Periodical Maintenance

for Engine Truck

Name of technician :

Section No. Inspection Items Inspection Contents Inspection method Result 250 Hrs
1 Engine Truck a. Exterior Vehicle body, oil leakage, water leakage, loose part, exterior damage Visual check O
b.Wheels Tire presure, wear or damage, rims hub nut Visual check, wrench, presure gauge O
c. Lamps Lamp condition, damage lamp Visual check O
d. Hydraulic oil Oil level, contamination, consistency Visual check O
e. Radiator Coolant level, antifreeze, requirment Visual check O
f.Engine Oil level, contamination, consistency, noise, exhaust Visual check, Operate, Listen to noise O
PRE g. Clutch Enggagement, pedal play Visual check, Operate O
INSPEC h. Brake pedal Pedal play, braking effect Visual check, Operate O
TION i. Brake fluid Fluid Level Visual check O
j. Parking Brake Operating Force, braking effect Visual check, Operate O
k. Steering wheel loosenes, play, vibration, veering Visual check, Operate, wrench O
l. Horn Sound Visual check, Listen to noise O
m. Instrument Functioning Visual check, Operate O
n. Load handling syste Part, oil leak, cracking, looseness, make certain that the SAS is function Visual check, Operate, Listen to noise, wrench O
o. Fuel Amount Visual check O
2 Main body (condition) a. Start up Proper starting, Abnormal noise, Open circuit in glow plug / heater actuation Visual check, Operate, Listen to noise O
Accelerator actuation, Rotating condition Visual check, Operate, Listen to noise O
b. Rotating
Rotating at idling (STD = 750 RPM), No load maximum rpm ( min-1 depend engine type) Rotating meter O
f. Valve Clearance( ( STD = In 0.18 ~ 0.22 mm. Ex 0.33 ~ 0.37 mm)) Thickness gauge O
3 Engine Oil Oil level, oil leak, loosing of bolts Visual check O
4 Change oil engine Change, level, leaks Change Oil O
5 Engine Oil Filter Change oil filter, Oil leak, damage, crack Visual check
6 Change Oil Filter Change filter, crack, damage Change
ENGINE 7 Air Filter Clean filter, damage, crack, Visual check, Detector, Wrench O
8 Change Air Filter (2000 hrs) Change filter, crack, damage Change
9 Fuel Filter Change Filter, drain water from sedimenter, leak, damage, crack Visual check, O
10 Change fuel filter (1000 hrs) Change filter, crack damage, leak Change
Coolant level in radiator, Dirt, Leak, Damage / degradation of hose, Radiator cap function Visual check, Examine by touch O
11 Cooling system
Fan belt (tension gauge (STD = 324 - 559 N), wear, damage), Crack / deformation / loose of fan / radia Visual check, Examine by touch, Scale, Tension gauge N O
12 Spark plug Damage / discontinuity in plug cord, Spark plug point clearance ( STD : 0,7 - 0,8 mm), Burnout Visual check, Examine by touch, Feeler gauge mm O
Change spark plug (1000 hrs) Change spark plug, damage, crack Change
13 Electric system Charging function, Battery fluid level, Loosing / decay of terminal, Loosing / damage in wiring harness Visual check, Examine by touch, Ampere / Volt meter V O
14 Tar from regulator Drain, clogging, bolt crack Visual check O
LPG 15 LPG Filter Clean, damage visual check O
system 16 Change LPG Filter (1000 hrs) Change filter, crack , damage Change
17 Overhaul LPG Regulator (1000 hrs) Clean, change O/H Kit regulator, crack, damage,leak visual check
18 Reserve Tank Coolant level, dirt, leak, damage Visual check, Operate, Listen to noise O
19 Radiator clean from dust, crack, damage leak, loose clam hose Visual check, Operate, Listen to noise O
20 Coolant level, leaks Visual check O
Cooling
Change coolant (2000 hrs) Change coolant, leaks Visual check
System
21 Radiator cap Radiator cap function, damage,valve opening pressure STD : 10.7 - 14.9 psi Visual check, Operate, radiator cap tester O
22 Fan belt Fan belt (tension gauge (STD = 324 - 559 N), wear, damage), Crack Visual check, Examine by touch, Wrench etc.. O
23 Radiator Fan loose of fan, crack, damage Visual check, Examine by touch, Wrench etc.. O
24 Chain Abnormal noise,Chain expansion, damage, crack, equal tension Visual check, Operate, chain wear scale O
Mast &
25 Lift cylinder Abnormal noise, Equal reach, crack, damage, leak Visual check, operate O
Att.
26 Tilt Cylinder Abnormal noise, Equal reach, crack, damage, leak Visual check, operate O
27 Mast & Att. Abnormal noise, Operation, crack, damage, leak Visual check, operate O
Fork 28 Forks Crack, wear, damage, lock fork of loose or damage Visual check, craking penetrant tester O
29 Hydraulic oil filter Oil leak, damage, crack Visual check, Operate, Examine by touch O
30 Change Oil Filter (1000 hrs) Change Filter Change
Hydraulic 31 Hydraulic oil Oil level, contamination, dirty Visual check, Operate, Measure O
system 32 Change hydraulic oil (1000 hrs) Change oil, level
33 Oil pump abnormal noise, leak, damage crack Visual check, O
34 Hose, Pipe Oil leak, , Damage, Degradation, Loosing of clamp, Friction with body, twisting Visual check, Examine by touch, O
35 Steering wheel Play, loose of bolt, damage Visual check, Operate, Wrench etc.. O
36 Change RR wheel bearing grease (2000 hrs) Change grase
Steering
37 Steering valve Abnormal noise, leak, Visual check, Operate, O
system
38 Hydraulic piping Oil leak, , Damage, Degradation, Loosing of clamp, Friction with body, twisting Visual check, Examine by touch, Wrench etc.. O
39 Steering cylinder Abnormal noise, leak, damage, crack Visual check, Examine by touch, O
40 Automatic Transmission Fluid (ATF) Oil leak, Oil level, Dirt, Visual check, Examine by touch, measure O
Torque 41 Change ATF (1000 hrs) Change fluid, level, leaks
Converte 42 Change Filter (1000 hrs) Change filter, crack, damage, leaks
r 43 Direction lever Operating forward & reverse Visual check, Examine by touch, O
44 Inching Pedal Play pedal, crack, damage Visual check, Examine by touch, Wrench etc.. O
45 Brake Fluid (1 to 3 ton) on Reserve Tank Fluid level, leak, dirty Visual check, O
46 Brake line, piping, hose Leak, , Damage, Degradation, Loosing of clamp, Friction with body, twisting Visual check, Examine by touch O
47 Service brake performance Push pedal brake Operating brake O
48 Parking brake performance Pull parking brake lever after stop the machine on Visual check, Wrench etc.. O
Brake 49 Change Brake fluid (1000 hrs) Change Change fluid
50 Wheel Cylinder (2000 hrs) change o/h kit, damage leak Change refer to RM book
51 Brake master cylinder (2000 hrs) change o/h kit, damage, leak Change refer to RM book
52 Drum Brake (2000 hrs) Abnormal wear, Brake drum inside diameter STD = 310 mm, limit 312 mm), damage, crack Visual check, vernier caliper mm
53 Brake shoes (brake linning) (2000 hrs) Measure thickness shoes Brake lining STD = 7.0 mm limit = 2.0 mm) , damage, clean Visual check, vernier caliper mm
Electrical Check electrolite level, terminal for rust & loseness, leak Visual check, Wrench etc.. O
54 Batterey
system Charging condition (STD 1500 rpm = 12.9~14.3 V) Voltmeter V O
55 Headlights Turn ON, crack, losennes, damage Visual check O
56 Turn signal lights Turn ON, crack, losennes, damage Visual check O
Lightings
Check 57 Stop & Tail lights Turn ON, crack, losennes, damage Visual check O
58 Back-up light Turn ON, crack, losennes, damage Visual check O
59 Beacon lamp/Flashing lamp Turn ON, crack, losennes, damage Visual check O
Periodical Maintenance
for Engine Truck
Name of technician :

Section No. Inspection Items Inspection Contents Inspection method Result 250 Hrs
OPS 60 Seat Switch Function, damage, Visual check, operate O
Greasing Center pin, damage bushing or pin Visual check, Grease gun, hydraulic jack O
61 Rear Axle
Greasing King pins & Tie rods Visual check, Grease gun, hydraulic jack O
62 Mast Support Greasing Visual Check, grease gun. O
Greasing 63 Tilt Cylinder rods Greasing, clean Visual Check, grease gun O
&
Lubricati 64 Lifting chains Damage, lubricating by engine oil Visual check, engine oil O
on 65 Mast channels & strip Lubricating by oil, wear strip, damage Visual check, engine oil O
66 Fork bars/shaft Lubricating by oil. Visual cehck, engine oil O
Pump drive shaft (7FD/FG35-
67 Greasing shaft, damage, crack. Loosennes Greasing, grease gun, visual check tools. O
A50 only)
Change grease & sealing bearing
68 Removal bearing, greasing bearing, change seal shaft Greasing, tools, visual check
FR Axle (2000 hrs)
Front
69 Bearing Front axle sahft (2000 hrs) Damage, crack, wear. Visual check
Axle
70 Diferential Oil leaks, loosennes, level oil Visual check
71 Change Oil (2000 hrs) Change oil, level, leaks Visual check
Tire &
Hub Bolt & Nuts (2000 hrs) Damage, crack, loose Visual check, tools.
Wheel 72
73 Wheels (2000 hrs) Abnormal noise, Crack, wear, damage, Rotate RH to LH (both FR & RR) Visual Check
Total 71
90 - 100 = 5 Item check Item Check 71

81-89 = 4 O X
71-80 = 3 X O 71
61-70 = 2 Percentage Persentage 100%
51-60 = 1 Skill Level Skill Level
less 50 = 0