Key Benefits of Preventive Maintenance
- Reduce cost
- Reduce downtime
- Improve equipment reliability and lifespan
- Increase efficiency and productivity
- Improve equipment health, safety and compliance
- Enhance customer satisfaction
Preventive maintenance involves performing routine tasks on a scheduled basis to prevent breakdowns and extend the lifespan of your equipment. Detecting potential issues before they escalate into major problems can result in cost-savings on repairs and replacements, minimize downtime, and enhance the dependability and productivity of operations. In simple business operations, it boils down to knowing and following proven steps in conducting preventive maintenance as below steps
Select appropriate PPE and competent personnel for the job/task required
Select and prepare appropriate tools/materials and crane equipment for the task to be performed.
Park machine, engage park brakes, place wheel chokes both sides of the rear wheel and allow engine to cool.
Place “out of service” and “personal danger” tags and Lock-out with your pad-lock.
Test the isolation switch for proper functioning by turning off the main isolation key and checking if the ignition light illuminates. If so, recheck the switch.
Ensure to complete risk assessment and explained to members of the team and place a life-test board on the machine
Check steering ball-studs and bell-crank, pin and bearing, “A”-Frame bearing, Hoist cylinder top bearing, Dog-bone bearing, Pivot-pin and bushing.
6Take all oil samples (Engine, Transmission, Steering, Differential, Final-Drives, Hydraulic and Front-Hubs).
Drain all engine, steering, hydraulic, transmission, front-hubs, differential, and final drive oils and inspect magnetic plugs on differential, final-drives, and front hubs.
Remove all engine, transmission, hydraulic, differential, steering, fuel, and breathers filters, including air-filters and cut/open oil filters, for visible debris.
Remove all engine, transmission, hydraulic, differential, steering, fuel, and breathers filters, including air-filters and cut/open oil filters, for visible debris.
Apply a thin film of clean engine oil to each seal of each new engine oil filter.
Install engine oil filters by hand. Tighten each new engine oil filter until the seal of each new engine oil filter contact the base of the oil filter housing.
To avoid possible spillage of oil, the filters must be one-quarter (1¼) of a turn away from each other. Always use the rotational index marks as a guide
Use caterpillar strap wrench in order to turn the filter to the amount that is required for the final installation.
Make sure that the installation tool does not damaged the filters and fix all filters removed with new seals where applicable
Clean transmission, torque-convertor and hoist screens and fuel water separator on fuel tank and change air-desiccant and drain water from air tanks.
Inspect main drive shaft and pump drive shaft spider bearings for wear and check induction hoses and clamps, fuel lines for possible leakages
Check turbo clamps and exhaust clamps for leakages, fan-hub and jokey pulley bearings and fan-belt for wear
Inspect radiator and coolant hoses and clamps for leaks and clean radiator if necessary.
Conduct inspection for chassis cracks, inspect skip condition (Liner and body cracks) and initiate backlog repairs and brake wear checks
Refill engine oil and carry out any other required oil change based on condition monitoring recommendations
The task involves informing team members to start the engine and conducting electrical checks on various components
Climb to the cab by using the three point of contact through the right access, blow the horn and start the engine and operate the engine at low idle for five (5) minutes.
Inspect the engine oil filters for oil leaks and maintain the oil level between “ADD” marks.
Stop the engine as the “FULL” mark is attained which is indicated on the low idle side of the dipstick and check tyre conditions (Pressures, Cuts and Wear).
By performing regular preventive maintenance on key assets and machines, maintenance and facilities managers can identify and address potential problems before they turn into major issues resulting in costly downtime and repairs.
Regular maintenance helps businesses reduce downtime and costly repairs, and adhere to preventive maintenance compliance, regulatory and safety standards. This ultimately translates into lower costs and increased productivity for businesses.
Given the benefits, 80% of industries worldwide are now opting for preventive maintenance as their leading maintenance strategy.
Perhaps it is time to consider where your own business stands with respect to implementing a preventive maintenance strategy.
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