KUYU CEMENT FACTORY DOCUMENT NO.

KCF/AG/QP/02

Inspection, PM & Check List Issue No Page 1 of 41

TITLE Issue Date Revision No.

Name Sign Date

Prepared by: Adugna Tulu (Senior Auto. Main. Engineer) ____ __________

Checked by: Tesfalem T/gebir (Auto & Quarry Manager) ____ __________
Approved by:______________________________(GM) ____ __________

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 KUYU CEMENT FACTORY DOCUMENT NO.KCF/AG/QP/02

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Contents Page No
1.Introduction............................................................................................................................................1
2. Objective.................................................................................................................................................1
2.1. Main Objective.................................................................................................................................1
2.2 Specific Objective..............................................................................................................................2
3.Machines, Dump Truck and Light Vehicle Periodic Service....................................................................2
3.1 Periodic Service.................................................................................................................................2
3.2 Preventive Maintenance.....................................................................................................................3
3.3 Inspection of Machine, Dump Truck and Light Vehicle....................................................................3
4. PM, Inspection and Check List of Machines, Dump Truck and Light Vehicle........................................3
4.1. PM, Inspection and Check List of Astra HD9 Dump Truck at 400Hr...............................................3
4.2. PM, Inspection and Check List of Astra HD9 Dump Truck at 800Hr...............................................5
4.3.PM, Inspection and Check List of Astra HD9 Dump Truck at 1600Hr..............................................6
4.4. PM, Inspection and Check List of Astra HD9 Dump Truck at 3200Hr.............................................7
4.5 PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 250 Hr..............8
4.6.PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 500Hr...............9
4.7.PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 1000Hr...........10
4.8.PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 2000Hr...........12
4.9.PM, Inspection and Check List for Toyota (Pickup, Dolphin and High Roof) At 5000 -10000km..13
5. 0.PM, Inspection and Check List for Toyota (Pickup, Dolphin and High Roof) At 20000-40000km14
5.1.PM, Inspection and Check List for Toyota (Pickup, Dolphin and High Roof) At 60,000km...........15
5.2.PM, Inspection and Check List Dozer D8R at 250Hr......................................................................16
5.3.PM, Inspection and Check List Dozer D8R at 500Hr......................................................................18
5.4.PM, Inspection and Check List Dozer D8R at 1000Hr....................................................................19
5.5.PM, Inspection and Check List Dozer D8R at 2000Hr....................................................................21
5.6 PM, Inspection and Check List Excavatorsy215C-8 and 336D2Lat 250 Hr....................................22
5.7.PM, Inspection and Check List of Excavatorsy215C-8 and 336D2L at 500Hr................................23
5.8.PM, inspection and check list of Excavatorsy215C-8 and 336D2L at 1000Hr................................25
5.9.PM, inspection and check list of Excavatorsy215C-8 and 336D2L at 2000Hr................................26
6.0. PM, Inspection and Check List for Fork Lift (CPCD50) at 250 Hr................................................28

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6.1.PM, Inspection and Check List For Fork Lift (CPCD50) at 500Hr..................................................28
6.2. PM, Inspection and Check List for Fork Lift (CPCD50) at 1000Hr...............................................29
6.3.PM, Inspection and Check List For Fork Lift (CPCD50) at 2000Hr................................................30
6.4.PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 250Hr................................32
6.5.PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 500Hr................................33
6.6.PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 1000Hr..............................35
6.7. PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 2000Hr.............................36

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 KUYU CEMENT FACTORY DOCUMENT NO.KCF/AG/QP/02

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1.INTRODUCTION
Kuyu cement plant has different machine (loader, excavator, crane. Forklift, dozer & drill
machine), Astra dump trucks, Sino trucks and light vehicle (Toyota high roof pickup and
dolphin). Depending on the maintenance manual each machine, dump truck and small vehicle
need periodic service, general service, corrective maintenance, preventive maintenance and
inspection.

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2. OBJECTIVE
2.1. Main Objective
The main objective of kuyu cement plant auto- garage is to increase the productivity of cement
for the benefit of company, society and employer of the plant by decrease down time of machine
dump truck and other machine that, there maintenance is related with auto garage.
2.2 Specific Objective
 Preventive maintenance, corrective maintenance, periodic service, general service and
inspection of light vehicle.
 Preventive maintenance, corrective maintenance, periodic service, general service and
inspection of trucks.
 Preventive maintenance, corrective maintenance, periodic service, general service and
inspection of machine.
 Preventive maintenance, corrective maintenance, periodic service, general service and
inspection of different size of generator.

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3.MACHINES, DUMP TRUCK AND LIGHT VEHICLE PERIODIC SERVICE

3.1 Periodic Service
Periodic service of each machine, light vehicle and dump truck depending on maintenances
manual. Astra dump and Sino truck periodic service at an interval 400hrs and 5000km engine oil
service with new oil filter and fuel filter respectively.
All machines and generator periodic service at an interval 250hr engine oil service with new oil
filter and fuel filter.
Light vehicle periodic service at an interval of 5000km engine oil service with new oil filter and
fuel filter
3.2 Preventive Maintenance
is a maintenance that happen/ done before failures. Lubricating each moving part of machines,
dump truck and small vehicles. According to maintenance manual change engine oil and other
spare parts.
3.3 Inspection of Machine, Dump Truck and Light Vehicle
Inspection is the processes known condition of machine, dump truck, light vehicle before riches final
failures it may be daily, weekly, monthly and yearly inspected.

4. PM, INSPECTION AND CHECK LIST OF MACHINES, DUMP TRUCK AND LIGHT
VEHICLE
4.1. PM, Inspection and Check List of Astra HD9 Dump Truck at 400Hr
System Lubricant Part Qnt
No Location Description 400Hr No No y Remark

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SAE15W4
1 Engine Change Engine Oil 0   32  
    Change Engine Oil Filter   2992544 2  
Inspection & Remedy
2 Engine Check Engine Oil Level        
    Check Engine Oil Leakage        
3 Gear box Check Gear box Oil Level        
    Check Gear box Oil Leakage        
4 Hydraulic Check Hydraulic System Oil Level        
    Check Hydraulic System Oil Leakage        
5 Steering Check Steering oil level        
    Check Steering oil leakage        
Check Differential & Final drive Oil
6 Level        
Differential/ Check Differential & Final drive Oil
  Final drive Leakage        
Check Function of all grease points &
7 Frame & work lubricate        
Check Condition of all joints, pivots &
  Equipment pins        
8 Cooling system Check Water (ELC) level & leakage        
    Check Fan for cracks/loose bolts        
    Check water manifold        
Check Radiator core, clean, passing of
    air        
9 Air conditioning Check function of cooling system        
    Clean Condenser        
    Clean Evaporator(cabin)        

4.2. PM, Inspection and Check List of Astra HD9 Dump Truck at 800Hr.
System
No Location Description 800Hr Lubricant No Part No Qnty Re
Change Engine Oil SAE15W40   32  
 1   Engine Change Engine Oil Filter   2992544 2  
    Change Primary Fuel filter   2992662 1  

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    Change Secondary Fuel filter   2994048 1  

Inspection & Remedy
2 Engine Check Engine Oil Level        
    Check Engine Oil Leakage        
3 Gear box Check Gear box Oil Level        
    Check Gear box Oil Leakage        
Check Hydraulic System Oil
4 Hydraulic Level        
Check Hydraulic System Oil
  Leakage        
5 Steering Check Steering oil level        
    Check Steering oil leakage        
Check Differential & Final drive
6 Differential/ Oil Level        
Check Differential & Final drive
  Final drive Oil Leakage        
Check Function of all grease
7 Frame & work points & lubricate        
Check Condition of all joints,
  Equipment pivots & pins        
Check Water (ELC) level &
Cooling leakage        
8 system
Check Fan for cracks/loose bolts      
   
Check water manifold      
   
Check Radiator core, clean,
    passing of air      
Air
9 conditioning Check function of cooling system      

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    Clean Condenser      
    Clean Evaporator(cabin)      

4.3.PM, Inspection and Check List of Astra HD9 Dump Truck at 1600Hr
No System Location Description 1600Hr Lubricant Part No Qnty Remark
No
  Change Engine Oil SAE15W40   32Lit  
    Change Engine Oil Filter   2992544 2  
Change Primary Fuel filter   2992662 1  
  1   Engine Change Secondary Fuel filter   2994048 1  
  Change Air cleaner     1  
   
  Change Gear box oil SAE80W90   17Lit  
Inspection & Remedy
2 Engine Check Engine Oil Level        
    Check Engine Oil Leakage        
3 Gear box Check Gear box Oil Level        
    Check Gear box Oil Leakage        
4 Hydraulic Check Hydraulic System Oil        
  Level
Check Hydraulic System Oil        
Leakage
5 Steering Check Steering oil level        
    Check Steering oil leakage        
6 Differential/ Check Differential & Final        
drive Oil Level
  Final drive Check Differential & Final        
drive Oil Leakage
7 Frame & work Check Function of all grease        
points & lubricate
  Equipment Check Condition of all joints,        
pivots & pins
    Check Water (ELC) level &        
    leakage
  Check Fan for cracks/loose        
 8 Cooling system bolts
Check water manifold        
Check Radiator core, clean,        
passing of air
9 Air conditioning Check function of cooling        

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    system
    Clean Condenser        
Clean Evaporator(cabin)        

4.4. PM, Inspection and Check List of Astra HD9 Dump Truck at 3200Hr.
No System Location Description 3200Hr Lubricant Part No Qnty Remark
No
  Change Engine Oil SAE15W40   32Lit  
    Change Engine Oil Filter   2992544 2  
    Change Primary Fuel filter   2992662 1  
    Change Secondary Fuel filter   2994048 1  
    Change Air cleaner     1  
    Change Gear box oil SAE80W90   17Lit  
 1  Engine
  Change Differential & Final SAE85W14   60Lit  
    drive oil 0
    Grease Front hub (Left & EP3   5Kg  
    Right)
    Change Steering Oil & Filter ATF   4Lit  
Change Hydraulic Oil SAE10W   70Lit  
Change Clutch fluid DOT4   0.5Lit  
Change Air drier   2992261 1  
Inspection & Remedy
2   Engine Check Engine Oil Level        
Check Engine Oil Leakage        
 3  Gear box Check Gear box Oil Level        
Check Gear box Oil Leakage        
4  Hydraulic Check Hydraulic System Oil        
  Level
Check Hydraulic System Oil        
Leakage
5   Check Steering oil leakage        
  Steering Check Steering oil level        
6 Differential/ Check Differential & Final        
Final drive drive Oil Level
Check Differential & Final        
drive Oil Leakage
 7 Frame & work Check Function of all grease        
equip. points & lubricate
Check Condition of all joints,        
pivots & pins

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    Check Water (ELC) level &        

  8  Cooling system leakage
Check Fan for cracks/loose        
bolts
Check water manifold        
    Check Radiator core, clean,        
 9  Air conditioning passing of air
Check function of cooling        
system
Clean Condenser        
Clean Evaporator(cabin)        
4.5 PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 250 Hr.
No System Description 250H Lubricant Part No Qnt
Location r No y Remark
Change Engine Oil SAE15W40   25Lit  
1 Engine Change Engine Oil filter   D17-002- 1  
    50+B
Inspection & Remedy
Check Engine for Oil Level        
2 Engine Check Engine for Oil Leakage        
   
Check Transmission Oil Level        
3 Transmission Check Transmission Oil        
    Leakage
Check Hydraulic system Oil        
4 Hydraulic Level
    Check Hydraulic system Oil        
Leakage
Check Final drive Oil Level        
5 Final drive Check Final drive Oil Leakage        
   
6 Frame & work Check Function of all Grease        
  equip. points
  Check Condition of all joints,        
pivots and pins
    Check Water (ELC) Level &        
    leakage
 7  Cooling Check Fan for cracks/loosen        
system bolts
Check Water Manifold        
Check Radiator core, clean,        
passing of air

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8 Air Check function of cooling        

  conditioning system
    Clean condenser        
  Clean Evaporator(cabin)        
9 Tire Check tire Pressure        
    Check condition of tires        
Check cabin lights, indicators &        
accessories
10 Electrical Check Electrolyte level of        
  system Battery
    Check/clean battery & its        
    terminals
  Check/clean Fuse board &        
display board
4.6.PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 500Hr.
No System Description 500Hr Lubricant Part No Qnty Remark
. Location No
Change Engine Oil SAE15W4   25Lit  
0
Change Engine Oil filter   D17-002- 1  
1 ENGINE 50+B
    Primary Fuel Filter   150- 1  
    1105020A
    Secondary Fuel Filter   D638-002- 1  
02+B
Inspection & Remedy
2 Engine Check Engine for Oil Level        
    Check Engine for Oil Leakage        
3 Transmission Check Transmission Oil Level        
    Check Transmission Oil Leakage        
Check Hydraulic system Oil Level        
4 Hydraulic Check Hydraulic system Oil        
    Leakage
5 Final drive Check Final drive Oil Level        
    Check Final drive Oil Leakage        
Check Function of all Grease points        
6 Frame & work Check Condition of all joints,        
  equip. pivots &pins
 
Check Water (ELC) Level &        
leakage

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Check Fan for cracks/loosen bolts        

7 Cooling system Check Water Manifold        
    Check Radiator core, clean, passing        
    of air
   
8 Air conditioning Check function of cooling system        
    Clean condenser        
    Clean Evaporator(cabin)        
9 Tire Check tire Pressure        
    Check condition of tires        

4.7.PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 1000Hr.
No System Description 1000H Lubricant Part No Qnt
Location r No y Remar
k
Change Engine Oil SAE15W4   25Li  
0 t
Change Engine Oil filter   D17-002- 1  
1 Engine 50+B
    Primary Fuel Filter   150- 1  
    1105020A
    Secondary Fuel Filter   D638-002- 1  
    02+B
Change Air cleaner assay   KD2640A5 1  
7
  Transmission Change Transmission Oil   SAE30W 30Li  
    t
Change Transmission Oil filter     1  
Inspection & Remedy
2 Engine Check Engine for Oil Level        
    Check Engine for Oil Leakage        
3 Transmission Check Transmission Oil Level        
    Check Transmission Oil        
Leakage
4 Hydraulic Check Hydraulic system Oil        
    Level
Check Hydraulic system Oil        
Leakage

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5 Final drive Check Final drive Oil Level        

    Check Final drive Oil Leakage        
6 Frame & work Check Function of all Grease        
  equip. points
  Check Condition of all joints,        
pivots &pins
7 Check Water (ELC) Level &        
  leakage
  Check Fan for cracks/loosen        
  Cooling system bolts
  Check Water Manifold        
  Check Radiator core, clean,        
  passing of air
Check function of cooling        
8 Air conditioning system
    Clean condenser        
    Clean Evaporator(cabin)        
9 Tire Check tire Pressure        
    Check condition of tires        
Check cabin lights, indicators        
& accessories
10 Electrical Check Electrolyte level of        
  system Battery
    Check/clean battery & its        
    terminals
  Check/clean Fuse board &        
display board
4.8.PM, Inspection and Check List for Wheel Loader (Zl50GN & China Lion 955) At 2000Hr.
No System Description 2000H Lubricant Part No Qnty
Location r No Remark
Change Engine Oil SAE15W4   25Lit  
0
Change Engine Oil filter   D17-002- 1  
1 Engine 50+B
    Primary Fuel Filter   150- 1  
    1105020A
    Secondary Fuel Filter   D638-002- 1  
    02+B
Change Air cleaner assay   KD2640A5 1  
7
Change Transmission Oil   SAE30W 30Lit  

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2  Transmission Change Transmission Oil filter     1  

   
 3 Hydraulic Change Hydraulic Oil   SAE10W 120Li  
    t
Change Hydraulic Oil Filter     1  
 4 Differential Change Differential & Final   SAE80W90 65Lit  
  & drive Oil(F&R)
Final drive
Inspection & Remedy
5 Engine Check Engine for Oil Level        
    Check Engine for Oil Leakage        
Check Transmission Oil Level        
6 Transmission Check Transmission Oil        
    Leakage
Check Hydraulic system Oil        
7 Hydraulic Level
    Check Hydraulic system Oil        
Leakage
8 Final drive Check Final drive Oil Level        
    Check Final drive Oil Leakage        
Check Function of all Grease        
9 Frame & points
  work equip. Check Condition of all joints,        
  pivots &pins
Check Water (ELC) Level &        
leakage
Check Fan for cracks/loosen        
10 Cooling bolts
  system Check Water Manifold        
    Check Radiator core, clean,        
    passing of air
 
Check function of cooling        
11 Air system
  conditioning Clean condenser        
    Clean Evaporator(cabin)        
 
12 Tire Check tire Pressure        
    Check condition of tires        
Check cabin lights, indicators        
& accessories
13 Electrical Check Electrolyte level of        

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system Battery
    Check/clean battery & its        
    terminals
    Check/clean Fuse board &        
display board
4.9.PM, Inspection and Check List for Toyota (Pickup, Dolphin and High Roof) At 5000 -10000km
No System Description 5000/ Lubricant Part No
Location 10000Km No Qnt Remark
y
1 Engine Change Engine Oil SAE15W40   7Lits  
    Change Engine Oil Filter   90915-YZZB3 1pcs  
  Inspection & Remedy
2 Engine Check Engine for oil level        
    Check Engine for oil leakage        
Check Gear box & clutch oil        
3 Gear box & level
  Clutch Check Gear box & clutch oil        
leakage
4 Steering Check steering oil level        
    Check steering oil leakage        
Differential Check differential for level        
5 & Check differential for leakage        
  Final drive Check condition of Brake pad        
    & shoe
Check function of all grease        
6 Frame & points & lubricate
  body Check condition of all joints,        
  pivots & pins
Check Water (ELC) Level &        
Leakage
Cooling Check Fan for cracks/Loose        
7 system bolts
    Check water manifold        
    Check radiator core, clean,        
    passing of air
Air Check function of cooling        
8 conditioning systems
    Clean condenser        
    Clean Evaporator (Cabin)        

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5. 0.PM, INSPECTION AND CHECK LIST FOR TOYOTA (PICKUP, DOLPHIN AND
HIGH ROOF) AT 20000-40000KM
No System Description 20,000/ Lubricant Part No
Location 40,000k No Qnt Remar
m y k
Change Engine Oil SAE15W40   7Lits  
1 Engine Change Engine Oil Filter   90915- 1pcs  
    YZZB3
    Change Fuel Filter   23390- 1pcs  
    OL041
INSPECTION &
REMEDY
Check Engine for oil level        
2 Engine Check filter (Lub. & Fuel)        
    Condition by cutting
    Check Engine for oil leakage        
Gear box & Check Gear box & clutch oil level        
3 Clutch Check Gear box & clutch oil        
  leakage
4 Steering Check steering oil level        
    Check steering oil leakage        
5 Differential Check differential for level        
  & Check differential for leakage        
  Final drive Check condition of Brake pad &        
  shoe
6 Frame & Check function of all grease        
  body points & lubricate
  Check condition of all joints,        
pivots & pins
7 Cooling Check Water (ELC) Level &        
  system Leakage
  Check Fan for cracks/Loose bolts        
    Check water manifold        
    Check radiator core, clean,        
passing of air
8 Air Check function of cooling systems        
  conditionin Clean condenser        
  g Clean Evaporator (Cabin)        
 
 

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5.1.PM, Inspection and Check List for Toyota (Pickup, Dolphin and High Roof) At 60,000km
No System Description 60,000km Lubricant Qnty Remark
Location No Part No
Change Engine Oil SAE15W40   7Lits  
Change Engine Oil Filter   90915- 1pcs  
YZZB3
Change Fuel Filter   23390- 1pcs  
1 Engine
OL041
   
Change Engine Coolant (ELC)        
   
    Change Air Filter   17801- 1pcs  
    0C010/20
2 Gear box & Change Gear box oil SAE85W90   4Lits  
  Clutch Change Transfer gear oil SAE85W90   2Lits  
    Change Clutch Fluid DOT4(HBF4)   1/2Lits  
3 Steering Change Steering oil ATF   2Lits  
4 Differential Change Differential oil SAE85W90   4Lits  
  & Change Front Hub Grease EP2/3      
Final drive (Right & Left)
  Inspection & Remedy
Check Engine for oil level        
5  Engine Check filter (Lub. &Fuel)        
  Condition by cutting
    Check Engine for oil leakage        
    Check Engine Valve Lash        
Check Gear box & clutch oil        
6 Gear box & level
  Clutch Check Gear box & clutch oil        
leakage
7 Steering Check steering oil level        
    Check steering oil leakage        
Check differential for level        
8 Differential Check differential for leakage        
  & Check condition of Brake pad        
  Final drive & shoe
 
9 Frame & Check function of all grease  Ep3      
  body points & lubricate
  Check condition of all joints,        
pivots & pins
Check Water (ELC) Level &        
Leakage

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Check Fan for cracks/Loose        

10 Cooling bolts
  system Check water manifold        
    Check radiator core, clean,        
    passing of air
 
Check function of cooling        
11 Air systems
  conditionin Clean condenser        
  g Clean Evaporator (Cabin)        
 
 
5.2.PM, Inspection and Check List Dozer D8R at 250Hr.
No System Description 250Hrs Lubricant Part No Remark
Location No Qnty
Engine Change Engine Oil SAE15W40   32.5Lits  

Change Engine Oil   1R-1808 1  

Inspection & Remedy        

  Check engine for oil leakage

Check filter condition        
2 Engine Sample for oil testing        
  Check for any leakage around        
engine
 3   Transmission Check T/M oil level        
Check T/M for oil leakage        
  Check oil level of hydraulic        
4 Hydraulic system
  Check hydraulic system for        
any leakage
5 final drive Check final drive oil level        
  Check final drive for oil      
leakage

Check function of all grease

points & lubricate.
6 Frame &Work Check Equalizer bar ends   SAE80W90    
  Equip. pins oil level
  Check / adjust track        
  Check condition of all joints,        

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pivots & pins

Check water (ELC) level &        
leakage
Check fan for cracks/loose        
7 Cooling bolts
  system Check water manifold        
    Check radiator core, clean &        
  passing of air
Check function of cooling       Optional
8 Air system
  conditioning Clean condenser       Optional
    Clean evaporator(cabin)       Optional
Check cabin lights, indicators        
&accessories
Check electrolyte level of the        
9 Electrical battery
  system Check/clean the battery &its        
    terminals
  Check /clean fuse board &        
display board
5.3.PM, Inspection and Check List Dozer D8R at 500Hr.
N System Description 500Hrs Lubricant Part No Remark
o Location No Qty
    Change Engine Oil SAE15W40   32.5Lit  
 1  Engine s
Change Engine Oil filter   1R-1808 1  
Change the primary fuel filter   326- 1  
1642/44
Change the secondary fuel   1R-0749 1  
filter
2 Change Transmission oil filter   337-5270 1  
Transmissio
n
3 Change hydraulic oil filter   126-1818 1  
Hydraulic (case drain)
    Inspection & Remedy        
    Check engine for oil leakage        
    Check filter condition ()        
4 Engine Sample for oil testing        
    Check for any leakage around        
engine
  Check T/M oil level        
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5 Transmissio Check T/M for oil leakage        

  n
 
  Check filter condition (By        
cutting)
6 Hydraulic Check oil level of hydraulic        
    system
  Check hydraulic system for        
any leakage
Check final drive oil level        
7 Final drive Check final drive for oil        
    leakage
    Check function of all grease        
points & lubricate
Frame Check Equalizer bar ends pins SAE80W90    
8 &Work oil level
  Equip. Check / adjust track        
    Check condition of all joints,        
  pivots & pins
    Check water (ELC) level &        
leakage
Cooling Check fan for cracks/loose        
9 system bolts
    Check water manifold        
    Check radiator core, clean &        
    passing of air
Check function of cooling       Optional
system
Air Clean condenser       Optional
10 conditioning Clean evaporator(cabin)       Optional
    Check cabin lights, indicators        
    &accessories
Check electrolyte level of the        
battery
11 Electrical Check/clean the battery &its        
  system terminals
    Check /clean fuse board &        
  display board
5.4.PM, Inspection and Check List Dozer D8R at 1000Hr.
No System Description 1000Hrs Lubricant No Part No Qty Remark
Location
    Change Engine Oil SAE15W40   32.5Lits  

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Change Engine Oil filter   1R-1808 1  

1 Engine Change the primary fuel filter   326-1642/44 1  
    Change the secondary fuel   1R-0749 1  
    filter
    Change outer air filter   6l-2505 1  
Change Transmission oil   337-5270 1  
2 Transmission filter
    Transmission oil change SAE50W   144 Lit.  
3 Hydraulic Change hydraulic oil filter   132-8875 1  
    Change hydraulic case drain   126-1818 1  
    oil filter
INSPECTION & REMEDY  
    Check engine for oil leakage        
    Check filter (Lub. & Fuel)        
4 Engine condition (By cutting)
    Sample for oil testing        
Check for any leakage around        
engine
  Check T/M oil level        
Check T/M for oil leakage &        
5 Transmission clean screen
    Check filter condition (By        
    cutting)
  Sample for oil testing        
  Check oil level of hydraulic        
system
6 Hydraulic Check hydraulic system for        
    any leakage
  Check filter condition        
Check final drive oil level        
Check final drive for oil        
7 final drive leakage
   
 
Check Equalizer bar ends    SAE80W90  
Frame pins oil level
8 &Work Check / adjust track        
  Equip. Check condition of all joints,        
    pivots & pins
    Check function of all grease        
  points & lubricate

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Check fan for cracks/loose        

bolts
Check water manifold        
Check water (ELC) level &
9 Cooling
leakage
  system
Check radiator core, clean &        
   
passing of air
   
Check function of cooling       Optional
 
system
10 Air Clean condenser       Optional
  conditioning Clean evaporator(cabin)       Optional
 
    Check cabin lights, indicators        
&accessories
Check electrolyte level of the        
11 Electrical battery
  system Check/clean the battery &its        
terminals
Check /clean fuse board &        
display board
5.5.PM, Inspection and Check List Dozer D8R at 2000Hr.
 No. System Description 2000Hrs Lubricant filter Part Remark
Location No No Qty
    Change Engine Oil SAE15W40   35.5Lits  
Change Engine Oil filter   1R-1808 1  
1 Engine Change the primary fuel filter   326-1642 1  
    Change the secondary fuel filter   1R-0749 1  
    Change outer air filter   6l-2505 1  
    Change inner air filter   6l-2506    
   
2 Transmission Change Transmission oil filter   337-5270 1  
    Transmission oil change SAE50W   144 Lit.  
Change hydraulic oil filter   132-8875 1  
Change hydraulic case drain oil   126-1818 1  
3 Hydraulic filter
    Change hydraulic oil, bleed the SAE10W   72 Lit.  
    system
Change the oil (Final drive, SAE50W   13.5Lit.  
4 Differential/ right)
  Fine Drive Change the oil (Final drive, SAE50W   13.5Lit.  
  left)
    Inspection & Remedy        

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    Check engine for oil leakage        

Check filter (Lub. & Fuel)        
5 Engine condition (By cutting)
    Check for any leakage around        
    engine
Engine valve lash        
    Check T/M oil level        
6  Transmission Check T/M for oil leakage &        
    clean screen
 
Check filter condition (By        
cutting)
Check oil level of hydraulic        
7 Hydraulic system
    Check hydraulic system for any        
leakage
Check filter condition        
Check final drive oil level        
8 final drive Check final drive for oil        
    leakage
    Check function of all grease        
points & lubricate
Check Equalizer bar ends pins SAE80W90      
9 Frame &Work oil level
  Equip. Check / adjust track        
    Check condition of all joints,        
  pivots & pins
    Check water (ELC) level &        
leakage
Check fan for cracks/loose        
bolts
Check water manifold        
Check radiator core, clean &        
passing of air
Check function of cooling       Optional
system
11 Air conditioning Clean condenser       Optional
    Clean evaporator(cabin)       Optional
5.6 PM, Inspection and Check List Excavatorsy215C-8 and 336D2Lat 250 Hr.
No System Location Description 250Hrs Lubricant Part No Rem
No Qnty
1 Engine Change Engine Oil SAE15W40   40Lit  

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s
Change Engine Oil filter   1R-1808 1  
Change oil filter (hydraulic
2 Hydraulic hammer)
Change hydraulic filter (pilot
&case drain)
Inspection & Remedy
Check engine for oil leakage
3 Engine Check filter condition
Test oil sample
Check final drive oil level
Swing bearing lubricate.
Check final drive for oil
4 final & swing leakage
drive Check circle drive oil level
Check swing drive for oil
leakage
Check function of all grease Ep3
points & lubricate.
5 Frame &Work Check bucket and
Equip. jackhammer
Check condition of all joints,
pivots & pins
Check oil level of hydraulic
6 Hydraulic system
Check hydraulic system for
any leakage
Check water (ELC) level &
leakage
Check fan for cracks/loose
7 Cooling system bolts
Check water manifold
Check radiator core, clean &
passing of air
Check function of cooling
8 Air conditioning system
Clean condenser
Clean evaporator(cabin)
Check cabin lights, indicators
&accessories
Check electrolyte level of the

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battery
9 Electrical system Check/clean the battery &its
terminals
Check /clean fuse board &
display board

5.7.PM, Inspection and Check List of Excavatorsy215C-8 and 336D2L at 500Hr.

No System Description 500Hrs Lubricant Filter Remark
Location No Part No Qty
    Change Engine Oil SAE15W4   32.5Lit  
    0 s
1 Engine Change Engine Oil filter   1R-1808 1  
Change primary fuel filter   438- 1  
5386
422- 1
Change Secondary fuel filter 7587
360- 1
Change Fuel filter(cartridge) 8960/58
Change Third fuel filter 1
Inspection & Remedy
Check engine for oil leakage
Check filter condition (cutting)
2 Engine Sample for oil testing
Check for any leakage around
engine
Check oil level of hydraulic
system
3 Hydraulic Check hydraulic system for
any leakage
Check filter condition
4 Final drive Check final drive oil level
Check final drive for oil
leakage
  Check function of all grease
points & lubricate
5 Frame &Work Check boom, bucket and
Equip. jackhammer condition
Check condition of all joints,
pivots & pins
Check water (ELC) level &
leakage

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Check fan for cracks/loose

6 Cooling system bolts
Check water manifold
Check radiator core, clean &
passing of air
Check function of cooling
7 Air conditioning system
Clean condenser
Clean Evaporator(cabin)
Check electrolyte level of the
battery
8 Electrical system Check/clean the battery &its
terminals
Check /clean fuse board &
display board
5.8.PM, Inspection And Check List Of Excavatorsy215C-8 And 336D2L At 1000Hr.
No System Description 1000Hr Lubricant No Filter Qty Remark
Location s Part No
  Change Engine Oil   SAE15W40   40Lits  
Change Engine Oil filter   1R-1808 1  
1 Engine Change primary fuel filter   438-5386 1  
Change secondary fuel   422-7587 1  
filter
Fuel filter(cartilage) 360- 1
8960/58
Change pilot hydraulic oil 1
filter 5I-8670X
2 Hydraulic Change hydraulic case 093-7521 1
  drain oil filter
  Change oil (partial hammer
use )
3 Final drive Change final drive oil SAE50 14 Lit
Inspection & Remedy
Check engine for oil
4 Engine leakage
Check filter (Lub. & Fuel)
condition (By cutting)
Check jackhammer bucket
Frame condition
5 &Work Equip. Check / adjust joint
Check condition of all

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joints, pivots & pins

Check fan for cracks/loose
bolts
6 Cooling Check water manifold
system Check radiator core, clean
& passing of air
Check oil level of
hydraulic system
7 Hydraulic Check hydraulic system for
any leakage
Check filter condition
8 Air Clean condenser
conditioning Clean evaporator(cabin)
Check electrolyte level of
the battery
9 Electrical Check/clean the battery
system &its terminals
Check /clean fuse board &
display board
5.9.PM, inspection and check list of Excavatorsy215C-8 and 336D2L at 2000Hr.
 No System Description 2000Hrs Lubricant filter Part Remark
Location No No Qty
  Change Engine Oil SAE15W4   40Lits  
0
Change Engine Oil filter   1R-1808 1  
Change the primary fuel filter   438-5386 1  
 1 Engine
Change the secondary fuel   422-7587 1  
  filter
  Fuel filter(cartilage)   360-8960/58 1  
  Change air filter   142-1339  1  
Change return hydraulic oil   179-8906 1  
  filter
Change hydraulic case drain   093-7521 1  
2 Hydraulic oil filter
  Change pilot hydraulic oil 5I-8670X
filter
Change hydraulic oil, bleed the SAE10W/ 200Lits  
system 15W40
Final and Change the oil (Final drive, SAE50W   7Lits  
 3 swing Drive right)
Change the oil (Final drive, SAE50W   7Lits  

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left)
Swing drive SAE50 17Lits
  Inspection &Remedy        
  Check engine for oil leakage        
Check filter (Lub. & Fuel)        
  condition (By cutting)
 4 Engine Check for any leakage around        
engine
Engine valve lash        
Check hydraulic system for        
 5 Hydraulic any leakage
Check filter condition        
Check final drive oil level        
 6 Final, Check final drive for oil        
undercarriage leakage
and swing Check carrier & track rollers.
drive
idlers wheels and wear
&abnormal noise.
7 Fuel tanker Clean fuel tanker
  Check function of all grease        
points & lubricate
  Check condition of boom,      
  bucket and jackhammer
8 Frame Check / adjust track        
&Work
Check condition of all joints,        
Equip.
pivots & pins
Check Track adjustment and
loosening the track
  Check water (ELC) level &        
  leakage
Check fan for cracks/loose        
bolts
9 Cooling Check water manifold        
  system
Check radiator core, clean &        
 
passing of air
Check function of cooling       Optional
system
 10 Air Clean condenser       Optional
conditioning Change receiver dryer
(refrigerant)
Clean evaporator(cabin)       Optional

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Check electrolyte level of the

battery
11 Electrical Check dash board at all.
system Check travel alarm
Check/clean the battery &its
terminals
Check /clean fuse board &
display board

6.0. PM, INSPECTION AND CHECK LIST FOR FORK LIFT (CPCD50) AT 250 HR.
No System Description 250Hr Lubrican Filter Part No Qnty Remar
. Location s t No

Change engine oil 15W40 17Lit

1 Engine s
Change engine oil filter 1-87610064-0 1
Inspection & Remedy
Check engine for oil leakage
2 Engine Check filter condition
Test oil sample
3 Frame &Work Check frame, pin, joint and
Equip. chain condition
Check hydraulic system for any
4 Hydraulic leakage
  Check filter condition
5 Tire Check tire pressure and tire
condition
Check water (ELC) level &
leakage
6 Cooling Check fan for cracks/loose bolts
system Check water manifold
Check radiator core, clean &
passing of air
Check electrolyte level of the
Electrical battery
7 system Check/clean the battery & its
terminals
Check /clean fuse board &
display board

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6.1.PM, Inspection and Check List For Fork Lift (CPCD50) at 500Hr.
N System Description 500Hr Lubrican Filter Part No Qnty R
o Location s t No k
Engine oil 15W40 17Lit
s
1 Engine Engine oil filter 1-87610064-0
Primary fuel filter 3931063/
FF5052
Secondary fuel filter 8-98036654-0
Third fuel filter
Inspection & Remedy
Check engine for oil leakage
2 Engine Check filter condition
Test oil sample
3 Frame &Work Check frame, pin, joint and chain
Equip. condition
Check hydraulic system for any
4 Hydraulic leakage
  Check filter condition
5 Tire Check tire pressure and tire
condition
Check water (ELC) level &
leakage
6 Cooling Check fan for cracks/loose bolts
system Check water manifold
Check radiator core, clean &
passing of air
Check electrolyte level of the
Electrical battery
7 system Check/clean the battery & its
terminals
Check /clean fuse board & display
board

6.2. PM, Inspection and Check List for Fork Lift (CPCD50) at 1000Hr.
No System Description 1000Hrs Lubricant Filter Part No Qnty Rem
Location No
Engine oil 15W40 17Lit

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s
1 Engine Engine oil filter 1-87610064-0 1
Primary fuel filter 3931063/FF5052 1
Secondary fuel filter 8-98036654-0 1
Third fuel filter 1
2 Air Change cleaner 1
cleaner
3 Hydraulic Change Hydraulic oil filter 25967-82001
Inspection & Remedy
Check engine for oil leakage
4 Engine Check filter condition
Test oil sample
Frame Check frame, pin, joint and
5 &Work chain condition
Equip.
Check hydraulic system for
6 Hydraulic any leakage
  Check filter condition
7 Tire Check tire pressure and tire
condition
Check water (ELC) level &
leakage
8 Cooling Check fan for cracks/loose
system bolts
Check water manifold
Check radiator core, clean &
passing of air
Check electrolyte level of the
Electrical battery
9 system Check/clean the battery & its
terminals
Check /clean fuse board &
display board
6.3.PM, Inspection and Check List For Fork Lift (CPCD50) at 2000Hr.
No System Description 2000Hrs Lubricant Filter Part No Qnty R
Location No
Engine oil 15W40 17Lits
Engine oil filter 1-87610064-0 1
1 Engine Primary fuel filter 3931063/FF5052 1

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Secondary fuel filter 8-98036654-0 1

Third fuel filter 1
Change Hydraulic oil filter 25967-82001 1
2 Hydraulic Change hydraulic oil SAE10W 75Lits
Change air cleaner 1
Inspection & Remedy
Check Clutch piston ring
3 Transmission worn
Check clutch disk are burned
and plate deformed
Check oil level
Check O-ring and replace
Torque Check spring tension and
4 converter replace
Check joints &pipe retighten
and replace packing
Check engine for oil leakage
5 Engine Check filter condition
Test oil sample
6 Frame &Work Check frame, pin, joint and
Equip. chain condition
Check hydraulic system for
7 Hydraulic any leakage
  Check filter condition
8 Check final Check hub reduction
dive/differentia lubrication condition
l
Check differential oil level
9 Braking system Check and adjusting brake
system
10 Steering system Check and adjust steering
system
11 Tire Check tire pressure and tire
condition
Check water (ELC) level &
leakage
12 Cooling system Check fan for cracks/loose
bolts
Check water manifold
Check radiator core, clean &

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passing of air
Check electrolyte level of the
Electrical battery
13 system Check/clean the battery & its
terminals
Check /clean fuse board &
display board
6.4.PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 250Hr.
No System Description 250Hr Lubricant Part No Rem
Location s No Qnty
1 Engine Change Engine oil 15W40 22&25
Change engine oil filter 13055724 & 02
VG61000070005
2 Hydraulic Replace hydraulic oil filter
system element
Replace pilot oil filter
Inspection & Remedy
3 Boom Check welding seam for
crack, slide block and rotate
pully condition
4 Derricking Check derricking cylinder
pivot pin lock bolts are loose
or not
5 Telescoping Check oil pipe and telescoping
system cylinder
6 Counter Check counter weight lifting
weight cylinder
Check engine for oil leakage
7 Engine Check filter condition
Test oil sample
Check final drive oil level
Check final drive for oil
8 final & leakage
swing drive Check circle drive oil level
Check circle drive for oil
leakage
9 Frame Check function of all grease Ep3
&Work points & lubricate.
Equip. Check bucket and jackhammer
Check condition of all joints,

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pivots & pins

Check oil level of hydraulic
10 Hydraulic system
Check hydraulic system for
any leakage
Check water (ELC) level &
leakage
11 Cooling Check fan for cracks/loose
system bolts
Check water manifold
Check radiator core, clean &
passing of air
12 Air Check function of cooling
conditioning system
Clean condenser
Clean evaporator(cabin)
13 Electrical Check cabin lights, indicators
system &accessories
Check electrolyte level of the
battery
Check/clean the battery &its
terminals
Check /clean fuse board & ○
display board
6.5.PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 500Hr.
N System Description 500Hrs Lubricant Part No Rem
o Location No Qnty
Change Engine oil 15W40 22&25
Change engine oil filter 13055724 & 02
1 Engine VG61000070005
Secondary fuel filter 612630888087 02
Primary fuel filter 612600081889 04
2 Winch Change gear oil (main
reducer &auxiliary)
3 Return-line Change hydraulic oil filter
filter element
Inspection & Remedy
Check engine for oil leakage
4 Engine Check filter condition

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Test oil sample

Check final drive oil level
Check final drive for oil
5 final & leakage
swing drive Check circle drive oil level
Check circle drive for oil
leakage
Check function of all grease Ep3
Frame points & lubricate.
6 &Work Check bucket and jackhammer
Equip. Check condition of all joints,
pivots & pins
7 Hook Check pully and bearing
8 Jib Check welding seam & pully
crack and damage
Check oil level of hydraulic
9 Hydraulic system
Check hydraulic system for
any leakage
Check water (ELC) level &
leakage
10 Cooling Check fan for cracks/loose
system bolts
Check water manifold
Check radiator core, clean &
passing of air
11 Air Check function of cooling
conditionin system
g Clean condenser
Clean evaporator(cabin)
12 Electrical Check cabin lights, indicators
system &accessories
Check electrolyte level of the
battery
Check/clean the battery &its
terminals
Check /clean fuse board &
display board

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6.6.PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 1000Hr.
No System Description 1000Hrs Lubricant Part No R
Location No Qnty
Change Engine oil 15W40 22&25
Change engine oil filter 13055724 & 02
1 Engine VG6100007000
5
Primary fuel filter 612600081889 04
Secondary fuel filter 612630888087 02
2 Steering Change Steering oil tank filter
system element
3 Brake system Change air dryer filter element
Inspection & Remedy
Check suspension U bolt
4 Wheel connection
alignment Check Trust rod & steering
wheel
5 Telescoping Check and lubricate internal
system and external slides blocks
Check engine for oil leakage
6 Engine Check filter condition
Test oil sample
Check final drive oil level
7 Final, axle & Check final drive for oil
swing drive leakage
Check circle drive oil level
Check swing drive for oil
leakage
Check axle housing welding
seams
Check function of all grease Ep3
8 Frame &Work points & lubricate.
Equip. Check bucket and jackhammer
Check condition of all joints,
pivots & pins
Check oil level of hydraulic
9 Hydraulic system
Check hydraulic system for
any leakage
Check water (ELC) level &
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leakage
Check fan for cracks/loose
10 Cooling bolts
system Check water manifold
Check radiator core, clean &
passing of air
Check function of cooling
Air system
11 conditioning Clean condenser
Clean evaporator(cabin)
Check cabin lights, indicators
&accessories
Check electrolyte level of the
12 Electrical battery
system Check/clean the battery &its
terminals
Check /clean fuse board &
display board
6.7. PM, Inspection and Check List of Zoom Lion Crane (25 & 55 Ton) at 2000Hr.
No System Description 2000 Lubricant Part No Rem
Location Hrs No Qnty
Change Engine oil 15W40 22&25
Change engine oil filter 13055724 & 02
VG61000070005
1 Engine Primary fuel filter 612600081889 04
Change engine coolant
Secondary fuel filter 612630888087 02
2 Steering Change Steering oil tank filter
system element
3 Brake system Change air dryer filter element
4 Transmission Change gear oil
5 Axle Change lubrication oil of hub
reducer and central reducer
High- Change High-temperature hose
6 temperature at the air pump outlet
hose
7 Steering Change hydraulic oil with filter
system element
8 Clutch control Change clutch brake fluid
mechanism

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9 Drive Change gear oil

axle(steerable)
10 Drive Change gear oil
axle(non-
steerable)
11 Hose, shock Change engine water hose and
and pad intercooling tube
12 Change rubber intake manifold
13 Change engine shock pad and
radiator shock pad
Inspection & Remedy
14 Fuel tanker Clean fuel tanker
Check water (ELC) level &
leakage
Cooling Check fan for cracks/loose
15 system bolts
Check water manifold
Check radiator core, clean &
passing of air
Check function of cooling
16 Air system
conditioning Clean condenser
Clean evaporator(cabin)
Check cabin lights, indicators
&accessories
Check electrolyte level of the
Electrical battery
17 system Check/clean the battery &its
terminals
Check /clean fuse board &
display board

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 KUYU CEMENT FACTORY DOCUMENT NO.KCF/AG/QP/02

Inspection, PM & Check List Issue No Page 1 of 41

TITLE Issue Date Revision No.

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