Preventative Maintenance Program

This document outlines the requirements for establishing and maintaining a preventative maintenance program for vehicles, equipment, machinery, and tools. The program aims to ensure safe and reliable operation, regulatory compliance, and adherence to manufacturer's specifications and recommended maintenance intervals.

Program Objectives

Ensure the safe and reliable operation of all vehicles, equipment, machinery, and tools.
Comply with all applicable safety regulations and standards.
Extend the lifespan of assets through proactive maintenance.
Minimize downtime and disruptions due to equipment failure.
Maintain equipment in accordance with manufacturer's specifications and recommendations.
Identify and address potential safety hazards before they result in incidents or injuries.

Scope

This program applies to all vehicles, equipment, machinery, and tools owned, leased, or operated by the organization. It encompasses all departments and personnel responsible for the operation, maintenance, and repair of these assets.

Responsibilities

Management: Provide the necessary resources and support for the implementation and maintenance of the preventative maintenance program.
Supervisors: Ensure that all personnel are trained on the proper maintenance procedures and that maintenance is performed according to schedule.
Maintenance Personnel: Perform scheduled maintenance tasks, document all maintenance activities, and report any equipment defects or safety hazards.
Operators: Conduct pre-operation inspections of equipment, report any equipment defects or safety hazards, and operate equipment in accordance with established procedures.

Program Components

Equipment Inventory

Maintain a comprehensive inventory of all vehicles, equipment, machinery, and tools covered by this program. The inventory should include the following information:

Equipment identification number
Description of equipment
Manufacturer
Model number
Serial number
Date of purchase or acquisition
Location
Manufacturer's recommended maintenance schedule
Warranty information

Maintenance Schedules

Develop detailed maintenance schedules for each piece of equipment based on manufacturer's recommendations, regulatory requirements, and operational experience. Maintenance schedules should include the following:

Frequency of maintenance tasks (e.g., daily, weekly, monthly, annually)
Specific maintenance tasks to be performed
Required tools and materials
Safety precautions
Estimated time to complete the task
Record-keeping requirements

Pre-Delivery or Frequent Inspections

Pre-delivery or frequent inspections are essential for identifying potential issues early. These inspections may include checking swing brakes, auxiliary power, and the load sensing system. [1] [1] [1]

Annual Inspections

Annual inspections are more in-depth and cover a broader range of components. These inspections include checking swing brakes, auxiliary power, and the load sensing system. [1] [1] [1]

Specific inspection items include:

Swing Brakes
Auxiliary Power
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 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
Operation and Safety Manuals in Storage Box
Capacity Decals Installed, Secure, Legible
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

[2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2] [2]

Maintenance Procedures

Develop detailed maintenance procedures for each maintenance task. These procedures should include step-by-step instructions, safety precautions, and required tools and materials. Ensure that all maintenance personnel are properly trained on these procedures.

Lubrication

Regularly grease and lubricate equipment to specifications to ensure smooth operation and prevent wear. [3]

Hydraulic Systems

Inspect hydraulic pumps, cylinders, hoses, lines, and fittings for leaks, damage, or wear. Check hydraulic fluid levels and condition, and replace filters as needed. [3] [3] [3] [3] [3]

Electrical Systems

Inspect electrical connections for corrosion or damage. Check the condition of batteries and battery fluid levels. Test instruments, gauges, switches, lights, and horns to ensure proper function. [3] [3] [3] [3]

Engine Maintenance

Monitor engine idle, throttle, and RPM. Regularly check engine fluids (oil, coolant, fuel) and replace air/fuel filters as needed. Inspect the exhaust system for leaks or damage. [3] [3] [3] [3]

Record Keeping

Maintain accurate records of all maintenance activities. These records should include:

Date of maintenance
Equipment identification number
Description of maintenance performed
Name of person performing maintenance
Parts replaced
Cost of maintenance
Any equipment defects or safety hazards identified
Date of next scheduled maintenance

Training

Provide comprehensive training to all personnel involved in the maintenance and operation of equipment. Training should cover:

Proper maintenance procedures
Safe operating procedures
Hazard identification and control
Emergency procedures
Record-keeping requirements

Regularly test all systems to ensure they are functioning correctly. [3]

Inspections

Conduct regular inspections of all vehicles, equipment, machinery, and tools to identify potential safety hazards and maintenance needs. Inspections should be performed by qualified personnel and documented appropriately.

Decals and Manuals

Ensure that all operation and safety manuals are present and in the storage box. Verify that all decals and placards are installed, secure, and legible. Incorporate all relevant safety publications. [3] [3] [3] [3]

Structural Integrity

Regularly inspect the general structural condition and welds of equipment. Ensure that all fasteners, pins, shields, and covers are in place and secure. [3] [3]

Program Evaluation

Regularly evaluate the effectiveness of the preventative maintenance program. This evaluation should include:

Review of maintenance records
Analysis of equipment downtime and repair costs
Feedback from operators and maintenance personnel
Compliance audits
Incident investigations

Based on the evaluation results, make necessary adjustments to the program to improve its effectiveness.