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Excavator Preventative Maintenance Checklist
Template Name: Excavator PM (Default)
Total Items: 84
Sections: 11
This document contains the complete excavator preventative maintenance checklist with all sections, items, and descriptions.
1. Visual Inspection
Item 1: Exterior and Undercarriage Overview
Description: Walk around the excavator and visually inspect for any obvious damage, loose components, or fluid leaks (oil, hydraulic fluid, coolant). Check that the undercarriage is clear of excessive mud or debris that could hide issues or impede movement.
Item 2: Safety Decals and Labels
Description: Ensure all safety decals, operational labels, and warning signs are present and legible, including load charts (if applicable) and instructional placards.
Item 3: Swing Bearing and House Swing Area
Description: Visually inspect the swing bearing area (where the upper structure meets the undercarriage) for excess grease purging, metal shavings, or debris. Check that the slew ring guard (if present) is secure. Look for any indication of abnormal movement or gaps in the swing bearing.
Item 4: Boom, Stick, and Attachment Condition
Description: Examine the boom and stick (arm) for cracks, dents, or structural damage, especially around welds and connection points. Check the attachment (bucket or other tool) for cracked welds, worn or missing teeth, or damaged cutting edges.
Item 5: Cylinders and Hoses (External)
Description: Inspect all visible hydraulic cylinders (boom lift, arm (stick) cylinder, bucket cylinder, and any auxiliary cylinders) for signs of oil leaks at seals or damage to the rod. Also check exposed hydraulic hoses and tube lines along the boom and stick for cracks, wear, or leaks.
Item 6: Tracks and Ground Contact
Description: Walk around the tracks (or wheels if a wheeled excavator) to check for proper tension and any noticeable damage. Ensure track pads/shoes are secure and not excessively worn or missing bolts. Look for any foreign objects lodged in the tracks or sprockets.
Item 7: Handrails, Steps, and Guards
Description: Verify that all handrails, grab handles, and steps are secure and undamaged. Ensure anti-slip surfaces on steps and the upper structure walkway are in good condition. Check that protective guards and covers (for example, over the swing motor, radiator, etc.) are in place and secure.
Item 8: Counterweight and Carbody
Description: Inspect the counterweight for any damage, cracks, or loose mounting bolts (if removable type). Ensure the carbody (the main lower frame) has no visible structural damage or missing bolts/nuts.
Item 9: House Slew Limit Stop (if equipped)
Description: If the excavator has mechanical swing stops or a house lock (transport pin), verify it is stored properly or engaged only as needed, and check that the mechanism is not damaged.
2. Engine Compartment
Item 1: Remove Debris and Clean Compartment
Description: Open the engine hood or covers and clear out any accumulated debris, leaves, or dirt from the engine compartment, especially around the radiator and coolers.
Item 2: Engine Oil Level and Filter
Description: Check the engine oil level using the dipstick and top off if needed with the correct grade. If a scheduled oil change is due, drain the oil and replace the oil filter and oil per manufacturer instructions.
Item 3: Fuel Filters and Water Separator
Description: Inspect the primary and secondary fuel filters for water or sediment. Drain the water separator (bowl or filter drain) of any water and replace fuel filters if due or if poor engine performance is noted.
Item 4: Air Filter and Intake
Description: Check the engine air filter restriction indicator (if equipped) and remove the air filter element. Tap out or blow out dust (if reusable) and replace it if it’s clogged or according to service interval. Wipe out the inside of the air cleaner housing and ensure the intake piping is secure with no cracks.
Item 5: Belts and Engine Accessories
Description: Inspect all drive belts (fan belt, alternator belt, AC compressor belt if present) for tension and signs of wear (cracks or glazing). Adjust belt tension or replace belts as necessary. Check engine accessory components (alternator, compressor) are securely mounted.
Item 6: Engine Coolant Level
Description: Verify coolant is at the proper level in the radiator or expansion tank (only open cap when engine is cool). Add coolant if low, using the correct type and mixture. Examine visible coolant hoses and connections for leaks or deterioration.
Item 7: Engine Cooling Fan and Shroud
Description: With engine off, inspect the fan for any damage (bent or cracked blades) and test for excessive play indicating a worn bearing. Ensure the fan shroud is properly aligned and secured to prevent contact with the fan.
Item 8: Exhaust System
Description: Inspect the exhaust manifold, turbocharger (if equipped), and muffler for soot marks or carbon buildup that could indicate leaks. Ensure exhaust pipes and mounts are secure and check that the rain cap (if present on the exhaust outlet) opens freely.
Item 9: Engine Leaks and Mounts
Description: Look over the engine block, oil pan, valve cover, and fuel injection pump for any signs of fluid leaks (oil, fuel, coolant). Check engine mounts for any broken bolts or deteriorated rubber, indicating the engine may not be securely seated.
Item 10: Pre-Start Engine Condition
Description: Before starting the engine, check critical fluid levels including engine oil, coolant, and also hydraulic oil (sight gauge) to ensure everything is filled. Verify no tools or rags are left in the compartment and that all caps (oil fill, dipstick, coolant) are secured.
3. Electrical System
Item 1: Battery and Connections
Description: Inspect the battery (or batteries) for secure mounting, clean terminals, and no cracks or bulging in the case. Clean any corrosion from terminals and cables. Check battery electrolyte level (if not maintenance-free) or indicator if present, and top up with distilled water if needed.
Item 2: Battery Load Test
Description: Perform a battery load test or monitor voltage during engine start to ensure the battery can provide sufficient power. Replace the battery if it fails to hold charge or deliver adequate cranking power.
Item 3: Charging and Starting Circuit
Description: With the engine running, measure alternator output to verify the charging system is functioning. Listen for alternator noise. Inspect starter wiring and connections for tightness and check that the starter motor is securely mounted.
Item 4: Fuses, Relays, and Control Modules
Description: Open the electrical control box or fuse panel. Check that all fuses are intact and of correct rating, and that no relays are loose. Look for any signs of overheated wires or components. Ensure control modules (ECU, etc.) are firmly connected and show no fault lights, if visible.
Item 5: Lights and Horn
Description: Activate all exterior lights: check operation of front and rear working lights, travel lights, blinkers/brake lights (if applicable), and beacon or strobe if fitted. Verify the horn works and is loud enough.
Item 6: Operator Display and Gauges
Description: Turn the ignition on and confirm all warning lights on the operator display illuminate during the self-test and go out after engine start (except those that should remain). Check that gauges read normally.
Item 7: Backup Alarm and Camera (if equipped)
Description: Put the excavator in reverse to test that the backup alarm sounds. If a rearview camera or other vision system is installed, verify that it powers on and provides a clear image.
Item 8: Wiring Harness and Connectors
Description: Trace main wiring harnesses for signs of rubbing, loose clamps, exposed wires, or pinched sections through the swing bearing area.
4. Hydraulic System
Item 1: Hydraulic Oil Level and Temperature
Description: Check the hydraulic oil level via the sight glass or dipstick with the machine on level ground and implements lowered. Ensure the oil is clean and at correct level.
Item 2: Hydraulic Filters
Description: Replace return, pilot, or case drain filters if due. Inspect removed filters for metal shavings.
Item 3: Hydraulic Pump and Valves
Description: Inspect the main pump(s) for leaks or loose fittings. Check control valve blocks and solenoids for damage or leakage.
Item 4: Travel Motors and Swing Motor for Leaks
Description: Inspect travel motors, swing motor, and swivel joint for leaks or damage.
Item 5: Auxiliary Hydraulic Circuit
Description: Inspect auxiliary lines and connectors. Engage aux control briefly to verify flow and relief operation.
Item 6: Cylinders and Hoses (Detailed)
Description: Inspect all cylinders for leaks, worn pins, cracked lugs, and damaged hoses.
Item 7: Hydraulic Tank Cap and Breather
Description: Ensure tank cap is tight and breather element is clean/unclogged.
Item 8: Operational Test for Hydraulic Functions
Description: Cycle all hydraulic functions without load to confirm smooth, responsive operation.
5. Undercarriage & Tracks
Item 1: Track Tension and Adjustment
Description: Measure track sag and adjust tension using grease adjuster valve as needed.
Item 2: Track Shoes and Pads
Description: Inspect shoes/pads for wear, loose bolts, cracks, or damage.
Item 3: Drive Sprockets
Description: Inspect sprocket teeth for wear or cracks and verify bolt tightness.
Item 4: Rollers and Idlers
Description: Inspect rollers and idlers for leaks, wear, and free movement.
Item 5: Track Frame and Guards
Description: Inspect track frame for cracks or loose guards.
Item 6: Final Drives (Travel Gearboxes)
Description: Check final drive oil level and inspect magnetic plugs for metal.
Item 7: Swing Bearing Bolts
Description: Visually inspect swing bearing bolts for looseness or missing bolts.
Item 8: Cleaning and Debris Removal
Description: Remove mud, rocks, or debris from undercarriage components.
6. Swing System
Item 1: Swing Brake Function
Description: Test swing brake or lock for proper engagement and release.
Item 2: Swing Gearbox Oil
Description: Check oil level/condition in swing drive gearbox.
Item 3: Swing Bearing and Grease
Description: Grease swing bearing fittings and inspect gear teeth if visible.
Item 4: Swing Motor and Relief
Description: Inspect swing motor for leaks and verify smooth swing operation.
Item 5: Swing Seal Guard
Description: Inspect swing bearing seal integrity and confirm guards are secure.
7. Boom, Stick & Attachment
Item 1: Boom and Stick Structural Check
Description: Inspect for cracks, bends, or stressed welds along boom and stick.
Item 2: Pins and Bushings Wear
Description: Check all joints for excessive play, wear particles, or missing retainers.
Item 3: Attachment Coupler (if equipped)
Description: Inspect coupler structure, locking mechanism, and safety pins.
Item 4: Bucket/Attachment Condition
Description: Inspect bucket teeth, cutting edges, or attachments for wear or cracks.
Item 5: Cylinder Attachments
Description: Check cylinder mounting points for cracks or loose hardware.
Item 6: Lubrication of Front End
Description: Grease all linkage and pivot points until clean grease extrudes.
Item 7: Auxiliary Attachment Hoses
Description: Inspect hoses on thumbs/attachments for leaks or abrasion.
8. Cooling System
Item 1: Radiator and Coolers
Description: Clean radiator, oil cooler, and charge air cooler fins.
Item 2: Coolant Strength and Level
Description: Test coolant for freeze/boil protection and proper level.
Item 3: Cooling System Leaks
Description: Inspect radiator, hoses, clamps, thermostat housing, and engine block.
Item 4: Water Pump and Fan Drive
Description: Inspect weep hole for leaks and check for pulley play or belt issues.
Item 5: Engine Temperature Performance
Description: Warm engine and monitor coolant temperature stability.
Item 6: Cab Heater Core (if applicable)
Description: Verify heater produces warm air and hoses are leak-free.
9. Fuel System
Item 1: Fuel Tank and Cap
Description: Inspect tank integrity and verify cap seals and vents properly.
Item 2: Fuel Lines and Injectors
Description: Check all lines for cracks, leaks, or loose fittings. Inspect injector area.
Item 3: Water Separator Operation
Description: Drain separator and check indicator functionality.
Item 4: Fuel Filter Change (if due)
Description: Replace fuel filters per interval and bleed air from system.
Item 5: Turbocharger & Aftertreatment (if applicable)
Description: Inspect DEF tank/lines, DPF regen status, and turbocharger for leaks.
10. Cab & Controls
Item 1: Operator Seat and Seat Belt
Description: Inspect seat/seat belt condition and verify latch/alarm operation.
Item 2: Control Levers and Joysticks
Description: Confirm smooth movement and neutral return.
Item 3: Pedals and Travel Controls
Description: Clean around pedals and verify proper operation.
Item 4: Monitor Panel and Alerts
Description: Verify warning lights, service codes, and maintenance indicators.
Item 5: Climate Controls
Description: Test AC/heater, fan speeds, and replace cab air filter if needed.
Item 6: Wipers and Washers
Description: Verify wiper/washers operate and replace blades if worn.
Item 7: Cab Accessories and Safety
Description: Check fire extinguisher, operator manual, and emergency exits.
Item 8: Parking Brake and Hold Function
Description: Verify parking brake or travel lock operates as designed.
11. Final Inspection
Item 1: Engine Start and Idle
Description: Start engine and verify warning lights clear and idle is smooth.
Item 2: Control Function Test
Description: Test boom, stick, bucket, and swing functions for smooth response.
Item 3: Travel and Brake Test
Description: Drive forward/reverse; verify even tracking and proper braking.
Item 4: High Speed Travel (if equipped)
Description: Test two-speed travel for smooth shifting and operation.
Item 5: Attachment Operation Test
Description: Test thumbs, breakers, or other attachments for full function.
Item 6: Warning Devices Test
Description: Test horn, backup alarm, and other warning devices.
Item 7: Monitoring During Operation
Description: Observe engine/hydraulic temps, pressure, and gauge behavior.
Item 8: Leak Check Post-Operation
Description: Inspect machine after shutdown for fresh leaks.
Item 9: House Swing Parking
Description: Park machine with house aligned and swing lock engaged if needed.
Item 10: Documentation and Clean-Up
Description: Record service, apply PM sticker, and clean machine surfaces.
Notes
- All items are marked required
- Condition ratings set during PM
- This template may be expanded as needed