A detailed Crawler Crane WEEKLY preventive maintenance checklists
General Inspection
- Check the crane for visible dents, scratches, or any signs of impact.
- Ensure all components are clean and free from debris.
- Evaluate the overall appearance to ensure proper maintenance.
- Examine structural components for cracks or deformities.
- Inspect hoses and cables for fraying or wear.
- Assess the condition of the boom and attachments.
- Inspect hydraulic hoses for wet spots or fluid accumulation.
- Check connections and fittings for signs of leakage.
- Test hydraulic functions to detect any performance issues.
- Verify the presence of guards on moving parts.
- Check covers for wear or damage, ensuring they are secure.
- Confirm that safety mechanisms are operational.
- Conduct a visual inspection of welds and joints.
- Look for any signs of bending or misalignment.
- Use a hammer to tap for unusual sounds indicating issues.
- Look for peeling paint or rust spots on the surface.
- Assess the protective coatings for degradation.
- Document any areas requiring touch-up or repainting.
- Use a torque wrench to check tightness according to specifications.
- Inspect for any missing or damaged fasteners.
- Ensure no fasteners are loose and can be tightened.
- Inspect each track link for signs of wear or damage.
- Check for proper tension and alignment of the tracks.
- Look for debris lodged between track links.
- Examine rollers for damage or excessive wear.
- Check idler wheels for free movement and lubrication.
- Ensure all components are clean and free of debris.
- Inspect pins for wear, bending, or deformation.
- Check bushings for proper lubrication and signs of wear.
- Ensure all connections are secure and functional.
- Listen for unusual sounds from the engine or hydraulic system.
- Observe for excessive vibration in the crane structure.
- Document any irregularities for further investigation.
- Inspect counterweights for any visible damage or wear.
- Ensure all securing mechanisms are intact and functional.
- Verify that counterweights are positioned correctly.
- Ensure the cab is clean and free of debris.
- Check that all controls function smoothly and accurately.
- Verify that safety equipment is accessible and operational.
- Inspect mirrors for cracks and secure mounting.
- Clean windows to ensure clear visibility.
- Check that any tinting or coatings are intact.
- Inspect ladders for wear and secure attachment.
- Ensure access points are unobstructed and safe.
- Check for any loose or damaged steps.
- Examine labels for any signs of wear or fading.
- Ensure that all critical information is clearly visible.
- Replace any illegible tags as needed.
- Check for any signs of erosion or instability.
- Look for debris or obstacles that could affect stability.
- Assess the ground for adequate support.
- Ensure the crane is on a stable, level surface.
- Check that outriggers are fully extended and locked.
- Inspect for any signs of ground disturbance under the outriggers.
Fluid Levels
- Locate the dipstick.
- Remove and wipe it clean.
- Reinsert the dipstick fully.
- Remove it again to check the level.
- Add oil if below the minimum mark.
- Locate the hydraulic fluid reservoir.
- Check the sight glass or dipstick.
- Add hydraulic fluid if below the recommended level.
- Ensure no contamination in the fluid.
- Locate the radiator cap.
- Check the coolant level in the reservoir.
- Open the cap carefully if needed.
- Add coolant if levels are low.
- Check the fuel gauge.
- Open the fuel cap.
- Inspect for any contamination.
- Refill with the appropriate fuel grade.
- Locate the transmission dipstick.
- Remove, wipe clean, and reinsert dipstick.
- Check fluid level against markings.
- Add transmission fluid as needed.
- Reinsert dipstick securely.
- Locate the brake fluid reservoir.
- Check fluid level against the appropriate mark.
- Add brake fluid if below recommended level.
- Ensure the cap is tightened after checking.
- Find the power steering reservoir.
- Check fluid level against the indicator.
- Add power steering fluid if low.
- Close the reservoir cap tightly.
- Locate the windshield washer fluid reservoir.
- Check fluid level; add fluid if low.
- Ensure the cap is securely closed after refilling.
- Identify the differential fill plug.
- Remove the plug and check fluid level.
- Add differential fluid if necessary.
- Replace and secure the fill plug.
- Visually inspect the engine area.
- Check hydraulic hoses and connections.
- Look for puddles or wet spots.
- Document any leaks found for repair.
- Check all fluid caps on reservoirs.
- Ensure each cap is tightened properly.
- Verify no caps are missing or damaged.
- Update the maintenance log with fluid levels.
- Note any fluids added or any issues found.
- Ensure all entries are clear and legible.
Electrical System
- Check for any signs of corrosion on terminals.
- Ensure terminals are securely tightened to prevent loose connections.
- Clean any corrosion with a suitable cleaning agent.
- Apply protective grease to terminals to inhibit future corrosion.
- Examine wiring for frays, cuts, or signs of wear.
- Ensure all connections are secure and tight.
- Look for any exposed wires that could cause shorts.
- Replace or repair damaged wiring as necessary.
- Turn on all lights and check for brightness and clarity.
- Test each signal to confirm it activates properly.
- Replace any burnt-out bulbs or malfunctioning signals.
- Document any issues for follow-up repairs.
- Press the emergency stop button to verify it functions.
- Check for any signs of damage or wear on the button.
- Ensure it resets properly after activation.
- Test the response of the crane to the emergency stop.
- Locate the fuse box and visually inspect each fuse.
- Replace any blown fuses with the correct amperage rating.
- Check for any signs of overheating around the fuse area.
- Document any replacements made during the inspection.
- Press the horn button to ensure it sounds loudly.
- Test any additional alarms to confirm they activate.
- Check for any signs of damage to the horn or speakers.
- Document any issues with auditory signals.
- Inspect the belt for signs of wear, cracks, or fraying.
- Check the tension to ensure it is neither too loose nor too tight.
- Adjust tension if necessary according to specifications.
- Replace the belt if it shows significant wear.
- Manually test each circuit breaker to ensure it resets.
- Check for any signs of tripping or malfunction.
- Inspect for any physical damage to the breakers.
- Document any breakers needing replacement or repair.
- Power on the control panel and check all indicators.
- Verify that each button and switch responds correctly.
- Look for any error messages or malfunctions on the display.
- Document any issues for further investigation.
- Examine all ground connections for signs of corrosion.
- Ensure connections are tight and secure.
- Clean any corroded areas using appropriate cleaning agents.
- Document any loose or corroded connections for repair.
- Check battery mounts and brackets for security.
- Ensure battery does not move when shaken gently.
- Inspect for signs of vibration damage or wear.
- Tighten or replace mounting hardware if necessary.
- Inspect wires and components for discoloration or burning.
- Check for any unusual smells indicative of overheating.
- Look for any exposed wires that may cause shorts.
- Document any findings for immediate repair.
- Power on the remote control and check battery levels.
- Test each function to ensure it operates correctly.
- Inspect for any physical damage to the remote.
- Document any issues with the remote control system.
- Check connectors for signs of corrosion or dirt.
- Use appropriate cleaning solutions to clean connectors.
- Ensure connectors are securely fastened after cleaning.
- Apply dielectric grease to prevent moisture ingress.
- Inspect the routing of harnesses for any pinch points.
- Ensure wires are secured with ties to avoid movement.
- Check for any areas where wires may rub against surfaces.
- Re-route or secure wires as necessary.
- Inspect covers and shields for all components.
- Ensure seals are intact and functioning properly.
- Clean any accumulated debris around electrical parts.
- Document any components needing better protection.
Operational Checks
- Engage each control mechanism individually.
- Observe for any resistance or delays.
- Ensure all controls return to neutral position.
- Check indicator lights for proper function.
- Document any irregularities for further inspection.
- Extend and retract the boom fully.
- Test all attachment functions individually.
- Observe for any unusual sounds or movements.
- Check for proper locking mechanisms.
- Ensure attachments respond promptly to controls.
- Lift a test load to check winch functionality.
- Lower the load smoothly and steadily.
- Inspect for any slippage or irregular movements.
- Check wire ropes for wear or fraying.
- Ensure safety mechanisms are operational.
- Rotate the crane 360 degrees slowly.
- Listen for grinding or unusual noises.
- Observe for any jerky or slow movements.
- Inspect slew bearings for wear or damage.
- Lubricate as necessary according to guidelines.
- Navigate the crane forward, backward, and sideways.
- Check for any hesitation or stalling.
- Ensure all directional controls respond promptly.
- Monitor for unusual vibrations or sounds.
- Test emergency stop functionality during travel.
- Activate the emergency stop switch.
- Ensure all crane functions cease immediately.
- Reset the emergency stop and check for normal operation.
- Test each emergency stop mechanism separately.
- Document any failures or required maintenance.
- Manually extend and retract each outrigger.
- Check for smooth operation without resistance.
- Inspect locking pins for proper engagement.
- Ensure outriggers are level and stable.
- Document any issues with operation.
- Test load indicators with known weights.
- Check for accuracy in readings.
- Inspect calibration settings and adjust if needed.
- Ensure visibility of indicators from the operator's position.
- Document any discrepancies for correction.
- Activate hydraulic functions and observe for leaks.
- Listen for unusual noises during operation.
- Inspect hoses and connections for wear.
- Check fluid levels and top up as necessary.
- Document any irregularities for maintenance.
- Monitor the crane's position on the ground.
- Check leveling indicators during operation.
- Ensure outriggers are properly deployed.
- Look for any signs of tipping or instability.
- Document any concerns regarding setup.
- Deploy all auxiliary equipment and test functions.
- Check for smooth operation and responsiveness.
- Inspect for any signs of wear or damage.
- Ensure locking mechanisms engage securely.
- Document any issues for further inspection.
- Inspect all controls for wear and functionality.
- Ensure indicators are readable and operational.
- Check accessibility of controls from the operator's seat.
- Test any additional features for proper operation.
- Document any accessibility issues for improvement.
- Conduct test lifts and observe load chart readings.
- Compare actual loads with displayed information.
- Ensure display updates in real-time.
- Check for any discrepancies in readings.
- Document findings and adjust as necessary.
- Test all communication devices for audio clarity.
- Ensure all personnel can hear and respond.
- Check for static or interference issues.
- Test communication during various crane operations.
- Document any communication failures or issues.
Safety Equipment
- Check for physical damage or wear.
- Test each limit switch for proper operation.
- Clean any dirt or debris from switches.
- Ensure all connections are secure.
- Inspect for visible damage or corrosion.
- Verify the pressure gauge is in the green zone.
- Ensure the extinguisher is mounted securely.
- Confirm accessibility in case of emergency.
- Look for frays or cuts in the fabric.
- Check all clips and connectors for functionality.
- Ensure proper storage to avoid damage.
- Replace any damaged equipment immediately.
- Inspect for fading or peeling labels.
- Clean any obstructions to visibility.
- Replace damaged or missing signage.
- Check that all required signs are present.
- Test each button for immediate response.
- Check for physical damage or wear.
- Ensure all buttons are clearly labeled.
- Confirm accessibility from operator's position.
- Inspect contents for expiration dates.
- Ensure all items are in good condition.
- Restock any used or missing supplies.
- Verify kit is easily accessible.
- Check for physical damage to the manual.
- Ensure it is up to date with current regulations.
- Verify its location is known to operators.
- Replace if lost or excessively damaged.
- Inspect hinges and locks for functionality.
- Check for physical damage or wear.
- Ensure barriers close securely and latch.
- Confirm compliance with safety regulations.
- Test the alarm in a quiet environment.
- Check for any obstructions to sound.
- Inspect wiring and connections for damage.
- Ensure compliance with local regulations.
- Press the horn button to check sound.
- Inspect for any physical damage.
- Verify that all warning devices are operational.
- Ensure clarity of sound in all directions.
- Check helmets, gloves, and vests for damage.
- Ensure all equipment fits properly.
- Verify availability of safety goggles and masks.
- Replace any damaged items immediately.
- Test each light for proper operation.
- Inspect for physical damage or dirt.
- Ensure all lights are securely mounted.
- Replace any burned-out bulbs immediately.
- Check for visible wear or fading.
- Ensure it is easily readable from operator's position.
- Confirm it reflects current load limits.
- Replace if damaged or outdated.
- Test radios for clarity and range.
- Inspect hand signal flags for damage.
- Ensure all devices are located within reach.
- Replace any malfunctioning equipment immediately.
Tracks and Undercarriage
- Visually check for any signs of cracks or tears.
- Look for foreign objects lodged in the tracks.
- Assess the overall condition and cleanliness of the tracks.
- Use a tension gauge to measure track tension.
- Refer to the manufacturer's specifications for proper tension.
- Adjust tension by loosening or tightening the track adjuster.
- Inspect for wear patterns or pitting on components.
- Check lubrication levels and apply grease as needed.
- Ensure all moving parts are free from obstructions.
- Use a pressure washer to remove dirt and mud.
- Inspect areas where dirt accumulates after cleaning.
- Ensure all components are accessible for future inspections.
- Measure track link length and compare to specifications.
- Look for cracks or deformation in the links.
- Replace any damaged or excessively elongated links.
- Visually inspect tracks for alignment with the frame.
- Adjust idlers and rollers if misalignment is detected.
- Ensure tracks run straight without deviation.
- Check each fastener with a torque wrench.
- Inspect for rust or corrosion and replace as needed.
- Tighten any loose fasteners to manufacturer's specifications.
- Identify all pivot points and joints that require lubrication.
- Use the appropriate type of lubricant as specified.
- Apply grease until it begins to ooze from the seals.
- Check for visible oil leaks around seals and fittings.
- Inspect cylinders for dents, scratches, or corrosion.
- Test cylinder operation for smoothness and responsiveness.
- Engage track drive motors in forward and reverse.
- Listen for abnormal noises during operation.
- Check for consistent power delivery during testing.
- Perform a visual inspection of all undercarriage components.
- Look for signs of excessive wear or structural damage.
- Document any issues that require attention or replacement.
- Inspect track pads for cracks, wear, or missing pieces.
- Measure pad thickness and compare to specifications.
- Replace any pads that do not meet safety standards.
- Check all grounding connections for corrosion or looseness.
- Inspect wiring for frays, cuts, or damage.
- Ensure all connections are tight and functioning properly.
- Listen for sounds that deviate from normal operation.
- Feel for vibrations that are unusual during machine movement.
- Document any irregularities for further investigation.
Boom and Attachments
- Examine the entire length of the boom.
- Look for visible cracks or deformations.
- Check for any signs of corrosion or rust.
- Use a flashlight to inspect hard-to-see areas.
- Inspect the exterior of each hydraulic cylinder.
- Look for signs of oil leakage around seals.
- Check for any dents or damage on the cylinder body.
- Ensure mounting points are secure.
- Inspect all pins and bushings for wear.
- Apply appropriate lubricant to all moving parts.
- Check that pins are fully inserted and locked.
- Look for signs of rust or corrosion.
- Check each attachment for structural integrity.
- Ensure all attachment points are secure.
- Test operation of each attachment.
- Look for signs of excessive wear or damage.
- Use a level to check boom alignment.
- Look for any misalignment or twisting.
- Check mounting brackets for tightness.
- Adjust as necessary to ensure proper alignment.
- Inspect wear pads for flatness and wear patterns.
- Look for cracks or detachment from the boom.
- Replace any worn or damaged wear pads.
- Document wear pad conditions for records.
- Check for smooth rotation of sheaves and pulleys.
- Look for signs of wear or damage on grooves.
- Ensure all sheaves are properly aligned.
- Lubricate as necessary to maintain operation.
- Inspect ropes and cables for fraying or cuts.
- Check for kinks or twists in the rigging.
- Look for damaged hooks or connectors.
- Replace any damaged rigging equipment immediately.
- Test each safety latch for smooth operation.
- Look for signs of wear or malfunction.
- Ensure latches fully engage and lock.
- Replace any faulty latches immediately.
- Check for peeling, chipping, or fading paint.
- Look for areas where rust may be forming.
- Assess the integrity of protective coatings.
- Touch up or repaint as necessary.
- Inspect hoses for cracks, blisters, or abrasions.
- Examine fittings for tightness and leaks.
- Look for signs of oil or fluid leakage.
- Replace any damaged hoses or fittings.
- Check each locking mechanism for proper function.
- Ensure locks fully engage and hold securely.
- Look for signs of wear or damage.
- Test operation after inspection.
- Check the angle indicator for accuracy.
- Test operation by moving the boom to different angles.
- Adjust calibration as needed.
- Document any discrepancies found.
- Inspect each auxiliary attachment for damage.
- Test functionality of each attachment.
- Check security of attachment points.
- Replace or repair any damaged components.
Use in Manifestly