CCL 2000

Visual inspection for deformation, cracks, corrosion, and damage at all welded and bolted connections. Special attention to fatigue cracks at high-stress weld joints which can develop gradually and cause catastrophic failure. Check for material degradation under chipped paint and surface rust.

Check foundation bolts for looseness and cracks in the pedestal structure. Inspect rotational components (sheaves, bearings, slew rings, slewing bearing axial clearance) for wear and proper lubrication. Measure slewing bearing grease samples for ferrography analysis per ILO 152 protocol.

Regular assessment of steel cables per ISO 4309: count broken wires, measure diameter reduction (discard if >7-10% loss), assess external and internal corrosion (pitting, rust streaks), check for signs of wear (kinks, crushing, birdcaging, broken strands). Ensure proper lubrication along entire length, particularly in sheave areas when crane stowed. Inspect elasticity and strand fracturing.

Perform hydraulic oil analysis via laboratory testing (ferrography and oil sampling at prescribed intervals). Measure leak-oil amount from all axial piston pumps and motors. The most common failure cause is dirty hydraulic oil leading to filter choking - test for contamination. Check all hoses for deterioration and proper connections.

Test slewing, luffing, and hoist brakes to ensure smooth engagement and secure load holding without slipping. Measure brake lining thickness at regular intervals per Planned Maintenance System (PMS). Verify disk brake clearances and document findings. Ensure all brakes are failsafe design per ILO standards.

Verify limit switch boxes and electrical covers remain sealed to maintain waterproofing. Check and calibrate electric and electronic settings per ILO 152. Inspect all electrical connections for corrosion and proper grounding. Test load indicator and control system electronics.