without sticking.
- Check for leaks around seals.
- Assess for any unusual noises during operation.
- Inspect the pump for signs of wear or leaks.
- Check the filter for dirt or debris buildup.
- Replace the filter if necessary.
- Ensure proper alignment and mounting of the pump.
- Look for particles or sediment in the fluid.
- Check for any unusual color changes.
- Perform a fluid sample analysis if needed.
- Replace fluid if contamination is present.
- Review manufacturer guidelines.
- Check fluid type and viscosity ratings.
- Ensure any replacements meet specifications.
- Document compliance for records.
- Listen for grinding or whining sounds.
- Monitor vibrations during operation.
- Identify the source of any abnormal noise.
- Address issues immediately to prevent damage.
- Check for rust or pitting on the reservoir.
- Look for leaks around seals and fittings.
- Ensure the reservoir is securely mounted.
- Clean the exterior to facilitate inspection.
- Remove the filter according to guidelines.
- Inspect for signs of blockage or damage.
- Clean any reusable filters thoroughly.
- Install new filters ensuring proper sealing.
- Activate each valve and observe operation.
- Check for smooth actuation without resistance.
- Look for leaks around valve bodies.
- Ensure all valves return to neutral position.
- Inspect routing to avoid sharp edges.
- Check clamps and supports for tightness.
- Look for signs of wear on the lines.
- Adjust or secure lines as necessary.
- Attach pressure gauge to the system.
- Activate the system and monitor readings.
- Compare results to manufacturer specifications.
- Address any discrepancies immediately.
- Check accumulator for leaks or damage.
- Measure pre-charge pressure as per specs.
- Test accumulator functionality under load.
- Replace if performance is inadequate.
- Record all inspections and repairs.
- Include dates and personnel involved.
- Note any parts replaced or issues found.
- Maintain a log for future reference.
4. Boom and Jib
- Use visual inspection techniques.
- Check for any visible cracks or bends.
- Look for any deformities in structure.
- Document any findings for further action.
- Remove any dirt or debris from pins and bushings.
- Inspect for any signs of wear or damage.
- Ensure proper lubrication is applied.
- Replace any worn components as necessary.
- Test all safety mechanisms thoroughly.
- Check for proper engagement of devices.
- Ensure indicators are operational.
- Replace any non-functional safety devices.
- Identify all lubrication points.
- Use appropriate lubricant as per specifications.
- Ensure even application at all pivot points.
- Wipe away excess lubricant to avoid buildup.
- Check horizontal and vertical alignment.
- Ensure jib is correctly positioned.
- Use measuring tools for accuracy.
- Make adjustments as necessary.
- Inspect surfaces for rust or peeling paint.
- Use a wire brush for minor corrosion.
- Document areas needing repainting.
- Apply protective coatings where required.
- Engage locking mechanisms fully.
- Check for any play or movement.
- Ensure indicators show locked status.
- Repair or replace any faulty locks.
- Inspect welds visually for cracks.
- Look for discoloration or excessive wear.
- Document any weak areas.
- Schedule repairs if necessary.
- Look for signs of hydraulic fluid leakage.
- Check seals and fittings for integrity.
- Inspect cylinder rods for scratches.
- Replace any damaged parts immediately.
- Check bolts and fasteners for tightness.
- Inspect attachment points for wear.
- Ensure no loose components.
- Replace any worn attachments.
- Operate boom and jib through full range.
- Listen for unusual noises during operation.
- Ensure movement is smooth and controlled.
- Document any operational issues.
- Obtain the latest load charts.
- Cross-check current configuration against limits.
- Ensure compliance with safety regulations.
- Update charts if necessary.
- Check wires for fraying or damage.
- Ensure connections are secure.
- Test functionality of electrical components.
- Replace any damaged wiring or connectors.
- Inspect stowage mechanisms for damage.
- Ensure transport locks function correctly.
- Check for secure stowage during transport.
- Document any issues requiring attention.
5. Load Handling Equipment
- Look for visible cracks, bends, or distortions.
- Measure the dimensions against manufacturer's specifications.
- Ensure latches engage securely and function properly.
- Clean hooks and latches to remove debris or corrosion.
- Inspect for visible signs of fraying or broken strands.
- Look for kinks or twists in the wire rope.
- Check the lubrication condition and apply as needed.
- Measure the diameter to ensure it meets specifications.
- Inspect for cuts, abrasions, or burnt areas.
- Check the stitching on slings for any unraveling.
- Verify the working load limit labels are intact.
- Ensure all connectors are free from corrosion.
- Perform a functional test of limit switches under safe conditions.
- Check for proper calibration of safety mechanisms.
- Inspect wiring and connections for wear or damage.
- Record the results of the tests for documentation.
- Look for visible cracks, bends, or distortions.
- Measure the dimensions against manufacturer's specifications.
- Ensure latches engage securely and function properly.
- Clean hooks and latches to remove debris or corrosion.
- Inspect for visible signs of fraying or broken strands.
- Look for kinks or twists in the wire rope.
- Check the lubrication condition and apply as needed.
- Measure the diameter to ensure it meets specifications.
- Inspect for cuts, abrasions, or burnt areas.
- Check the stitching on slings for any unraveling.
- Verify the working load limit labels are intact.
- Ensure all connectors are free from corrosion.
- Perform a functional test of limit switches under safe conditions.
- Check for proper calibration of safety mechanisms.
- Inspect wiring and connections for wear or damage.
- Record the results of the tests for documentation.
- Ensure all equipment has visible load capacity markings.
- Check for any outdated or illegible labels.
- Replace labels as necessary to maintain clarity.
- Confirm that labels comply with industry standards.
- Ensure all equipment is stored in designated areas.
- Check for proper stacking to prevent damage.
- Verify that equipment is clean and dry before storage.
- Organize items by type and load capacity for easy access.
- Check for visible wear on links and side plates.
- Measure elongation against manufacturer specifications.
- Inspect for rust or corrosion that may weaken the chain.
- Ensure chain lubrication is adequate and applied.
- Perform calibration checks using known weights.
- Record all calibration results for future reference.
- Inspect load cell wiring for any damage.
- Confirm that weight indicators display correct readings.
- Verify compatibility of accessories with load types.
- Assess condition and functionality of each accessory.
- Check load ratings against the intended use.
- Ensure compliance with industry standards.
- Check for structural integrity and any visible damage.
- Test functionality under load, if safe to do so.
- Verify that all connections are secure and operational.
- Ensure compliance with load specifications.
- Check for any updates or changes to load capacities.
- Ensure the chart is free from damage and legible.
- Verify that it is located in a visible area.
- Confirm that all operators are familiar with its information.
- Check training records for validity and expiration.
- Ensure all operators understand load handling procedures.
- Verify certifications are up to date and properly documented.
- Conduct refresher training if necessary.
- Conduct the test with a load that is within limits.
- Check responsiveness of emergency stop functions.
- Document any issues encountered during testing.
- Ensure all safety protocols are followed during the test.
- Inspect hoses and connections for fluid residue.
- Check the condition of seals and gaskets.
- Monitor hydraulic fluid levels during operation.
- Record any leaks for immediate attention.
- Inspect tags for clarity and legibility.
- Check expiration dates on inspection stickers.
- Replace any outdated or missing tags promptly.
- Ensure tags are placed in visible locations.
6. Undercarriage and Tracks
- Check for visible wear on track surfaces.
- Measure track tension according to manufacturer specifications.
- Ensure tracks are aligned correctly with the undercarriage.
- Inspect rollers for dents, cracks, or wear.
- Ensure idlers rotate freely without obstruction.
- Apply appropriate lubricant to rollers and idlers.
- Look for oil or hydraulic fluid leaks.
- Inspect components for signs of wear or damage.
- Check seals and gaskets for integrity.
- Test the operation of the drive mechanism.
- Listen for unusual noises during operation.
- Inspect for any signs of overheating.
- Check for cracks, tears, or missing track pads.
- Measure pad thickness against specifications.
- Replace any worn or damaged pads immediately.
- Use alignment tools to assess track positioning.
- Make adjustments as needed to correct alignment.
- Recheck alignment after adjustments.
- Look for signs of wear on the sprocket teeth.
- Ensure all mounting hardware is tight.
- Replace worn sprockets as necessary.
- Use appropriate tools to remove dirt and debris.
- Pay special attention to areas around rollers and chains.
- Ensure all components are free of obstructions.
- Inspect the entire frame for visible damage.
- Check welds and joints for integrity.
- Report and address any structural issues found.
- Measure chain links for elongation.
- Look for broken or damaged links.
- Replace chains showing excessive wear.
- Identify all pivot and connection points.
- Apply manufacturer-recommended lubricant.
- Ensure excess lubricant does not accumulate.
- Check the tension adjustment mechanism.
- Verify proper tension is maintained during operation.
- Adjust tension as necessary.
- Look for rust spots or corrosion on metal parts.
- Use appropriate rust removal or prevention products.
- Ensure treated areas are properly protected.
- Check that all guards are intact and not damaged.
- Ensure fasteners are secure and functional.
- Replace any missing or damaged covers immediately.
Use in Manifestly