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I want to build a preventative maintenance practice for vehicles, equipment, machinery and tools that require maintenance as per manufacture's specification and interval. I want to make sure the practice also address the following requirements: 1. an equipment inventory list is used, 2. an inspection schedule is setup that meets manufacturer and legislation requirements, 3. inspection and maintenance records are kept, 4. deficient equipment is removed from service until repaired

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Published by SALUS

Preventative Maintenance Program ================================

This document outlines the preventative maintenance program for all vehicles, equipment, machinery, and tools. The program is designed to ensure equipment reliability, safety, and compliance with manufacturer's specifications and relevant safety regulations. It includes a comprehensive equipment inventory, a scheduled inspection plan, meticulous record-keeping, and a procedure for removing defective equipment from service.

Equipment Inventory

A comprehensive inventory of all vehicles, equipment, machinery, and tools must be maintained. This inventory serves as the foundation for the preventative maintenance program. The inventory should include the following information for each item:

  • Unique identification number
  • Description of the equipment
  • Manufacturer
  • Model number
  • Serial number
  • Date of purchase or acquisition
  • Location
  • Warranty information
  • Service history

The equipment inventory should be regularly updated to reflect any changes, such as new acquisitions, disposals, or changes in location. This inventory will be crucial for scheduling inspections and maintenance activities effectively.

Scheduled Inspection Plan

A scheduled inspection plan will be established to ensure that all equipment is regularly inspected according to manufacturer guidelines and legal requirements. The inspection plan should include:

  • Inspection frequency: Inspections should be conducted at regular intervals, taking into account manufacturer's recommendations, equipment usage, and environmental factors. Consider pre-delivery or frequent (quarterly) inspections and annual (yearly) inspections.
  • Inspection checklists: Detailed checklists should be developed for each type of equipment, outlining the specific items to be inspected. These checklists should be based on manufacturer's recommendations and relevant safety regulations.
  • Inspection procedures: Standardized procedures should be established for conducting inspections, including the use of appropriate tools and equipment.
  • Personnel training: All personnel involved in conducting inspections should be properly trained and qualified.
  • Documentation: All inspections should be documented, including the date of inspection, the name of the inspector, the items inspected, and any findings or recommendations.

The inspection plan should cover all critical components and systems, including:

  • Power System: Engine idle, throttle, and RPM; Engine fluids (oil, coolant, fuel); Air/fuel filter; Exhaust system; Batteries; Battery fluid; Battery charger; Fuel reservoir, cap, and breather.
  • Hydraulic/Electric System: Hydraulic pumps; Hydraulic cylinders; Cylinder attachment pins and pin retainers; Hydraulic hoses, lines, and fittings; Hydraulic reservoir, cap, and breather; Hydraulic filter; Hydraulic fluid; Electrical connections; Instruments, gauges, switches, lights, horn.
  • Boom Assembly: Boom weldments, Hose/cable carrier installations, Pivot pins and pin retainers, Sheaves, sheave pins, Bearings, Wear pads, Covers or shields, Extend/retract chain or cable systems.
  • Platform Assembly: Platform, Railing, Gate, Floor, Rotator, Lanyard anchorage point.
  • Turntable Assembly: Swing bearing, Oil coupling, Swing drive system, Turntable lock.
  • Chassis Assembly: Tires, Wheel nuts/bolts, Wheel bearings, Oscillating axle/lockout cylinder systems, Extendable axle systems, Steer components, Spindle thrust bearing/washers, Drive hubs.
  • Functions/Controls: Platform controls, Ground controls, Function control locks, guards, or detents, Footswitch, Emergency stop switches (ground \& platform), Function limit or cutout switch systems, Drive brakes.
  • General: All decals/placards installed, secure, legible; Annual machine inspection due; No unauthorized modifications or additions; All relevant safety publications incorporated; General structural condition and welds; All fasteners, pins, shields, and covers.

Examples of inspection items include checking engine fluids, inspecting hydraulic components, verifying the functionality of safety devices, and examining structural welds. For boom lifts, inspections should include emergency stop switches, function limit or cutout switch systems and capacity indicators. [1] [1] [1]

Meticulous Record-Keeping

Detailed records of all inspections and maintenance activities must be maintained. These records provide a valuable history of equipment performance and can help identify potential problems before they lead to failures. The records should include:

  • Date of inspection or maintenance
  • Name of the inspector or mechanic
  • Equipment identification number
  • Description of the work performed
  • Parts replaced
  • Cost of repairs
  • Downtime
  • Any recommendations for future maintenance

These records should be stored in a secure and accessible location, either electronically or in hard copy. The records should be retained for the life of the equipment or as required by law.

Procedure for Removing Defective Equipment

A clear procedure must be in place for removing defective equipment from operation until all necessary repairs are completed and safety standards are met. This procedure should include:

  • Identification of defective equipment: Any equipment that is found to be defective or unsafe during an inspection or maintenance activity should be immediately identified and tagged.
  • Removal from service: Defective equipment should be removed from service and taken to a designated repair area.
  • Lockout/tagout procedures: Lockout/tagout procedures should be implemented to prevent the accidental start-up of defective equipment during repairs.
  • Repair and inspection: Defective equipment should be repaired by qualified personnel and inspected to ensure that it meets all safety standards.
  • Return to service: Equipment should not be returned to service until all necessary repairs have been completed and it has been inspected and approved for use.

This procedure ensures that no defective equipment is used, preventing potential accidents and injuries.

Inspection and Maintenance Schedules

Preventive maintenance and inspection schedules should include regular checks of various components. These checks should be performed at pre-delivery or frequent (quarterly) inspections and annual (yearly) inspections.

Areas to inspect include:

  • Swing Brakes: Inspect swing brakes during pre-delivery or frequent inspections and annual inspections.
  • Auxiliary Power: Inspect auxiliary power during pre-delivery or frequent inspections and annual inspections.
  • Load Sensing System: Inspect the load sensing system during pre-delivery or frequent inspections and annual inspections.
  • Engine Idle, Throttle, and RPM: Check engine idle, throttle, and RPM during pre-delivery or frequent inspections and annual inspections.
  • Engine Fluids: Regularly check engine fluids such as oil, coolant and fuel during pre-delivery or frequent inspections and annual inspections.
  • Air/Fuel Filter: Inspect the air and fuel filters during pre-delivery or frequent inspections and annual inspections.
  • Exhaust System: Inspect the exhaust system during pre-delivery or frequent inspections and annual inspections.
  • Batteries: Inspect the batteries during pre-delivery or frequent inspections and annual inspections.
  • Battery Fluid: Check the battery fluid during pre-delivery or frequent inspections and annual inspections.
  • Battery Charger: Inspect the battery charger during pre-delivery or frequent inspections and annual inspections.
  • Fuel Reservoir, Cap and Breather: Inspect the fuel reservoir, cap, and breather during pre-delivery or frequent inspections and annual inspections.
  • Hydraulic Pumps: Inspect hydraulic pumps during pre-delivery or frequent inspections and annual inspections.
  • Hydraulic Cylinders: Inspect hydraulic cylinders during pre-delivery or frequent inspections and annual inspections.
  • Cylinder Attachment Pins and Pin Retainers: Inspect cylinder attachment pins and pin retainers during pre-delivery or frequent inspections and annual inspections.
  • Hydraulic Hoses, Lines, and Fittings: Inspect hydraulic hoses, lines, and fittings during pre-delivery or frequent inspections and annual inspections.
  • Hydraulic Reservoir, Cap, and Breather: Inspect the hydraulic reservoir, cap, and breather during pre-delivery or frequent inspections and annual inspections.
  • Hydraulic Filter: Inspect the hydraulic filter during pre-delivery or frequent inspections and annual inspections.
  • Hydraulic Fluid: Check the hydraulic fluid during pre-delivery or frequent inspections and annual inspections.
  • Electrical Connections: Inspect electrical connections during pre-delivery or frequent inspections and annual inspections.
  • Instruments, Gauges, Switches, Lights, Horn: Inspect instruments, gauges, switches, lights, and the horn during pre-delivery or frequent inspections and annual inspections.
  • Operation and Safety Manuals: Ensure operation and safety manuals are in the storage box during pre-delivery or frequent inspections and annual inspections.
  • Capacity Decals: Verify capacity decals are installed, secure, and legible during pre-delivery or frequent inspections and annual inspections.
  • All Decals/Placards: Ensure all decals and placards are installed, secure, and legible during pre-delivery or frequent inspections and annual inspections.
  • Annual Machine Inspection Due: Verify the annual machine inspection is due during pre-delivery or frequent inspections and annual inspections.
  • No Unauthorized Modifications or Additions: Confirm there are no unauthorized modifications or additions during pre-delivery or frequent inspections and annual inspections.
  • All Relevant Safety Publications Incorporated: Ensure all relevant safety publications are incorporated during pre-delivery or frequent inspections and annual inspections.
  • General Structural Condition and Welds: Inspect the general structural condition and welds during pre-delivery or frequent inspections and annual inspections.
  • All Fasteners, Pins, Shields, and Covers: Inspect all fasteners, pins, shields, and covers during pre-delivery or frequent inspections and annual inspections.

Specific components like the boom assembly, platform assembly, turntable assembly, and chassis assembly also require regular inspection.

  • Boom Assembly: Inspect boom weldments, hose/cable carrier installations, pivot pins and pin retainers, sheaves, sheave pins, bearings, wear pads, and covers or shields during pre-delivery or frequent inspections and annual inspections.
  • Platform Assembly: Inspect the platform, railing, gate, floor, rotator, and lanyard anchorage point during pre-delivery or frequent inspections and annual inspections.
  • Turntable Assembly: Inspect the swing bearing, oil coupling, swing drive system, and turntable lock during pre-delivery or frequent inspections and annual inspections.
  • Chassis Assembly: Inspect tires, wheel nuts/bolts, wheel bearings, oscillating axle/lockout cylinder systems, extendable axle systems, steer components, and spindle thrust bearing/washers during pre-delivery or frequent inspections and annual inspections.

Functions and controls should be checked regularly, including platform and ground controls, function control locks, guards, or detents, the footswitch, emergency stop switches, function limit or cutout switch systems and drive brakes. [2] [2] [2]

This comprehensive preventative maintenance program will help ensure the safety and reliability of all equipment, minimizing downtime and promoting a safe working environment.

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2 source record(s)

Sources used for this answer

[1] JLG - Boom Lifts : 1500AJP - Service (PN 31215061)

Page 52

Open source document

Source excerpt

# SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule <table><tr><th rowspan="2">AREA</th><th>INTERVAL</th><th></th></tr><tr><td>Pre-Delivery¹ or Frequent² (Quarterly) Inspection</td><td>Annual³ (Yearly) Inspection</td></tr><tr><td>Emergency Stop Switches (Ground &amp; Platform) arrest all platform movement</td><td>1,3,6</td><td>1,3,9</td></tr><tr><td>Function Limit or Cutout Switch Systems</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Capacity Indicator</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Drive Brakes</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Swing Brakes</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Auxiliary Power</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Power System</td><td></td><td></td></tr><tr><td>Engine Idle, Throttle, and RPM</td><td>1,3,7</td><td>1,3,7</td></tr><tr><td>Engine Fluids: Oil</td><td>4</td><td>4</td></tr><tr><td>Engine Fluids: Coolant</td><td>1,4,7</td><td>1,4,7</td></tr><tr><td>Air Filter</td><td>1,4</td><td>1,4</td></tr><tr><td>Fuel Filter(s)</td><td>1,5</td><td>1,5</td></tr><tr><td>Drain Oil Build Up in 2-Stage Vaporizer (LP Only)</td><td>1,4</td><td>1,4</td></tr><tr><td>Exhaust System</td><td>1,4</td><td>1,4</td></tr><tr><td>Batteries</td><td>1,4</td><td>1,4</td></tr><tr><td>Battery Fluid</td><td>4</td><td>4</td></tr><tr><td>Battery Charger</td><td>1,3</td><td>1,3</td></tr><tr><td>Intake System</td><td>1,2</td><td>1,2</td></tr><tr><td>Glow Plug (Diesel Only)</td><td>1,2,3</td><td>1,2,3</td></tr><tr><td>Serpentine Belt, Tensioner, Pulleys</td><td>1,2,3</td><td>1,2,3</td></tr><tr><td>Fuel Reservoir, Cap, and Breather</td><td>1,3,4</td><td>1,3,4</td></tr><tr><td>Hydraulic/Electric System</td><td></td><td></td></tr><tr><td>Hydraulic Pumps</td><td>1,2,4</td><td>1,2,4</td></tr><tr><td>Hydraulic Cylinders</td><td>1,2,4,5</td><td>1,2,4,5</td></tr><tr><td>Cylinder Attachment Pins and Pin Retainers</td><td>1,2</td><td>1,2</td></tr><tr><td>Hydraulic Hoses, Lines, and Fittings</td><td>1,2,4</td><td>1,2,3,4</td>…

[2] JLG - Boom Lifts : E300AJ, E300AJP - Service (PN 31215951)

Page 42

Open source document

Source excerpt

# SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule <table><tr><th rowspan="2">AREA</th><th colspan="2">Inspections</th></tr><tr><td>Pre-Delivery¹ or Frequent 2 (Quarterly) Inspection</td><td>Annual³ (Yearly) Inspection</td></tr><tr><td colspan="3">Functions/Controls</td></tr><tr><td>Platform Controls return to neutral/offwhen released</td><td>1,3,6,9</td><td>1,3,6,9</td></tr><tr><td>Ground Controls return to neutral/offwhen released</td><td>1,3,6,9</td><td>1,3,6,9</td></tr><tr><td>Function Control Locks, Enclosures, Guards, Boot or Detents</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Footswitch</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Emergency Stop Switches (Ground &amp; Platform) arrest all platform movement</td><td>1,3,6</td><td>1,3,6</td></tr><tr><td>Function Limit or Cutout Switch Systems</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Capacity Indicator</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Drive Brakes</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Swing Brakes</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Synchronization and Sequence system</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Auxiliary Power</td><td>1,3,9</td><td>1,3,9</td></tr><tr><td>Power System</td><td></td><td></td></tr><tr><td>Batteries</td><td>1,2</td><td>1,2</td></tr><tr><td>Battery fluid level correct</td><td>4</td><td>4</td></tr><tr><td>Battery Charger</td><td>1,2,3</td><td>1,2,3</td></tr><tr><td>Motors free of damage</td><td>2</td><td>4</td></tr><tr><td>All electrical connections tight, free of frays and corrosion</td><td>1,2</td><td>1,2</td></tr><tr><td colspan="3">Hydraulic/ElectricSystem</td></tr><tr><td>Hydraulic Pumps</td><td>1,2,4</td><td>1,2,4</td></tr><tr><td>Hydraulic Cylinders</td><td>1,2,4,5</td><td>1,2,4,5</td></tr><tr><td>Cylinder Attachment Pins and Pin Retainers</td><td>1,2</td><td>1,2</td></tr><tr><td>Hydraulic Hoses, Lines, and Fittings</td><td>1,2,4</td><td>1,2,4</td></tr><tr><td>Hydraulic Reservoir, Cap, and Breather</td><td>1,2,3,4,5…

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