ii
1-1. GENERAL
A permanent record of the services, repairs, and modifications made to these vehicles must be recorded. Insure you document all maintenance and repair that you perform on the TICO Work Requests.
1-2. CLEANING INSTRUCTIONS
a. Cleaning is an after operation service performed by operations personnel to keep the vehicle in a state of readiness. Facilities and material available to operators for vehicle cleaning can vary greatly in differing operating conditions. However, vehicles must be maintained in as clean a condition as available cleaning equipment, materials, and operational situations permit. Pressure wash if possible.
WARNING - Mineral Spirits are flammable and will not be used
near an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and/or damage to equipment.
WARNING - Protective gloves, clothing, and/or respiratory
equipment must be worn whenever caustic, toxic, or flammable cleaning solutions are used. Failure to do this may result in injury to personnel and/or damage to equipment.
CAUTION - Do not allow caustic or flammable cleaning
compounds to come into contact with rubber, leather, vinyl, fiberglass cabs or canvas materials.
Damage to equipment will result.
CAUTION - Do not use compressed air when cleaning vehicle
interiors. Damage to equipment will result.
CAUTION - Do not allow water to enter air cleaner assembly air
intake weather cap. Damage to engine will occur.
NOTICE - Remember to clean windshield wipers of debris on a
regular basis to ensure proper vision.
TICO, July 2015
1-3. PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
a. Designated Intervals. 1. PM Service interval for TICO tractors is 500 hours. 2. Certain areas, due to the conditions, will have service intervals lessened as needed 3. New tractors or vehicles with new engines installed will have a 50-hour “Initial” service performed. 4. Also during the initial service on the new tractors ensure that all attaching hardware is physically
checked for tightness.
b. Procedures.
1. For troubleshooting malfunctions, refer to your supervisor. 2. Malfunctions are to be reported to the maintenance supervisor at once. 3. Wiping cloths are needed to remove dirt or grease during inspections and maintenance.
c. Trouble spots. 1. Check all bolts, nuts and screws. If loose, bent, broken, or missing, tighten or report conditions to
maintenance personnel. 2. Look for loose, chipped paint, rust and cracks at welds. Remove rust and or loose paint; spot paint as
required. If a cracked weld is found, report the situation to maintenance personnel. 3. Inspect electrical wires and connectors for cracked or broken insulation. Also look for bare wires, and
loose or broken connections. Tighten loose connections. Report other problems to maintenance personnel.
4. Check hoses and fluid lines for wear, damage and leaks. Ensure clamps and fittings are tight. (Refer to Para. 1-4 for information on leaks.)
5. Check pivot points for security and operation. 6. Check data, caution, and warning plates/decals for security and legibility.
Not Ready/Available If a vehicle is not able to perform the mission, equipment will be reported as not serviceable
d. Correct Assembly or Stowage. 1. Check each component for installation as an assembly, in the right place, and with no missing or
damage.
NOTICE - Dirt, grease, oil, and debris may cover up a serious
problem. Clean as you check. Following precautions printed on container, use Mineral Spirits on all metal surfaces. On rubber or plastic material, use soap and water.
NOTICE - Designated intervals are performed under usual
operating conditions. PM intervals must be performed more frequently, as determined by the maintenance manager, when operating under unusual conditions.
iv
1-4. FLUID LEAKAGE
Wetness around seals, gaskets, fittings, or connections indicates a leakage. A stain also denotes leakage. If a fitting or connector is loose, tighten it. If broken or defective, report it.
1-5. LUBRICATION REQUIREMENTS
For lubrication requirements and procedures SEE TICO LUBRICATION ORDER in the Operator’s Manual.
WARNING REVIEWS
WARNING REVIEWS
CAUTION - No tractor will be operated with a fuel leak. WHEN
IN DOUBT, NOTIFY YOUR SUPERVISOR. All leaks must be reported immediately to your supervisor or to maintenance personnel. Failure to do this will result in damage to vehicle and/or components.
WARNING - EXHAUST GASES CAN KILL
Brain damage or death can result from heavy exposure. Precautions must be followed to ensure personal safety when the engine of any vehicle is operated for any purpose.
1. Do not operate vehicle engine in enclosed areas. 2. Do not idle vehicle engine with vehicle windows closed. 3. Be alert at all times for exhaust odors. 4. You must be alert for exhaust poisoning symptoms. They are:
• Headache • Dizziness • Sleepiness • Loss of muscular control
5. If you see another person with exhaust poisoning symptoms:
• Remove person from area • Expose to open air • Keep person warm • Do not permit physical exercise
• Administer artificial respiration, if necessary • Notify medical personnel.
THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION.
WARNING - Do not perform fuel or battery system checks,
inspections, or maintenance while smoking, near sparks or open flames. Fuel may ignite and batteries may explode causing damage to vehicle and injury or death to personnel.
TICO, July 2015
WARNING REVIEWS
WARNING - Mineral spirits is flammable and will not be used
near an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and/or damage to equipment
WARNING - Avoid using a fire extinguisher in unventilated
areas. Prolonged inhalation/exposure to extinguishing agent or fumes from burning material may cause injury to personnel. Using fire extinguisher in a windy area will cause rapid dispersal of extinguishing agent and reduce effectiveness in fire control.
WARNING - Vehicle operation in snow is a hazardous condition.
Operator must travel at reduced speeds and be prepared to meet sudden changes in road conditions. Apply brakes gradually when stopping vehicle on ice or snow. Sudden braking will cause wheels to lock and vehicle to slide out of control causing damage to vehicle and injury or death to personnel.
WARNING - Do not rely on wet service brakes. Keep applying
brakes until they dry out and uneven braking ceases. Failure to do this may cause damage to vehicle and injury or death to personnel
WARNING - Exhaust components are hot after prolonged
vehicle use. Ensure exhaust system components are cool before removing/installing exhaust assembly. Failure to do this will result in injury to personnel.
WARNING - Chock blocks shall be used when parking a vehicle
with inoperative parking brakes, when operating in extreme cold conditions, when parking on inclines, or whenever and wherever maintenance is being performed. Failure to do so may result in injury to personnel or damage to equipment.
WARNING - Vehicle speed must be reduced consistent with
weather and road/terrain conditions. Obstacles such as stumps, potholes and boulders must be avoided. Failure to use basic safe driving techniques/skills may result in injury or death to personnel and damage to equipment.
TICO TRACTORS
PREVENTATIVE MAINTENANCE CHECKS AND SERVICES
- 1 –
TICO, July 2015
“A” P.M. Every 500 Hours
DRIVE IN CHECKS
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
1 DRIVERS SEAT OPERATION –
CONDITION
Insure that all seat adjustments operate correctly. Check seat for
air leaks. Check that seat back, cushion and arm (if equipped) are
secure and that no rips or tears exist. Lubricate all hinge points on
seat frame with spray silicone or equivalent. Insure seat stops are
in place. Insure seat restraints are in place and serviceable
Seat will not adjust,
seat base cracked or
unserviceable.
Restraints missing or
unserviceable.
2 SEAT BELT OPERATION –
CONDITION
Check that belt is in good condition, no fraying or cuts. Insure
that the belt is securely fastened to the seat frame. Check
operation of belt latch. Buckle belt across seat bottom when
finished.
Seat belt missing,
damaged or
defective.
3 HORN OPERATION
Press the horn button on the floor to check operation. Check by-
pass horn (If equipped) by turning the ignition key to the run
position and depressing by-pass button. The warning horn should
sound. Check both horns for secure mounting. The city horn (If
equipped) can be checked by pressing the center button of the
steering wheel.
Either horn is
defective.
4 WINDSHIELD WIPER
OPERATION
Check that windshield wiper works when ignition switch is turned
on and works in both high and low positions. Insure wiper does
not hit the molding on either side of the windshield. Check motor,
arm and wiper blade for secure mounting and serviceability.
Check mounting of the switch into the dash as well as the knob
mounting to the switch to ensure they are secure. Insure the wiper
“parks” in the proper position.
Windshield wipers
inoperative.
5 DOME LIGHT
Check light for operation. Check that the wiring is mounted
correctly and secure. Check the lens for serviceability.
Floor switch
Pull cable
2
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
6 DEFROSTER FAN AND HEATER
Check fan operation. Check that fan wiring and mounting are
secure. Check that the heater fan operates on both high and low
speeds, check that the coolant control valve is on and check the
heater core for leaks. Check that heater wiring and mounting is
secure. Check that the vent hoses are in place and serviceable.
Check the air intake screen for cleanliness and serviceability.
Check operation of AC (If equipped)
Defroster or heater
inoperative.
Air intake screen
unserviceable.
Heater core leaking.
AC inoperative.
7 DASH LIGHTS Check that all dash lights are operational when the light switch is
turned “ON”
8 ALL GAUGES AND VEHICLE
CONTROLS
Check that all gauges are operational. Insure that all controls
operate properly: brake pedal, 5th
wheel release valve, boom
control, park and trailer brake air valves and knobs. All light
switches are secure and operational. On mechanical engines
adjust air throttle to 60PSI pedal depressed. Trucks equipped with
electronic engines and transmissions will have warning and shut
down lights that come on and go off.
NOTE:
Check at idle at
operating
temperature. Oil Pressure:
Below 12 PSI
Voltmeter:
Above 15 VDC or
Below 12 VDC
Temperature:
Above 220 Degrees
Air Pressure:
Above 125 PSI
Below 90 PSI
Any control valve
sticking or leaking.
Engine, transmission
light stays on.
9 HEAD LINER AND FLOOR MAT
Check that the insulation material is secured to the ceiling of the
cab. Floor mat is in place and serviceable
.
10 INTERIOR FOR LOOSE OR
MISSING SCREWS AND
HARDWARE
Insure that all dash screws, wiring loom clamps, screws and any
other interior clamps are in place and secure. Tighten all hardware
and fasteners that were found loose.
11 GLASS AND LATCH
ASSEMBLIES
No cracked or missing glass. Latches in place and secure. Side
window tracks in place and holding glass firmly.
Any glass missing,
broken, or not
mounted properly.
12 CAB DOOR
Air operated door should operate smoothly. Lubricate upper
bushings with spray silicone or a light weight lubricant such as
WD40. Lower bushings should be greased via zerk fittings.
Panels should not be so cloudy as to obstruct vision.
Door panels cloudy
or damaged.
Door is stiff, hard to
open or close.
Door slams open or
close.
WARNING - If
gauges, instruments, or instrument lights are inoperable or not within ranges described in these checks, immediately shut off engine and notify supervisor. Continued operation of vehicle may result in injury or damage to equipment.
3
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
13 AIR LEAKS – PARK BRAKE
RELEASED
With the parking brakes released and full air pressure, chock the
wheels to prevent the tractor from rolling and listen for air leaks
while walking around the vehicle. Observe the air gauge for
pressure drops. With full air pressure (120 PSI) apply service
brakes and listen for air leaks, also observe the air gauge for a
drop in operating pressure.
Any air leaks or
vehicle fails to
maintain air pressure.
14 PARKING BRAKE OPERATION
After checking for air leaks with the engine off, pump the brakes
and observe the air pressure. At approximately 60 PSI the parking
brakes should apply and the vehicle should not move forward or
back.
Parking brakes do not
engage when
pressure drops.
Parking brakes fail to
hold vehicle.
15 BOOM OPERATION
Raise boom to highest level and back down again. This process
should be done several times to insure the boom operates properly.
Boom fails to operate
properly.
16 STEERING WHEEL AND
COLUMN
Insure the column is secure. Check that steering wheel is secure
and no cracks are present. Insure the steering mounting bolts are
tight and the column does not move up or down.
Steering column is
not secure.
Steering wheel is
unserviceable if a
spoke missing or
cracked.
WARNING - Do
not place any part of your body into a pinch position between the boom assembly and frame. Severe injury or death may occur. Always use the boom safety bar when working under boom assembly.
4
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
17 STEERING OPERATION
Steering should operate right and left smoothly. There should be
no vibration or hard spots in the steering
Steering binds or
sticks.
Excessive play in
steering.
18 TRANSMISSION OPERATION
Check operation of shift control into forward and reverse. Check
for excessive play in the shifter. No slipping should be evident in
forward or reverse. Insure the engine starts only in the neutral
position.
ELECTRONIC TRANSMISSION: Check shift pad for cracked
cover, transmission should only shift into drive or reverse when
the brakes are applied.
Excessive play in the
shifter.
Engine starts in (D)
or (R).
Electronic
transmission goes
into drive or reverse
without applying
brakes.
EXTERNAL CAB CHECKS
19 ALL LIGHTS – OPERATIONS Check all lights. All lights should be in working order. All wiring
will be secure in wire looms and any splices/repairs will have heat
shrink on them to protect from arcing and corrosion.
Any lights inoperable
or any bare wires.
20 CAB PROTECTION BAR
Check for loose mounting bolts, cracked welds or accident
damage.
Any cracks or
accident damage
evident
21 CAB CONDITION Check for cracks in the cab, loose mounting bolts, or accident
damage.
Cracks or holes that
would allow water to
enter into cab.
22 MIRRORS AND BRACKETS Insure mirrors and bracket mounts are secure. No broken or loose
mirrors.
Mirror missing or
loose
5
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
23 BUMPER AND FENDER Check that bumper bolts /welds are secure. Bumper not
excessively bent to the point of making the vehicle unsafe. Check
fender for damage and secure mounting. Make sure there are no
sharp edges or extrusions that could be a potential hazard.
Bumper or fender
excessively
bent/damaged.
24 GLAD HANDS, HOSES &
HANGERS
Check glad hands for damage. Insure that rubber washers are in
serviceable condition. Hoses should not have any cracks or tears
in the casing. If tractor is equipped with hose hangers insure they
are fastened to the rail on the cab protection bar. Some units are
equipped with a basket type holder.
Glad hands damaged.
If rubber washers are
missing or
unserviceable.
Hoses are cracked.
ENGINE COMPARTMENT
CHECKS
25 AIR CLEANER DUCTWORK
Inspect the air inlet piping including all joints, clamps, hoses and
connections to insure they are tight. That there are no holes or
tears in the system. Be sure to check the supports for the air intake
pipe making sure they are not broken or loose.
Any loose
connections or worn
components.
Any cracks or
openings between the
air cleaner and the
turbocharger.
Support bracket loose
or broken.
26 AIR FILTER
Air Filter
Change Every Six Months Or
When Unserviceable.
NOTE:
(WRITE DATE ON FILTER)
Check the air filter restriction indicator. If red replace the air
filter. Record the date changed on the filter with a Yellow Paint
Marker. If the air restriction indicator is green check the date on
the air filter, if the date is over six months replace the air filter.
Always insure the air filter cap is tight. Insure the air restriction
indicator is serviceable.
RESET THE AIR FILTER RESTRICTION INDICATOR
LOCATED ON THE FILTER HOUSING
Air restriction
indicator is red or air
filter date is over six
months old.
6
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
27 ALTERNATOR
Check alternator and insure that all mounting bolts and brackets
are secure and that no cracks are present. Inspect pulley for cracks
and/or damage. Insure that all wiring is tight and secured out of
the way. Check for broken wires.
Any cracks.
Any hardware
missing or any
broken wires.
28 WATER PUMP
Inspect the water pump for any signs of leakage. Any leakage of
coolant.
29 FAN, FAN CLUTCH, FAN HUB &
IDLER
Check fan hub for noise or vibration. Inspect the fan clutch (If
equipped) for operation. Inspect fan for broken or bent blades.
Inspect the idler pulley. Inspect the fan shroud for serviceability.
Any noise or
vibration.
Bent or broken
blades.
Worn idler pulley.
Fan clutch is
inoperative.
30 BELTS – CONDITION &
TENSION
Check that all belts have adequate tension. Inspect the belts for
cracks or excessive wear on the drive side.
Belt not adjusted
properly.
Any cracks or
excessive wear.
31 EXHAUST SYSTEM
Check the exhaust manifold and all piping for cracks, holes, or any
leaks. Insure that all clamps are tight. Check condition of the
muffler. Insure that the muffler guard is secure.
Any cracks, holes or
exhaust leaks.
Any loose mounting
hardware.
32 TURBOCHARGER
Inspect the turbocharger for any cracks, exhaust or oil leakage.
Check that all clamps and mounting hardware are secure. Check
turbo oil supply line and drain tube for any leaks, chaffing or
abrasions.
Any cracks, holes,
exhaust or oil leaks
found.
Any loose mounting
hardware.
Any lines or tubes
rubbing.
7
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
33 RADIATOR & TRANSMISSION
COOLER
Check all mounting bolts (Self-locking only) for the radiator and
transmission cooler. Insure the fan shroud is in place and secure.
Inspect all lines and hoses for leaks, abrasions, chaffing and
proper mounting (To include all clamps are in place). Inspect the
radiator and transmission oil cooler for leaks. Insure the
transmission oil cooler is properly mounted. Inspect the overflow
bottle; insuring that it will hold fluid and that the cap and line are
in place. If equipped with CAC, insure it is mounted properly and
no leaks present.
Any leaks found.
Any mounting
hardware missing or
improperly mounted.
Overflow bottle
unserviceable.
34 REVERSE BLOW THE
RADIATOR
Using shop air pressure (No more than 40-50 lbs) with proper
blow gun attachment carefully blow out the radiator (DO NOT
TOUCH THE RADIATOR FINS WITH THE BLOW GUN) Do
this in the opposite direction of the normal air flow. If the radiator
has been oil fouled you will have to steam clean the unit to clear
the radiator.
35 STARTER
Check the mounting of the starter. Insure that all mount bolts are
in place and tight. Inspect the cables for chaffing or abrasions.
Insure that cable connections to the starter posts are tight and
clean. Once cleaned be sure to spray with battery terminal sealer.
Any mounting
hardware loose or
missing.
Any cables worn or
chaffed.
36 HYDRAULIC PUMP & PTO
PTO Type Pump Mounted On
Transmission
Check to insure the mounting bolts are in place and secure. Check
all gaskets and hoses to insure there are no leaks.
Any mounting
hardware missing or
loose.
Any leaks at the PTO
pump or hoses.
NOTICE - Tighten
mounting bolts of the radiator just enough to compress the rubber mounting cushions. Over-torqueing will
cause damage due to excessive vibration.
NOTICE - Improper
airflow will cause the vehicle to run hot and shut down. Continued use in this condition can result in engine/transmission damage
8
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
37 HYDRAULIC TANK
Inspect the hydraulic tank for secure mounting, damage or leaks.
Insure that both return and suction ball valves located at the
bottom of the tank are wired in the open position (THE VALVE
HANDLE IN LINE WITH THE HOSE). Check the fluid level
with the boom in the down position. Fluid level should be no
lower than the bottom of the screen or at the full mark if equipped
with a dipstick. If the fluid is milky colored it is contaminated
and needs to be changed. Remember to date the filter when it is
changed. Insure the vent tube (If equipped) is free of any
blockage.
Tank not mounted
properly.
Any damage that will
cause leaks or greatly
reduce the amount of
fluid it can hold.
The valves not wired
into place.
Fluid contaminated
or level below the
full mark.
38 HYDRAULIC TANK CAP
Insure that the tank cap has a gasket in place. Cap should fit
snugly when installed. Chain should be secured.
Gasket missing or
loose.
Chain missing.
39 AIR COMPRESSOR
Check that all mounting bolts and hardware are in place and
secure. Check for leaks at all connections and mounting areas.
Any mounting
hardware missing or
loose.
Any leaks.
40 AIR COMPRESSOR LINES
Inspect the air compressor discharge line and air intake lines for
proper mounting, holes, abrasions or chaffing. Inspect the air
govenor for proper mounting.
Any leaks or damage
to the lines.
Wiring harnesses is
too close to
compressor.
41 FUEL PUMP
Electronic
Inspect the supply and the fuel injection pump for secure
mounting and leaks. Inspect all lines and hoses for leaks,
including the fuel lines running to and from the fuel tank. Inspect
the fuel injectors for leaks. Inspect the wiring to the fuel injector
pump (If equipped).
Any item not
mounted securely.
Any fuel leaks.
NOTICE - Insure
there is no dirt present around the cap as this can get into the hydraulic system and will cause system problems and failures.
NOTICE - Insure all
wiring harnesses are properly secured away from the compressor and its lines. The compressor develops a great deal of heat, which can melt the insulation and cause a short.
9
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
42 THROTTLE SYSTEM
Electronic
Inspect the throttle system. Trucks equipped with electronic foot
pedals should operate freely, no restriction. Insure there is no
trash around pedal to limit its travel.
Throttle not operating
properly.
Trash in vicinity of
pedal.
43 BATTERY BOX
Insure that the battery box is mounted securely. Inspect the cover
for damage and proper fit. Check that the hold down latches hold
the cover down securely.
Box not mounted
securely.
Latch does not hold
cover in place.
44 BATTERY & CABLES
Disconnect both battery cables (Negative cable first). Clean the
battery and the battery compartment to include the cable ends and
the battery posts (Always wear eye and hand protection when
working with batteries). Reconnect the battery cables (Negative
cable last). Insure that cable ends are tight, sprayed with
protector. Inspect the entire length of the battery cables to insure
that there is no chaffing, abrasions or bare spots. Insure rubber
mat is in place under battery, and that all battery hold downs are in
place and tight. Check electrolyte in battery cells. Fill as
necessary with distilled water.
Battery
unserviceable.
Cables worn or not
mounted correctly.
Battery low on
electrolyte.
Terminals corroded.
Battery fails load test.
45 CLEAN & INSPECT ALL WIRE
TERMINALS
Clean and insure all wire terminals which are exposed to the
weather are tight. This includes the wiring found on the starter
and frame solenoids. Spray all terminals with protectant.
Any loose
connections.
46 CAB MOUNTS – LIFT PUMP &
CYLINDER
Check lift pump, lift cylinder, cab latches, cab pivots, and cab
pivot bolts for tightness and wear. Insure cab raises and lowers at
an even rate, if not then adjust. Check the operation of all
components of the system. Check for leaks and or chaffing.
Insure that the cab safety latch is in place and secure. Inspect the
power cable to the cab lift pump for proper routing. Insure there is
no wear or abrasions on the cable. Make sure the cab lift pump
fluid is not contaminated.
Any air or hydraulic
leaks present.
Any wear on the
hydraulic lines or
fittings of the cab lift
system.
The power cable not
routed properly or
worn.
WARNING - Don't
smoke, have open flames, or make sparks around batteries, especially if the caps are off. Batteries can explode and cause injury or death. Remove all jewelry such as rings, bracelets, etc. If jewelry contacts battery terminal, a direct short will result, causing instant heating of tools, severe injury to personnel, or damage to equipment. All ways wear face protection when working around batteries.
10
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
47 CHECK COOLANT LEVEL &
PROTECTION
Check that the coolant level is at the bottom of the filler neck. On
units equipped with a surge tank, insure coolant level is up to
sight glass. Using a syringe type tester, insure coolant is protected
to at least -25 degrees F. Top off tank with a 50/50 mixture of
Ethyl Glycol (Green) antifreeze.
Coolant is low.
Coolant leaks are
present.
Not protected to
proper level.
48 AIR DRYER AND SPITTER
VALVE (IF EQUIPPED)
Check all mounting bolts and wiring. Check the operation of the
air dryer and spitter valve. Air dryer should purge when
compressor reaches approximately 120 PSI. The air dryer
assembly will be replaced yearly, or sooner if warranted by the
presence of excessive moisture in the air system. Check date on
assembly to determine serviceability. Write the date on any new
assembly that is replaced.
Not mounted
properly.
Air dryer does not
purge.
Spitter valve
inoperative.
System not serviced
yearly.
UNDER THE VEHICLE
CHECKS
49 DRAIN ENGINE OIL, CHANGE
OIL FILTERS
Remove the engine oil plug and drain oil. Check and clean all
metal particles from the magnetic plug. If any large pieces are
present bring it to the attention of the maintenance supervisor.
After all the oil is drained, reinstall the drain plug and torque to
approximately 55 FT LBS. Remove the oil filter,drain oil from
filter, discard the filter, and clean the oil filter base. Fill the new
filter with clean oil and lubricate the rubber seal of the filter.
Install the filter hand tight until the gasket comes in contact with
the filter base then an additional ¾ turn. Fill the crankcase with
approximately 15 quarts of 15W40 oil. Recheck the oil level after
the engine has run, adjust if necessary.
WRITE PM DATE ON FILTER)
Excessive metal on
magnetic plug.
50 PRIMARY FUEL FILTER
Secondary Fuel Filter
Remove water sensor wires from the bottom of the primary fuel
filter and spin the primary filter off of the housing, drain fuel and
dispose of the filter. Lubricate the new filter gasket, clean the
filter base and spin on the new filter. Install the filter hand tight
until the gasket comes in contact with the filter base then an
additional ¾ turn. Connect the water sensor wires and prime the
filter using the hand pump on the filter housing..
DO NOT OVERTIGHTEN.
(WRITE PM DATE ON FILTERS)
Fuel filters are
leaking or damaged.
11
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
51 FUEL TANK
Check the fuel tank brackets and straps for secure mounting.
Insure the step plate is tack welded to the fuel tank straps on older
units. On newer units make sure the tread plates are securely
bolted to tank. Check fuel suction, return and vent lines for any
signs of chaffing, abrasions, leaks or blockage. Inspect the fuel
tank cap gasket and chain for serviceability. Check welds for
cracks or leaks.
Leaks are present.
Steps are not secured
to tank.
Cap is loose or
missing.
Tank straps are loose
or broken.
52 CLEAN THE TRANSMISSION
BREATHER. CHECK THE
TRANSMISSION FLUID
Clean excessive dirt from around the transmission breather using a
clean shop towel. Insure the vent cap moves freely. Check
transmission fluid level and adjust as necessary.
Transmission oil
level is not correct
53 REAR AXLE FLUID LEVEL Remove the fill plug. Oil level should be at the bottom of the fill
hole. Check to see if the oil is contaminated (MILKY
COLORED). If contaminated change the oil. If not contaminated,
top off as needed and reinstall the plug. Check the pinion seal for
leaks. On planetary rears, check wheel end fluid level. Insure vent
is clean and turns freely.
Oil low or
contaminated.
Fluid leak.
54 DRIVE SHAFT & U-JOINTS
Check for excessive play in the u-joints. Insure bolts are tight and
there is no evidence of movement in the cap. Insure the drive
shaft is properly timed. Check for any excessive play or wear in
either the transmission or rear axle yokes.
Any excessive play in
the u-joints, yokes or
driveline.
Drive line not
properly timed.
55 INSPECT ALL COMPONENTS
FOR LEAKS
From under the tractor, do a visual check of the radiator, the
engine, the transmission and the hydraulic system for any leaks
Any leaks.
56 DRAIN THE AIR TANKS
Place a drain pan under the petcock hose located on the left frame
rail and drain the air tank of all fluid. Place the drain pan under
the dry tank and pull the cord to drain the tank. Inspect the
drainage, if it is oil contaminated write up the tractor for a
compressor check.
Drain cord or petcock
inoperative.
Drainage
contaminated with
oil.
57 AIR TANKS – CONDITION &
MOUNTING
Inspect the air tanks for excessive rust or damage. Insure that the
mounting brackets are secure and that tanks do not move in the
brackets.
Tanks damaged to the
point of air leakage.
Air tanks loose.
58 INSPECT ALL HOSES & LINES Inspect all hoses, lines from under the tractor, looking for leaks,
cuts, abrasions, improper mounting or routing.
Any leaks, cuts,
abrasions, improper
mounting or routing.
NOTICE - DO NOT
TORQUE THE MOUNTING BOLTS OVER 35 FT LBS. DO NOT USE AN AIR IMPACT ON THE DRIVE LINE COMPONENTS.
12
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
59 CHANGING HYDRALIC FILTER
Remove tie-wrap from the cut-off valve and close the valve.
Remove the old filter and discard. Lubricate the new filter gasket
and fill the filter with clean oil. Install the filter hand tight until the
gasket comes in contact with the filter base, then an additional ¼
turn. Open the cut-off valve and secure in place with a new tie-
wrap. Check the hydraulic fluid with the boom down to insure
proper oil level.
Write PM Date On Filter
Tie-wraps not in
place.
Any hydraulic leaks
present.
Oil level low or
contaminated.
60 POWER STEERING FILTER
Insure there is no dirt on the reservoir (or on the underside of the
cab floor) that is going to fall into the reservoir once it is opened.
Remove the top of the reservoir canister, remove and replace the
reservoir filter. Inspect the rubber gasket to insure it is not
damaged or that it has not become swollen or out of shape.
Replace if necessary.
Leaks or missing
components
5TH
WHEEL & BOOM
61 BOOMS, PINS, & BUSHINGS
Inspect boom bolts and welds for cracks. Check boom pin and
bosses for excessive play by moving boom side to side. Check
for cracked, worn or damaged bushings by cycling the boom up
and down. Inspect the lower supports, pins and cylinder block
attachment for loose bolts or broken welds.
Any broken welds.
Any cracked, worn,
or damaged bushings.
62 CYLINDERS, HOSES,FITTINGS
Inspect the cylinders, fittings and lines for hydraulic leaks. Check
condition and routing of all lines to insure no lines are rubbing or
deterioating. Insure lube fittings accept lubrication.
Any worn or leaking
lines or fittings. Any
lube fitting that will
not accept
lubrication.
63 BOOM AND TRANSMISSION
COVERS
Inspect the covers for any loose attachment points, bent or
protruding metal.
Loose cover.
Protruding metal.
13
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
64 RELEASE CYLINDER
Check the 5th
wheel release cylinder operation. Check rod end to
insure it is secure. Inspect for any air leaks. Be sure the “Over the
Road” lock is not engaged. The 5th
wheel will not unlatch if it is
applied.
Air leaks present.
Poor operation.
65 5TH
WHEEL PEDESTAL AND
BUSHINGS
Lift the 5th
wheel up and forward to check for play in the pedestal
bushings. Insure the pedestal bolts are in place and secure. On
70K-Lb fifth wheels check welds at pedestal welded to boom.
Any bolts missing or
loose.
Cracks at or around
welds.
66 5TH
WHEEL PLATE AND JAWS
Carefully inspect the 5th
wheel plate for damage, cracks and or
wear around the jaw opening. Inspect the jaw pins are not
protruding above the plate level. Inspect the jaws for excessive
wear and proper operation by using the test tool. No more than
3/8 inch play in jaws.
Any damage or
excessive wear to the
plate or jaws.
Jaw pins above the
plate.
STEERING, AXLES & BRAKES
67 SUSPEND FRONT AXLE Jack up the front of the tractor placing a jack under the front
steering axle. Place two jack stands under the axle. This will
facilitate greasing the king pins. Insure that the park brakes are set
and that the rear wheels are chocked. Leave the vehicle on jack
stands for the next 3 steps.
Spring pins will not
take grease.
68 FRONT SPRINGS Visually inspect the front springs for broken or cracked leaves.
Inspect the hangers and pins for wear using a pry bar. Insure that
the grease fittings take lubrication (Insure all axle mounting U-
bolts are torqued and not damaged.).
Any cracked or
broken leaves. Any
loose bolts.
14
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
69 STEERING COMPONENTS Have an assistant move the steering wheel left and right
continuously while you inspect the pitman arm, drag link ends and
tie rod ends for excessive play. Play will show as up and down
movement in the component. Inspect the steering gear box for
leaks and loose mounting bolts and hardware. Insure steering
stops are in place and properly adjusted. Steering shaft u-joints
should have no play. Check fluid level and adjust as necessary.
Any excessive wear
found in any steering
components.
Any loose mounting
hardware.
Any oil leaks.
Steering stops
missing or
improperly adjusted.
70 KING PINS & WHEEL
BEARINGS
Inspect the king pin play by prying up between the wheel and rim
with a large pry bar. Maximum movement is ¼” measured at the
bottom of the tire before greasing. Check wheel bearing play by
pushing in at the top of the tire. Little or no play should be
noticed. Grease front end while suspended. Lower truck.
King pin play greater
than ¼”.
Noticeable wheel
bearing play.
71 FRONT HUBS Inspect the front hub caps for leaks. Check and adjust oil level.
Do not overfill. Check for contaminated oil (milkly colored oil.)
Any leaks.
Overfull on oil.
Oil is contaminated.
72 LOWER SUPPORT & TORQUE
ARMS
Inspect lower support structure and welds for cracks. Inspect
torque arms and bolts.
Any cracked welds.
Any frame cracks.
Any loose bolts.
73 FRAME & CROSS MEMBERS Throughly inspect the frame for cracks, especially at the rear axle
where lower support structure ends and the area between the cab
protection bar and the boom pin. Inspect all cross members for
cracks or loose bolts and mounting hardware.
Any frame cracks or
loose mounting
hardware.
74 ENGINE & TRANSMISSION
MOUNTS
Inspect the engine mounts. The rubber mounts should be in good
shape and not flattened out. Inspect all bolts associated with the
engine mounts, transmission mounts and cradle system.
Any hardware
missing or loose.
75 GREASE ALL FITTINGS Grease all lubrication points. Insure that the king pins and
universal joints are purged. Purging means to continue to lube the
area until all old grease and moisture is flushed from the
component and you are getting new fresh grease from the seals.
This procedure also applies to spring pins. Don’t forget the
fittings under the 5th
wheel. Any fitting that does not take grease
must be repaired immediately. Wipe clean any excess grease.
Any fitting that will
not accept grease.
Any universal that
will not purge at all
four journals.
76 BRAKE LININGS Inspect the front and rear brake linings for cracks and wear. The
minimum lining thickness for the front linings is ¼” and 3/8” for
the rear. Be sure to record the measurements on the PM checklist.
Check the entire area for any signs of wheel seal leakage.
Linings worn past
minimum thickness.
Cracks in the shoes.
Any signs of wheel
seal leakage.
15
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
77 ADJUST ALL BRAKES, INSPECT
CHAMBERS
Insure that the air pressure is at least 90 PSI. Chock the wheels
and release the parking brake. Adjust manual adjusting brakes by
tightening the slack adjuster until the shoes come in contact with
the drums. Back off the front and rear shoes a 1/4 turn. Check
automatic slack adjusters by depressing the brake pedal and
measuring the stroke of the rod. It should not be over 2” for a type
30 chamber or 1 ½” for a type 20 chamber. Adjust as needed.
Inspect each of the brake chambers for leaks, cracks, or corrosion.
Insure the chambers are secure.
Brakes will not
adjust, a brake
chamber has a leak, a
crack, is corroded or
not secured.
78 DRUMS, WHEELS, RIMS &
LUGS
Inspect the drums, wheels and rims for cracks and corrosion.
Check for missing or stripped lugs and nuts.
Any wheels or rims
cracked, missing lugs
or studs
79 TIRES Inspect the rear tires for wear. Inspect the steer tires for any
unusual wear which may indicate front end promblems. Report
any worn tires to the Operations Department. Air tires to 100 PSI
Any bald tires.
Front tires wearing
unevenly.
80 APPLY NEW PM STICKER Remove the old sticker completely. Apply a new sticker using a
black permanent marker to fill out the required information.
“B” P.M. EVERY 3,000 HOURS (To include all items listed in “A” P.M.)
81 ELECTRONIC
TRANSMISSION
CHANGE INTERNAL
TRANSMISSION FILTER
Place a catch pan underneath the truck to catch any lost fluid.
Remove bolts holding filter caps on, remove caps. Remove filters,
gaskets and o rings and discard all items. Replace filters using
new gasket and o rings. Install caps and torque capscrews 38 to 45
FT LB. using the torque sequence supplied in the filter kit.
DO NOT OVER TORQUE OR USE AN IMPACT WRENCH
TO TIGHTEN CAPSCREWS
Top off transmission with TES 295 Synthetic ATF fluid. Start
truck and run, check for leaks and proper fluid level. Check fluid
level when cold, final reading will be done when truck is hot, at
idle and on level ground.
DO NOT OVER FILL TRANSMISSION.
(CHANGE FILTER EVERY 3,000 HOURS)
82 PRIORITIZED POWER
STEERING SYSTEM
Insure there is no dirt on the reservoir or on the underside of the
cab floor that is going to fall into the reservoir once it is opened.
Remove the top of the reservoir canister. Remove and replace the
reservoir filter. Inspect the rubber gasket to insure it is not
damaged or that it has not become swollen or out of shape.
Replace gasket if necessary. Check fluid level and top off as
necessary, using TES 295 Synthetic ATF fluid.
16
ITEM TO CHECK: WHAT TO LOOK FOR: NOT READY IF:
83 CHANGE CRANKCASE FILTER
QSB Tier 4-I & Final and ISB 10
Disconnect the crankcase breather tube. Remove the crankcase
ventilation filter cover cap screws. Remove the filter cover.
Remove the crankcase ventilation filter from the rocker lever
cover. Inspect the filter gasket located on the rocker lever cover
for tears, cuts, or brittleness. If any of these conditions are present
discard gasket. Clean the filter mounting surface and o ring
sealing surfaces on the rocker lever cover. Clean the filter cover
with warm soapy water, dry with compressed air. If the gasket
was removed, install a new gasket into the rocker lever cover
groove. Apply clean 15W-40 engine oil to the O-rings on the
filter. Install the filter onto the rocker lever cover. Install the filter
cover. Install the cover cap screws. Tighten the cap screws,
starting with the inner-most cap screws and working outward in a
circular motion. Torque cap screws 62 IN LB. Connect crankcase
breather tube. Operate engine and check for leaks.
“C” P.M. EVERY 6,000 HRS. (To include all items listed in “A” and “B” P.M.)
84 CHANGE TRANSMISSION
FLUID
Drain and dispose of fluid. Install drain plug and torque 18 to 24
FT LB.
DO NOT OVER TORQUE OR USE AND IMPACT
WRENCH TO INSTALL PLUG.
Fill transmission with 17 quarts of TES 295 ATF fluid. Check
cold level of fluid, bring truck to operating temp and check hot
level. Adjust as necessary. Truck must be in neutral on level
ground. DO NOT OVERFILL TRANSMISSION
(CHANGE FLUID EVERY 6,000 HRS.)
17
(1) LOCATION: (2) EQUIPMENT NUMBER (3) TYPE OF INSPECTION: (4) DATE:
"A" P.M.
1 Driver Seat - Operation - Condition 34 Reverse Blow The Radiator 67 Suspend Front Axle
2 Seat Belt - Operation - Condition 35 Starter - Mount Bolts & Cables 68 Front Springs - Condition of Springs
3 Horn Operation 36 Hydraulic Pump - Leaks - Mounting 69 Steering Components - Check Fluid Level
4 Windshield Wiper - Operation - Condition 37 Hydraulic Tank - Condition - Fluid Level 70 King Pins - Wheel Bearings
5 Dome Light - Operation 38 Hydraulic Tank Cap - Tight - Gasket Present 71 Front Hubs - Oil Level
6 Defrost, Fan, Heater & AC Operation 39 Air Compressor - Mounting 72 Low er Support & Torque Arms
7 Dash Lights - Operation 40 Air Compressor Discharge Line & Governor 73 Frame & Cross Members
8 All Gauges & Vehicle Controls - Operation 41 Fuel Pump & Lines - Leaks 74 Engine & Transmission Mounts - Bolts
9 Headliner & Floor Mat - Condition 42 Throttle System - Condition - Leaks 75 Grease All Lubrication Fittings - Write Up
10 Interior For Loose or Missing Screw s 43 Battery Box, Cover & Latches - Condition Fittings That Will Not Take Grease
11 Glass and Latches - Operation - Condition 44 Batteries & Cables 76 Brake Lining Level (Percentage)
12 Cab Door - Operation - Condition 45 Clean & Inspect All Wire Terminals Left Front
13 Air Leaks (Park Brake Released) 46 Cab Mounts, Lift Pump & Cylinder Left Rear
Service Brake Not Applied 47 Check Coolant Level & Protection Right Front
Service Brake Applied Coolant Level _______ Protection _______ Right Rear
14 Parking Brake Operation 48 Air Dryer & Spitter Valve (If Equipped) 77 Adjust All Brakes & Inspect Chambers
15 Boom Operation 78 Drums, Wheels, Rims & Lugs
16 Steering Wheel & Column - Condition 49 Drain Oil, Change Filters - Refill 79 Tires - Condition & Air Pressure
17 Steering - Operation 50 Change The Fuel Filters 80 Apply New PM Sticker
18 Transmission - Operation 51 Fuel Tank - Straps & Mounting "B" P.M.
52 Clean Trans Vent - Check Fluid Level 81 Change External Transmission Filter MT
19 All Lights - Condition - Operation 53 Clean Rear Axle Vent - Check Fluid Level 82 Change Internal Transmission Filter ELEC
20 Cab Protection Bar - Condition - Cracks 54 Drive Shaft, Universal Joints & Yokes 83 Prioritized Pow er Steering System
21 Cab Condition - Damages - Cracks 55 Inspect All Components For Leaks 84 Change Crankcase Filter (ISB 2010 only)
22 Mirrors & Brackets - Condition - Secure 56 Drain The Air Tanks 85 Change DEF Filter (ISB 2010 only)
23 Bumper & Fender - Condition - Secure 57 Air Tanks - Condition & Mounting Brackets "C" P.M.
24 Glad Hands, Washer, Hoses & Hangers 58 Inspect All Air Hoses & Lines 86 Change Transmission Fluid - 6,000 Hours
59 Change Hydraulic Filters
25 Air Cleaner Ductw ork & Clamps 60 Check The Transmission Linkage "A" P.M. includes items 1 thru 80
26 Air Filter & Air Restriction Indicator
27 Alternator - Mounting Brackets & Bolts 61 Boom, Pins & Bushings - Condition "B" P.M. includes items 1 thru 85
28 Water Pump - Leaks 62 Lift Cylinders, Hoses & Fittings
29 Fan, Fan Clutch, Fan Hub & Idler Pulley 63 Boom Cover & Transmission Cover "C" P.M. includes items 1 thru 86
30 Belts - Condition - Tension 64 Release Cylinder - Operation
31 Exhaust System - Clamps - Leaks 65 Fifth Wheel Pedestal & Bushings
32 Turbocharger - Clamps - Leaks 66 Fifth Wheel Plate & Jaw s - Condition - Slack
33 Radiator, Transmission Cooler & CAC
TICO TRACTOR PM WORKSHEET, MAY 2012
TICO - TERMINAL SERVICES TRACTOR PM WORKSHEET
FIFTH WHEEL & BOOM
STEERING, AXLES & BRAKES
UNIT: ______________ DATE: ______________ HOBBS HOURS: ______________ LOCATION: ______________
MECHANIC: ______________________________ REPAIR ORDER #: ______________________________
CODES: R = Repaired D = Defective X = OK A = Adjusted NE = Not Equipped
EXTERNAL CAB CHECKS
DRIVE IN CHECKS
ENGINE COMPARTMENT CHECK
UNDER THE VEHICLE CHECKS
18
(5) HOBBS METER READING: (6) LAST PM DATE (7) LAST PM HOBBS (8) TYPE OF LAST PM
INSTRUCTIONS FOR USE OF THIS FORM
Fill in all blocks with the requested information.
(1) The location that owns the equipment, (2) The equipment bumper number, (3) The type of inspection performed. I.e. Request for heavy repair, Preventative
Maintenance, etc., (4) The date of the inspection, (5) The HOBBS Meter Reading at the time of inspection, (6) Date of the last PM., (7) HOBBS at last PM., (8) Type
of last PM, “B” “C” (9) Printed Name and Signature of the person performing the inspection, (10) Printed name and signature of the maintenance supervisor, (11)
The item number from the PMCS manual, (12) The status symbol for the fault (status symbols listed below), (13) The deficiencies or shortcoming found, (14) The
corrective actions taken, (15) The initials of the person who performed the repairs.
STATUS SYMBOLS:
X = Dead lined, Not-Mission Capable Equipment must be repaired immediately
/ = Shortcoming, needs to be repaired Equipment can be operated
PM = Equipment due service Equipment can be operated
(9) PRINTED NAME AND SIGNATURE OF PERSON PERFORMING INSPECTION: (10) PRINTED NAME AND SIGNATURE OF MAINTENANCE SUPERVISOR:
(11)
ITEM #
(12)
STATUS
SYMBOL
(13)
DEFECIENIES OR SHORTCOMINGS
(14)
CORRECTIVE ACTIONS TAKEN (15)
INITIALS
19
(8)
ITEM #
(9)
STATUS
SYMBOL
(10)
DEFECIENIES OR SHORTCOMINGS
(11)
CORRECTIVE ACTIONS TAKEN (12)
INITIALS
20
CHASSIS LUBRICATION DIAGRAM:
* = Both Sides
**= Both Sides Front And Rear
21
LUBRICATION CHART:
Key No. Part/Description Lubricant Used/Notes
1 Coolant/Antifreeze 50/50 Ethyl-Glycol / Water
(Also Refer to Engine Manufacture’s Specs.)
2 Engine Oil SAE 15W-40
(Also Refer to Engine Manufacture’s Specs.)
3 Slack Adjusters
Brake Cam Pivot Lithium Grease #1
4 Front Axle King Pins Lithium Grease #1
5 Tie Rod Ends Lithium Grease #1
6 Transmission Fluid TES-295 Synthetic Transmission Fluid
(Also Refer to Engine Manufacture’s Specs.)
7 Diesel Fuel Ultra-Low Sulfur
8 Universal Joints Lithium Grease #1
9 Rear Axle Differential 80-140 Synthetic
(Also Refer to Engine Manufacture’s Specs.)
10 Drive Line Slip Yoke Lithium Grease #1
11 Spring Shackle Pins Lithium Grease #1
12 Front Wheel Bearings 80-140 Synthetic
(Also Refer to Engine Manufacture’s Specs.)
13 Drag Link Ends Lithium Grease #1
14 Spring Guide Pin (If Equipped) Lithium Grease #1
15 Hydraulic Automatic Transmission Fluid
16 Steering Fluid Automatic Transmission Fluid
17 Cab Lift Pump Automatic Transmission Fluid
18 Steering Shaft U-Joints Lithium Grease #1
22
BOOM AND FIFTH WHEEL LUBRICATION DIAGRAM:
* = Both Sides
**= Both Sides Front And Rear
19 Steering Slip Joint Lithium Grease #1
20 Boom Pivot Lithium Grease #1
21 Cylinder Bearings Lithium Grease #1
22 Fifth Wheel Pivot Lithium Grease #1
23 Fifth Wheel Top Plate Lithium Grease #1
24 Fifth Wheel Jaws Lithium Grease #1