Preventive Maintenance Manual - DRF

Preventive Maintenance Manual - DRF
What is Preventive Maintenance?

To perform proactive maintenance under a plan schedule to prevent
unnecessary breakdown
Importance of Preventive Maintenance

prevent unplanned breakdown
reduce maintenance cost
increase machine reliability and availability
Preventive Maintenance Schedule
Plan A 250 hrs
Plan B 500 hrs
Plan C 1000hrs
Plan D 2000hrs
* Remark: For new machine 50 hours machine warranty maintenance

to be carry out after handing over according to Plan C and included
adjusting engine valve tappet clearance
Preventive Maintenance Cycle

START
250hr
250hr
2000hr
250hr
1500hr
500hr
250hr
B
250hr
250hr
1000hr
250hr
Before You Start the PM Job I

1.
To ensure the truck is park in a safe working place place safety

cones and fence off area if necessary
Before You Start the PM Job II

2.
Walk around the machine and check for any damage and leakage
3.
Carry out a function test on all function to check for defects
Before You Start the PM Job III

4.
Turn off the main electric power and remove the key
Before You Start the PM Job IV

5.
Use the wood block to secure the machine on a flat position
Before You Start the PM Job V

6.
Hang up Machine Under Repair signs on the machine (one on

steering wheel and one on trucks rear)
Oils and Lubricants for PM Jobs

With TWD1240 engine and TE32000 Transmission
Engine Oil:
Both ACEA E3 and VDS-2 (SAE15W40)
Transmission Oil:
Dexron III
Hydraulic Oil:
(ISO-L HV68)
Drive Axle and Gear Oil:
API-GL5 or MIL-L-2105B (SAE80W140)
Brake Oil:
(ISO-L HV68)
Grease:
Universal grease, type EP according to NLGI grade 2 with

3-5% molybdenum sulphide
Remarks:
1. For details please refer Section F of Maintenance Manual DFR400-450
2. ( ) above viscosity depends on the ambient temperature, please refer same Section F
3. For engine oil outside Europe market API : CE, CF, CF-4, CG-4, CH-4 (SAE15W40)
can be used BUT oil change every 250 hours or 12 months
Oils and Lubricants for PM Jobs

With TWD1031 engine and HR36000 Transmission
Engine Oil:
API-CD (SAE15W40)
Transmission Oil:
API-CD (SAE15W40)
Hydraulic Oil:
(ISO-L HV68)
Drive Axle and Gear Oil:
API-GL5 or MIL-L-2105B (SAE80W140)
Brake Oil:
(ISO-L HV68)
Grease:
Universal grease, type EP according to NLGI grade 2 with

3-5% molybdenum sulphide
Remarks:
1. For details please refer Section F of Maintenance Manual DFR400-450
2. ( ) above viscosity depends on the ambient temperature, please refer same Section F
PM Plan A - Engine
1)
Check Air Filter indicator
3)
Replace Oil and Oil Filter
4)
Replace Fuel Filter
5)
Check Cooling Water
6)
Clear Debris form Radiator Surface
7)
Check Pulley and all Vee-belts
8)
Check Starting, Stopping and Running
9)
Check for Oil, Fuel and Water Leakage
10)
Check Turbocharger and Exhaust for Leak
11)
Replace Fuel / Water Separator Filter
PM Plan A - Engine
1) Check Air Filter indicator
Check the indicator when the engine is
running. If it shows red, the main filter
element is dirty and need to replace
PM Plan A - Engine
3) Replace Oil and Filter
Change it because to remove all
the solid contaminants and
sludge that collected by the filter,
to reduce the restriction of oil
flow
Please Remember to Lubricate
the O-rings on the new filter
Tighten to contact and then
another half to three quarter turn
by HAND
PM Plan A - Engine
3) Replace Oil and Filter
Properties of engine oil will
deteriorate due to heat and
carbon contamination.
Change filter because to remove
all the solid contaminants and
sludge that collected by the filter,
to reduce the restriction of oil
flow
another half to three quarter turn
by HAND
OIL Filter
PM Plan A - Engine
4) Replace Fuel Filter
Change it because choke or dirty
fuel filter may restrict fuel
delivery to the injectors
Cause fuel injector having
improper fuel spraying pattern
into the combustion chamber.
Thus affecting engine efficiency
another half
turn by HAND
PM Plan A - Engine
4) Replace Fuel Filter (Fuel Pre-Filter)
Disconnect the cabling from the
sensor water in fuel
another half to three quarter
turn by HAND
PM Plan A - Engine
4) Replace Fuel Filter
Cause fuel injector having
improper fuel spraying pattern
into the combustion chamber.
Thus affecting engine efficiency
another half turn by HAND
PM Plan A - Engine
5) Check Cooling Water Condition and Level
Checked the coolant level to
prevent engine overheat
PM Plan A - Engine
6) Clear Debris from Radiator Surface
Check any debris form radiator
surface to prevent engine
overheat
PM Plan A - Engine
7) Check Pulley and All Vee-belts
Check the tension of belt, if it
looses, tight it
It should not be possible to
depress V-belt more than 10-12
mm mid-way between the
pulleys
If the belt still loose, after retighten, replace a new belt
Loose belts may affect engines
cooling, air condition, and
electrical performance
PM Plan A - Engine
8) Check Starting, Stopping and Running
Starting
Check all oil level (engine oil, gearbox
oil, hydraulic fluid, axle and planetary
gear oil)
Bleed air out of fuel system
Turn the starter key to position
3(starting position) and release it when
the engine has started
PM Plan A - Engine
8) Check Starting, Stopping and Running
Running
Never race a cold engine, nor run the
engine at critically low speed
Run engine at 1400rpm till the
temperature gauge read about 80deg
Celsius
Warming up the engine oil is essential
so that it is circulating correctly before
turbocharger works at high speed
PM Plan A - Engine
9) Check for Oil, Fuel and Water Leakage
Look under the truck to find any
liquid leakages
If find a leakage, please address
where the liquid from and shut down
the machine immediately
PM Plan A - Engine
10) Check Turbocharger and Exhaust for Leak
Check that the oil line to and from
the turbocharger do not leak
Check that all connection between
the turbo and inter-cooler do not
leak.
Renew all broken gasket
seals and studs to confirm gas tight
between connection
Pressure may build up in a blocked
crankcase vent. This may force oil
into the inlet air system of the
turbocharger and engine
PM Plan A - Engine
11) Replace Fuel / Water Filter
Drain the filter and remove the filter
from the top.
Loose the bolts under the filter, to
clean the dirt from the trap
Put the new filter in
After that refuel inside the water/
fuel filter
Replace the o-ring for the cover
PM Plan A Transmission & Propeller Shaft

16)
Check and Top up Transmission Oil
17)
Check Propeller Shaft Connection Bolts
18)
Check Sensor on Propeller Shaft Flange
PM Plan A Transmission & Propeller Shaft

16) Check and Top up Transmission Oil
Check the oil level with the engine
at idling speed
Fill it up until the oil up to FULL
mark
PM Plan A - Transmission & Propeller Shaft

17) Check Propeller Shaft Connecting Bolt
Loose bolt are prone to shear under
load and vibration
Re-tighten the bolt to 200 Nm on
transmission side and parking brake
side
PM Plan A Drive Axle & Brake

24)
Check Tightness of Axle Mounting Bolts
25)
Check for Oil Leak from Axle and WDB
PM Plan A Drive Axle & Brake

24) Check Tightness of Axle Mounting Bolts
Loose bolt are prone to shear under
load and vibration
Re-tighten the bolt to 2350Nm
PM Plan A - Drive Axle & Brake

25) Check for Oil Leak from Axle and WDB
Check for oil leakage from filling
point and drain plug
PM Plan A Steering Axle

30)
Check for Damage and Free Play in Linkage
31)
Check Overload Protection Sensor

30) Check for Damage and Free Play in Linkage
Check for cracks on linkage

area
Check for any abnormal

movement

31) Check Overload Protection Sensor
Check any damage on

sensor
PM Plan A - Spreader
36) Check Twistlock Pin and Mechanism
37) Check Sensor for Twistlock Indication
38) Check and Adjust 20/40 Chain and Stopper
Check
the
twistlock
function
correctly
Clean the twistlock from any dirt
Check the link arm, check pin and
lock nut
Press in the alignment pin so that
the head is flush with the spreader
beams underside. Check the
distance to sensor alignment, the
distance should be 5 +/- 3mm
Check the lock guide and lift pin can
move freely
Fit a pray bar between the lift pin
and the lock guide and check the
clearance, max clearance: 1-1.5mm
Check wears of the lift pin. Change
the pin if needed
Check all sensor sensing light
(yellow) is lit up when contacting
Run out the spreader to the 40foot position
Measure how much the chain can
be pressed in by the hole closest
to the middle of the attachment.
When the chain is pressed in with
a force of 250N, it should move
20-40 mm from the resting
position
Adjust the chain if needed
For 20 position stopper
Both protruding arms are to in
contact with the stoppers at the
same time and the distance
between the spreader beam and
spreader motor mounting is at
least 3mm
Adjust by switching the washers
between the left and right stopper
The distance between the right
and left twistlock should be
5853+/-3mm
For 40 position stopper
Both left and right side stoppers
to be in contact at the same time.
Each stopper is provided with an
adjusting bolt.
Adjust the
needed
chain
tension
if
Distance between right and left

twistlock should be 11985+/-3mm
PM Plan A Telescopic Boom and Lift Cylinder

44) Check Boom Mounting Bracket & Pin
45) Check Lift Cylinder Mounting Bracket & Pin

44) Check Boom Mounting Bracket and Pin
Loose pins are prone to shear under
load and vibration
Check any crack around bracket
area, dye test may needed for
further testing

45) Check Lift Cylinder Bracket & Pin
Loose pins are prone to shear under
load and vibration
Check any crack around bracket
area, dye test may needed for
further testing
PM Plan A - Hydraulic
57)
Check Oil Level in Main and Brake Tank
58)
Accumulator Minimum Pressure

Check by Brake (20 Times)
59)
Measure Oil Pressure per Hydraulic Plate

a) Main Pressure
b) Brake Pressure
c) Servo Pressure
d) Steering Pressure
e) Charging Pressure
57) Check Oil Level in Main and Brake Tank
Ensure sufficient hydraulic and
brake oil inside the tank by reading
the oil level on sight glass
58) Accumulator Minimum Pressure Check by Brake (20 Times)
Start the engine and let it idle for
approx. 5 minutes (until the
accumulator
charging
valve
switches to cooling)
Turn off the engine and turn the
start key to position I
Apply and release the brake several
times, and count the number of
times that applied on the brake
before warning light is activated
(It should be apply the brake 20
times before the warning light for
light brake pressure is activated)
If warning light is activated before
applied the brake 20 times, theres
probably a defect inside the system.
A further inspection is needed
59) Measure Oil Pressure per Hydraulic Plate
(Main Pressure)
Start the engine and allow it at idle
There are 4 measure points for
main oil pressure
All pressure should be the same
Test Point
(Brake Pressure)
Gives brake when testing brake
pressure
Find setting pressure in hydraulic
plate
Test Point
(Servo Pressure)
Servo pressure should be around
35+/- 5 bars
Test Point
(Steering Pressure)
Allow the engine to run in midspeed range and turn the steering
wheel to full lock in one direction.
Test Point
(Charging Pressure)
Allow the engine to run, release all
the pressure from the accumulator
Check the pressure after completed
re-charging (Maximum)
Check the pressure when starts to
re-charge (Starting)
Test Point
PM Plan - Electrical
66) Check Battery Water and Top Up
67) Check All Work Light and Indication Light
66) Check Battery Water and Top up
Check the battery voltage with the
operating menu for electrical system.
Engine off 23-25V, and engine at
max rpm 27-29V
Turn off the engine and the main
electrical power
Clean the battery area and grease
the battery terminal
Check the fluid level inside the cells,
top up with distilled water if needed
67) Check All Work Light and Indication Lamp
Operate every lights to ensure

functionally
PM Plan - General
68)
Check Tightness of Wheel Nut
69)
Check Tyre Condition and Pressure
70)
Check Horn, Reverse Alarm and Beacon
71)
Grease Sliding Surface, Greasing Point and Chain
PM Plan - General
68) Check Tightness of Wheel Nut
Check tightness by re-torque all

the nuts to 400Nm
PM Plan - General
69) Check Tyre Condition and Pressure
Check for cracks, dents and

corrosion on rims
Check for tyres pressure and

thread depth. Renew badly
worn tyres
Remove all foreign object

embedded in the tyres.
PM Plan - General
70) Check Horn, Reverse Alarm and Beacon
Operate each items to ensure

proper function
PM Plan - General
71) Grease Sliding Surface, Greasing Point and Chain
Sliding Surface
Scrap away the old grease

Apply grease only on the sliding
plate areas only
PM Plan - General
71) Grease Sliding Surface, Greasing Point and Chain
Greasing Points
Clean nipple heads before and

injecting in new grease
Pump new grease into the

nipples until the old grease is
force out
Remove all extra grease
PM Plan Function Test

72)
Test Overload Protection System
73)
Test Twistlock Safety Inter-lock System
74)
Test All Hydraulic Function
75)
Check for Any Leaks

72) Test Overload Protection System
Recommended to test with an

operator

74) Test All Hydraulic Function
Test all the hydraulic function

such as lifting, side shifting,
spreader and tilt functions with
operator to find anything that
need to adjust

68) Check for All Leaks
After testing the machine, walk

around and find any possible
leaking from the machine
PM Plan B - Engine
01)
02)
Replace Air Filter*
03)
04)
Replace Fuel Filter
05)
Check Cooling Water
06)
07)
08)
09)
10)
11)
12)
Clean Oil Cleaner (Not Applicable for Volvos Engine)*
PM Plan B - Engine
02)
Replace Air Filter
Dirty air filter could reduce the

airflow and affect engines
performance
After
removing
the
filter
cartridge, it recommends to
clean the internal area with a
clean cloth
Safety filter element must not be

cleaned and reused
PM Plan B Transmission & Propeller Shaft

16)
Check and Top up Transmission Oil
17)
Check Propeller Shaft Connection Bolts
18)
Check Sensor on Propeller Shaft Flange
19)
Replace Transmission Oil Filter*

19) Replace Transmission Oil Filter
Choke filter would reduced oil

required for engaging and
lubrication of the gears
Remove the filter with filter tool
Lubricate the o-ring with

transmission oil
Fit the new filters and then other

two-thirds turn

Choke filter would reduced oil

required for engaging and
lubrication of the gears
Lubricate the o-ring with

transmission oil
Fit the new filters and then other

two-thirds turn
Transmission Oil
Filter
PM Plan B Drive Axle and Brake

26) Check Differential and Hub Oil Level and Top up*
PM Plan B Drive Axle and Brake

26) Check differential and Hub Oil Level and Top Up
Drive the truck forward so that

the mark at the filling hole hub is
horizontal (For wheel hub)
Remove the level plug and

check the oil inside
Refill as necessary
PM Plan B Steering Axle

30)
31)
32)
Check Wheel Alignment*
PM Plan B Steering Axle

32) Check Wheel Alignment
All wheels should in the same

direction
Both rear wheels should parallel

with others
If both wheels are not align,

check steering axle
PM Plan B - Spreader
39) Check Planetary Gear Oil and Brake Oil*
PM Plan B Spreader
39)
Check Planetary Gear Oil and Brake Oil

Check the level glass for
hydraulic and gear oil
Refill it if needed
PM Plan B Telescopic Boom & Lift Cylinder

45) Check Lift Cylinder Mounting Bracket and Pin
PM Plan B - Hydraulic
57)
58)

59)

a) Main Pressure
b) Brake Pressure
c) Servo Pressure
PM Plan C - Engine
01)
02)
Replace Air Filter
03)
04)
Replace Fuel Filter
05)
Check Cooling Water
06)
07)
08)
09)
10)
11)
12)
Clean Oil Cleaner (Not Applicable for Volvos Engine)
13)
Replace Cooling Water Filter *
PM Plan C - Engine
13)
Replace Cooling Water Filter

Close the shut-off valve on the
filter bracket
Lubricate the o-ring with oil
Tight the filter with half to three
quarter turn
Open the shut-off valve
PM Plan C Transmission & Propeller Shaft

17) Check Propeller Shaft Connection Bolts
18) Check Sensor on Propeller Shaft Flange
20) Replace Transmission Oil*
21) Check and Clean Magnetic Filter*
22) Clean the Breather*
PM Plan C - Transmission & Propeller Shaft

20)
Replace Transmission Oil

Remove the drain plug and let
the oil drain out to the container
Check for metal particles in the
old oil for prediction of
component damage in the gear
box
Refit the drain plug after the oil
has drain
Fill up with transmission oil to
the MIN mark on dipstick
Run the engine until the oil has
reached working temperature,
check the oil level and top up to
the MAX mark on dipstick

21)
Check and Clean Magnetic Filter

Check for metal particles on the
filter for prediction of component
damage in the gear box

22)
Clean the Breather

To allow free ventilation of
vapour
To prevent pressure built-up in
the gearbox
PM Plan C Drive Axle and Brake

26) Check Differential and Hub Oil Level and Top up
27) Replace Differential and Hub Oil*
28) Clean the Breather*
29) Check the Parking Brake Pad and Function*

27)
Replace Differential and Hub Oil

Drive the truck forward until the
oil drain plug is at its lowest
point of travel (For Differential)
Drive the truck forward so that
the mark at the filling hole hub is
horizontal (For wheel Hub)
Remove the oil plug and drain
the oil and refit the plug
Repeat the procedure on the
other wheel

28)
Clean the Breather

To allow free ventilation of
vapour
To prevent pressure built-up in
the drive axle

29)
Check the Parking Brake Pad and Function

Release the parking brake
Check the parking brake calliper
can move on the bracket
Check the clearance between
the brake pad and brake disc.
The clearance should be
approximately 1mm
Adjust as needed
PM Plan C Steering Axle

30)
31)
32)
Check Wheel Alignment
33)
Check Steering Axle Rubber Mounting*
PM Plan C Steering Axle

33)
Check Steering Axle Rubber Mounting

Check the rubber element for
damage
Replace it if needed
Check surrounding area for any
cracks
PM Plan C Spreader
39) Check Planetary Gear Oil and Brake Oil
40) Replace Planetary Gear Oil and Brake Oil*
41) Check Rotator Mounting Bolt*
42) Check Sliding Plate on Beam and Yoke*
PM Plan C Spreader
40)
Replace Planetary Gear Oil and Brake Oil

Drain the hydraulic fluid in upper
level and gear oil in lower level
PM Plan C Spreader
41)
Check Rotator Mounting Bolt

Re-torque all mast, spreader
mounting bolts
PM Plan C Spreader
42
Check Sliding Plate on Beam and Yoke

Remove Cover Plate, spacer
plate and glide plate
Measure slide plates thickness
(Thickness should be at least
25mm)
Check the slide plate clearance
by measuring the distance
between the slide plate and the
edge for the cover plate (The
clearance should be 1mm)
Fit or remove the spacer until
the distance is correct
Fit the cover plate
PM Plan C Spreader
42
Check Sliding Plate on Beam and Yoke

Park the machine with the
attachment as down as possible
and let the spreader has a 40 cm
remaining to the 20-foot position
Remove the attaching bolts for the
slide plate bracket
Remove the slide plates guide
pin
Pull out the slide plate with
space plate and bracket
Measure the slide plate with a
minimum 10mm thickness
Place the slide plate in correct
position and check the clearance
between spreader beam and slide.
Clearance should be maximum 1
mm with all slide plates mounted
PM Plan C Telescopic Boom & Lift Cylinder

45) Check Lift Cylinder Mounting Bracket and Pin
46) Check Sliding Plate on Outer Boom*
PM Plan C Telescopic Boom & Lift Cylinder

46)
Check Sliding Plate on Outer Boom

Remove Cover Plate, spacer
plate and glide plate
Measure slide plates thickness
(Thickness should be at least
25mm)
Check the slide plate clearance
by measuring the distance
between the slide plate and the
edge for the cover plate (The
clearance should be 1mm)
Fit or remove the spacer until
the distance is correct
Fit the cover plate
PM Plan C - Hydraulic
57)
58)

59)

a) Main Pressure
b) Brake Pressure
c) Servo Pressure
60)
61)
62)
Replace all high Pressure Filter*

Replace Servo Oil Filter *
Replace Brake Oil Cooling Filter *
60)
Replace all High Pressure Filter

Choke filter will restrict the flow
of oil supply
A hydraulic system is sensitive
to impurities. A small damage
to the piston rod chromium
plating can cause leakage from
seals
Replace the o-ring between the
filter head and the bowl, and
other o-ring on adaptor
Fit the bowl and tighten it to
140Nm
61)
Replace Servo Oil Filter

Release the brake pressure
of oil supply
Replace the o-ring on adaptor
62)
Replace Brake Oil Cooling Filter

Release the brake pressure
of oil supply
Replace the o-ring on adaptor
PM Plan D - Engine
01)
02)
03)
04)
05)
06)
07)
08)
09)
10)
11)
12)
13)
14)
15)

Replace Air Filter
Replace Fuel Filter
Check Cooling Water
Clean Oil Cleaner (Not Applicable for Volvos Engine)
Replace Cooling Water Filter (Not Applicable)
Check Mounting Bracket and Bolt*
Check and Adjust Valve Tappet Clearance*
PM Plan D - Engine
14)
Check Mounting Bracket and Bolt

Check all the mounting bolts
Re-tight it if needed
PM Plan D - Engine
15)
Check and Adjust Valve Tappet Clearance

Turn the crankshaft in its normal
direction until the inlet valve of
No.6 cylinder has just opened
and the exhaust valve has not
yet closed fully
Check the valve clearance on
No.1 and adjust as necessary
The sequence to check valve
clearance from no.1, 5,3,6,2,4
The sequence to check inlet and
exhaust valve from no.6,
2,4,1,5,3
PM Plan D Transmission & Propeller Shaft

17) Check Propeller Shaft Connection Bolts
18) Check Sensor on Propeller Shaft Flange
20) Replace Transmission Oil
21) Check and Clean Magnetic Filter
22) Clean the Breather
23) Check Mounting Bracket and Bolt*
PM Plan D - Transmission & Propeller Shaft

23) Check Mounting Bracket and Bolt
Check all the mounting bolts
Re-tight it if needed
PM Plan D Steering Axle

30)
31)
32)
Check Wheel Alignment
33)
Check Steering Axle Rubber Mounting
34)
Check Wheel Hub Bearing and Lock Nut*
35)
Check Knuckle Pin Bearing and Lock Nut*

34)
Check Wheel Hub Bearing and Lock Nut

Remove the hub cover
Wipe grease off the wheel cover and
hub bearing
Bend up the lock washers tabs,
remove the lock nut and lock washer
Torque the nut with 250Nm
Rotate the hub with 10 revolutions
Re-torque the nut with 250 Nm
Check the spacer ring inside the
wheel hub is positioned up against
the wheel spindle. If not, re-torque it
by increasing 50 Nm.
Fit the lock nut and tighten with
250Nm. Lock the bearing nut and
lock nut with the lock washer
Fill the bearing casing with grease
and fit it

35)
Check Knuckle Pin Bearing and Lock Nut

Check that the knuckle pin
rotates
smoothly
with
a
maximum free play of 0.25mm.
PM Plan D Telescopic Boom & Lift Cylinder

48)
Check Mast Mounting Bracket and Pin
49)
Grease Greasing Point (Apply Jack First)
50)
Check Alignment of Lifting Chain
51)
Adjust the Slackness of Lifting Chain
52)
Measure Chain Extension Over 25 Links

a) Big Chain (left/right)
53)
Check Mounting Bracket for Tilt Cylinder
54)
Check Sliding Plate and Rollers on Carriage
55)
56)
Check Sliding Plate and Rollers on Mast

General Visual Inspection for Crack*
PM Plan D Telescopic Boom & Lift Cylinder

56)
General Visual Inspection for Crack

Inspect the boom and lifting
cylinder for damage or wear
Run the function of boom and
lifting cylinder to listen any
unusual sound
PM Plan D Hydraulic
57)
58)
59)
60)
61)
62)
63)
64)
65)

a) Main Pressure
b) Brake Pressure
c) Servo Pressure
Replace all high Pressure Filter
Replace Servo Oil Filter
Replace Brake Oil Cooling Filter (Not Applicable)
Replace Main Hydraulic Oil and Brake Oil*
Replace Main and Brake Tank Breather Filter*
Replace Return Oil filter*
PM Plan D Hydraulic
63)
Replace Main Hydraulic Oil and Brake Oil

The oil qualities deteriorate over
time due to contamination and
heat.
Deteriorated
oil
causes
abnormal wear and corrosion in
components like pumps and
valve.
Remove the bottom plug of the
hydraulic tank and drain off the
oil
bleed air from all variable pumps
before starting engine
PM Plan D - Hydraulic
64)
Replace Main and Hydraulic Tank Breather Filter

Choke breather filter would
cause pressure built-up in tank
PM Plan D - Hydraulic
65)
Replace Return Oil Filter

of oil supply
This
may
cause
overpressuring the pump delivery
line causing hose rupture

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Preventive Maintenance Manual - DRF

What is Preventive Maintenance?

Importance of Preventive Maintenance

Preventive Maintenance Schedule

Plan A 250 hrs

Plan B 500 hrs

* Remark: For new machine 50 hours machine warranty maintenance

Preventive Maintenance Cycle

Before You Start the PM Job I

To ensure the truck is park in a safe working place place safety

Before You Start the PM Job II

Carry out a function test on all function to check for defects

Before You Start the PM Job III

Before You Start the PM Job IV

Use the wood block to secure the machine on a flat position

Before You Start the PM Job V

Hang up Machine Under Repair signs on the machine (one on

Oils and Lubricants for PM Jobs

Both ACEA E3 and VDS-2 (SAE15W40)

Drive Axle and Gear Oil:

API-GL5 or MIL-L-2105B (SAE80W140)

Universal grease, type EP according to NLGI grade 2 with

Oils and Lubricants for PM Jobs

Drive Axle and Gear Oil:

API-GL5 or MIL-L-2105B (SAE80W140)

Universal grease, type EP according to NLGI grade 2 with

Check Air Filter indicator

Replace Oil and Oil Filter

Replace Fuel Filter

Check Cooling Water

Clear Debris form Radiator Surface

Check Pulley and all Vee-belts

Check Starting, Stopping and Running

Check for Oil, Fuel and Water Leakage

Check Turbocharger and Exhaust for Leak

Replace Fuel / Water Separator Filter

PM Plan A Transmission & Propeller Shaft

Check and Top up Transmission Oil

Check Propeller Shaft Connection Bolts

Check Sensor on Propeller Shaft Flange

PM Plan A Transmission & Propeller Shaft

PM Plan A - Transmission & Propeller Shaft

PM Plan A Drive Axle & Brake

Check Tightness of Axle Mounting Bolts

Check for Oil Leak from Axle and WDB

PM Plan A Drive Axle & Brake

PM Plan A - Drive Axle & Brake

PM Plan A Steering Axle

Check for Damage and Free Play in Linkage

Check Overload Protection Sensor

PM Plan A Steering Axle

Check for cracks on linkage

Check for any abnormal

PM Plan A Steering Axle

Check any damage on

37) Check Sensor for Twistlock Indication

38) Check and Adjust 20/40 Chain and Stopper

Distance between right and left

PM Plan A Telescopic Boom and Lift Cylinder

45) Check Lift Cylinder Mounting Bracket & Pin

PM Plan A Telescopic Boom and Lift Cylinder

PM Plan A Telescopic Boom and Lift Cylinder

Check Oil Level in Main and Brake Tank