KALMAR PRESENTATION DRF PM_eng(V1)

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

A

●

D ●

250hr

A

2000hr

●

250hr

B●

1500hr

500hr

250hr

●B 250hr

●

A

250hr

●

1000hr

●

C

A

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 truck’s 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 • Please Remember to Lubricate the O-rings on the new filter • Tighten to contact and then 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 • Please Remember to Lubricate the O-rings on the new filter • Tighten to contact and then another half turn by HAND

PM Plan A - Engine 4) Replace Fuel Filter (Fuel Pre-Filter) • Change it because choke or dirty fuel filter may restrict fuel delivery to the injectors • Disconnect the cabling from the sensor water in fuel • 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 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 • Please Remember to Lubricate the O-rings on the new filter • Tighten to contact and then 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 engine’s 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

PM Plan A – Steering Axle 30) Check for Damage and Free Play in Linkage •

Check for cracks on linkage area

•

Check for any abnormal movement

PM Plan A – Steering Axle 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

PM Plan A - Spreader 36) Check Twistlock Pin and Mechanism • 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 beam’s 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

PM Plan A - Spreader 37) Check Sensor for Twistlock Indication • Check all sensor sensing light (yellow) is lit up when contacting

PM Plan A - Spreader 38) Check and Adjust 20/40 Chain and Stopper • 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

PM Plan A - Spreader 38) Check and Adjust 20/40 Chain and Stopper 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

PM Plan A - Spreader 38) Check and Adjust 20/40 Chain and Stopper 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

PM Plan A – Telescopic Boom and Lift Cylinder 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

PM Plan A – Telescopic Boom and Lift Cylinder 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

PM Plan A - Hydraulic 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

PM Plan A - Hydraulic 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, there’s probably a defect inside the system. A further inspection is needed

PM Plan A - Hydraulic 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

PM Plan A - Hydraulic 59) Measure Oil Pressure per Hydraulic Plate (Brake Pressure) • Gives brake when testing brake pressure • Find setting pressure in hydraulic plate

Test Point

PM Plan A - Hydraulic 59) Measure Oil Pressure per Hydraulic Plate (Servo Pressure) • Servo pressure should be around 35+/- 5 bars

Test Point

PM Plan A - Hydraulic 59) Measure Oil Pressure per Hydraulic Plate (Steering Pressure) • Allow the engine to run in midspeed range and turn the steering wheel to full lock in one direction.

Test Point

PM Plan A - Hydraulic 59) Measure Oil Pressure per Hydraulic Plate (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

PM Plan - Electrical 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

PM Plan - Electrical 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

PM Plan – Function Test 72) Test Overload Protection System •

Recommended to test with an operator

PM Plan – Function Test 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

PM Plan – Function Test 68) Check for All Leaks •

After testing the machine, walk around and find any possible leaking from the machine

PM Plan B - Engine 01)

Check Air Filter indicator

02)

Replace Air Filter*

03)

Replace Oil and Oil Filter

04)

Replace Fuel Filter

05)

Check Cooling Water

06)

Clear Debris form Radiator Surface

07)

Check Pulley and all Vee-belts

08)

Check Starting, Stopping and Running

09)

Check for Oil, Fuel and Water Leakage

10)

Check Turbocharger and Exhaust for Leak

11)

Replace Fuel / Water Separator Filter

12)

Clean Oil Cleaner (Not Applicable for Volvo’s Engine)*

PM Plan B - Engine 02)

Replace Air Filter •

Dirty air filter could reduce the airflow and affect engine’s 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*

PM Plan B – Transmission & Propeller Shaft 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

PM Plan B – Transmission & Propeller Shaft 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

Transmission Oil Filter

PM Plan B – Drive Axle and Brake 24) Check Tightness of Axle Mounting Bolts

25) Check for Oil Leak from Axle and WDB

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)

Check for Damage and Free Play in Linkage

31)

Check Overload Protection Sensor

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 36) Check Twistlock Pin and Mechanism 37) Check Sensor for Twistlock Indication 38) Check and Adjust 20/40 Chain and Stopper 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 44) Check Boom Mounting Bracket & Pin

45) Check Lift Cylinder Mounting Bracket and Pin

PM Plan B - 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

PM Plan C - Engine 01)

Check Air Filter indicator

02)

Replace Air Filter

03)

Replace Oil and Oil Filter

04)

Replace Fuel Filter

05)

Check Cooling Water

06)

Clear Debris form Radiator Surface

07)

Check Pulley and all Vee-belts

08)

Check Starting, Stopping and Running

09)

Check for Oil, Fuel and Water Leakage

10)

Check Turbocharger and Exhaust for Leak

11)

Replace Fuel / Water Separator Filter

12)

Clean Oil Cleaner (Not Applicable for Volvo’s Engine)

13)

Replace Cooling Water Filter *

PM Plan C - Engine 13)

Replace Cooling Water Filter • Close the shut-off valve on the filter bracket • Remove the filter with filter tool • 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 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 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

PM Plan C - Transmission & Propeller Shaft 21)

Check and Clean Magnetic Filter • Check for metal particles on the filter for prediction of component damage in the gear box

PM Plan C - Transmission & Propeller Shaft 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 24) Check Tightness of Axle Mounting Bolts

25) Check for Oil Leak from Axle and WDB

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*

PM Plan C – Drive Axle and Brake 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

PM Plan C – Drive Axle and Brake 28)

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

PM Plan C – Drive Axle and Brake 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)

Check for Damage and Free Play in Linkage

31)

Check Overload Protection Sensor

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 36) Check Twistlock Pin and Mechanism 37) Check Sensor for Twistlock Indication 38) Check and Adjust 20/40 Chain and Stopper 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 plate’s 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 plate’s 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 44) Check Boom Mounting Bracket & Pin

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 plate’s 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)

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

60) 61) 62)

Replace all high Pressure Filter* Replace Servo Oil Filter * Replace Brake Oil Cooling Filter *

PM Plan C - Hydraulic 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

PM Plan C - Hydraulic 61)

Replace Servo Oil Filter • Release the brake pressure • Choke filter will restrict the flow of oil supply • Replace the o-ring on adaptor

PM Plan C - Hydraulic 62)

Replace Brake Oil Cooling Filter • Release the brake pressure • Choke filter will restrict the flow 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)

Check Air Filter indicator Replace Air Filter 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 Clean Oil Cleaner (Not Applicable for Volvo’s 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 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 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)

Check for Damage and Free Play in Linkage

31)

Check Overload Protection Sensor

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*

PM Plan D – Steering Axle 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 washer’s 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

PM Plan D – Steering Axle 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)

Check Oil Level in Main and Brake Tank Accumulator Minimum Pressure Check by Brake (20 Times) Measure Oil Pressure per Hydraulic Plate a) Main Pressure b) Brake Pressure c) Servo Pressure d) Steering Pressure e) Charging 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 • Choke filter will restrict the flow of oil supply • This may cause overpressuring the pump delivery line causing hose rupture