Basic Maintenance

Introduction
 Safety
 Preventive Maintenance
 ISO Symbols
 Contaminant
 TA1 & Walk around
Inspection
 MIS Tasks
Topik 1
 Safety
 Preventive Maintenance
 ISO Symbols
 Contaminant
 TA1 & Walk around
Inspection
 Maintenance Interval
Schedule
 Safety

 Causes of Accidents
 Accident prevention
 Working on Workshop
 Working on Equipment
 Using tools
 Safety

 Causes of Accidents
 Lack of maintenance
 Irregular maintenance/inspection tools
 Incorrect/unsafe replacement of part
 Obvious negligence as faulty work practice
 Safety

 Accident prevention
 Standard Operational Procedure
 Safety sign
 Job safety Analyst
 Safety Gear/equipment
Safety Gear
Working on Workshop

 Cleanliness
 Housekeeping
 Safety
Working on Equipment

 Park Machine
 Engaged Parking Brake
 LOTO
 3 point Contact
 JSA
 Safety devices
 Wheel chock
 Lockout and Tagout

Always use correct lockout/tagout procedures

when servicing a machine.
Hazardous Areas
Tools

 Hand tools
 Machining tools
 Electric tools
 Warning

Too many jokes during the work does make people

laugh but can lead to lifelong suffering.
Topik 2
 Safety
 Preventive Maintenance
 ISO Symbols
 Contaminant
 TA1 & Walk around
Inspection
 Maintenance Interval
Schedule
 Purpose

The purpose of this lesson is to introduce you to

preventive maintenance, why it is important, and the
types of PM Technicians are responsible for
performing.
 Preventive Maintenance

 Preventive Maintenance
 Benefit
 General task
 Preventive Maintenance Checklist
 Preventive Maintenance is ?

Preventive maintenance (PM) is a program in which

wear, tear, and change are anticipated and
continuous corrective actions are taken to ensure
machine reliability and performance
 PM Benefit

• Improved system reliability

• Reduction of unscheduled downtime caused by
significant breakdowns
• Lower owning and operating costs
• Better parts inventory management
 Preventive Maintenance

Primary Link between the Customer and the Dealer

General task
PM tasks:
 Inspections

 Adjustments

 Tests

 Fluid changes

 Filter replacement

 Lubrication
Preventive Maintenance Checklist
Finding the Check List
Finding the Check List
Finding the Check List
PM Check List
Using PM Check List
Topik 3
 Safety
 Preventive Maintenance
 ISO Symbols
 Contaminant
 TA1 & Walk around
Inspection
 Maintenance Interval
Schedule
 Purpose

The purpose of this lesson is to introduce you to

the ISO symbols that you will see on a daily basis
as a PM Technician
 Symbols

 Basic
 System
 Advanced
 Additional
 Safety
 Basic symbols

Level Indicator Oil Pressure Temperature

Filter Water/Coolant Intake Air Exhaust Gas

 System symbols

Engine Transmission

Hydraulic Fuel Brake

 Advanced symbols

Engine Engine Oil Hydraulic Oil Brake

Coolant Oil/Fluid

Engine Engine Oil Hydraulic Oil Transmission Oil

Coolant Temperature Filter
Level
 Additional symbols

Grease
Engine Start and
Lubrication Point
Engine Stop

Read Operator’s Service Indicator/Read

Manual Technical Manual
 Basic safety symbols
No Step Stay Safe Crushing
Distance From
Machine

Shield Eyes Shock Hazard High Voltage

Hot Surface –
Safety Alert Burns to Fingers Keep Hands
or Hands Away

No Hands –
Keep Hands Flammable Read
Away Operator’s
Manual
Exercise
1 Hydraulic Oil Filter

2 Brake System Temp

3 Engine Oil Pressure

4 Fuel Water Separator

5 Engine Exhaust Gas

6 Transmission Oil Level

Topik 4
 Safety
 Preventive Maintenance
 ISO Symbols
 Contaminant
 TA1 & Walk around
Inspection
 Maintenance Interval
Schedule
 Purpose

The purpose of this lesson is to introduce you to

the Contamination Control during perform
preventive maintenance
Contamintation
 This section consists of the
following lessons :
 Introduction
 Sources
 Responsibilities
 S•O•S Sampling
 General tips
Introduction
Introduction
Introduction
Source of Contamination
House keeping
New Oil
Machine Operation
Maintenance
Responsibilities
 New oil Responsibilities

Important procedures when dealing with new oil:

• Store oil drums inside
• Use drum covers
• Filter new oil from bulk tanks and 55-gallon drums
• Ensure lube trucks are supplying clean oil
Maintenance Responsibilities
SOS
SOS
SOS Analysis
Sampling Methods
Sampling with an Oil Valve Probe
Sampling with Vacuum Extraction
SOS Sample Documentation
SOS notes
General Tips for Oil
 Machine Setup

Machine Setup

Refill Capacity &

Oil Type

Cleanliness

Machine Setup
 Oil Refill Capacities

Machine Setup

Refill Capacity &

Oil Type

Cleanliness

For each system, refer to the Lubricant Viscosities and Capacities (Refill)
sections of the OMM for information on the type and amount of oil required.
 Maintaining Cleanliness

Machine Setup

Refill Capacity &

Oil Type

Cleanliness

Procedures for maintaining cleanliness

Topik 5
 Safety
 Preventive Maintenance
 ISO Symbols
 Contaminant
 TA1 & Walk around
Inspection
 Maintenance Interval
Schedule
 Purpose

The purpose of this lesson is to introduce you to

benefit of machine inspection and perform TA 1 &
walk around inspection
TA1 & Walk around Inspection
This section consists of the
following lessons :
 Machine Inspection Benefits

 Machine Inspection
Preparation
 Download Fault Codes

 Lower-Level Inspections

 Middle-Level Inspections

 Upper-Level Inspections

 Implement/Attachment
Inspections
Machine Inspection Benefits
 Identifies potential problems
 Uncovers overlooked
problems
 Enables planned/scheduled
follow up maintenance and
service
 Reduces customer downtime
 Helps control O&O costs
Machine Inspection Preparation
 Park in Service Position
 Park in a level place clear
 Move the transmission control
switch to the PARK position
 Apply the parking brake
 Lower the truck body
 Turn OFF engine & remove the key
 Install LOTO
Machine Inspection Preparation

Note: During Upper-Level Inspections raise the

truck body and secure to the rear frame with body
retaining pins or cables
 Walk-Around Inspection

 Make sure the area is free

of personnel
 Walk around and inspect for
visible signs of fluid leaks
 Check all liquid level

Note: If the TA1 and PM Service are not being performed at the same time,
refer to the OMM or PM Checklist for additional checks and inspections.
Download Machine Fault Codes

Using either of these methods:

 Electronic Technician (ET)
 Advisor Monitoring System
Observe Engine Exhaust Colors

Start the machine and

watch exhaust color:
 White smoke

 Blue smoke

 Black smoke

 Gray smoke
Listen for Unusual Noises
Excessive noise:
 Stopped:

 Hydraulic pumps
 Engine
 When travel:
 Transmission
 Differential
 Final drives
 Drive train
Tubes, hoses & Wiring Harness
Inspection Guidelines
Check for:
 Rubbing against:
 One another
 Sharp corners
 Bolt heads
 Not properly secured:
 Missing clips and wire
ties
 P-clips not attached
Harness Connector Inspection
Guidelines
Check for:
 Rubbing against:
 Machine frame
 Sharp edges
 Not properly secured in
place
Hydraulic Cylinder Inspection
Guidelines
Check for:
 Oil leaks

 Nicked, scored, or pitted

cylinder rods
 Damage or wear to
linkage pins
 Lower-Level Inspections
 Tires and Rims
 Front Wheels and Brakes
 Rear Final Drives, Brakes, and
Wheel Spindles
 Differential Housing
 Drive Shaft
 Transmission and Transfer
Gears
 Rear Axle Housing Support
 Hoist Control Valve
 Rear Engine/Torque Converter
Mounts
 Brake Accumulator
 Oil Coolers and Lines
 Steering Cylinders and Steering
Linkage
 Engine Damper, Front Engine
Trunnion, Support, Trunnion
Mounts, and Support Mounts
 Secondary Steering/Brake
Release Pump
 Engine Oil Pan
 Machine Frame
Tires and Rims
Check for:
 Tire
 Proper inflation
 Cuts, cracks, splits, or bruises in
the tread or sidewall area;
bumps or bulges
 Safe tread depth
 Rim
 Cracks, pits from corrosion, or
other visible damage to rims
Front Wheels
Check the following for leaks:
 Sealing surface
– between the wheel cover and
the wheel hub
– between the various brake
pack housing components
 Area around the drain and fill
plugs
Front Wheels and Brakes
Check the following for leaks:
 Dou-cone seal
– between the wheel hub and
the brake pack housing
– between the brake pack
housing and the axle housing
 Brake cooling oil and hydraulic
oil lines and connectors
Rear Final Drives

Check the following for leaks:

 Sealing surface between the
axle cover and the final drive
planet carrier
 Area around the drain and fill
plugs
Rear Final Drives, Brakes, and
Wheel Spindles
Check the following for leaks:
 Sealing surface between
 final drive housing and the rear wheel
housing
 various brake pack housing components
 Dou-cone seal between
 the rear wheel housing and wheel spindle
 between the brake pack housing and the
rear wheel housing
 Brake cooling oil and hydraulic oil lines
and connectors
Differential Housing
Check for leaks at Sealing surface :
 Differential housing and the
transmission housing
 Differential housing and the wheel
spindles
 Area around the drain and fill
plugs

Check for loose or damaged axle

housing joints, bolts, pins, and
retainers:
 Lateral control arm
 Transmission housing and axle
housing support
Drive Shaft

Check for:
 Loose or missing U-joint retainer
bolts
 Worn or loose U-joints or drive
shaft spline
 Grease leaking from U-joint seals
or from drive shaft spline
Transmission and Transfer Gears
Check for:
 Leaks around hose connections
 Rubbing, damaged, or worn
hoses
 Rubbing, damaged, or worn
wiring harnesses or connectors
 Oil leakage around the drain and
fill plugs
 Oil or dirt buildup on the
transmission and transfer gear
housings.
Rear Axle Housing Support

Check for:
 Loose or damaged
 spherical bearing retainer bolts
 retainer block mounting bolts
 Irregular-shaped pin bores or
excessive pin wear
 Damaged grease lines or
fittings
Hoist Control Valve
Check for:
 Leaks around connection points
for hose and control valve
components
 Rubbing, damaged, or worn
 Hoses
 wiring harnesses and connectors
Rear Engine/Torque Converter
Mounts
Check for:
 Structural damage to support
brackets and engine
supports
 Structural damage or weld
cracks on frame supports
 Loose or damaged support
mounting bolts
Brake Accumulator

Check Service Brake &

Parking Brake Accumulators
for:
 Leaks around hose connection
points
 Rubbing, damaged, or worn:
 Hoses
 Wiring harnesses and connectors
Oil Coolers and Lines

Check for:
 Leaks around hose
connections
 Rubbing, cracked, or
damaged hoses
 Loose connections
 Improperly secured hoses
Steering Cylinders and Steering
Linkage
Check steering cylinder for:
 Oil leaks indicated by dirt or oil
buildup around the cylinder lip seal
 Damage to cylinder rods
 Oil leaks at hose connections
(Refer to “Hydraulic Cylinder Inspection Guidelines”
for inspection procedure)
Check steering linkages for:
 Broken or damaged grease lines,
fittings, seals, and covers
 Visible damage or wear to linkage
pins
 Excessive play in steering linkages
 Pull or pry on tie rods to check for
excessive linkage wear
 Engine Damper, Front Engine,
Trunnion Mounts, Support Mounts
 Check:
 Fluid-filled engine damper
for fluid leaks
 Trunnion and support
mounts for:
 Structural damage
 Loose or damaged bolts
 Worn or damaged rubber
pads
Secondary Steering/Brake Release
Pump
Check for:
 Oil leaks at pump connections
 Rubbing, damaged, or worn:
 Hoses or tubes
 Wiring harnesses or connectors
 Loose wiring connections
Engine Oil Pan

Check for leaks around:

 The oil pan mounting flange
 The oil level sensor
 Drain valve
 Dipstick tube
 Turbo lube return
Machine Frame

Check for:
 Damage to frame

 Structural cracks

 Cracked welds

Reference Special Instructions REHS1227

(Small OHT) or REHS0541 (Large OHT)
for detailed instructions regarding frame
maintenance, inspection, and repair
 Middle-Level Inspections
 Mud Flaps
 Front Suspension Cylinders
 Fuel Line, Pump, and Filter
Base
 Exhaust Manifold
 Turbocharger
 Front Brake Lines and
Components
 Steering Valves
 Hydraulic Tank
 Fuel Tank
 Rear Suspension Cylinders
 Electrical Components
 Work Lights
 Radiator, Aftercooler, and AC
Condenser
 Cylinder Head and Valve Cover
 Water Pump
Mud Flaps

Check for:
 Loose or missing mounting
nuts, bolts, brackets, and
straps
 Bent or damaged fenders
 Potential interference with
tires
Front Suspension Cylinders
Check for:
 Oil leaks around the cylinder lip seal

 Nicked, scored, or pitted cylinder rods

 Loose or missing cylinder boot

 Structural damage or weld cracks

 Damaged or loose steering arm or cylinder

cap bolts
 Damaged or loose suspension cylinder
mounting bolts
 Rubbing, damaged, or worn wiring

harnesses or connectors
Front Suspension Cylinders

 Improperly lubricated bearing

cap
 Broken or damaged grease
lines, grease fittings, or grease
seals
 Cylinder charge height
(Dimension “x”)
Reference the OMM & T&A
manual for measurement
specifications
Fuel Line, Pump, and Filter Base

Check for:
 Damaged, rubbing, or
worn fuel or hydraulic
lines
 Loose connections
 Leaks
Exhaust Manifold

Check for:
 Black soot, indicating a
loose, broken, or damaged
connection at joints
 Cracks or other damage in
the manifold housing
Turbocharger
Check for:
 Black soot indicated:
 Loose connections at the joints
 Loose or broken mounting bolts
 Dirt tracks which may indicate loose
or damaged at:
 Air inlet tubes and compressor
housing
 Turbo boost air lines
 Wastegate and lines
Front Brake Lines & Components
Inspect :
 Service brake valve
 Cab brake manifold
 Front brake slack adjuster
(located on the left hoist cylinder
frame support )
Check for:
 Leaks around hose connections
 Rubbing, damaged, or worn
hoses, wires, harnesses, and
connectors
 Steering Valves

Check for:
 Leaks around connection points
 Rubbing, damaged, or worn hoses, wiring harnesses and
connectors
Hydraulic Tank
Check for:
 Mounting
 Tank cap seals for damage
 Breather
 Hydraulic lines for leaks and
loose or damaged
connections
 Sight glasses for damage or
leaks
Fuel Tank
Check for:
 Leaks
 Structural damage to tank or
welds
 Plugged breather
 Damaged fill cap or fill cap
seal
 Loose or damaged bolts
 Worn or damaged rubber
mounts
 Rear Suspension Cylinders
Check for:
 Oil leaks, nicked, scored, or pitted
cylinder rods
 Loose or missing cylinder boot
 Structural damage or weld cracks
 Broken grease lines or fittings
 Loose, damaged, or missing pin
retaining bolts
 Irregular-shaped pin bores
Cylinder charge height (Dimension “x”)
 Rubbing, damaged, or worn wiring
Reference the OMM & T&A manual for
measurement specifications
harnesses or connectors
Electrical Components
Check the following for proper
operation:
 Compartment covers, latches, and
hinges
 Battery disconnect switch

 Engine disconnect switch

 Auxiliary start (jump start) receptacle

 Starter and alternator circuit breakers

 Machine lockout control and light

 Engine lockout control and light

 Machine access light switch

Work Lights
Check road lights, turn
signals, hazard flashers and
other lights for:
 Proper operation
 Cracked or broken lenses
 Damaged wiring harnesses
 Loose or damaged mounting
brackets
Radiator, Aftercooler, & AC
Condenser
Check for:
 Plugged screens
 Plugged cores
 Damaged fins

Note: Inspect both sides of cores

when possible
Cylinder Head and Valve Cover

Check for:
 Oil and dust buildup around
the sealing surfaces of the
valve covers or cylinder
head gasket
Water Pump
Check primary and
auxiliary pumps for
coolant leaks:
 Around water pump
mounting flange
 Through the weep hole in
the water pump housing
 Upper-Level Inspections
 Steps and Handrails
 Hood and Platform
 Pre-Cleaner and Air Cleaner
 Pulleys, Belts, Compressor
Clutch, and Alternator
 Cooling Fan, Fan Guard,
and Shroud
 Steering Tank and Lines
 Cab Exterior
 Cab Interior
 Cab Mounts
 Upper and Lower Radiator
Lines, Air Inlet Lines, and
Aftercooler Lines
 Radiator Cap
 Hydraulic Pump Compartment
 Auto-Lube Pump, Tank, and
Injectors
 Rear Brake Lines and
Components
Steps and Handrails

Ensure that steps and

handrails are in place and
check for:
 Damaged, missing, or loose
bolts
 Damage to steps or handrails
 Excessive dirt or debris
Hood and Platform

Check for :
 Debris or excessive dirt on
service platform
 Loose or damaged bolted
access covers
 Proper function of access
panels, latches, and hinges
 Loose or damaged platform
mounts and bolts
Pre-Cleaner and Air Cleaner
Check for:
 Dirt and/or debris in the air
pre-cleaner
 Loose or damaged hose
clamps on air inlet tube
 Loose or damaged air cleaner
covers and clamps
Pulleys, Belts, Compressor Clutch,
and Alternator
Check for:
 Cracked, worn or
broken belts
 Proper belt tension
 Oil leaks around air
condition compressor
clutch
Cooling Fan, Fan Guard,
& Shroud
Check for:
 Loose, damaged, or missing
bolts
 Loose or damaged wire fan
guard
 Loose or damaged fan
shroud
 Damaged, cracked, or
missing engine fan blades
Steering Tank and Lines
Check for:
 Loose or damaged tank mounts and

mounting bolts
 Leaks at tank assembly sealing surface

gasket, nuts, and bolts

 Cracks or leaks in oil level sight glass

 Leaks at hydraulic filter bases and line

connections

Make sure breather is clean and properly

ventilating
 Check by depressing the pressure relief

button on top of breather

Cab Exterior

Check for:
 Bent or damaged cab structure
 Cracked or broken glass
 Damaged or missing mirrors
 Worn or broken windshield
wiper arm or wiper blade
Cab Interior

Check for:
• Excessive dirt in cab air filter
• Proper function of seat and seat
belt
• Wear or damage to seat belt
• Seat belt replacement date
• Proper function of door and
latches
• Worn or broken window latches
or slides
• Damaged or inoperable gauges
and controls
• Proper function of backup alarm
Cab Mounts

Check for:
 Loose or damaged bolts
 Worn or damaged rubber
mounts
 Upper and Lower Radiator Lines,
Air Inlet Lines, and Aftercooler Lines

Check for:
 Rubbing, cracked, or damaged hoses
 Loose, over-tightened, or damaged hose
clamps
Radiator Cap
Hydraulic Pump Compartment
Check for:
 Leaks around hose connection
points
 Rubbing, damaged, or worn
hoses
 Loose or damaged hose
clamps on pump suction lines
 Rubbing, damaged, or worn
wiring harnesses or
connectors
Auto-Lube Pump, Tank, Injectors

Check for:
 Leaks around hose connection points
 Rubbing, damaged, or worn hoses, wiring
harnesses and connectors
Rear Brake Lines and Components
Inspect the following components:
 Parking brake valve
 TCS control valve
 Rear brake slack adjuster
 Secondary brake pressure switch
 Brake diverter valve

Check for:
 Leaks around hose connections
 Rubbing, damaged, or worn hoses
 Rubbing, damaged, or worn wiring
harnesses or connectors
Implement/Attachment Inspections

 Hoist Cylinder Inspection

 Truck Body Inspection
 Hoist Cylinder Inspection
Check for:
 Oil leaks
 Damage to cylinder rods
 Damage or wear to truck
body linkage pins and
retainer plates
 Grease leaking from frame
bearing retainer or cap
 Broken/damaged grease
Refer to “Hydraulic Cylinder Inspection lines and fittings
Guidelines” for inspection procedure
Truck Body Inspection
Check for excessive wear,
structural damage, or weld
cracks on:
 Body liner
 Canopy
 Heated body exhaust ports
 Rock ejectors
Check for improper
adjustment, excessive wear,
or damage to:
 Rocker shoes and rest
pads
 Frame rest pads
 Body position switch
Topik 6
 Safety
 Preventive Maintenance
 ISO Symbols
 Contaminant
 TA1 & Walk around
Inspection
 Maintenance Interval
Schedule
Operation Maintenance and Manual

 The OMM includes:

 Safety
 Product Information
 Operation
 Maintenance
 Reference Information
 Index
PM Interval Schedule
MIS section
 Task
instruction
 Maintenance Interval Schedule
 When Required  Every 3 Years After Date of
Installation or Every 5 Years
 Initial 8 Service Hours
After Date of Manufacture
 Every 10 SH or Daily
 Every 4000 SH or 1 Year
 Every 50 SH or Weekly
 Every 6000 SH or 3 Years
 Initial 250 Service Hours
 Every 12 000 SH or 6 Years
 Every 250 SH or Monthly
 Every 709 750 L (187 500 US
 Initial 500 Service Hours gal) of Fuel or 9000 SH
 Every 500 SH or 3 months  Every 1 419 500 L (375 000 US
 Every 1000 SH / 6 Months gal) of Fuel or 18 000 SH
 Every 2000 Se H or 1 Year  Every 6000 SH or 4 Years
 Every Year
 Every 3000 SH or 2 Years
 When Required
Clean Clean/Replace
 Air Conditioner Filter - Clean
 Cab Air Filter
 Cooling System Relief Valve  Engine Air Filter Primary
 Engine Air Precleaner Element
 Screen (Brake Oil Cooler) Replace
 Screen (Torque Converter  Engine Air Filter Secondary
Sump) Element
 Screen (Torque Converter,  Ether Starting Aid Cylinder
Hoist, and Brake Oil Cooler) Inspect
 Suction Screen (Transmission  Oil Filter
Tank)
 Air Tank
 Window
 When Required
Replace/Inspect Reset
 Battery or Battery Cable  Circuit Breakers

 Window Wiper Change

Inspect/Clean/Replace  Cooling System Coolant (ELC)

 Suction Screen (Hoist, Torque Test

Converter, and Brake Tank)  Traction Control System (TCS)

Adjust Fill
 Rear Axle Housing End Play  Window Washer Bottle
Recycle
 Battery
 Initial 8 Service Hours
Replace
 Oil Filter (Parking Brake Release)
 Oil Filter (Steering Pump Case Drain)
 Oil Filter (Steering)
 Oil Filter (Torque Converter)
 Oil Filter (Transmission)
 Every 10 SH / Daily
Check
 Steering System Oil Level
 Suspension Cylinder
 Transmission Tank Oil Level
Drain
 Air Tank Moisture and Sediment
 Fuel Tank Water and Sediment
Inspect
 Engine Air Filter Service
Indicator
 Seat Belt
Engine Oil Level - Log Additions
Test
 Backup Alarm
 Brakes, Indicators and Gauges
 Braking System
 Braking System
 Secondary Steering
Check
 Cooling System Coolant Level
 Engine Oil Level
 Hoist, Torque Converter and
Brake Tank Oil Level
 Every 50 SH / Weekly
Lubricate
Check
 Body Pivot Bearings
 Magnetic Plug (Differential)
 Front Suspension Cylinder Rods
 Magnetic Plug (Wheels)
 Hitch

 Hoist Cylinder Bearings

 Rear Axle A-Frame Bearing

 Rear Axle Housing Lateral

Control Rod Bearings

 Rear Suspension Cylinder
Bearings
 Steering Cylinder Bearings

 Steering Tie Rod & Pin Bearings

 Initial 250 Service Hours

 Engine Valve Lash and Bridge - Adjust

 Engine Valve Rotators - Inspect
 Frame and Body Support Pads - Clean/Inspect
 Every 250 SH / Monthly
When required, 10, 50 SH
Check
 Air Dryer
 Differential and Final Drive Oil
Level
 Front Wheel Oil Level
 Tire Inflation
 Front Wheel Oil
Clean
 Air Conditioner Filter
 Air/Hydraulic Cylinder Breather
Lubricate
 Fan Drive Bearing and Belt
Tightener Pulley
 Drive Shaft Slip Joint
SOS engine
Belts - Inspect/Adjust/Replace
Cab Air Filter - Clean/Replace
Engine Oil and Filter - Change
Clean/Inspect - Frame and Front
Wheel Oil
 Every 500 SH / 3 Months
When required,10, 50, 250 SH Replace
SOS  Breather (Fuel Tank)

 Coolant level 1  Breather (Torque Converter)

 Differential  Fuel Filter (Oil Renewal System)

 Final drive  Fuel System Primary Filter

 Front wheel  Fuel System Secondary Filter

 Hoist, TC and Brake tank oil  Oil Filter (Parking Brake Release)

 Steering system  Oil Filter (Steering Pump Case

 Transmission Drain)
Clean  Oil Filter (Steering)

 Breather (Transmission Tank)  Oil Filter (Torque Converter)

 Engine Crankcase Breather  Oil Filter (Transmission)

 Fuel Tank Cap and Strainer  Engine Oil Filter (Oil Renewal

 Magnetic Screen (Transmission)

System)
 Every 500 SH / 3 Months
Replace
 Oil Filter (Torque Converter)
 Oil Filter (Transmission)
Change
 Front Wheel Oil - Change
Differential and Final Drive Oil - Inspect
Fuel System - Prime
Suspension Cylinder - Check
Engine Oil Filter (Oil Renewal System)
 Every 1000 SH / 6 Months

When required, 10, 50, 250, 500 Inspect

 Frame and Body
Replace
 Rollover Protective Structure
 Air Dryer Desiccant
(ROPS)
 Breather (Differential and Final
 Service Brakes
Drive)
Change  Steering Linkage

 Hoist, Torque Converter and Frame and Body Support Pads -

Brake Tank Oil Clean/Inspect
 Steering System Oil Seat Suspension - Inspect/Lubricate
 Transmission Tank Oil
 Every 2000 SH / 1 Year

 When required, 10, 50, 250, 500, 1000

 Differential and Final Drive Oil - Change
 Rear Axle Housing End Play - Adjust
 Differential Thrust Pin Clearance - Check
 Cooling System Coolant Sample (Level 2) - Obtain
 Refrigerant Dryer - Replace
 Every 3000 SH / 2 Years

 When required, 10, 50, 250, 500, 1000

 Clean
 Cooling System Pressure Cap - Clean/Replace

 Cooling System Relief Valve

 Radiator Core

 Engine Valve Lash and Bridge - Adjust

 Engine Valve Rotators - Inspect
Component Location
Student Task
 Task

 Procedure change (drain and fill):

 Engine Oil
 Hydraulic Oil
 Final Drive Oil
 Transmission Oil
 Steering Oil
 Coolant

Refer to Operation and Maintenance Manual or SGD

 Task

 List job description for :

 PM 500 service hours
 PM 1000 service hours
 PM 2000 service hours

Refer to Operation and Maintenance Manual or SGD

 Task

 Explain the procedure to:

 Check cooling system
 Replace and Clean air filter
 Adjust valve
 Inspect differential trust pin clearance
 Radiator cap test
 Adjust belt

Refer to Operation and Maintenance Manual or SGD

 Task

 Explain the procedure to:

 Replace hydraulic filter
 Check Suspension cylinder
 SOS sample using vacuum extraction and valve probe
 Inspect differential trust pin clearance
 Release hydraulic system
 Jumper cables

Refer to Operation and Maintenance Manual or SGD

 Task
 Explain procedure to:
 Check engine coolant (ELC)
 Check steering linkage
 Inspect service brake
 Prime fuel system
 Replace Torque Converter Inlet Oil Filter
 Replace Oil filter (engine, transmission and parking brake
release)

Refer to Operation and Maintenance Manual or SGD

Thank you