PREVENTIVE MAINTENANCE FOR STANDBY GENERATOR SETS

WEEKLY: WITH ENGINE RUNNING

START THE ENGINE

OIL PRESSURE

FUEL PRESSURE

ENGINE CRANKCASE

FREQUENCY (RPM) AND GENERATED

VOLTAGE

RADIATOR LOUVERS

LEAKS AND NOISES

WEEKLY: WITH ENGINE RUNNING

AUTOMATIC SWITCH (IF EQUIPPED)

 FUEL LEVEL

BATTERY CHARGER

MALFUNCTIONS
AINTENANCE FOR STANDBY GENERATOR SETS
WEEKLY: WITH ENGINE RUNNING

THE FOLLOWING OPERATIONAL CHECKS ARE INTENDED TO

CHECK THE GENERATOR OPERATION AND THE ENGINE
STARTING, LUBRICATING AND FUEL SYSTEM AS WELL AS
OVERALL OPERATION. THE CHECK SHOULD TAKE NO LONGER
THAN FIVE MINUTES TO COMPLETE. LONGER PERIODS OF
OPERATION ARE NOT REQUIRED. A MORE BENIFICIAL TEST
WILL BE PERFORMED ANNUALLY WITH THE ENGINE
OPERATING UNDER LOAD.

CHECK FOR PROPER OPERATING OIL PRESSURE. REFER TO THE

OPERATION AND MAINTENANCE GUIDE FOR THE CORRECT
PRESSURE READING.

CHECK FOR PROPER OPERATING OIL PRESSURE. REFER TO THE

OPERATION AND MAINTENANCE GUIDE FOR THE CORRECT
PRESSURE READING.

CHECK THE OIL LEVEL. MAINTAIN THE OIL LEVEL BETWEEN

THE ADD AND FULL MARKS ON THE ENGINE STOPPED SIDE OF
THE DIPSTICK.

CHECK AND RECORD READINGS.

CHECK FOR PROPER OPERATION (ABLE TO OPEN AND CLOSE

FREELY).

CHECK FOR LEAKS AND UNSUAL NOISES.

WEEKLY: WITH ENGINE RUNNING

CHECK THAT ALL SWITCHES ARE IN PROPER POSITION FOR

AUTOMATIC START.
CHECK THE FUEL LEVEL; REFILL WHEN BELOW THREE-
FOURTHS FULL

RECORD CHARGING AMPERAGE READING.

REPORT ANY MALFUNCTION AND MAKE NECESSARY REPAIRS

 PREVENTIVE MAINTENANCE FOR STANDBY GENERATOR SETS
WEEKLY: WITH ENGINE RUNNING

START THE ENGINE

OIL PRESSURE

FUEL PRESSURE

ENGINE CRANKCASE

FREQUENCY (RPM) AND GENERATED

VOLTAGE

RADIATOR LOUVERS

LEAKS AND NOISES

WEEKLY: WITH ENGINE RUNNING

AUTOMATIC SWITCH (IF EQUIPPED)

 FUEL LEVEL

BATTERY CHARGER

MALFUNCTIONS
AINTENANCE FOR STANDBY GENERATOR SETS
WEEKLY: WITH ENGINE RUNNING

THE FOLLOWING OPERATIONAL CHECKS ARE INTENDED TO

CHECK THE GENERATOR OPERATION AND THE ENGINE
STARTING, LUBRICATING AND FUEL SYSTEM AS WELL AS
OVERALL OPERATION. THE CHECK SHOULD TAKE NO LONGER
THAN FIVE MINUTES TO COMPLETE. LONGER PERIODS OF
OPERATION ARE NOT REQUIRED. A MORE BENIFICIAL TEST
WILL BE PERFORMED ANNUALLY WITH THE ENGINE
OPERATING UNDER LOAD.

CHECK FOR PROPER OPERATING OIL PRESSURE. REFER TO THE

OPERATION AND MAINTENANCE GUIDE FOR THE CORRECT
PRESSURE READING.

CHECK FOR PROPER OPERATING OIL PRESSURE. REFER TO THE

OPERATION AND MAINTENANCE GUIDE FOR THE CORRECT
PRESSURE READING.

CHECK THE OIL LEVEL. MAINTAIN THE OIL LEVEL BETWEEN

THE ADD AND FULL MARKS ON THE ENGINE STOPPED SIDE OF
THE DIPSTICK.

CHECK AND RECORD READINGS.

CHECK FOR PROPER OPERATION (ABLE TO OPEN AND CLOSE

FREELY).

CHECK FOR LEAKS AND UNSUAL NOISES.

WEEKLY: WITH ENGINE RUNNING

CHECK THAT ALL SWITCHES ARE IN PROPER POSITION FOR

AUTOMATIC START.
CHECK THE FUEL LEVEL; REFILL WHEN BELOW THREE-
FOURTHS FULL

RECORD CHARGING AMPERAGE READING.

REPORT ANY MALFUNCTION AND MAKE NECESSARY REPAIRS

 PREVENTIVE MAINTENANCE FOR STANDBY GENERATOR SETS
WEEKLY: BEFORE STARTING THE ENGINE

DATE:

WALK-AROUND INSPECTION

BELTS

COOLING SYSTEM

BLOCK HEATER

AIR CLEANER INDICATOR

ENGINE CRANKCASE

GOVERNOR

FUEL SYSTEM

AIR SYSTEM(IF EQUPPED)

BATTERIES
 GAUGES

BATTEY CHARGER

GENERATOR AND CONTROL PANEL

PERFORMED BY:

CHECKED BY :
NTENANCE FOR STANDBY GENERATOR SETS
WEEKLY: BEFORE STARTING THE ENGINE

REMARKS
 PREVENTIVE MAINTENANCE SERVICE CHECKLIST
DATE :_____________
CHECKING ITEM SERVICE REQUIRED STATUS REMARKS CHECKING ITEM SERVICE REQUIRED STATUS REMARKS
ENGINE BRAKE SYSTEM
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
visually inspect condition of engine rotation check for free travel
Engine GOOD REPAIR REPLACE N/A brake pedal GOOD REPAIR REPLACE N/A
check for working noise from engine check for pedal travel
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check that exhaust gas has proper color check for proper operation
GOOD REPAIR REPLACE N/A check that lever is securely locked and has sufficeint level GOOD REPAIR REPLACE N/A
check for engine oil leak stroke
lubrication system parking brake lever
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check engine oil for level and dirt check for proper operation
GOOD REPAIR REPLACE N/A
Brake Master cylinder, wheel GOOD REPAIR REPLACE N/A
visually check for fuel leak from pipe, pump or tank cylinder check for fluid level. Change brake fluid.
fuel system
GOOD REPAIR REPLACE N/A fork GOOD REPAIR REPLACE N/A
clean for fuel level check forks for damaged, deformation or wear
GOOD REPAIR REPLACE N/A
check for coolant level LOADING SYSTEM
cooling system GOOD REPAIR REPLACE N/A chain & sheave GOOD REPAIR REPLACE N/A
check for coolant leak check chains for tension, deformation, damage or rust
GOOD REPAIR REPLACE N/A check piston rod, rod screw and rod end for looseness, GOOD REPAIR REPLACE N/A
check fan belt for tension and damage deformation or damage
POWER TRAIN check for cylinders for proper operation GOOD REPAIR REPLACE N/A

check clutch pedal for free travel and clearance between cylinders
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
pedal surface and floor when clutch is unlocked check for oil leaks
frictional clutch GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check for noise and operation check pins and cylinder bushings for wear or damage
GOOD REPAIR REPLACE N/A hydraulic pump GOOD REPAIR REPLACE N/A
check for slipping and engagement check hydraulic pump for oil leaks or noise
transmission GOOD REPAIR REPLACE N/A
check for oil leaks HYDRAULIC SYSTEM
GOOD REPAIR REPLACE N/A hydraulic reservior GOOD REPAIR REPLACE N/A
check for oil leaks check for oil level. Change oil
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
torque converter check control valve and clutch for proper operation check levers for looseness at link
control lever
transmission
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check inching valve for proper operation check proper operation
GOOD REPAIR REPLACE N/A control valve GOOD REPAIR REPLACE N/A
checkinching pedal for free travel and pedal travel check for oil leaks
front axle GOOD REPAIR REPLACE N/A hose, piping hose, reel& swivel joint check for oil leaks, looseness, collapse,deformation and GOOD REPAIR REPLACE N/A
check for oil leak damage
WHEELS ELECTRICALS
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check for inflation pressure check battery electrolyte level. Clean battery.
battery
tires GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check for cracks or damage securely held down
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check for undue wear overhead guard & load check for tight installation
backrest
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check for looseness check for deformation, cracks or damage
tire fastners
GOOD REPAIR REPLACE N/A turn signal GOOD REPAIR REPLACE N/A
check for damage check for proper operation and tight installation
rim, side ring GOOD REPAIR REPLACE N/A horn GOOD REPAIR REPLACE N/A
check rim, side ring and disk wheel for damage check for proper operation and tight installation
STEERING SYSTEM lights and lamps check for proper operation and tight installation GOOD REPAIR REPLACE N/A

GOOD REPAIR REPLACE N/A back up buzzer GOOD REPAIR REPLACE N/A
check for peripheral play check for proper operation and tight installation
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check for vertical looseness check for dirt or damage
steer handwheel rear view mirror
GOOD REPAIR REPLACE N/A GOOD REPAIR REPLACE N/A
check for sideway looseness check for good field of vision
GOOD REPAIR REPLACE N/A meters GOOD REPAIR REPLACE N/A
check for proper operation check meters for operation
power steering GOOD REPAIR REPLACE N/A body GOOD REPAIR REPLACE N/A
check for operation check items repaired in preceding inspection, If any

OVERALL CONDITION:

EXCELLENT CONDITION LOCATION:

A LITTLE WEAR AND GOOD CONDITION

WORKABLE BUT MINOR REPAIR REQUIRED DRIVER'S NAME & SIGNATURE :

WORKABLE BUT MAJOR REPAIR REQUIRED

CANNOT DETERMINE OVERALL CONDITION INSPECTED NAME & SIGNATURE:

NOT APPLICABLE
 DAILY PREVENTIVE MAINTE
DATE :_____________

CHECKING ITEM
ENGINE

Engine

lubrication system

fuel system

cooling system

POWER TRAIN

frictional clutch
transmission

torque converter transmission

front axle

WHEELS

tires

tire fastners

rim, side ring

STEERING SYSTEM

steer handwheel
power steering

BRAKE SYSTEM

brake pedal

parking brake lever

Brake Master cylinder, wheel cylinder

fork
LOADING SYSTEM
chain & sheave

cylinders

hydraulic pump

HYDRAULIC SYSTEM
hydraulic reservior

control lever

control valve

hose, piping hose, reel& swivel

joint
ELECTRICALS

battery

overhead guard & load backrest

turn signal

horn

lights and lamps

back up buzzer

rear view mirror

meters

body

OVERALL CONDITION:
 DAILY PREVENTIVE MAINTENANCE SERVICE C

SERVICE REQUIRED

GOOD
visually inspect condition of engine rotation
GOOD
check for working noise from engine
GOOD
check that exhaust gas has proper color
GOOD
check for engine oil leak
GOOD
check engine oil for level and dirt
GOOD
visually check for fuel leak from pipe, pump or tank
GOOD
clean for fuel level
GOOD
check for coolant level
GOOD
check for coolant leak
GOOD
check fan belt for tension and damage

check clutch pedal for free travel and clearance between GOOD
pedal surface and floor when clutch is unlocked
GOOD
check for noise and operation
GOOD
check for slipping and engagement
 GOOD
check for oil leaks
GOOD
check for oil leaks
GOOD
check control valve and clutch for proper operation
GOOD
check inching valve for proper operation
GOOD
checkinching pedal for free travel and pedal travel
GOOD
check for oil leak

GOOD
check for inflation pressure
GOOD
check for cracks or damage
GOOD
check for undue wear
GOOD
check for looseness
GOOD
check for damage
GOOD
check rim, side ring and disk wheel for damage

GOOD
check for peripheral play
GOOD
check for vertical looseness
GOOD
check for sideway looseness
GOOD
check for proper operation
 GOOD
check for operation

GOOD
check for free travel
GOOD
check for pedal travel
GOOD
check for proper operation
check that lever is securely locked and has sufficeint level GOOD
stroke
GOOD
check for proper operation
GOOD
check for fluid level. Change brake fluid.
GOOD
check forks for damaged, deformation or wear
 GOOD
check chains for tension, deformation, damage or rust
check piston rod, rod screw and rod end for looseness, GOOD
deformation or damage
GOOD
check for cylinders for proper operation
GOOD
check for oil leaks
GOOD
check pins and cylinder bushings for wear or damage
GOOD
check hydraulic pump for oil leaks or noise

GOOD
check for oil level. Change oil
GOOD
check levers for looseness at link
GOOD
check proper operation
GOOD
check for oil leaks
check for oil leaks, looseness, collapse,deformation and GOOD
damage

GOOD
check battery electrolyte level. Clean battery.
GOOD
securely held down
GOOD
check for tight installation
GOOD
check for deformation, cracks or damage
 GOOD
check for proper operation and tight installation
GOOD
check for proper operation and tight installation
GOOD
check for proper operation and tight installation
GOOD
check for proper operation and tight installation
GOOD
check for dirt or damage
GOOD
check for good field of vision
GOOD
check meters for operation
GOOD
check items repaired in preceding inspection, If any

EXCELLENT CONDITION LOCATION:

A LITTLE WEAR AND GOOD CONDITION
WORKABLE BUT MINOR REPAIR REQUIRED DRIVER'S NAME & SIGNATURE :
WORKABLE BUT MAJOR REPAIR REQUIRED
CANNOT DETERMINE OVERALL CONDITION INSPECTED NAME & SIGNATURE:
NOT APPLICABLE
SERVICE CHECKLIST

STATUS REMARKS

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

 REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

REPAIR REPLACE N/A

NATURE :

GNATURE:
 DAILY MAINTENANCE OF AUTOMATIC SEAMING MACHINE

ü NORMAL û

make sure that the automatic oil lubricator are filled with lubricant as per Eye sight glasses mounted on each unit.

make sure that the air spray lubricator are filled with lubricant as per tye sight glasses mounted on each unit.

make sure all grease nipples are greased before starting the machine, chains and sprocket should also be wiped
with a little grease

check out all safety devices to make sure they are functioning correctly

clean the guide plates, feeding table, etc that come in contact with the can body

check if the output cans like to the specifications of can all the same

check if need to adjust the tightness of timing spiral chains

thoroughly clean the rolls and chucks and lifting unit

check if need to replenish the oil cup of air line lubricator

LUBRICATION
ITE
M DESCRIPTION cond. T1 T2 T3 T4 T5 T6
NO.

1 OIL AUTOMATIC LUBRICATOR

a knockout rod
b seaming cam
2 Air spray lubricator
3 lubricate the brushes on infeed table sprocket shaft
4 lubricate the brushes on infeed table tuning spiral
5 side wall of lower main body (18 times every 8 hours)
6 filler, sleeve and ball bearings
7 seaming roll bearings(every 4 hours)
8 inlet feed table timing(every 4 hours)

9 Gearboxes oil level: Medium High Medium Low

a feeding chain drive
b driving of cover magazine
c uppen main driving
d discharge 6-pocket taurret

grease
seaming head
seaming lever arm fittings
shaft bushing cam followers
seaming rolls

motor pulley
motor bearings
filler drive coupling seaming head mechanism

cover magazine gears and bushes

infeed coveyor chain sprickets

infeed timing spiral support bushings

Lower lifter plate

lifting cam shaft
main base drive gears

oil automatic lubricator

air line lubricator
MING MACHINE

ABNORMAL REMARKS
ed on each unit.

n each unit.

also be wiped

T7 T8 REMARKS

REMARKS Lubricants Inventory

grease______kg/L
oil______kg/L
cooking oil______kg/L
ord grease______kg/L
 DAILY MAINTENANCE OF AUTOMATIC SEAMING

ü NORMAL

make sure that the automatic oil lubricator are filled with lubricant as per Eye sight glasses mounted on each unit.

make sure that the air spray lubricator are filled with lubricant as per tye sight glasses mounted on each unit.

make sure all grease nipples are greased before starting the machine, chains and sprocket should also be wiped with a li

check out all safety devices to make sure they are functioning correctly

clean the guide plates, feeding table, etc that come in contact with the can body

check if the output cans like to the specifications of can all the same

check if need to adjust the tightness of timing spiral chains

thoroughly clean the rolls and chucks and lifting unit

check if need to replenish the oil cup of air line lubricator

LUBRICATION

ITEM
NO. DESCRIPTION Condition time 1taken

1 seaming head
a seaming lever arm fittings
b shaft bushing cam followers
2 seaming rolls
3
4 motor pulley (every 4 working hours)
5 motor bearings(every 4 working hours)
6 filler drive coupling seaming head mechanism(every 4 working hours)

cover magazine gears and bushes

infeed coveyor chain sprickets

infeed timing spiral support bushings

 Lower lifter plate
lifting cam shaft
main base drive gears

7 oil automatic lubricator

8 air line lubricator

9 Gearboxes oil level: Medium High

a feeding chain drive
b driving of cover magazine
c uppen main driving
d discharge 6-pocket taurret

LUBRICATION

ITEM
NO. DESCRIPTION Condition time 1taken

1 seaming head
1.1 seaming lever arm fittings
1.2 shaft bushing cam followers
1.3 seaming rolls
1.4 motor pulley
1.5 motor bearings
1.6 filler drive coupling seaming head mechanism
2 cover magazine and infeed conveyor
2.1 cover magazine gears and bushes
2.2 infeed coveyor chain sprickets
3 infeed timing spiral support bushings
4 Lower lifter plate
5 lifting cam shaft
6 main base drive gears
7 oil automatic lubricator
8 air line lubricator
OMATIC SEAMING MACHINE

û ABNORMAL REMARKS
mounted on each unit.

nted on each unit.

should also be wiped with a little grease

TION
time taken time taken time taken time taken REMARKS
2 3 4 5
 Medium Low REMARKS Lubricants Inventory
grease______kg/L
oil______kg/L
cooking oil______kg/L
ord grease______kg/L

TION
time taken time taken time taken time taken REMARKS
2 3 4 5

REMARKS Lubricants Inventory

grease______kg/L
oil______kg/L
cooking oil______kg/L
ord grease______kg/L
1.428571
 LUBRICATION FOR SB-45 AUTOMATIC SEAMER MACHINE

DATE : ___________________ ü NORMAL û ABNORMAL LINE: ____________

ITEM
NO. DESCRIPTION Condition time 1taken time 2taken time 3taken time 4taken time 5taken

1 OIL AUTOMATIC LUBRICATOR

1.1 knockout rod - oil (daily)
1.2 seaming cam - oil (daily)
2 Air spray lubricator
3 lubricate the brushes on infeed table sprocket shaft
4 lubricate the brushes on infeed table tuning spiral
5 side wall of lower main body (18 times every 8 hours) - grase
6 filler, sleeve and ball bearings
7 seaming roll bearings(every 4 hours) - grease
8 inlet feed table timing(every 4 hours) - grease

9 Gearboxes oil level: Medium High Medium Low REMARKS

9.1 feeding chain drive
b driving of cover magazine
c uppen main driving
d discharge 6-pocket taurret

LUBRICATION FOR SB-15 AUTOMATIC SEAMER MACHINE

DATE : ___________________ ü NORMAL û ABNORMAL LINE: ____________

ITEM
NO. DESCRIPTION Condition time 1taken time 2taken time 3taken time 4taken time 5taken

1 seaming head
1.1 seaming lever arm fittings
1.2 shaft bushing cam followers
1.3 seaming rolls
1.4 motor pulley (every 4 working hours)
1.5 motor bearings (every 4 working hours)
filler drive coupling seaming head mechanism (every 4 working
1.6 hours)
2 cover magazine gears and bushes (every 4 working hours)
3 infeed coveyor chain sprockets - 2 times a day
4 infeed timing spiral support bushings - 2 TIMES A DAY REMARKS
5 Lower lifter plate and lower side drive gears - 2 times a day
6 lifting cam shaft
7 main base drive gears - 2 times a day
8 oil automatic lubricator
9 air line lubricator
 LUBRICATION FOR SB-29 AUTUMATIC SEAMER MACHINE

DATE: ü NORMAL û ABNORMAL

ITEM
NO. DESCRIPTION Condition time 1taken time 2taken time 3taken time 4taken time 5taken

1 bed plate

1.1 seven fittings in cluster adjacent to cover feed shaft

1.2 one fiiting on feed frame under feed taurret

2 cover feed

2.1 one fitting on cap feed support bearing inside guard

2.2 cap feed clutch, cap feed slide way and connecting link

3 drive case

3.1 two fittings on drive shaft

3.2 sight glass in drive gear case

4 knockout & cap centering cam

4.1 one fiting in rim of cam

4.2 cam groove, rolls & knockout rod guides

5 upper turret

5.1 four fitting at top of upper turret adjacent to spindle sleeve

5.2 one fitting to left of no. 1 spindle sleeve(to center shaft)

5.3 four fittings, one on each D.S cam drive gear sleeve above
seaming cam

6 lower turret

6.1 one fitting on hallow shaft above lower turret hub

6.1. one fitting on top of surface of lower turret hub

2

6.2 four fittings. One on each lower mandrel bushings

6.3 four fittings, one in end of each lower chuck cam roll pin

7 can feed & discharge tables

7.1 3 fittings on side of timer bracket below feed table

7.2 3 fittings oin ends of ilde gear studs

7.3 1 fitting on timer shaft steady bearing

7.4 1 fitting on discharge table bearing

8 Feed turret

8.1 1 fitting on top of feed turret shaft

8.2 7 fittings, one on each feed arm slide block

8.3 9 fittings on internal gear

8.4 cap pushers & rolls

9 seaming head
9.1 4 fittings, one on right outside surface of each finger below head
body(finger pin bearings)

9.2 4 fittings, one on left outside surface of each finger below head
body

9.3 4 fittings, one on each seaming cam roll pin

10 motor drive
E

INE: ____________

REMARKS Personnel Names

Lubricants Inventory
grease______kg,L
oil______kg,L
cooking oil______kg,L
ord grease______kg,L

INE: ____________

REMARKS Personnel Names

Lubricants Inventory
grease______kg,L
oil______kg,L
cooking oil______kg,L
ord grease______kg,L
E

REMARKS
 Lubricants Inventory
grease______kg/L
oil______kg/L
cooking oil______kg/L
ord grease______kg/L
preventive maintenance service schedule
daily
checking item

ENGIN

Engine

PCV device
governor or injection pump

lubrication system

fuel system

cooling system

power t

frictional clutch

transmission
 transmission

torque converter transmission

front axle

whee

tires

tire fastners

rim, side ring

wheel bearing

axle

steering s
steer handwheel

steering gear box

knuckle rear axle

power steering

brake sys

brake pedal

parking brake lever

rod, cable, etc

 rod, cable, etc

hoses and pipes

brake master cylinder, wheel cylinder

brake drum & brake shoe

back plate

fork

mast & lift bracket

loading sy

chain & sheave

optional attachment

cylinders

hydraulic pump

hydraulic system

hydraulic reservior
 hydraulic reservior

return filter

control lever

control valve

hose, piping hose, reel& swivel joint

electric

ignition device ( for gasoline truck)

starter

battery

wiring

safety apparatus & accessories

overhead guard & load backrest

turn signal
horn
lights and lamps
bavk up buzzer

rear view mirror

meters
drivers seat

body

grease-up & oil change

service required

ENGINE
visually inspect condition of engine rotation
check for working noise from engine
check that exhaust gas has proper color
check air cleaner element for dirt and clean
check crankcase air breather for dirt and clean
check that valve clearance is correct
retighten cylinder head bolt
check cylinders for proper compression
check metering valve and pipe for clogging or damage
check no load maximum rpm
check for engine oil leak
check engine oil for level and dirt
replace engine oil
replace engine oil filter cartridge
visually check for fuel leak from pipe, pump or tank
check fuel filter for clogging
clean fuel filter
replace fuel filter cartridge
check that injection nozzle has correct inject press and pattern
check carbureter link mechanism for looseness or dirt
check for ignition timing
check for injection timing
drain off water from fuel tank
clean fuel tank
clean for fuel level
check for coolant level
check for coolant leak
check hoses for deterioration
check radiator cap for condition and installation
clean and change coolant
check fan belt for tension and damage

power train
check clutch pedal for free travel and clearance between pedal surface and floor when
clutch is unlocked
check for noise and operation
check for slipping and engagement
check change lever for operation and looseness
check for oil leaks
change oil
check for oil leaks
check for oil level or change oil
check change lever for operation and looseness
check control valve and clutch for proper operation
check inching valve for proper operation
checkinching pedal for free travel and pedal travel
replace line filter element
check for oil leak
change oil
check mounting bolts for looseness

wheels
check for inflation pressure
check for cracks or damage
check for tread wear
check for undue wear
check for spikes, stones, or foreign matter
check for looseness
check for damage
check rim, side ring and disk wheel for damage
check for looseness and noise
clean and repack grease
check axle for deformation, cracks or damage

steering system
check for peripheral play
check for vertical looseness
check for sideway looseness
check for proper operation
check mounting bolts for looseness
check king pins for looseness or damage
check for deflection, deformation, cracks or damage
check for mounting condition
check for operation
check for oil leaks
check for monting parts and joints for looseness
brake system
check for free travel
check for pedal travel
check for proper operation
check for air mixed in brake piping
check that lever is securely locked and has sufficeint level stroke
check for proper operation
check for operation
check for looseness
check for damage, leakage or collpase
check for loose connection or clamping parts
check for fluid leaks
check for fluid level. Change brake fluid.
check master cylinder and wheel cylinders for proper operation
check master cylinder and wheel cylinder for fluid leaks or damage
check master cylinder piston cup, and check valve for war or damage. Change
check drum mounting part for looseness
check lining for wear
check brake shoes for proper operation
check anchor pin for rust
check return spring for dteioration
check automatic clearance adjuster for operation
check drum for wear or damage
check back plate for deformation
check for cracks
check mounting parts for looseness
check forks for damaged, deformation or wear
check for stooper bins for damage or wear
check for base and hook weldings for defective cracks or wear
check cross members on outer and inner masts for defective weld, cracks or damage
check tilt cylinder bracket nad mast for defective weld, cracks or damage
check for defective weld, cracks or damage of the lift bracket
check for roller bearings for looseness
check mast support bushings for wear or damage
check mast support cap bolts for looseness
check lift cylinder tail bolts, pistons rod head bolts, u-bolts, and piston head guide bolts
for looseness
check roller, roller pins and welded parts for cracks or damage
loading system
check chains for tension, deformation, damage or rust
lubrication of chains
check connetion of chain anchor pin and chain for looseness
check sheaves for deformation or damage
check sheave bearing for looseness
perform general inspection
check piston rod, rod screw and rod end for looseness, deformation or damage
check for cylinders for proper operation
check for oil leaks
check pins and cylinder bushings for wear or damage
check hydraulic pump for oil leaks or noise
check pump drive gear for wear

check for oil level. Change oil

clean suction strainer
drain foreign matter
replace return filter
check levers for looseness at link
check proper operation
check for oil leaks
check relief valve and tilt lock valve for proper operation
measure relief pressure
check for oil leaks, looseness, collapse,deformation and damage
change hoses
electricals
checkdistributor cap for crack
check spark plug for burn
adjust spar plug clearnce
clean spark plug
check distributor cap high-voltage cord for installation
check distributor segment for burn
check distributor center piece for wear or damage
apply grease on shaft, cam heel and breaker fulcrum
check high voltage cord for breakage
check pinion gear for correct engagement
check battery electrolyte level. Clean battery
check specific gravity of electrolyte
check wires harness for damage and clamps for looseness
check connection for looseness

check for tight installation

check for deformation, cracks or damage
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for dirt or damage
check for good field of vision
check meters for operation
check for ldamage or loose bolts
check frame and cross members for damage or cracks
check for loose rivets or bolts
check items repaired in preceding inspection, If any
inspection general condition of body
after cleaning, check for greased condition of chassis
check oil condition of oil and fluid reservior
 tools daily monthly trimonthly semiannually annually
8hrs 200 hrs 600hrs 1200hrs 2400hrs

ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü l l
ü ü ü
thickness gauge ü ü
torque wrench ü
compression gauge ü
ü ü
tachometer ü
ü ü ü ü ü
ü ü ü ü ü
l l l
l l l
ü ü ü ü ü
ü ü ü
ü ü ü
l l l
nozzle tester ü ü
ü ü ü
timing ü ü
ü
ü ü ü
ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü
ü ü ü ü
l l l
ü ü ü ü ü

ü ü ü ü ü

ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü
ü ü ü ü ü
 l l
ü ü ü ü l
ü ü ü ü
ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
l l
ü ü ü ü ü
l l
test hammer ü ü ü ü

tire gauge ü ü ü ü ü
ü ü ü ü ü
depth gauge ü ü ü ü
ü ü ü ü ü
ü ü ü ü
test hammer ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü
l l
ü ü ü ü

tem
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
test hammer ü ü ü ü
ü ü ü ü ü
ü ü ü ü
ü ü ü ü

ü ü ü ü ü
scale ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü
 ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü l l
ü
ü
l
test hammer ü ü ü ü
ü
ü
ü
ü
ü
ü
ü
penetrant test ü
test hammer ü
ü ü ü ü ü
ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü

ü ü ü ü

ü ü ü ü

ü ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü

ü ü ü ü ü
 ü ü
ü ü
l l
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü
oil pressure gauge ü ü
ü ü ü ü ü
l

ü ü ü
ü
plug gap gauge ü ü ü
ü ü ü
ü
ü
ü
ü ü ü
tester ü
ü ü ü
ü ü ü ü
hydro-meter ü ü ü
ü ü ü ü
ü ü ü

test hammer ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü ü ü ü
ü ü
ü
ü
ü ü ü ü ü
ü
ü ü ü ü
ü
initial at 25 hrs
initial at 200 hrs
1 or 2 years
 DAILY PREVENTIVE MAINTENANCE SERVICE CHECKLIST
DATE :_____________

CHECKING ITEM SERVICE REQUIRED STATUS REMARKS

ENGINE
visually inspect condition of engine rotation GOOD REPAIR REPLACE N/A
Engine check for working noise from engine GOOD REPAIR REPLACE N/A
check that exhaust gas has proper color GOOD REPAIR REPLACE N/A
check for engine oil leak GOOD REPAIR REPLACE N/A
lubrication system
check engine oil for level and dirt GOOD REPAIR REPLACE N/A
visually check for fuel leak from pipe, pump or tank GOOD REPAIR REPLACE N/A
fuel system
clean for fuel level GOOD REPAIR REPLACE N/A
cooling system check for coolant level GOOD REPAIR REPLACE N/A
check for coolant leak GOOD REPAIR REPLACE N/A
check fan belt for tension and damage GOOD REPAIR REPLACE N/A
POWER TRAIN
GOOD REPAIR REPLACE N/A
check clutch pedal for free travel and clearance between pedal surface and floor when clutch is unlocked
frictional clutch GOOD REPAIR REPLACE N/A
check for noise and operation
check for slipping and engagement GOOD REPAIR REPLACE N/A
transmission check for oil leaks GOOD REPAIR REPLACE N/A
check for oil leaks GOOD REPAIR REPLACE N/A
check control valve and clutch for proper operation GOOD REPAIR REPLACE N/A
torque converter transmission
check inching valve for proper operation GOOD REPAIR REPLACE N/A
checkinching pedal for free travel and pedal travel GOOD REPAIR REPLACE N/A
front axle check for oil leak GOOD REPAIR REPLACE N/A
WHEELS
check for inflation pressure GOOD REPAIR REPLACE N/A
tires check for cracks or damage GOOD REPAIR REPLACE N/A
check for undue wear GOOD REPAIR REPLACE N/A
check for looseness GOOD REPAIR REPLACE N/A
tire fastners
check for damage GOOD REPAIR REPLACE N/A
rim, side ring check rim, side ring and disk wheel for damage GOOD REPAIR REPLACE N/A
STEERING SYSTEM
check for peripheral play GOOD REPAIR REPLACE N/A
check for vertical looseness GOOD REPAIR REPLACE N/A
steer handwheel
check for sideway looseness GOOD REPAIR REPLACE N/A
check for proper operation GOOD REPAIR REPLACE N/A
power steering check for operation GOOD REPAIR REPLACE N/A
BRAKE SYSTEM
check for free travel GOOD REPAIR REPLACE N/A
brake pedal check for pedal travel GOOD REPAIR REPLACE N/A
check for proper operation GOOD REPAIR REPLACE N/A
check that lever is securely locked and has sufficeint level stroke GOOD REPAIR REPLACE N/A
parking brake lever
check for proper operation GOOD REPAIR REPLACE N/A
Brake Master cylinder, wheel cylinder check for fluid level. Change brake fluid. GOOD REPAIR REPLACE N/A
fork check forks for damaged, deformation or wear GOOD REPAIR REPLACE N/A
LOADING SYSTEM
chain & sheave check chains for tension, deformation, damage or rust GOOD REPAIR REPLACE N/A
check piston rod, rod screw and rod end for looseness, deformation or damage GOOD REPAIR REPLACE N/A
check for cylinders for proper operation GOOD REPAIR REPLACE N/A
cylinders
check for oil leaks GOOD REPAIR REPLACE N/A
check pins and cylinder bushings for wear or damage GOOD REPAIR REPLACE N/A
hydraulic pump check hydraulic pump for oil leaks or noise GOOD REPAIR REPLACE N/A
hydraulic reservior check for oil level. Change oil GOOD REPAIR REPLACE N/A
check levers for looseness at link GOOD REPAIR REPLACE N/A
control lever
check proper operation GOOD REPAIR REPLACE N/A
control valve check for oil leaks GOOD REPAIR REPLACE N/A
hose, piping hose, reel& swivel joint check for oil leaks, looseness, collapse,deformation and damage GOOD REPAIR REPLACE N/A
ELECTRICALS
overhead guard & load check for tight installation GOOD REPAIR REPLACE N/A
backrest check for deformation, cracks or damage GOOD REPAIR REPLACE N/A
turn signal check for proper operation and tight installation GOOD REPAIR REPLACE N/A
horn check for proper operation and tight installation GOOD REPAIR REPLACE N/A
lights and lamps check for proper operation and tight installation GOOD REPAIR REPLACE N/A
back up buzzer check for proper operation and tight installation GOOD REPAIR REPLACE N/A
check for dirt or damage GOOD REPAIR REPLACE N/A
rear view mirror
check for good field of vision GOOD REPAIR REPLACE N/A
meters check meters for operation GOOD REPAIR REPLACE N/A
body check items repaired in preceding inspection, If any GOOD REPAIR REPLACE N/A

OVERALL CONDITION:
EXCELLENT CONDITION
LOCATION:
A LITTLE WEAR AND GOOD CONDITION
WORKABLE BUT MINOR REPAIR REQUIRED
DRIVER'S NAME & SIGNATURE :
WORKABLE BUT MAJOR REPAIR REQUIRED
CANNOT DETERMINE OVERALL CONDITION
INSPECTED NAME & SIGNATURE:
NOT APPLICABLE
preventive maintenance service schedule
daily
checking item

ENGINE

Engine

lubrication system

fuel system

cooling system

power train

frictional clutch

transmission

torque converter transmission

front axle

wheels

tires

tire fastners

rim, side ring

wheel bearing
 axle

steering system
steer handwheel

steering gear box

knuckle rear axle

power steering

brake system

brake pedal

parking brake lever

rod, cable, etc

hoses and pipes

brake master cylinder, wheel cylinder

brake drum & brake shoe

fork

mast & lift bracket

loading system

chain & sheave

 optional attachment

cylinders

hydraulic pump

hydraulic system
hydraulic reservior

control lever

control valve

hose, piping hose, reel& swivel joint

electricals
battery
wiring

overhead guard & load backrest

turn signal
horn
lights and lamps
bavk up buzzer

rear view mirror

meters

grease-up & oil change

service required

ENGINE
visually inspect condition of engine rotation
check for working noise from engine
check that exhaust gas has proper color
check air cleaner element for dirt and clean
check for engine oil leak
check engine oil for level and dirt
visually check for fuel leak from pipe, pump or tank
clean for fuel level
check for coolant level
check for coolant leak
check hoses for deterioration
check radiator cap for condition and installation
check fan belt for tension and damage

power train
check clutch pedal for free travel and clearance between pedal surface and floor when
clutch is unlocked
check for noise and operation
check for slipping and engagement
check change lever for operation and looseness
check for oil leaks
check for oil leaks
check for oil level or change oil
check change lever for operation and looseness
check control valve and clutch for proper operation
check inching valve for proper operation
checkinching pedal for free travel and pedal travel
check for oil leak
check mounting bolts for looseness

wheels
check for inflation pressure
check for cracks or damage
check for tread wear
check for undue wear
check for spikes, stones, or foreign matter
check for looseness
check for damage
check rim, side ring and disk wheel for damage
check for looseness and noise
check axle for deformation, cracks or damage

steering system
check for peripheral play
check for vertical looseness
check for sideway looseness
check for proper operation
check mounting bolts for looseness
check king pins for looseness or damage
check for deflection, deformation, cracks or damage
check for mounting condition
check for operation
check for oil leaks
check for monting parts and joints for looseness
brake system
check for free travel
check for pedal travel
check for proper operation
check for air mixed in brake piping
check that lever is securely locked and has sufficeint level stroke
check for proper operation
check for operation
check for looseness
check for damage, leakage or collpase
check for loose connection or clamping parts
check for fluid leaks
check for fluid level. Change brake fluid.
check drum mounting part for looseness
check forks for damaged, deformation or wear
check for base and hook weldings for defective cracks or wear
check cross members on outer and inner masts for defective weld, cracks or damage
check tilt cylinder bracket nad mast for defective weld, cracks or damage
check for defective weld, cracks or damage of the lift bracket
check for roller bearings for looseness
check mast support bushings for wear or damage
check mast support cap bolts for looseness
check lift cylinder tail bolts, pistons rod head bolts, u-bolts, and piston head guide bolts
for looseness
check roller, roller pins and welded parts for cracks or damage
loading system
check chains for tension, deformation, damage or rust
lubrication of chains
check connetion of chain anchor pin and chain for looseness
check sheaves for deformation or damage
check sheave bearing for looseness
perform general inspection
check piston rod, rod screw and rod end for looseness, deformation or damage
check for cylinders for proper operation
check for oil leaks
check pins and cylinder bushings for wear or damage
check hydraulic pump for oil leaks or noise
check pump drive gear for wear
hydraulic system
check for oil level. Change oil
check levers for looseness at link
check proper operation
check for oil leaks
check relief valve and tilt lock valve for proper operation
check for oil leaks, looseness, collapse,deformation and damage
electricals
check battery electrolyte level. Clean battery
check wires harness for damage and clamps for looseness
check for tight installation
check for deformation, cracks or damage
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for dirt or damage
check for good field of vision
check meters for operation
check items repaired in preceding inspection, If any
after cleaning, check for greased condition of chassis
check oil condition of oil and fluid reservior
 tools monthly
200 hrs

ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü

ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
test hammer ü

tire gauge ü
ü
depth gauge ü
ü
ü
test hammer ü
ü
ü
ü
 ü

ü
ü
ü
ü
ü
ü
ü
test hammer ü
ü
ü
ü

ü
scale ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
test hammer ü
ü
ü
ü
ü
ü
ü
ü
ü

ü
ü
ü
ü
ü
 ü
ü
ü
ü
ü
ü
ü

ü
ü
ü
ü
ü
ü

ü
ü
test hammer ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
preventive maintenance service schedule
daily
checking item

ENGINE

Engine

lubrication system

fuel system

cooling system

power train

frictional clutch

transmission

torque converter transmission

front axle

wheels
 tires

tire fastners

rim, side ring

wheel bearing
axle

steering system
steer handwheel

steering gear box

knuckle rear axle

power steering

brake system

brake pedal

parking brake lever

rod, cable, etc

hoses and pipes

brake master cylinder, wheel cylinder

brake drum & brake shoe

fork

mast & lift bracket

 mast & lift bracket

loading system

chain & sheave

optional attachment

cylinders

hydraulic pump

hydraulic system
hydraulic reservior

control lever

control valve

hose, piping hose, reel& swivel joint

electricals

ignition device ( for gasoline truck)

starter

battery

wiring

safety apparatus & accessories

overhead guard & load backrest

turn signal
horn
lights and lamps
bavk up buzzer

rear view mirror

meters
grease-up & oil change
service required

ENGINE
visually inspect condition of engine rotation
check for working noise from engine
check that exhaust gas has proper color
check air cleaner element for dirt and clean
check crankcase air breather for dirt and clean
check for engine oil leak
check engine oil for level and dirt
replace engine oil
replace engine oil filter cartridge
visually check for fuel leak from pipe, pump or tank
check fuel filter for clogging
clean fuel filter
replace fuel filter cartridge
check carbureter link mechanism for looseness or dirt
drain off water from fuel tank
clean for fuel level
check for coolant level
check for coolant leak
check hoses for deterioration
check radiator cap for condition and installation
clean and change coolant
check fan belt for tension and damage

power train
check clutch pedal for free travel and clearance between pedal surface and floor when
clutch is unlocked
check for noise and operation
check for slipping and engagement
check change lever for operation and looseness
check for oil leaks
check for oil leaks
check for oil level or change oil
check change lever for operation and looseness
check control valve and clutch for proper operation
check inching valve for proper operation
checkinching pedal for free travel and pedal travel
check for oil leak
check mounting bolts for looseness

wheels
check for inflation pressure
check for cracks or damage
check for tread wear
check for undue wear
check for spikes, stones, or foreign matter
check for looseness
check for damage
check rim, side ring and disk wheel for damage
check for looseness and noise
check axle for deformation, cracks or damage

steering system
check for peripheral play
check for vertical looseness
check for sideway looseness
check for proper operation
check mounting bolts for looseness
check king pins for looseness or damage
check for deflection, deformation, cracks or damage
check for mounting condition
check for operation
check for oil leaks
check for monting parts and joints for looseness
brake system
check for free travel
check for pedal travel
check for proper operation
check for air mixed in brake piping
check that lever is securely locked and has sufficeint level stroke
check for proper operation
check for operation
check for looseness
check for damage, leakage or collpase
check for loose connection or clamping parts
check for fluid leaks
check for fluid level. Change brake fluid.
check drum mounting part for looseness
check forks for damaged, deformation or wear
check for stooper bins for damage or wear
check for base and hook weldings for defective cracks or wear
check cross members on outer and inner masts for defective weld, cracks or damage
check tilt cylinder bracket nad mast for defective weld, cracks or damage
check for defective weld, cracks or damage of the lift bracket
check for roller bearings for looseness
check mast support bushings for wear or damage
check mast support cap bolts for looseness
check lift cylinder tail bolts, pistons rod head bolts, u-bolts, and piston head guide bolts
for looseness
check roller, roller pins and welded parts for cracks or damage
loading system
check chains for tension, deformation, damage or rust
lubrication of chains
check connetion of chain anchor pin and chain for looseness
check sheaves for deformation or damage
check sheave bearing for looseness
perform general inspection
check piston rod, rod screw and rod end for looseness, deformation or damage
check for cylinders for proper operation
check for oil leaks
check pins and cylinder bushings for wear or damage
check hydraulic pump for oil leaks or noise
check pump drive gear for wear
hydraulic system
check for oil level. Change oil
check levers for looseness at link
check proper operation
check for oil leaks
check relief valve and tilt lock valve for proper operation
check for oil leaks, looseness, collapse,deformation and damage
electricals
checkdistributor cap for crack
adjust spar plug clearnce
clean spark plug
apply grease on shaft, cam heel and breaker fulcrum
check pinion gear for correct engagement
check battery electrolyte level. Clean battery
check specific gravity of electrolyte
check wires harness for damage and clamps for looseness
check connection for looseness
safety apparatus & accessories
check for tight installation
check for deformation, cracks or damage
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for dirt or damage
check for good field of vision
check meters for operation
check items repaired in preceding inspection, If any
after cleaning, check for greased condition of chassis
check oil condition of oil and fluid reservior
 tools trimonthly
600hrs

ü
ü
ü
ü
ü
ü
ü
l initial at 25 hrs
l initial at 200 hrs
ü
ü
ü
l
ü
ü
ü
ü
ü
ü
ü
l
ü

ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
test hammer ü
 tire gauge ü
ü
depth gauge ü
ü
ü
test hammer ü
ü
ü
ü
ü

ü
ü
ü
ü
ü
ü
ü
test hammer ü
ü
ü
ü

ü
scale ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
test hammer ü
ü
ü
ü
ü
ü
ü
ü
ü
 ü

ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü

ü
ü
ü
ü
ü
ü

ü
plug gap gauge ü
ü
ü
ü
ü
hydro-meter ü
ü
ü

test hammer ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
preventive maintenance service schedule
daily
checking item

ENGINE

Engine

PCV device

lubrication system

fuel system

cooling system

power train

frictional clutch

transmission

torque converter transmission

 torque converter transmission

front axle

wheels

tires

tire fastners

rim, side ring

wheel bearing

axle

steering system
steer handwheel

steering gear box

knuckle rear axle

power steering

brake system

brake pedal

parking brake lever

rod, cable, etc

hoses and pipes

brake master cylinder, wheel cylinder

brake master cylinder, wheel cylinder

brake drum & brake shoe

fork

mast & lift bracket

loading system

chain & sheave

optional attachment

cylinders

hydraulic pump

hydraulic system

hydraulic reservior

return filter

control lever

control valve

hose, piping hose, reel& swivel joint

electricals

ignition device ( for gasoline truck)

starter

battery
 battery

wiring

safety apparatus & accessories

overhead guard & load backrest

turn signal
horn
lights and lamps
bavk up buzzer

rear view mirror

meters
drivers seat

grease-up & oil change

service required

ENGINE
visually inspect condition of engine rotation
check for working noise from engine
check that exhaust gas has proper color
check air cleaner element for dirt and clean
check crankcase air breather for dirt and clean
check that valve clearance is correct
check metering valve and pipe for clogging or damage
check for engine oil leak
check engine oil for level and dirt
replace engine oil
replace engine oil filter cartridge
visually check for fuel leak from pipe, pump or tank
check fuel filter for clogging
clean fuel filter
replace fuel filter cartridge
check that injection nozzle has correct inject press and pattern
check carbureter link mechanism for looseness or dirt
check for ignition timing
drain off water from fuel tank
clean fuel tank
clean for fuel level
check for coolant level
check for coolant leak
check hoses for deterioration
check radiator cap for condition and installation
clean and change coolant
check fan belt for tension and damage

power train
check clutch pedal for free travel and clearance between pedal surface and floor when
clutch is unlocked
check for noise and operation
check for slipping and engagement
check change lever for operation and looseness
check for oil leaks
change oil
check for oil leaks
check for oil level or change oil
check change lever for operation and looseness
check control valve and clutch for proper operation
check inching valve for proper operation
checkinching pedal for free travel and pedal travel
replace line filter element
check for oil leak
change oil
check mounting bolts for looseness

wheels
check for inflation pressure
check for cracks or damage
check for tread wear
check for undue wear
check for spikes, stones, or foreign matter
check for looseness
check for damage
check rim, side ring and disk wheel for damage
check for looseness and noise
clean and repack grease
check axle for deformation, cracks or damage

steering system
check for peripheral play
check for vertical looseness
check for sideway looseness
check for proper operation
check mounting bolts for looseness
check king pins for looseness or damage
check for deflection, deformation, cracks or damage
check for mounting condition
check for operation
check for oil leaks
check for monting parts and joints for looseness
brake system
check for free travel
check for pedal travel
check for proper operation
check for air mixed in brake piping
check that lever is securely locked and has sufficeint level stroke
check for proper operation
check for operation
check for looseness
check for damage, leakage or collpase
check for loose connection or clamping parts
check for fluid leaks
check for fluid level. Change brake fluid.
check drum mounting part for looseness
check forks for damaged, deformation or wear
check for stooper bins for damage or wear
check for base and hook weldings for defective cracks or wear
check cross members on outer and inner masts for defective weld, cracks or damage
check tilt cylinder bracket nad mast for defective weld, cracks or damage
check for defective weld, cracks or damage of the lift bracket
check for roller bearings for looseness
check mast support bushings for wear or damage
check mast support cap bolts for looseness
check lift cylinder tail bolts, pistons rod head bolts, u-bolts, and piston head guide bolts
for looseness
check roller, roller pins and welded parts for cracks or damage
loading system
check chains for tension, deformation, damage or rust
lubrication of chains
check connetion of chain anchor pin and chain for looseness
check sheaves for deformation or damage
check sheave bearing for looseness
perform general inspection
check piston rod, rod screw and rod end for looseness, deformation or damage
check for cylinders for proper operation
check for oil leaks
check pins and cylinder bushings for wear or damage
check hydraulic pump for oil leaks or noise
check pump drive gear for wear

check for oil level. Change oil

clean suction strainer
drain foreign matter
replace return filter
check levers for looseness at link
check proper operation
check for oil leaks
check relief valve and tilt lock valve for proper operation
measure relief pressure
check for oil leaks, looseness, collapse,deformation and damage
electricals
checkdistributor cap for crack
adjust spar plug clearnce
clean spark plug
apply grease on shaft, cam heel and breaker fulcrum
check pinion gear for correct engagement
check battery electrolyte level. Clean battery
check specific gravity of electrolyte
check wires harness for damage and clamps for looseness
check connection for looseness
safety apparatus & accessories
check for tight installation
check for deformation, cracks or damage
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for dirt or damage
check for good field of vision
check meters for operation
check for ldamage or loose bolts
check items repaired in preceding inspection, If any
after cleaning, check for greased condition of chassis
 tools semiannually annually
1200hrs 2400hrs

ü ü
ü ü
ü ü
l l
ü ü
thickness gauge ü ü
ü ü
ü ü
ü ü
l l initial at 25 hrs
l l initial at 200 hrs
ü ü
ü ü
ü ü
l l
nozzle tester ü ü
ü ü
timing ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
l l
ü ü

ü ü

ü ü
ü ü
ü ü
ü ü
l l
ü l
ü ü
ü ü
 ü ü
ü ü
ü ü
l l
ü ü
l l
test hammer ü ü

tire gauge ü ü
ü ü
depth gauge ü ü
ü ü
ü ü
test hammer ü ü
ü ü
ü ü
ü ü
l l
ü ü

ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
test hammer ü ü
ü ü
ü ü
ü ü

ü ü
scale ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
 l l
test hammer ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü

ü ü

ü ü

ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü

ü ü
ü ü
ü ü
l l
ü ü
ü ü
ü ü
ü ü
oil pressure gauge ü ü
ü ü

ü ü
plug gap gauge ü ü
ü ü
ü ü
ü ü
ü ü
hydro-meter ü ü
ü ü
ü ü

test hammer ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
ü ü
preventive maintenance service schedule
daily
checking item

ENGINE

Engine

PCV device
governor or injection pump

lubrication system

fuel system

cooling system

power train

frictional clutch

transmission
 transmission

torque converter transmission

front axle

wheels

tires

tire fastners

rim, side ring

wheel bearing

axle

steering system
steer handwheel

steering gear box

knuckle rear axle

power steering

brake system

brake pedal

parking brake lever

rod, cable, etc

 rod, cable, etc

hoses and pipes

brake master cylinder, wheel cylinder

brake drum & brake shoe

back plate

fork

mast & lift bracket

loading system

chain & sheave

optional attachment

cylinders

hydraulic pump

hydraulic system

hydraulic reservior
 hydraulic reservior

return filter

control lever

control valve

hose, piping hose, reel& swivel joint

electricals

ignition device ( for gasoline truck)

starter

battery

wiring

safety apparatus & accessories

overhead guard & load backrest

turn signal
horn
lights and lamps
bavk up buzzer

rear view mirror

meters
drivers seat

body

grease-up & oil change

service required

ENGINE
visually inspect condition of engine rotation
check for working noise from engine
check that exhaust gas has proper color
check air cleaner element for dirt and clean
check crankcase air breather for dirt and clean
check that valve clearance is correct
retighten cylinder head bolt
check cylinders for proper compression
check metering valve and pipe for clogging or damage
check no load maximum rpm
check for engine oil leak
check engine oil for level and dirt
replace engine oil
replace engine oil filter cartridge
visually check for fuel leak from pipe, pump or tank
check fuel filter for clogging
clean fuel filter
replace fuel filter cartridge
check that injection nozzle has correct inject press and pattern
check carbureter link mechanism for looseness or dirt
check for ignition timing
check for injection timing
drain off water from fuel tank
clean fuel tank
clean for fuel level
check for coolant level
check for coolant leak
check hoses for deterioration
check radiator cap for condition and installation
clean and change coolant
check fan belt for tension and damage

power train
check clutch pedal for free travel and clearance between pedal surface and floor when
clutch is unlocked
check for noise and operation
check for slipping and engagement
check change lever for operation and looseness
check for oil leaks
change oil
check for oil leaks
check for oil level or change oil
check change lever for operation and looseness
check control valve and clutch for proper operation
check inching valve for proper operation
checkinching pedal for free travel and pedal travel
replace line filter element
check for oil leak
change oil
check mounting bolts for looseness

wheels
check for inflation pressure
check for cracks or damage
check for tread wear
check for undue wear
check for spikes, stones, or foreign matter
check for looseness
check for damage
check rim, side ring and disk wheel for damage
check for looseness and noise
clean and repack grease
check axle for deformation, cracks or damage

steering system
check for peripheral play
check for vertical looseness
check for sideway looseness
check for proper operation
check mounting bolts for looseness
check king pins for looseness or damage
check for deflection, deformation, cracks or damage
check for mounting condition
check for operation
check for oil leaks
check for monting parts and joints for looseness
brake system
check for free travel
check for pedal travel
check for proper operation
check for air mixed in brake piping
check that lever is securely locked and has sufficeint level stroke
check for proper operation
check for operation
check for looseness
check for damage, leakage or collpase
check for loose connection or clamping parts
check for fluid leaks
check for fluid level. Change brake fluid.
check master cylinder and wheel cylinders for proper operation
check master cylinder and wheel cylinder for fluid leaks or damage
check master cylinder piston cup, and check valve for war or damage. Change
check drum mounting part for looseness
check lining for wear
check brake shoes for proper operation
check anchor pin for rust
check return spring for dteioration
check automatic clearance adjuster for operation
check drum for wear or damage
check back plate for deformation
check for cracks
check mounting parts for looseness
check forks for damaged, deformation or wear
check for stooper bins for damage or wear
check for base and hook weldings for defective cracks or wear
check cross members on outer and inner masts for defective weld, cracks or damage
check tilt cylinder bracket nad mast for defective weld, cracks or damage
check for defective weld, cracks or damage of the lift bracket
check for roller bearings for looseness
check mast support bushings for wear or damage
check mast support cap bolts for looseness
check lift cylinder tail bolts, pistons rod head bolts, u-bolts, and piston head guide bolts
for looseness
check roller, roller pins and welded parts for cracks or damage
loading system
check chains for tension, deformation, damage or rust
lubrication of chains
check connetion of chain anchor pin and chain for looseness
check sheaves for deformation or damage
check sheave bearing for looseness
perform general inspection
check piston rod, rod screw and rod end for looseness, deformation or damage
check for cylinders for proper operation
check for oil leaks
check pins and cylinder bushings for wear or damage
check hydraulic pump for oil leaks or noise
check pump drive gear for wear
hydraulic system
check for oil level. Change oil
clean suction strainer
drain foreign matter
replace return filter
check levers for looseness at link
check proper operation
check for oil leaks
check relief valve and tilt lock valve for proper operation
measure relief pressure
check for oil leaks, looseness, collapse,deformation and damage
change hoses
electricals
checkdistributor cap for crack
check spark plug for burn
adjust spar plug clearnce
clean spark plug
check distributor cap high-voltage cord for installation
check distributor segment for burn
check distributor center piece for wear or damage
apply grease on shaft, cam heel and breaker fulcrum
check high voltage cord for breakage
check pinion gear for correct engagement
check battery electrolyte level. Clean battery
check specific gravity of electrolyte
check wires harness for damage and clamps for looseness
check connection for looseness
safety apparatus & accessories
check for tight installation
check for deformation, cracks or damage
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for proper operation and tight installation
check for dirt or damage
check for good field of vision
check meters for operation
check for ldamage or loose bolts
check frame and cross members for damage or cracks
check for loose rivets or bolts
check items repaired in preceding inspection, If any
inspection general condition of body
after cleaning, check for greased condition of chassis
check oil condition of oil and fluid reservior
 tools annually
2400hrs

ü
ü
ü
l
ü
thickness gauge ü
torque wrench ü
compression gauge ü
ü
tachometer ü
ü
ü
l initial at 25 hrs
l initial at 200 hrs
ü
ü
ü
l
nozzle tester ü
ü
timing ü
ü
ü
ü
ü
ü
ü
ü
ü
l
ü

ü
ü
ü
ü
 l
l
ü
ü
ü
ü
ü
l
ü
l
test hammer ü

tire gauge ü
ü
depth gauge ü
ü
ü
test hammer ü
ü
ü
ü
l
ü

ü
ü
ü
ü
ü
ü
ü
test hammer ü
ü
ü
ü

ü
scale ü
ü
ü
ü
ü
ü
 ü
ü
ü
ü
l
ü
ü
l
test hammer ü
ü
ü
ü
ü
ü
ü
ü
penetrant test ü
test hammer ü
ü
ü
ü
ü
ü
ü
ü
ü
ü

ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü

ü
 ü
ü
l
ü
ü
ü
ü
oil pressure gauge ü
ü
l 1 or 2 years

ü
ü
plug gap gauge ü
ü
ü
ü
ü
ü
tester ü
ü
ü
hydro-meter ü
ü
ü

test hammer ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
I DAILY PREVENTIVE MAINTENACE

1 Before start up Clean up machine by removing label,foreign debris,

dried glue from all part tracks,cover

2 Lubrication Oil the following parts

a.small pulley in cold glue pots
b.cold glue belt pulley on operating side
c.both ends of hot melt glue wheel shaft
d.side bar of the label supply area
e.greasing of all bearings
3 Hydraulic Fill the reservoir with hydraulic oil (SAE-10,or
system SAE-20)or automatic transmission oil
Oil level in reservoir (1" below oil port)

4 Pump & Motor Check oil filter

Check all system components for oil leaked
Motor is operating in right direction

5 Overhead belt Check tightness

6 Shear pin Glue pot shear pin
Coupling shear pin
7 Knives Flat knives sharp ends extends out 1mm
Round knives face down towards label,out 1mm
8 After operation Remove the cold glue belt from the pulley
and put it in water cover the paste with wet cloth
Clean the belt
Every time when re-install cold glue belt after
removing it for cleaning or change new belt
are on top take care that the depressor are on
top of lower layer of belt
In case the paste dry and stick to the rubber
scraper.and then it cannot run when re start the
machine,

Donot tighten the belt to run the machine but by

he machine running "JIGGLE" the scraper
loosen from the belt and it can run again

II. MONTHLY PREVENTIVE MAINTENANCE

 1 Inspection Check all belts and parts for mis-alignment
and wear

Check all grease fittings

Clean the hot glue pot, drain out old glue

Repeat till totally clean

Add hydraulic oil to hydraulic pump

Check oil system components for oil leaks

Check oil filter clogging

Check and calibrate relief valve

CAUTION:
Take care when using Teflon tape for sealing
NPT threads, because the oil flow may be blocked
due to a piece of Teflon clogged at the port of
Solenoid valve.

III ANNUAL PREVENTIVE MAINTENACE

1 Pulley Check pulley assembly for wear

assembly

2 Cold glue pot Check Cold glue assembly for wear

a.small pulley for cold glue pot
b.Cold glue belt pulley

3 Hot melt glue Check hot glue pot assembly for wear
 pot assembly a.both end of hot melt glue wheel shaft

4 Label magazine Check label magazine assembly for wear

assembly

5 Overhead belt Check overhead belt assembly for wear

assembly
Check overhead belt roller pressure
a.Rollers over label pick up
b.Roller over curling bar
c.Other rollers

6 Knives Check knives for wear

a.Flat knives

b.Round knives

7 Seaming Check for wear

Rubber pad

8 Oil filter Check for wear

9 Pump and Motor Check bearings for wear

Check oil flow

Check motor temperature

10 Shear pin Check for wear

coupling
Assurance of non-contamination
of good labels

For smooth operation of the

moving parts

Do not operate pump without oil

in any condition
Remember:
Bleed all air from hydraulic syst
to prevent the abnormal operati

Filter cleaning is recommended

to protect clog up
Periodic inspection is required

Belt tightener rollers should lift

appx 4.8mm as a container
passes them
Protects the machine from dam

Maybe re-used re-sharpened,or

replaced if worn out
Repace if any

Do not use high pressure

it can blow out seals from beari

Heat the pot to 105˚C-not higher

Refill the pot with fresh glue

Maintain level @ 25.4mm below

filler port with hydraulic cylinder
in down position

Replaced oil seals if any

Clean or replace if needed

Set @ 105 psi maximum

Replace bushing if needed

Replace bushing if needed

Replace bushing if needed

Repair if needed

Replace bushing if needed

3 kg spring pressure
2 kg spring pressure
0.5 kg spring pressur

Replace if any
Install the knives wit
the sharp ends extends out 1 m
from milled surface of knife
block.

Replace if any
Install the knives with blade fac
down towards the label stack
and extends out 1 m

Replace if any

Replace if any

Replace if any
Motor is operating in right
direction
Use temp gun

This pin is the one that protect

machine from damag