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Preventive Maintenance Manual - DRF
Preventive Maintenance Manual - DRF
Plan C 1000hrs
Plan D 2000hrs
250hr
2000hr
250hr
1500hr
500hr
250hr
B
250hr
250hr
1000hr
250hr
Walk around the machine and check for any damage and leakage
3.
Turn off the main electric power and remove the key
Transmission Oil:
Dexron III
Hydraulic Oil:
(ISO-L HV68)
Brake Oil:
(ISO-L HV68)
Grease:
Remarks:
1. For details please refer Section F of Maintenance Manual DFR400-450
2. ( ) above viscosity depends on the ambient temperature, please refer same Section F
3. For engine oil outside Europe market API : CE, CF, CF-4, CG-4, CH-4 (SAE15W40)
can be used BUT oil change every 250 hours or 12 months
API-CD (SAE15W40)
Transmission Oil:
API-CD (SAE15W40)
Hydraulic Oil:
(ISO-L HV68)
Brake Oil:
(ISO-L HV68)
Grease:
Remarks:
1. For details please refer Section F of Maintenance Manual DFR400-450
2. ( ) above viscosity depends on the ambient temperature, please refer same Section F
PM Plan A - Engine
1)
3)
4)
5)
6)
7)
8)
9)
10)
11)
PM Plan A - Engine
1) Check Air Filter indicator
Check the indicator when the engine is
running. If it shows red, the main filter
element is dirty and need to replace
PM Plan A - Engine
3) Replace Oil and Filter
Change it because to remove all
the solid contaminants and
sludge that collected by the filter,
to reduce the restriction of oil
flow
Please Remember to Lubricate
the O-rings on the new filter
Tighten to contact and then
another half to three quarter turn
by HAND
PM Plan A - Engine
3) Replace Oil and Filter
Properties of engine oil will
deteriorate due to heat and
carbon contamination.
Change filter because to remove
all the solid contaminants and
sludge that collected by the filter,
to reduce the restriction of oil
flow
Please Remember to Lubricate
the O-rings on the new filter
Tighten to contact and then
another half to three quarter turn
by HAND
OIL Filter
PM Plan A - Engine
4) Replace Fuel Filter
Change it because choke or dirty
fuel filter may restrict fuel
delivery to the injectors
Cause fuel injector having
improper fuel spraying pattern
into the combustion chamber.
Thus affecting engine efficiency
Please Remember to Lubricate
the O-rings on the new filter
Tighten to contact and then
another half
turn by HAND
PM Plan A - Engine
4) Replace Fuel Filter (Fuel Pre-Filter)
Change it because choke or dirty
fuel filter may restrict fuel
delivery to the injectors
Disconnect the cabling from the
sensor water in fuel
Please Remember to Lubricate
the O-rings on the new filter
Tighten to contact and then
another half to three quarter
turn by HAND
PM Plan A - Engine
4) Replace Fuel Filter
Change it because choke or dirty
fuel filter may restrict fuel
delivery to the injectors
Cause fuel injector having
improper fuel spraying pattern
into the combustion chamber.
Thus affecting engine efficiency
Please Remember to Lubricate
the O-rings on the new filter
Tighten to contact and then
another half turn by HAND
PM Plan A - Engine
5) Check Cooling Water Condition and Level
Checked the coolant level to
prevent engine overheat
PM Plan A - Engine
6) Clear Debris from Radiator Surface
Check any debris form radiator
surface to prevent engine
overheat
PM Plan A - Engine
7) Check Pulley and All Vee-belts
Check the tension of belt, if it
looses, tight it
It should not be possible to
depress V-belt more than 10-12
mm mid-way between the
pulleys
If the belt still loose, after retighten, replace a new belt
Loose belts may affect engines
cooling, air condition, and
electrical performance
PM Plan A - Engine
8) Check Starting, Stopping and Running
Starting
Check all oil level (engine oil, gearbox
oil, hydraulic fluid, axle and planetary
gear oil)
Bleed air out of fuel system
Turn the starter key to position
3(starting position) and release it when
the engine has started
PM Plan A - Engine
8) Check Starting, Stopping and Running
Running
Never race a cold engine, nor run the
engine at critically low speed
Run engine at 1400rpm till the
temperature gauge read about 80deg
Celsius
Warming up the engine oil is essential
so that it is circulating correctly before
turbocharger works at high speed
PM Plan A - Engine
9) Check for Oil, Fuel and Water Leakage
Look under the truck to find any
liquid leakages
If find a leakage, please address
where the liquid from and shut down
the machine immediately
PM Plan A - Engine
10) Check Turbocharger and Exhaust for Leak
Check that the oil line to and from
the turbocharger do not leak
Check that all connection between
the turbo and inter-cooler do not
leak.
Renew all broken gasket
seals and studs to confirm gas tight
between connection
Pressure may build up in a blocked
crankcase vent. This may force oil
into the inlet air system of the
turbocharger and engine
PM Plan A - Engine
11) Replace Fuel / Water Filter
Drain the filter and remove the filter
from the top.
Loose the bolts under the filter, to
clean the dirt from the trap
Put the new filter in
After that refuel inside the water/
fuel filter
Replace the o-ring for the cover
17)
18)
25)
31)
PM Plan A - Spreader
36) Check Twistlock Pin and Mechanism
PM Plan A - Spreader
36) Check Twistlock Pin and Mechanism
Check
the
twistlock
function
correctly
Clean the twistlock from any dirt
Check the link arm, check pin and
lock nut
Press in the alignment pin so that
the head is flush with the spreader
beams underside. Check the
distance to sensor alignment, the
distance should be 5 +/- 3mm
Check the lock guide and lift pin can
move freely
Fit a pray bar between the lift pin
and the lock guide and check the
clearance, max clearance: 1-1.5mm
Check wears of the lift pin. Change
the pin if needed
PM Plan A - Spreader
37) Check Sensor for Twistlock Indication
Check all sensor sensing light
(yellow) is lit up when contacting
PM Plan A - Spreader
38) Check and Adjust 20/40 Chain and Stopper
Run out the spreader to the 40foot position
Measure how much the chain can
be pressed in by the hole closest
to the middle of the attachment.
When the chain is pressed in with
a force of 250N, it should move
20-40 mm from the resting
position
Adjust the chain if needed
PM Plan A - Spreader
38) Check and Adjust 20/40 Chain and Stopper
For 20 position stopper
Both protruding arms are to in
contact with the stoppers at the
same time and the distance
between the spreader beam and
spreader motor mounting is at
least 3mm
Adjust by switching the washers
between the left and right stopper
The distance between the right
and left twistlock should be
5853+/-3mm
PM Plan A - Spreader
38) Check and Adjust 20/40 Chain and Stopper
For 40 position stopper
Both left and right side stoppers
to be in contact at the same time.
Each stopper is provided with an
adjusting bolt.
Adjust the
needed
chain
tension
if
PM Plan A - Hydraulic
57)
58)
59)
PM Plan A - Hydraulic
57) Check Oil Level in Main and Brake Tank
Ensure sufficient hydraulic and
brake oil inside the tank by reading
the oil level on sight glass
PM Plan A - Hydraulic
58) Accumulator Minimum Pressure Check by Brake (20 Times)
Start the engine and let it idle for
approx. 5 minutes (until the
accumulator
charging
valve
switches to cooling)
Turn off the engine and turn the
start key to position I
Apply and release the brake several
times, and count the number of
times that applied on the brake
before warning light is activated
(It should be apply the brake 20
times before the warning light for
light brake pressure is activated)
If warning light is activated before
applied the brake 20 times, theres
probably a defect inside the system.
A further inspection is needed
PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic Plate
(Main Pressure)
Start the engine and allow it at idle
There are 4 measure points for
main oil pressure
All pressure should be the same
Test Point
PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic Plate
(Brake Pressure)
Gives brake when testing brake
pressure
Find setting pressure in hydraulic
plate
Test Point
PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic Plate
(Servo Pressure)
Servo pressure should be around
35+/- 5 bars
Test Point
PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic Plate
(Steering Pressure)
Allow the engine to run in midspeed range and turn the steering
wheel to full lock in one direction.
Test Point
PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic Plate
(Charging Pressure)
Allow the engine to run, release all
the pressure from the accumulator
Check the pressure after completed
re-charging (Maximum)
Check the pressure when starts to
re-charge (Starting)
Test Point
PM Plan - Electrical
66) Check Battery Water and Top Up
PM Plan - Electrical
66) Check Battery Water and Top up
Check the battery voltage with the
operating menu for electrical system.
Engine off 23-25V, and engine at
max rpm 27-29V
Turn off the engine and the main
electrical power
Clean the battery area and grease
the battery terminal
Check the fluid level inside the cells,
top up with distilled water if needed
PM Plan - Electrical
67) Check All Work Light and Indication Lamp
PM Plan - General
68)
69)
70)
71)
PM Plan - General
68) Check Tightness of Wheel Nut
PM Plan - General
69) Check Tyre Condition and Pressure
PM Plan - General
70) Check Horn, Reverse Alarm and Beacon
PM Plan - General
71) Grease Sliding Surface, Greasing Point and Chain
Sliding Surface
PM Plan - General
71) Grease Sliding Surface, Greasing Point and Chain
Greasing Points
73)
74)
75)
PM Plan B - Engine
01)
02)
03)
04)
05)
06)
07)
08)
09)
10)
11)
12)
PM Plan B - Engine
02)
After
removing
the
filter
cartridge, it recommends to
clean the internal area with a
clean cloth
17)
18)
19)
Transmission Oil
Filter
26) Check Differential and Hub Oil Level and Top up*
Refill as necessary
31)
32)
PM Plan B - Spreader
36) Check Twistlock Pin and Mechanism
37) Check Sensor for Twistlock Indication
38) Check and Adjust 20/40 Chain and Stopper
39) Check Planetary Gear Oil and Brake Oil*
PM Plan B Spreader
39)
PM Plan B - Hydraulic
57)
58)
59)
PM Plan C - Engine
01)
02)
03)
04)
05)
06)
07)
08)
09)
10)
11)
12)
13)
PM Plan C - Engine
13)
31)
32)
33)
PM Plan C Spreader
36) Check Twistlock Pin and Mechanism
37) Check Sensor for Twistlock Indication
38) Check and Adjust 20/40 Chain and Stopper
39) Check Planetary Gear Oil and Brake Oil
40) Replace Planetary Gear Oil and Brake Oil*
41) Check Rotator Mounting Bolt*
42) Check Sliding Plate on Beam and Yoke*
PM Plan C Spreader
40)
PM Plan C Spreader
41)
PM Plan C Spreader
42
PM Plan C Spreader
42
PM Plan C - Hydraulic
57)
58)
59)
60)
61)
62)
PM Plan C - Hydraulic
60)
PM Plan C - Hydraulic
61)
PM Plan C - Hydraulic
62)
PM Plan D - Engine
01)
02)
03)
04)
05)
06)
07)
08)
09)
10)
11)
12)
13)
14)
15)
PM Plan D - Engine
14)
PM Plan D - Engine
15)
31)
32)
33)
34)
35)
49)
50)
51)
52)
53)
54)
55)
56)
PM Plan D Hydraulic
57)
58)
59)
60)
61)
62)
63)
64)
65)
PM Plan D Hydraulic
63)
PM Plan D - Hydraulic
64)
PM Plan D - Hydraulic
65)