8.

1 AVAILABILITY
Utilization and availability metrics depend on how many hours a machine must
work, and how much time can be devoted to maintenance and repair.

8.1.1 Utilization and Availability Defined:

Utilization = The time the machine is used divided by The time the machine is required
to work and able to work

Availability = The time the machine is required to work and able to work divided by The
time the machine is required to work

The diagram at top shows how this works over a 24-hour period and gives the following
formulas:

Utilization = W / T-D

Availability = T-D / T

Where:

W = Operating hours or the time the machine works.

T = the time the machine is required to work in a given period.
D = the downtime experienced by the machine that prevents it from working when
needed.
 8.1.2 Total Productive Maintenance

A. Calculation of Overall Equipment Effectiveness, (OEE) in TPM is the product of

Equipment Availability, Quality performance (non-scrap or reworked product) and
Speed (throughput) is not really a complete analysis. It does not take account of
equipment costs and profits, and so it is not a good measure for comparing machines
or systems, or for comparing the effect of equipment deterioration over time. OEE is
only a part of the Life Cycle Risk Cost/Profit perspective. Within those inherent
limitations the OEE concept is useful for monitoring equipment effectiveness and
performance.

OEE = Availability x Throughput Rate x Quality Rate

B. Production Losses and Overall Equipment Effectiveness

Total Calendar Time

Scheduled
Downtime Scheduled Production Time

Set-up
Time
Available Operating Time
Availability Unplanned
Reported Actual Operating Time
Stoppages
Minor
Unrecorded Actual Production Time
Stoppages
Throughput
Rate Reduced
Full Rate Production Time
Speed

Rejects &
Quality Rate Rework
In-Quality Production Time
8.2 DAILY CHECK & MAINTENANCE

I. DAILY CHECK

A. Heavy Equipment Checklist

The operation of heavy equipment must be safe and to ensure the safety of the
operators a daily checklist must be maintained. This checklist makes sure the heavy
equipment is safe to use and will not harm any employees working around the
machinery. The Occupational Safety and Health Administration (OSHA) has general
guidelines concerning the daily inspection, but it leaves a lot of the specifics of the
checklist up to the employer.

1. Date, Equipment Identification and Operator

• Every heavy equipment checklist must have areas where the date of the
inspection can be documented. Along with the date of inspection, the
checklist must have a section where the equipment can be identified,
generally with a heavy equipment identification number. Each heavy
equipment checklist must have the inspector's name documented or listed
somewhere as well as the operator's name. These two names are
generally the same because OSHA requires that the operator perform an
operational inspection before use.
2. Fluids and Gauges

• The operator of the heavy equipment must check the fluid levels in the
machinery before operating the vehicle or equipment. All fluids must be
checked including hydraulic fluids, coolant levels, oil levels and any other
fluids used by the heavy equipment. Once the operator has checked to
make sure all fluid levels are within allowable limits, he needs to check the
gauges of the equipment to make sure they are operating properly and
recording properly. These gauges include air pressure levels, fluid levels,
temperature gauges, electrical fault lights and other gauges used during
operation of the heavy equipment.

3. Movable Parts
• The operator must check to make sure all visible movable components are
working properly and without obstructions. Every piece of heavy
equipment is required to have properly inflated tires, tracks that are not
obstructed by any debris and free flowing members such as dump beds,
buckets or turning capabilities. The operator or inspector must run the
heavy equipment through its entire capabilities to make sure the
equipment has a full turning radius and the buckets or dump beds can be
moved through their full cycle or radius. The checklist must have a section
 for checking fans, belts, wiper blades and other small movable
components on the heavy equipment.
4. Safety Equipment

• A heavy equipment checklist must record an inspection on all the safety

equipment in the machinery. This includes lights, turn signals, warning
sounds, fire extinguisher, mirrors, safety cages or roll bars and seat belts,
along with the overall cleanliness of the equipment including the cab.

B. Heavy Equipment Safety Inspection Checklist

Periodic inspection is crucial to the safe operation of heavy equipment and

vehicles. If equipment is damaged or worn, the safety of your workers is at risk.
Furthermore, periodic inspections can help you prevent further expensive
damage to your valuable equipment. Develop a safety checklist for the heavy
equipment you own and use that checklist regularly.

1. Exterior Inspection

• Walk around your heavy equipment every morning before the workday
begins. With your safety checklist in hand, look for cracks or damage to
the exterior frame of the vehicle. Shocks and springs should not show
signs of leakage. Determine whether the axles are straight, check for
loose or sagging wiring and look for signs of oil leakage under the vehicle.
You should also remove excess debris accumulated on the exterior before
you start the operating the equipment. Debris may hide a problem.

• Check all tires if the heavy equipment has wheels. Properly inflate tires to
the recommended pressure. Look for signs of wear, such as tread or
sidewall separation, and immediately change tires that show bulges. Make
sure all lug nuts are present on the wheel and replace wheels if you see
cracks in them.

• If the vehicle runs on a track, check for the proper amount of slack.
Replace worn or damaged treads immediately.

2. Engine

• The fuel system on your heavy equipment should show no signs of

leakage. The fuel cap and brake lines should be in place and fluid levels
full. Oil levels for both the engine and hydraulic system should stay full as
well. Check the steering mechanism for too much play.
 While the engine is running, the motor shouldn't exhibit any unnecessary
sounds or produce excessive exhaust fumes. Pay special attention to
leaks or emissions below or in front of the operator's seat.

3. Operator's Cab

• Your heavy equipment safety checklist should contain a number of items

to check from the operator's seat in the cab. A safety roll bar must protect
the driver in the absence of a cab and the operator's seat must have a
seat belt. All safety signage must remain in place. Attach a fire
extinguisher to the piece of heavy equipment and check it periodically.

• Windshields should be clean in an enclosed cab. Wipers and horn should

be fully functional. Heating and air conditioning vents should also be clean
and make sure you follow a schedule for replacing air filters. All gauges
must be fully functioning and all lights both inside and outside the cab
should operate.

II. MAINTENANCE
Heavy Equipment Maintenance
Operating heavy equipment costs a lot of money. Failing to make repairs to that
equipment due to a poor equipment maintenance policy is simply not good business.
Running through a maintenance checklist can take as little as 15 minutes a day and
may easily catch a problem before it becomes several days' lost work due to equipment
repairs. Poorly maintained heavy equipment may also pose a safety hazard to your
employees.

A. Definitions

1. Corrective maintenance:

A reactive maintenance system, characterized by run-to-failure breakdowns

and repairs after the breakdown occurs.

2. Preventative maintenance (PM):

A maintenance system that uses a procedural approach with schedules and

guidelines that attempts to prevent breakdowns with maintenance
procedures.

Preventive maintenance inspections are simply a straight-forward systematic

approach to checking the condition of vehicles or equipment at planned
intervals. They can be measured in several ways: by time, mileage, hours of
 operation, fuel consumption, or a combination of all four that best suits the
needs of an individual fleet.

3. Productive maintenance:

A maintenance system that strives to predict breakdowns through analysis of

historical data.

4. Total Productive Maintenance (TPM):

Total Productive Maintenance (TPM) is an equipment management program
that emphasizes operator involvement and ownership of equipment
performance. The goals of a TPM program are to maximize equipment
productivity, maximize equipment availability and make quality product by
eliminating causes of equipment defects, losses and wastes through
expanding and engaging the knowledge, skills and abilities of the front-line
people running the process.
Often referred to as "total production maintenance" or "total productivity
maintenance", the formal name for the TMP introduced is "Total
Productive Maintenance". That is the method of training operators to get
involved in maintenance task too.

Total Productive Maintenance

Production Losses and Overall Equipment Effectiveness

Total Calendar Time

Scheduled Scheduled Production Time

Downtime
Set-up Available Operating Time
Time
Availability Unplanned
Reported Actual Operating Time
Stoppages
Minor
Unrecorded Actual Production Time
Throughput Rate Stoppages
Reduced Full Rate Production Time
Speed
Rejects
In-Quality
Quality Rate and
Production Time
Rework
B. Processes/Procedures
1. Daily Maintenance

• Set a schedule for equipment maintenance and stick to it. There are
certain tasks to perform daily, while other tasks need completing on a
longer schedule. Once you decide on a schedule, prepare a maintenance
checklist.

Walk around each piece of heavy equipment in operation daily. While you
perform a visual inspection, look for worn parts and signs of oil or coolant
leakage. Make sure to inflate tires to the required pressure. Take time to
clean debris away from the machine. Feel belts and chains to make sure
there isn't too much slack in them. Lubricate linkages that call for daily
grease. Make sure safety signage and safety equipment is in place. Check
the fluid levels on oils, coolant and hydraulics. Top them up as needed.
Failure to keep the proper amounts of fluids in your heavy equipment can
shorten its life. Check the air filter and clean it if necessary.

2. Quarterly Maintenance
• When your piece of heavy equipment has 500 service hours or about 3
month's services, you should perform a more thorough maintenance
check. Change the engine's oil and both the engine oil filter and hydraulic
oil filter. Replace the diesel fuel filter also as part of the 3-month
equipment maintenance procedure.

3. End of Season Maintenance

• At the end of the season or at least once a year, change the transmission
fluid as well as the hydraulic oil. Check your radiator to make sure it's in
good condition. Check hoses and belts.
Wash the entire vehicle. Pay special attention to cleaning the engine and
the undercarriage. Clean the cab and its air filters. Make sure the air
conditioning unit is clean. Make sure all lights are operational and replace
defective bulbs.
Inspect the tires for signs of wear and tear. Replace worn tires during the
off season so you don't lose valuable work time.
4. Preventive Maintenance (PM)
Identify problem areas and prevent premature failure caused from conditions
such as lube fittings that aren’t taking grease, lines that are worn, frayed and
exposed electric lines, leaking fluids, and any part that is broken or worn-out.
View them as part of the overall maintenance program.
4.1 Four Categories of PM

Of course, it depends on what type of maintenance is being performed,

service intervals and vehicle mileage or machine hours operated, but
preventive maintenance usually falls into four categories.

PM-A involves minor maintenance work that is performed every 4,000 to

15,000 miles or one or two months apart. This work could include such
things as lube jobs, vehicle inspection, or tire inspection and inflation.

PM-B covers maintenance service that is performed less frequently and

is more complex than PM-A. Adjustment in engine performance or oil
and filter changes would fall into this category. Service intervals in PM-B
could range from 6,000 to 20,000 miles or two to four months.

PM-C encompasses more complex maintenance service, such as minor

and major component testing, brake overhaul and replacement, fuel
injector overhaul and replacement, and driveline adjustments.
Maintenance in this category occurs between 25,000 and 40,000 miles
or every six to 12 months.

PM-D is the category for major, planned jobs. This maintenance pertains
to work such as in-frame or out-of-frame diesel engine overhauls or
replacing or rebuilding gasoline engines. Service in this category
generally is performed between 75,000 to 250,000 miles or 16 to 24
months.

4.2 Preventive Maintenance Procedures & Forms

A. Process

As equipment arrives at the site a determination is made if the

equipment should be placed on a preventative maintenance schedule
based on the type of equipment, calibration requirements, etc.

To ensure equipment is tracked and preventative maintenance work is

performed on a timely basis the following process is used. The site
management representative is responsible for ensuring the process is
followed.

REGISTER IS MONITORED WEEKLY FOR SCHEDULED

ADDED TO PM
EQUIPMENT
REGISTER
RETIRED EQUIPMENT REMOVED FROM REGISTER

NEW EQUIPMENT
ARRIVES
PREVENTATIVE WORK STEPS, SCHEDULE AND SAFETY PLACED ON
MAINTENANCE FORM
RECORD FORM
CREATED PREVENTATIVE MAINTENANCE WORK RECORDED
All records must be legible, readily retrievable, protected and stored to
prevent damage, deterioration or loss.

B. Equipment Register

All equipment at a site that requires calibration or routine preventative

maintenance is listed on the Equipment Register form by the designated
maintenance representative for the site. The register contains
information on equipment’s:

• Description
• Make
• Model
• Serial Number
• Location
• Next Scheduled PM Date

As appropriate equipment is added to a site’s inventory it is added to the

register as well as equipment that is removed permanently from the site
is removed from the register.

Each week the Equipment Register is reviewed for scheduled

preventative maintenance for equipment at the site.

Each quarter a copy of the Equipment Register is sent to the appropriate

management representative for the site.

C. Preventive Maintenance Record

Each piece of equipment on the Equipment Register is assigned a

Preventative Maintenance Record form. This form contains information
on the equipment including:

• Equipment data
• Safety instructions for the item
• Description of preventative maintenance requirements for the
equipment
• Preventative maintenance frequency and history
 As scheduled preventative maintenance is performed on the equipment
the maintenance record shall be completed.

The form is to be retained locally.

4.3 Repair Procedures & Forms

A. Process

During preventative maintenance work or other requested repairs activity

is tracked and documented by use of the following process.

This process ensures documented work performed, costs and

management approval for material associated with the project activity.

REPAIR OR MAINTENANCE
MAINTENANCE REQUEST FORM IS
REQUEST IS COMPLETED AS WORK IS PERFORMED
REQUIRED NEEDED

WORK ORDER MAINTENANCE

IF NEEDED A
FORM IS LOG FORM
MATERIAL
COMPLETED UPDATED AS
REQUISITION FORM
& RETAINED NEEDED
IS COMPLETED

All records must be legible, readily retrievable, protected and stored to

prevent damage, deterioration or loss.

B. Maintenance Request Form

Maintenance requests are originated by the client or internal requestor

completing a Maintenance Request Form and submitting the form to the
designated maintenance representative for the site. The form contains
information regarding:

• Originators Information
• Location of the problem
• Defective equipment details
• Description of the problem or corrective action requested

Each Maintenance Request Form is to be retained in a file folder with all

appropriate other documents, copies of invoices, etc. and retained locally
at the site.

C. Work Order Form

 The designated maintenance representative takes information from the
Maintenance Request Form investigates the problem and documents
work performed on the Work Order Form. Data contained on the Work
Order Form includes:
• Maintenance Request input
• Corrective actions completed
• Manpower details
• Materials used or needed for repairs and cots

Each Work Order Form activity is then entered onto the Maintenance Log
form. If equipment, parts, etc. are required the Material Requisition Form
shall be completed and approved prior to purchasing.

D. Maintenance Log Form

The Maintenance Log contains in chronological order all Work Order

activity with line item summaries of reported date, maintenance issue,
location, costs and completion date.

Each quarter a copy of the Maintenance Log is sent to the appropriate

management representative for the site.

E. Material Requisition Form

Material is requested for and approved via the Material Requisition Form.

A purchase order is assigned by the designated maintenance

representative (which must appear on all invoices).

The form is submitted to the Project Manager for review and approval.
Any single Material Requisition Form representing a single value of say
P50,000 or more requires approval from senior management prior to
placing any orders.

The Material Requisition Form is to be kept with all Work Order Forms.
5. Total Productive Maintenance
Investigate if the introduction of TPM will help you reduce lost time on
operating equipment to a tune of 30% or better. This is typical for companies
that do not have advanced Preventive Maintenance and Predictive
Maintenance (PdM) practices in place. Insure you meet the requirements for
a Successful TPM introduction to your facility.

C. Checklists
1. Checklist for an Equipment Operator

Anyone who operates equipment on a job site or in the workplace has a

responsibility to pay attention to safety for himself and those around him.
Before you begin using a piece of equipment, do a safety checklist to make
sure the equipment is ready to be operated properly. This applies to forklifts in
a warehouse or backhoes on the job site.

1.1 Maintenance Log

• Check the maintenance log prior to starting up a piece of machinery.

Make sure the log is up to date, and make sure any needed repairs were
noted and signed off that they were done. If you notice that the machine
has missed maintenance cycle, or a repair was noted but not signed off,
report it to your supervisor immediately. If there is no maintenance log
associated with the machine, then find out if your supervisor can access
the log for you.

1.2 Instruction Manual

• Before starting up a piece of equipment, review the manufacturer's

instruction manual to refresh yourself on procedures you may have
forgotten. Sometimes you can go quite a while without an equipment
problem, and you can forget what you should do if something were to go
wrong. Rather than hope you have another incident-free day, review the
safety procedures in the manual before getting started.

1.3 Safety Equipment

• In some cases, a piece of machinery will have its own set of safety
equipment that goes with it. A list of the safety equipment that should be
with a machine should be listed on the machine itself, or on a separate
list included with the maintenance log. Check to make sure all necessary
safety equipment is in place and that it is functional. Some pieces of
safety equipment include small fire extinguishers, chains to anchor the
equipment and blocks to hold the equipment in place when you park. If
safety equipment is missing or not functioning properly, point it out to
your supervisor.

1.4 Analyze the Work Area

• Take the time to look around the area where you will be operating the
machinery to identify potential safety issues so you can avoid them
during your workday. Low power lines, steep drop-offs of roads or open
floors, muddy roads and narrow roadways should be noted, and you
should develop a plan to avoid them during the day.
2. Inspection Checklist (PM)
Equipment inspections should be performed by drivers or operators on a
routine basis and periodically by fleet mechanics. As part of these inspections,
a visual inspection should include the following:
• Tires, wheels, steering, suspension, drive systems
• Coolant, exhaust, fuel systems
• Lights and other electrical system parts
• Leaks, both liquid and air
• Body damage, both accumulated and new
• Mirrors, interior and exterior
• Brakes, service and parking
• Windshield wipers
• Instruments and gauges
• Coupling devices
• Safety devices
• Emergency equipment

2.1 A Heavy Equipment Preventive Maintenance Check List

Heavy equipment is expensive and must have a preventive maintenance

program developed in order for it to last as long as possible. The heavy
equipment maintenance department must maintain a preventive maintenance
checklist on each piece of equipment to comply with Occupational Safety and
Health Administration (OSHA) regulations. This checklist must be scheduled,
conducted and documented.

2.1.1 Date, Time and Inspector

• Each heavy equipment preventive maintenance checklist must

record the date of the inspection, the time the inspection was
conducted and the name of the inspector who completed the
checklist. This is not only required for record keeping purposes,
but also to enable the maintenance mechanic or repair person
to later ask the specific inspector questions about the faults
found during the checklist inspection.

2.1.2 Checklist Sections

• Most heavy equipment preventive maintenance checklists are

broken up into sections, with each section listing the parts that
need to be inspected. A preventive maintenance checklist has
sections such as what should be inspected from the ground,
what parts need to be looked at in the engine compartment and
what parts should be inspected in the cab. Many such lists
include a safety equipment section where the inspector can
record the operational readiness of the safety equipment such
 as fire extinguishers, warning lights and sounds, safety lights
like turn signals and overhead protection devices, cages and roll
bars.

2.1.3 Section Breakdown

• Each section of a heavy equipment preventive maintenance

checklist will be broken down into categories. One category will
be a list of parts or items to inspect, another category will list the
things to look for when inspecting that item or part, and the last
category should have a space for additional comments or
problems found during the inspection. These categories record
what is specifically inspected on the heavy equipment and notify
the maintenance mechanic or repair-person what requires
attention or repair.

3. Heavy Equipment Checklist (Sample)

3.1 General

Heavy equipment is required

to be checked before operation.

The operation of heavy equipment must be safe and to ensure the safety of
the operators a daily checklist must be maintained. This checklist makes sure
the heavy equipment is safe to use and will not harm any employees working
around the machinery. The Occupational Safety and Health Administration
(OSHA) have general guidelines concerning the daily inspection, but it leaves
a lot of the specifics of the checklist up to the employer.

3.2 Vehicle Heavy Equipment Inspection Checklist

 Regularly inspecting heavy equipment
ensures efficient and safe operation.

Heavy equipment must be maintained in peak operating condition for both

optimum efficiency and safety. Big machines breaking down or unable to get
the job done cost the owner money. Unreliable equipment can also be
hazardous for operators and those in the vicinity. An inspection checklist will
help ensure that the equipment is ready to go when the work starts. Going
through the checklist each day before start-up or regularly during around-the-
clock operations will reduce downtime and improve the bottom line.

3.2.1 Safety

• Manufacturers are regulated and also motivated to install

various safety features on heavy equipment to avoid accidents
and possible injury. Check all lights and alarms for proper
functioning. Stationary heavy equipment such as printing
presses, forging equipment and other big machines will have
safety covers. The machine will not operate or start if the cover
is open. Inspect all safety covers and connections.

Road-going heavy equipment such as bulldozers, dump trucks

or other earth moving machines will have various safety
features in the cab. Check all switches and displays indicating
safe operation. Burned out light bulbs or damaged speakers
could mean missing an important safety warning.
3.2.2 Lubrication and Coolant

• Just about every heavy machine requires lubrication for moving

parts. Constant operation from shift to shift can result in fluids
and lubricants going dry. The inspection checklist will make sure
the levels are topped off and ready for a day's labor.
Some machines with either fuel or electric motors will have
cooling systems for the engines or other components that
generate high heat. Check all lubrication and coolant reservoirs
 for proper levels. Fans and circulating pumps should be
inspected. Also inspect any lubrication points for grease gun
injection and make sure the associated gears, cams, shafts or
bearings are operating smoothly.

3.2.3 Drive Train and Power Source

• Whether heavy equipment moves or is stationary, it will have a

drive train for transmitting power to the machine and a power
source. Heavy construction equipment will have gasoline or
diesel engines. Heavy production equipment on the factory floor
will be powered electrically, hydraulically or even by steam.
Inspect the engine for all filters, connections, fluid levels and
response to operator input.
Heavy equipment that moves will have wheels or track treads.
Even if the machine never goes on the road, be sure the tires
have plenty of tread and acceptable wear. Track treads should
be fully lubricated and with plenty of depth (tracks treads wear
thin with use and will fail the same as a rubber tire.) Production
equipment must operate according to specification for maximum
output. Inspect for worn moving parts, gears, shafts, cams or
bearings. Follow manufacturer recommend procedures for
examining all access points.

3.3 Equipment Safety Inspection Checklist

Even the tools used in performing checks

should be checked for wear and tear.

The daily use of manual and powered equipment eventually provokes a

breakdown in their durability. Routine checks of equipment are vital in
maintaining its use and your personal safety. Following a few simple practices
will provide you with methodology to increase the lifespan of your tools and
keep you or your company from needless spending.

3.3.1 Operation Manual

A good way to create safety checklists is to study the manual from the
equipment manufacturer. Research will have already been conducted in
several different areas of stress testing. The manufacturer will perform
tests, ranging from heat and cold exposure to corrosion and conductivity.
Using the manual will help establish the general limitations of your
equipment.
3.3.2 Engineering Protocols
A good practice in determining risk is performing a Zurich Hazard
Analysis. Using engineering methods, you evaluate the risk as it pertains
to the equipment and how it is used by you or the business. The
equipment may pose a minimal risk in a benign environment, where the
risk is substantially higher in a corrosive atmosphere. Determining the
prolonged exposure between the two environments by means of
operation and stress tests allows the user to establish safety checks that
are necessary to prolong the equipment's lifespan and ensures overall
safety.
3.3.3 Preventive Maintenance
Perform preventive maintenance routinely. Doing this will allow the user
to examine equipment's regular use. For example, using a bulldozer
every day will require lubrication checks, and making sure fluid levels,
hoses and fasteners like screws and bolts are in place and secure. For
simpler things like manual hand tools, you can look for corrosion like
rust, and make sure it is maintaining its original physical appearance. If
you use a screwdriver every day, the edges on the head will need to
maintain smooth, machined lines like every hand tool.
3.3.4 Visual Inspections
In some cases, all that is needed are visual verifications. Looking at
things like windshields on vehicles is self-explanatory; if there are no
cracks or huge chips in the glass, they are structurally sound. Inspect the
tread on tires for foreign objects like nails or other sharp objects, and
that the tread is free from wear. You can inspect the items for corrosion
buildup. Examine electrical cords for exposed wiring. Inspect lines and
hoses for leaks. Check temperature and pressure gauges on equipment
that runs continuously.
3.3.5 Audit Yourself
Perform audits to maintain the integrity of your safety. Have a checklist
for your checklist. Keeping a record of your safety checks will help you
determine if you are adequately checking for the safe use of your
equipment; if an accident does occur, you have a written document that
the equipment was being cared for. The complete picture in safety
checklists is using the checklists to verify everything is operable. Human
error is the root cause of most accidents. The equipment may fail, but it's
up to the human factor to foresee or prevent its failure.
4. Operator/Equipment Inspection Checklist (Selected Equipment only)

4.1 Front End Loader Operator Check List

Daily operational inspection - this inspection is done with a checklist that must
be signed by the operator and filed in the maintenance department.

4.1.1 Basic Information Requirement

• Every front end loader operator checklist must have the basic
information recorded at the top of the checklist. This includes the
operator's name, date of the inspection, equipment number to
identify the front end loader and time of the inspection. Most
checklists record the type of machine as well as the model
number.

4.1.2 Checklist Sections

• Most front end loader checklists are broken up into sections, such
as a section on what to inspect on the outside, inside the cab and
inside the engine as well as a section on the safety devices that
are required to be on the machinery. Each section is also broken
up into categories or lists what to check under that particular
section. The sections record comments about the part, whether it
is in good shape or needs attention and whether the operator
needed to do anything to the part such as add oil, grease or
replace a minor part. This record keeping assists the maintenance
department keep a proper preventive maintenance program and
lets them know what needs repaired when the operator finds
defects or damage.

4.1.5 Outside the Front End Loader

• An outside inspection is done on the front end loader by the

operator and recorded on the checklist. The operator checks for
any damage to the front end loader, any fluid leaks that can be
seen on the ground under the equipment, condition of the tires and
inspection of the bucket assembly. The operator also records the
condition of the handrails, mirrors and outside safety devices.

4.1.6 Inside the Cab

• The operator of a front end loader documents on the checklist the

condition of the cab of the equipment. Most of the checklist
concerns what is inside the cab and the conditions of each item
must be recorded. The operator checks to ensure all the gauges
 are working properly such as the oil gauge or temperature gauge.
The cleanliness of the cab needs to be recorded and all the safety
equipment inside the cab needs to be inspected to make sure it is
operational and not damaged. The checklist must also document
the condition of the brakes such as the parking brake and service
brakes. These are only a few of the things that need to be
inspected by the front end loader operator, but the checklist
documents several devices that the operator is required to inspect
before operation.

4.1.7 Operational Inspection

• As part of the daily checklist, the operator is required to check the

operation of the front end loader. The operator turns on the engine
to conduct this inspection. The controls of the front end loader
must be operated and are run through their cycles. The lights and
safety horns must be checked to ensure they are working properly.
The movement of the bucket must be operated through its cycle by
the operator. The front end loader operator records the findings of
this inspection on the daily checklist. The checklist is kept in the
cab during the operation of the front end loader so any problems
can be recorded.

4.2 Backhoe Loader Pre-Operation Checklist

Backhoe loaders aid in urban engineering and small construction projects.

Two different models are available, the two-wheel and the four-wheel. Both
have the same operation and pre-operation standards. You must read the
manual and perform a pre-operation inspection before using a backhoe
loader. As the machine's operator, the safety of the machine is your
responsibility.

4.2.1 Specialty Attachments

• Backhoe loaders usually have specialty attachments for different

purposes, all of which should be intact before you proceed to its
operation. Some of the attachments you need to check include
clamping and ripper buckets, boom attachment, pole erector,
street sweeper, asphalt cutter, hydraulic breaker and ripper tooth.

4.2.2 Safety Equipment

• To ensure safety during the loader's operation, you must also

check whether safety equipment such as fire extinguisher, back-up
alarm and seat belt are in place.
 4.2.3 Personal Protective Equipment

• As the machine's operator, you must to wear protective equipment

during operation. The gear you must have ready includes safety
glasses, hard hat, safety-toed shoes, gloves and hearing
protection.

4.2.4 Operator's Station

• Once your equipment and other attachments are in place, you are
now set to mount the operator's station. Make sure to fasten your
seat belt and keep the platform clear of debris. You have to clean
up your boots and hands to remove mud and grease prior to
operation as handling the controls with oily and greasy hands
proves dangerous.

4.2.5 Controls

• Before starting the machine, you have to ensure that all controls
are in neutral position. Allow the hydraulic system to warm up for
operation. Check the dials and gauges to ensure that the gears
are working properly. All control levers must also be checked, in
addition to the brakes, steering and transmission.

4.2.6 Clearance

• After the physical inspection of the backhoe loader, the next thing
on your checklist is the safety of people and objects around the
equipment. Get to know the location before moving to ensure
enough clearance. To do this, you have to be aware of the
dimensions and weights of your machine.

You must observe overhead clearance if operating the backhoe

loader on the road. There might be a service station, motel
canopy, and billboard or hanging electrical line somewhere; you
have to take notice of these. Also, if you transport the backhoe
loader using a trailer, the dimension of the trailer must be taken
into account.

Moving the backhoe loader off-road can be a bit trickier, which is

why you should walk the route first to inspect for depressions,
gullies or other obstacles that may cause accidents.

D. Summary

The need to improve safety and maintenance records and the extreme competitiveness
of the construction business demands that contractors continuously look for new ways
to improve safety and reduce maintenance costs. Companies in the industrial sector
have found effective equipment maintenance increases profits and improves safety
performance.
E. FORMS (SAMPLE ONLY)

1. Construction Equipment Inspection

Project Name: Project Location:

Inspected by: Date of Inspection:
Equipment Name: Number:

OK BAD N/A Remarks OK BAD N/A Remarks

Tracks, tires,
wheels __ __ __ _______________Motor (wiring) __ __ __ ______________
Brakes __ __ __ _______________Radiator __ __ __ ______________
Horn __ __ __ _______________Belts __ __ __ ______________
Lights __ __ __ _______________Hoses __ __ __ ______________
Clutch __ __ __ _______________
Windshield
Wiper __ __ __ _______________
Glass __ __ __ _______________
Rear View Shop
Mirror __ __ __ _______________Equipment
Body __ __ __ _______________Lubrication Points __ __ __ ______________
Cover __ __ __ _______________Loose Bearings __ __ __ ______________
Frame __ __ __ _______________Guards __ __ __ ______________
Dump
Mechanism __ __ __ _______________Belt Tension __ __ __ ______________
Steering __ __ __ _______________Loose Gears __ __ __ ______________
Fire
Extinguisher __ __ __ _______________Brakes __ __ __ ______________
Signal System __ __ __ _______________Vibration __ __ __ ______________
Fuel & Gas
Lines __ __ __ _______________Pneu. Interlocks __ __ __ ______________
Fuel Tank __ __ __ _______________Exhaust System __ __ __ ______________
Exhaust
System __ __ __ _______________Proper RPM __ __ __ ______________
Boom __ __ __ _______________Overload Protect __ __ __ ______________
Boom Hoist __ __ __ _______________Mech. Switch __ __ __ ______________
Sheaves __ __ __ _______________Ground Continuity __ __ __ ______________
Hooks, __ __ __ _______________Limit Switches __ __ __ ______________
Grab Bars,
Steps __ __ __ _______________Cords __ __ __ ______________
Warning Lights __ __ __ _______________Plugs/Receptacles __ __ __ ______________
2. Heavy Equipment Inspection

FREQUENCY: Heavy Equipment – Inspect daily and prior to use on site

Inspection Date: __ /__/ __ Time: ____ Equipment Type __________ Unit # ______

Required Daily and prior to use on site:

Tires or tracks Good Need repair N/A

Hydraulic oil
Hose condition
Oil leak/Lube
Cab, mirrors, seat belt and glass
Horn and gauges
Lights
Turn signals
Back-up lights and alarm
Brake condition (dynamic service, park, etc.)
Fire extinguisher condition
Engine oil
Transmission fluid
Brake fluid
Cooling system fluid
Windshield wipers and fluid
Coupling devices and connectors
Exhaust system
Blade/Boom/Ripper condition
Ground engaging attachment
Frame, ladders and steps
Power cable and/or hoist cable(s)
Steering (standard and emergency)

Additional Inspection required prior to use on Site:

1) Does equipment emit noise levels above 90 decibels? Ο Yes Ο No

2) If so, has an 8-hour noise dosimetery been performed? Ο Yes Ο No
Document results of noise dosimetery: ______________________________________________
Maintenance completed (where applicable) __________________________________________
Defects and repair needed: _______________________________________________________
_________________________________________________________________________________
______________________________________________________________________________
General safety condition: ________________________________________________________
______________________________________________________________________________

Operator’s or Mechanic’s Signature: ____________________________________