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Logbook

MSF Car number

Country

Mission

Stamp of the mission:

MK1(before 2007)

1
2
Technical data (based on the Landcruiser HZJ 78/79 series) ....................... 4

Identification Card ........................................................................................ 5

Responsibilities of the driver ........................................................................ 6

Warning ........................................................................................................ 7

Inventory of materials in the car ................................................................... 8

Check-ups under the drivers responsibility ................................................... 9

User's vehicle guideline .............................................................................. 12

Use of 4 wheel traction H4 and L4 ............................................................. 13

Warning lights on the dash board ............................................................... 14

Precautions to take in the rainy season ....................................................... 15

Break-in period ........................................................................................... 15

Speed limits ................................................................................................ 16

Choice of periodicity of maintenance ......................................................... 17

Periodical maintenance ............................................................................... 18

Special services .......................................................................................... 19

Maintenance logbook ................................................................................. 20

3
Technical data (based on the Landcruiser HZJ 78/79
series)
Engine oil:
Quality: API specs: CF, if not available, CE or CD may be used
ACEA specs: B3, if not available B2 may be used; do not use
B1.
CCMC specs: PD2 if not available D5 or D4 may be used.
Viscosity: preferably SAE 15W-40, if not available 10W-40 or 10W-30.
Even 20W- oil may be used.
Capacity: 10 L (without filter)
11.3 L (with filter)

Gear box oil:


Quality: API specs: GL5, if not available, GL4 may be used.
Viscosity: 80W-90, if not available 75W-90 or 90 oil may be used.
Capacity: 2.2 L

Transfer box oil:


Quality: API specs GL5, if not available, GL4 may be used.
Viscosity: 80W-90, if not available SAE 90 oil may be used.
Capacity: 2.1 L

Front and rear axle oil:


Quality: API specs: GL5.
Viscosity: 80W-90, if not available SAE 90 oil may be used.
Capacity: Front: 2.6 L
Rear: 2.4 L

Power steering oil:


Quality: ATF (Automatic Transmission Fluid), type dextron
Capacity: No oil change required. If necessary, top up until
proper level

Brake and clutch fluid: SAE J 1703E or DOT 4

Coolant: do not use pure water; use anti-freeze or special coolant or


water with an rust inhibitor and lubricating additive.

4
Identification Card
ARTICLE: MSF No.:

DESCRIPTION
BRAND: OPTIONS:
MODEL:
YEAR:
CHASSIS No:
VIN (Vehicle
Identification
Number)*
KEY NO: DOCUMENTATION:
LHD/RHD:
SUPPLIER:

PURCHASE
DONOR: SUPPLIER:
ORDER No:
INVOICE No:
ARRIVAL ......../......../....... FREIGHT REF.:
DATE:

ALLOCATION FIRST .........../........../.........


USED ON:
LOCATION: DATE: .........../........../.........
LOCATION: DATE: .........../........../.........
LOCATION: DATE: .........../........../.........
LOCATION: DATE: .........../........../.........

FINAL DESTINATION
DATE: .........../........../..... TO:
....
* Example: JTERB71J300004265

5
Responsibilities of the driver

The security of the persons being transported.


When driving his car, he strongly respects the traffic rules. He adapts his speed
depending on the conditions of the road, of the load and when approaching people.

Safety belts
He wears the safety belt at all times and makes sure all passengers do so too.

Speed limits
He respects the speeds limits as stated on page 13 of this logbook

The correct loading of the transported goods


He loads and offloads his car and makes sure the cargo is well secured and strapped
down.

The state of the car and its correct maintenance. He does the daily and weekly
checks, plans in cooperation with his supervisor the periodical services and participates
when the mechanic works on his car.
The updating of the logbook.

In case of mechanical problems


He must notify immediately the workshop or the MSF supervisor.

The tools and spare parts in the car


He must regularly check the material (see page 6 for the detailed list) for completeness
and cleanness.

The cleanness of the car


Body, chassis, engine...

In case of an accident
He must immediately notify the MSF supervisor and local authorities.

When the driver has to use the car, although it should be in repair, he must write
down problems on the pages of the logbook foreseen for remarks next to the last service
done. This must be signed by the supervisor so as to free the driver of responsibility in
case of problems.

6
Warning
The driver should always have his driver license and a copy of the car papers with him.

The driver uses an MSF car for the needs of a program.

The use of the car for private needs or for the transportation of persons (or goods) not
involved in the program without the authorization of the manager is in all cases forbidden
and must be exceptional.

If the driver
- is drunk on duty,
- steals fuel or any goods,
- damages his car through neglect or on purpose,
- is responsible for an accident,
he will be fired according to the local legislation.
In the rare case of expat driving, the expat will be sent home immediately.

Read and approved

Name of the driver Date Signature

7
Inventory of materials in the car

1 spare wheel.............….......................... ............ ............ ............ ............


1 2nd spare wheel (optional)..................... ............ ............ ............ ............
1 Hi-lift jack............................................ ............ ............ ............ ............
1 original Toyota jack.............................. ............ ............ ............ ............
1 original Toyota jack handle.................. ............ ............ ............ ............
1 Toyota tool bag containing::................ ............ ............ ............ ............
2 flat spanners......................... ............ ............ ............ ............
1 double-bladed screwdriver... ............ ............ ............ ............
1 adjustable spanner................ ............ ............ ............ ............
1 wheel brace.......................... ............ ............ ............ ............
1 pain of pliers........................ ............ ............ ............ ............
1 kit tools driver...................................... ............ ............ ............ ............
Others: ................................................... ............ ............ ............ ............
................................................... ............ ............ ............ ............
................................................... ............ ............ ............ ............

The tools- driver Kit is necessary for every long trip. It can be managed separately from
the rest of material in the car.

Read and approved

Name of the driver Date Signature

8
Check-ups under the drivers responsibility

Every morning
Time: 10 mín.

Before starting, check:


Engine oil level,
Coolant level,
Brake and clutch fluid level,
Windscreen washer water level,
Cleanliness of radiator and mosquito net fixation,
Condition of all tyres (pressure by sight, cracks on both sides),
Possible leaks under the car,

After starting the vehicle check:


Whether there are any abnormal noises,
Indicators, lighting and dashboard warning lights,
Presence of inboard equipment,

Every week in addition to the daily check


Time: 1 hour

Clean the vehicle inside (do not use water) and outside
Drain the fuel sedimentor from water
Clean the air filter
Check the battery (proper fixation and water level)
Power steering oil level
Steering wheel free-play*
Check tyre pressure and condition of the tyres (see tyre pressure table)
Check for presence of valve caps
Check and clean front and rear axel breather
Check exhaust pipe and silencer condition and fixation*
Check the springs and all bushes from the front and rear suspension
Check shock absorbers (check bushes and no leaks)*
Front and rear stabilizer bar bushes control*
Check functioning of doors, locks, seat belts and (warning) lights
Fill up the two fuel tanks

9
Severe conditions1: additional weekly checks
Time: minimal 2 hours.

Check brake and clutch fluid level


Clean front and rear brakes (take off rear brake drum) from mud
Grease the drive shafts (6 nipples) and steering system.
Check rear spring leaves for cracks and alignment*
Check and grease the HiLift jack
Front wheel bearings free play*
Check the front and rear axle oil:
- If water mixture (milky appearance), change oil next service
- If water mixture (milky appearance) and level too high, change oil immediately
- If different pressure level at opening, check axle breathers

*In case of problem, write it in the logbook and inform the logistic officer

1
Severe conditions are defined as frequent wading and/or driving in mud and/or sand.
The maintenance interval should be 100 hours or 2000 Km (see page 17)
10
Tyre inflation table
Normal conditions

Use Loaded* Not loaded


Pressure BAR PSI BAR PSI
Front tyre 3.0 43 2.5 to 3.0 35 to 43
Rear tyre 3.5 51 3.0 43
*For a Pick Up heavily loaded on tarmac road, it‟s advisable to put 3.5 in front tyre and
4.0 on rear tyre.

Severe conditions (sand or mud)


* Re-inflate all tyres before exeeding the maximum recommended speed!

Use Extreme conditions, Maximum speed 40 km/h


maximum speed 20 km/h
Pression BAR PSI BAR PSI
Front tyre 1.0 43 1.5 35
Rear tyre 1.3 51 1.9 43

11
User's vehicle guideline

Fastening and spreading of the load


Respect the maximum load to prevent any damage to the car.
Max recommended load HZJ Pick-up HZJ Hardtop
On good roads and tracks 900 800
On bad tracks 750 600

Always keep at least 6 cm between the rear axle and the suspension bumper (3 to 4
fingers of the hand in vertical position).
Always place the load as low as possible and the heaviest charge in the middle.
The load must always be correctly tightened with ropes or belts.
Do not carry anything but the spare wheels and the hi-lift jack on the roofrack.

Cleaning of the vehicle


Attention: always clean the car with fresh water. Never use sea water.
Attention : be careful with the electrical parts. Do not spill water on the alternator, the
relays, under the dashboard or inside of the car. Do not clean the body without water.
Attention: mine-mats or ballistic blankets should never become wet! Never clean a
car inside with water if ballistic blankets are fitted!
In case of problems of disinfection, absolutely do not wash the car with chloride. Use
cresyl, HAC or lysol.

12
Use of 4 wheel traction H4 and L4
The Land Cruiser in „normal‟ circumstances will only have the rear wheels driven.
To engage 4WD you have to press the H4 button or shift to L4 (low gear)

Do not hesitate to use the 4 wheel traction


(H4 or L4) on slippery soil (water, mud,
sand) or steep tracks, but never on normal
roads.
If you have free wheel hubs, and want to
use 4 wheel drive, make sure that they are
in "lock" position.
To engage 4 wheel drive, meaning shifting
from H2 to H4, you don`t need to slow
down or to reduce speed, providing that
you do it before and not during the
difficult pass. If you have the H4 button on the dashboard you can shift it on and off
at any time.
Avoid shifting from H2 to H4 or L4 during the difficult pass. When shifting to or
from L4, it is compulsory that the vehicle is totally stopped.
The green 4WD indicator light will illume once four wheel drive has engaged. To
help engage or disengage four wheel drive during driving, it might help to decellerate
or to make small steering movements or use the clutch.

13
Warning lights on the dash board
Procedures to follow when lights beam. Red lights means stopping immediately and
orange lights are warning lights - inform the logistic officer.

Warning light oil pressure “OIL”


Attention, stop immediately. Check the oil level; do not
start the engine again before knowing the origin of the
problem.

Warning light for water in diesel filter


Presence of water in the water sedimenter, stop and drain it.

Battery warning light


Stop the car and check the fan belt as well as the connections between
alternator and battery.

Brake warning light "Brake"


Make sure the hand brake is completely released and check brake fluid
level.

Air filter dust filling up indicator


Clean air filter.

Safety belts warning light


Fasten safety belt.

4WD indicator light


Four-wheel drive has engaged (H4 or L4)

Timing belt warning light "T Belt"


Continue and inform your supervisor.

Coolant temperature gauge


Attention, stop immediately when the needle is approaching the red zone. Check the
cooling system.

14
Precautions to take in the rainy season
Crossing a pool or a creek
A car is not a submarine.
Before crossing, walk into the water to check the depth. The level of the water should
not exceed the side foot step.
Use low range (L4).
Once out of the water, dry the brakes by slightly braking until they work properly.

ATTENTION, do perform the additional weekly checks for severe conditions!

Break-in period
During the first 1000 kilometers:
Avoid the use of full throttle.
Drive gently: the engine should run neither too fast nor too slow.
Do not go faster than 80 km/hour.

15
Speed limits

To be filled with the logistic officer in agreement with the coordination

For this vehicle, the maximum acceptable speed, to keep a safe driving is:

on ROADS …. km/hour

on TRACKS …. km/hour

in URBAN AREAS …. km/hour

when going through villages,


on crowded roads,
on market days,
or when approaching refugee camps.

In case of rain, the speed must be reduced by at least 20 kmlhour.

The persons being transported may ask the driver to slow down whenever they doubt for
their safety or whenever they feel that the speed is too high. Several unrespected
requests will lead to a warning.

In the opposite case, when the person asks the driver to go faster, he is in no case to grant
this request.

The driver has to be aware that he may be fired according to local legislation if involved
in an accident for which he is responsible.

16
Choice of periodicity of maintenance
The choice of the periodicity of maintenance has to be determined according to the
conditions of use specific to every country or mission.

Some vehicles have been fitted with an hour counter to facilitate -independent of the
conditions of use- proper scheduling of services according to the real functioning time.

If the vehicle is fitted with an hour counter, it should be serviced every 100 hours and
for the vehicles without hour counter, the periodicity of maitenance depends on the
condition of use.

In good conditions, the vehicle should be serviced every 100 hours or 5,000 Km, i.e. an
average speed of 50/60 km/hour, on tarmac roads and relative good tracks.

In average conditions, the vehicle should be serviced every 100 hours or 3,000 Km,.i.e.
an average speed of 30/40 km/hour, on a mixture of hardened or tarmac roads and
tracks.

In severe conditions, the vehicle should be serviced every 100 hours or 2,000 Km, i.e.
an average speed of 15/20 km/hour, on very difficult tracks, sandy roads or frequent use
of 4X4.

To understand and interpret correctly the right sequence of the different kinds of services

Period in km "A" Mini "B" Filter "A" Mini "C" Complete "A" Mini
2,000 2,000 4,000 6,000 8,000 10,000
3,000 3,000 6,000 9,000 12,000 15,000
5,000 5,000 10,000 15,000 20,000 25,000

In hours "A" Mini "B" Filter "A" Mini "C" Complete "A" Mini
Always 100 200 300 400 500

Anyway, the order of maintenance is always:


A (mini), then B (filter), followed by A (mini) and then C (complete)
The details of the different services (A, B, C) are given on the following pages.

17
Periodical maintenance
(Every 100 hours under the mechanic’s responsibility, assisted by the driver)

Mini service "A":

Weekly check, plus:

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Check the condition and tension of the fan/alternator belts
Check the oil level in gearbox and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer bars,
bushes of stock absorbers, bushes of front and rear suspension, rear spring blades
Check shock absorbers for leakage
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the free play in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check body and chassis condition (cracks, bumps…)

Filter service "B":

Service "A", plus:

Change the oil filter


Change the fuel main filter
Check the free play in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs

18
Complete service "C":

Service "B", plus:

Change oil in front and rear axle.


Check free play in steering knuckle arm bearings and grease the front axle hubs.
Check the freeplay in the rear wheel bearings.
Check free play in universal joints (in rear and front propshaft)
Check tightening of bolts and nuts of suspension.
Check and clean rear brake shoes and drums.
Check rear brake cylinders for cup leakage.
Check tyres for regular wear.
Check and grease door-locks and hinges.
Check and grease window winder.
Check and grease seats rails.
HF radio wiring control, antenna earth connection cleaning and tightening.

Special services
To be done by the workshop of reference, to be done at the same time as service “C”
and to be written service remark sheet.

Service 1,200 hours or 50,000 Km (whatever comes first)


Service “C”, plus:

Change oil in gear- and transferbox.


Check timing belt cover (if water ingress, change belt tensioner)
Add fuel additive to the tank for injection system cleaning
Inspect, grease and adjust all wheel bearings
Check for cracks in body and weld (using a MIG welder) if need be.
Replace the third fuel filter (when fitted)

Service: every 2,400 hours or 100,000 Km


Service1,200 hour or 50.000 km, plus:

Change brake- and clutch fluid


Change the timing belt and the belt tensioner (HZJ75/78/79)
Change coolant

19
Maintenance logbook

The maintenance periodicity of the car is 100 hours or:

km

At (place of mission):
km

At (place of mission):
km

At (place of mission):

20
Service "A" done at 100 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 200 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

21
kilometers Detail all furnishings and spares-Remarks-Work still to be done

22
Service "B" done at 200 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 300 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
23
kilometers Detail all furnishings and spares-Remarks-Work still to be done

24
Service "A" done at 300 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 400 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

25
kilometers Detail all furnishings and spares-Remarks-Work still to be done

26
Service "C" done at 400 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check the condition
Check shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

27
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 500 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

28
Service "A" done at 500 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 600 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

29
kilometers Detail all furnishings and spares-Remarks-Work still to be done

30
Service "B" done at 600 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 700 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
31
kilometers Detail all furnishings and spares-Remarks-Work still to be done

32
Service "A" done at 700 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 800 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

33
kilometers Detail all furnishings and spares-Remarks-Work still to be done

34
Service "C" done at 800 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

35
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 900 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

36
Service "A" done at 900 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 1000 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

37
kilometers Detail all furnishings and spares-Remarks-Work still to be done

38
Service "B" done at 1000 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 1100 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
39
kilometers Detail all furnishings and spares-Remarks-Work still to be done

40
Service "A" done at 1100 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “Special“ at 1200 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

41
kilometers Detail all furnishings and spares-Remarks-Work still to be done

42
Service "Special" done at 1200 hours or at km
Clean the vehicle
Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Replace the air filter
Check the condition and tension of the fan/alternator belts
Change the oil in front and rear axles
Change oil in gear- and transferbox
Check shock absorbers for leakage
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the steering system linkage
Check the freeplay in the rear wheel bearings
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails
Check timing belt cover (if water ingress, change belt tensioner)
Add fuel additive to the tank for injection system cleaning
Inspect, grease and adjust all wheel bearings

43
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear spring
blades. rear spring
blades. blades
Check
Check anthegrease
condition of thewinders
window suspension: rubber bushes, spring blades and shock.

Battery connection condition (clean, grease, replace battery-clamps if needed)


Check for cracks in body and weld (using a MIG welder) if need be
Replace the third fuel filter (when fitted)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 1300 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

44
Service "A" done at 1300 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 1400 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

45
kilometers Detail all furnishings and spares-Remarks-Work still to be done

46
Service "B" done at 1400 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 1500 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
47
kilometers Detail all furnishings and spares-Remarks-Work still to be done

48
Service "A" done at 1500 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 1600 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

49
kilometers Detail all furnishings and spares-Remarks-Work still to be done

50
Service "C" done at 1600 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

51
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 1700 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

52
Service "A" done at 1700 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 1800 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

53
kilometers Detail all furnishings and spares-Remarks-Work still to be done

54
Service "B" done at 1800 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 1900 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
55
kilometers Detail all furnishings and spares-Remarks-Work still to be done

56
Service "A" done at 1900 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 2000 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

57
kilometers Detail all furnishings and spares-Remarks-Work still to be done

58
Service "C" done at 2000 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

59
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 2100 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

60
Service "A" done at 2100 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 2200 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

61
kilometers Detail all furnishings and spares-Remarks-Work still to be done

62
Service "B" done at 2200 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 2300 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
63
kilometers Detail all furnishings and spares-Remarks-Work still to be done

64
Service "A" done at 2300 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “Special“ at 2400 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

65
kilometers Detail all furnishings and spares-Remarks-Work still to be done

66
Service "Special" done at 2400 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Replace the air filter
Check the condition and tension of the fan/alternator belts
Change the oil in front and rear axles
Change oil in gear- and transferbox
Check shock absorbers for leakage
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the steering system linkage
Check the freeplay in the rear wheel bearings
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails
Add fuel additive to the tank for injection system cleaning
Inspect, grease and adjust all wheel bearings

67
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Change brake- and clutch fluid
Change the timing belt and the belt tensioner. (HZJ75/78/79)
Change coolant
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
an grease of thewinders
window suspension: rubber bushes, spring blades and shock.

Battery connection condition (clean, grease, replace battery-clamps if needed)


Check for cracks in body and weld (using a MIG welder) if need be
Replace the third fuel filter (when fitted)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 2500 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

68
Service "A" done at 2500 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 2600 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

69
kilometers Detail all furnishings and spares-Remarks-Work still to be done

70
Service "B" done at 2600 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 2700 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
71
kilometers Detail all furnishings and spares-Remarks-Work still to be done

72
Service "A" done at 2700 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 2800 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

73
kilometers Detail all furnishings and spares-Remarks-Work still to be done

74
Service "C" done at 2800 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

75
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 2900 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

76
Service "A" done at 2900 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 3000 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

77
kilometers Detail all furnishings and spares-Remarks-Work still to be done

78
Service "B" done at 3000 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 3100 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
79
kilometers Detail all furnishings and spares-Remarks-Work still to be done

80
Service "A" done at 3100 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 3200 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

81
kilometers Detail all furnishings and spares-Remarks-Work still to be done

82
Service "C" done at 3200 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

83
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 2900 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

84
Service "A" done at 2900 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 3000 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

85
kilometers Detail all furnishings and spares-Remarks-Work still to be done

86
Service "B" done at 3000 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 3100 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
87
kilometers Detail all furnishings and spares-Remarks-Work still to be done

88
Service "A" done at 3100 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 3200 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

89
kilometers Detail all furnishings and spares-Remarks-Work still to be done

90
Service "C" done at 3200 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

91
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 3300 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

92
Service "A" done at 3300 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 3400 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

93
kilometers Detail all furnishings and spares-Remarks-Work still to be done

94
Service "B" done at 3400 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 3500 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
95
kilometers Detail all furnishings and spares-Remarks-Work still to be done

96
Service "A" done at 3500 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “Special“ at 3600 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

97
kilometers Detail all furnishings and spares-Remarks-Work still to be done

98
Service "Special" done at 3600 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Replace the air filter
Check the condition and tension of the fan/alternator belts
Change the oil in front and rear axles
Change oil in gear- and transferbox
Check shock absorbers for leakage
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the steering system linkage
Check the freeplay in the rear wheel bearings
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails
Check timing belt cover (if water ingress, change belt tensioner)
Add fuel additive to the tank for injection system cleaning
Inspect, grease and adjust all wheel bearings

99
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear spring
blades. rear spring
blades. blades
Check
Check the condition
an grease of thewinders
window suspension: rubber bushes, spring blades and shock.

Battery connection condition (clean, grease, replace battery-clamps if needed)


Check for cracks in body and weld (using a MIG welder) if need be
Replace the third fuel filter (when fitted)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 3700 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

100
Service "A" done at 3700 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 3800 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

101
kilometers Detail all furnishings and spares-Remarks-Work still to be done

102
Service "B" done at 3800 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 3900 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
103
kilometers Detail all furnishings and spares-Remarks-Work still to be done

104
Service "A" done at 3900 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 4000 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

105
kilometers Detail all furnishings and spares-Remarks-Work still to be done

106
Service "C" done at 4000 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

107
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 4100 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

108
Service "A" done at 4100 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 4200 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

109
kilometers Detail all furnishings and spares-Remarks-Work still to be done

110
Service "B" done at 4200 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 4300 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
111
kilometers Detail all furnishings and spares-Remarks-Work still to be done

112
Service "A" done at 4300 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check the condition
Check shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “C“ at 4400 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

113
kilometers Detail all furnishings and spares-Remarks-Work still to be done

114
Service "C" done at 4400 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Check the oil level in gear box and transfer box
Change the oil in front and rear axles
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the rear wheel bearings
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails

115
Check an grease window winders
Clean the air filter and replace if needed
Check the condition and tension of the fan/alternator belts
Battery connection condition (clean, grease, replace battery-clamps if needed)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 4500 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

116
Service "A" done at 4500 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “B“ at 4600 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

117
kilometers Detail all furnishings and spares-Remarks-Work still to be done

118
Service "B" done at 4600 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the freeplay in the front wheel bearings and adjust if needed
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check the freeplay in the steering system linkage. Adjust if it‟s necessary
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 4700 HOURS or at KM

Name of responible for maintenance: Date:


Signaure:
119
kilometers Detail all furnishings and spares-Remarks-Work still to be done

120
Service "A" done at 4700 hours or at Km

Clean the vehicle


Change the engine oil
Change the fuel pre-filter
Drain the fuel main filter from water
Clean the air filter and the little bowl (air blowing and/or washing)
Check the condition and tension of the fan/alternator belts
Check the oil level in gear box and transfer box
Check the oil level in axles and change if water mixture (milky)
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades.
spring blades.
blades.
Check
Check the condition
shock of the
absorbers for suspension:
leakage rubber bushes, spring blades and shock.

Check the condition of the exhaust pipe and its insulators (rubber mountings).
Check the freeplay in the front wheel bearings and adjust if needed
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard.
Check body and chassis condition (cracks, bumps...)
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “Special“ at 4800 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

121
kilometers Detail all furnishings and spares-Remarks-Work still to be done

122
Service "Special" done at 4800 hours or at km

Clean the vehicle


Change the engine oil
Change the oil filter
Change the fuel pre-filter
Change the fuel main filter
Replace the air filter
Check the condition and tension of the fan/alternator belts
Change the oil in front and rear axles
Change oil in gear- and transferbox
Check shock absorbers for leakage
Check the condition of the exhaust pipe and its insulators (rubber mountings)
Check for presence and wear of rubber stoppers at hood and all doors
Check the different warning lights of the dashboard
Check condition of engine and gearbox mountings
Check and clean front brake pads and discs.
Check and clean front brake pads and discs
Check and clean front brake pads and discs.
Check and clean rear brake shoes and drums (take off drums)
Check rear brake cylinders for cup leakage
Check free play in steering knuckle arm bearings and grease front wheel hubs
Check the freeplay in the steering system linkage
Check the freeplay in the rear wheel bearings
Check free play in universal joints (in rear and front propshaft)
Check tyres for regular wear
Check tightening of bolts and nuts of suspension
Check and grease door-locks, hinges and seat rails
Add fuel additive to the tank for injection system cleaning
Inspect, grease and adjust all wheel bearings

123
Clean the 2 axle breathers and their hoses
Grease the drive shafts (6 nipples) and steering system
Change brake- and clutch fluid
Change the timing belt and the belt tensioner. (HZJ75/78/79)
Change coolant
Check the condition of the suspension: rubber bushes of front and rear stabilizer
stabilizer bars,
bars, bushes of bushes of stock absorbers,
stock absorbers, bushes of bushes of rear
front and frontsuspension,
and rear suspension,
rear spring
suspension,
rear rear spring blades
spring blades.
blades.
Check
Check the condition
an grease of thewinders
window suspension: rubber bushes, spring blades and shock.

Battery connection condition (clean, grease, replace battery-clamps if needed)


Check for cracks in body and weld (using a MIG welder) if need be
Replace the third fuel filter (when fitted)
Radio wiring control, antenna ground connection cleaning and tightening
Stick on the dashboard the sticker «next service mileage»

NEXT SERVICE “A“ at 4900 HOURS or at KM

Name of responible for maintenance: Date:

Signature:

kilometers Detail all furnishings and spares-Remarks-Work still to be done

124

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