TICO Pro-Spotter PM MANUAL -...

TICO, July 2015

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TICO Manufacturing

TICO Pro-Spotter PM MANUAL

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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.

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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

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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.

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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.

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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

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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.

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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.

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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

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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.

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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


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.

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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


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


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


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


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


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


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


7 Diesel Fuel Ultra-Low Sulfur

8 Universal Joints Lithium Grease #1

9 Rear Axle Differential 80-140 Synthetic


10 Drive Line Slip Yoke Lithium Grease #1

11 Spring Shackle Pins Lithium Grease #1

12 Front Wheel Bearings 80-140 Synthetic


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

TICO Pro-Spotter PM MANUAL -...

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