Maintenance, troubleshooting, and shutdown procedures
Maintenance, troubleshooting, and shutdown procedures
This domain tests whether you keep the machine serviceable, diagnose faults safely, and shut down so it is fit for the next shift.
Maintenance
- Follow the manual's daily, weekly and periodic intervals: lubrication chart, track shoe bolt torque, track tension, brake adjustment, hydraulic filters and oil sampling.
- Re-inspect wire rope and sheaves against removal criteria at each interval and record rope location and date.
- RCL/LMI calibration is periodic and after any repair affecting it; keep the certificate with the machine. Third-party inspection and load test certificates are usually annual.
- Isolate energy before maintenance: engine off, key controlled, hydraulic pressure relieved, boom blocked or lowered per the manual.
Troubleshooting
- Match symptom to system: slow or drifting hoist (dragging brake, holding valve, relief setting, cold oil), swing drift (swing brake), repeated two-block alarm (limit switch, weight, wiring), derate (engine fault code), hot hydraulics (cooler, oil level, relief).
- Never adjust a relief valve to gain "more power" - you exceed design pressure and void the basis of the load chart.
- Never troubleshoot with a load suspended; land it first.
Shutdown
Land the load and unhook; lower and rest the boom as the manual directs; set swing brake and house lock; park level and chock tracks; idle to cool, shut down, remove the key, secure the cab. Refuel with the engine off. Complete the log and tag out any defect.
Worked example
Hoist drifts down with a load held. Land the load, then check brake adjustment and holding-valve pressure against the manual. If the brake is worn past the limit, tag out and repair - never work under a load held only by a suspect brake.
Traps
Field-adjusting relief valves; fitting an unapproved rope; skipping the log after a repair; leaving the boom raised and unsecured at shift end.