930E - 500hr Mech Service

• undefined

Asset ID

• Work Order Number

• Crew

• Shift

• SMU Hours

• Start time

  Date

• End time

  Date

General Warning

• Tasks completed must either be PASS (no issues) or FAIL (issues found) and must include coding A/B/C/D to verify actions taken, and relevant comments to
  support.
  Tasks marked 'Non-Tech:' are approved to be completed by a Serviceperson
  Notify Supervisor / Leading Hand of any faults / defects which are safety critical or will require
  attention prior to returning the truck to production.

• Critical Defect Identified, Equipment Requires Immediate Repair - A

• Defect Identified – RTS Completed - B

• Minor Defect Identified and Repaired - C

• No Defects Identified - D

Specific Hazards to be aware of:

• undefined

Sign On:

• Add signature

  Sign

• Authorised to Isolate

  Yes

  No

• Competent to Maintain

  Yes

  No

• Competent to Operate

  Yes

  No

Fluids - Change and Test Frequency

• Non-Tech:
  Carry out brake testing as per procedure (Komatsu 930E-
  4 Pre-shift Brake Test as per the Operation &
  Maintenance Manual).

• Service brake

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Fault details

• Add signature

  Sign

• Add signature

  Sign

• Park Brake

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Fault Details

• Add signature

  Sign

• Add signature

  Sign

• Retarder

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Retarder (DID panel displays Test System test failed)

• Fault details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech: Verify ladder raises when park brake released.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Ladder raises and latches when park brake released.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Fault details

• Add signature

  Sign

• Add signature

  Sign

• Check Engine for unusual noises and vibrations (include
  fan drives and turbochargers).

• Belts squealing

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Detail

• Add signature

  Sign

• Add signature

  Sign

• Bearing Noise

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Detail

• Add signature

  Sign

• Add signature

  Sign

• Knocking

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• Details

• Add signature

  Sign

• Non-Tech: Clean air filter dust bowls (cups), ensure bowls are permitted to dry before re-installing

  Sign

• Non-Tech: Wash the fuel cooler (RH side of radiator) with a low pressure hose. Check for obstructions and clean as required.

  Sign

• Non-Tech: Clean Battery box

  Sign

• Check operation of Slow Mode system including illuminated switch and external blue cab light (Only on ID 263 - 267, 291 - 292)

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

Running Checks

• Non-Tech: SAFEmine – Hold in button for 8 second. Release and watch start up. Ensure lights flash and alarm beeps. Place finger over light sensor on face, lights must dim.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech: 2Way – Check buttons and dial on face are intact and functioning. Check speaker and face mounting. Conduct 2 way radio check. Face is clear to read. Communication through the speaker is clear

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech: Check operation of all vehicle lights and horns (head / tail / clearance / brake lights / indicators / PLM / windrow / reverse). Note: Do not operate air horn in workshop

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• Details

• Add signature

  Sign

• Non-Tech: Check operation: - All instrument gauges and illumination. - All warning systems, alarms & reverse camera. - All vehicle controls and switches

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech: Check operation of windscreen wipers and washers. Wiper blades: no visible cracks, tears or missing rubber in squeegee edge. (no smear on the windscreen) - Washer nozzles: Spray is even on the windscreen, no blockage

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Conduct visual inspection of tray rope Fail - external cuts/wear on rubber (>D5mm x L20mm)

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech: Check all aerials for damage / security.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Non-Tech: Check cabin for general wear or damage: · Door and Window operation.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech:
  Check the operation of the A/C vents temperature and
  record temp:

• Cold Temp

• Hot Temp

• Add signature

  Sign

• Non-Tech: Check condition of seat and operation and seat belts.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check operation of • Body up switch = light will illuminate on the dash • Hoist limit switch = cylinder travel stops x52mm before full extension. • Clean the sensing areas of any dirt accumulation and inspect the wiring for any signs of damage. • Check operation of hoist actuator linkage.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Visual Inspection for movement in hoist cylinder bearings and body pivots. Check pivot pin retainer bolts. Check for adequate lubrication. Report to Supervisor if movement is >1mm

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Report to Supervisor if
  movement is >1mm

• LH Top measurement

• Notify Supervisor

• Add signature

  Sign

• Add signature

  Sign

• LH Lower measurement

• Notify Supervisor

• Sign

• Add signature

  Sign

• RH Top measurement

• Notify Supervisor

• Add signature

  Sign

• Add signature

  Sign

• RH Lower measurement

• Notify Supervisor

• Add signature

  Sign

• Add signature

  Sign

• Inspect condition of tray, Inspect for cracking, damage, and missing or damaged wear package - Photos are required

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• Turn steering wheel in both directions to check correct operation, wear, damage and security - check for nose cone, and 'dog bone' movement. Check for adequate lubrication. Nosecone Bearing Wear limits Maximum Wear Limit for Operation - 2.54 mm (0.099" inch) Raise Notification for Schedule Replacement of Bearing - 2.55 - 2.64 mm (0.x00" in - 0.x03") Stop Truck to Replace Bearing - 2.65 mm (0.x04") or greater

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Measurement mm

• Complete an RTS for change at next service

  Sign

• Add signature

  Sign

• Report to Supervisor - Bearing needs to be replaced before truck can be returned to work

• Who Reported

  Sign

• Inspect and record steering tie rod movement.
  Record positions as per the diagram below.
  Measure and record movement in steering linkage
  bushes/bearings.
  If movement exceeds 2.0 mm complete RTS, change
  next service.
  If movement exceeds 2.5 mm change immediately.

  

• Pos1 mm

• RTS Completed

  Sign

• Requires Replacement - Notify Supervisor immediately

  Sign

• Serviceability:

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Pos2 mm

• RTS Completed

  Sign

• Requires Replacement - Notify Supervisor immediately

  Sign

• Serviceability:

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Pos3 mm

• RTS Completed

  Sign

• Requires Replacement - Notify Supervisor immediately

  Sign

• Serviceability:

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Pos4 mm

• RTS Completed

  Sign

• Requires Replacement - Notify Supervisor immediately

  Sign

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Pos5 mm

• RTS Completed

  Sign

• Requires Replacement - Notify Supervisor immediately

  Sign

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Pos6 mm

• RTS Completed

  Sign

• Requires Replacement - Notify Supervisor immediately

  Sign

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• Non-Tech:
  Check operation of emergency shutdown system (cab
  and 2x ground level emergency stop switches).

• Accumulator Discharges

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check steering accumulators bleed down on shut down (90 seconds max)

• Add signature

  Sign

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• Non-Tech: Ensure all Emergency Stop Button labelling is legible and in place

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech: Ensure all Emergency Stop Buttons are: - Clearly visible and identifiable as an E-stop - Have a button that can be actuated by the palm of a person’s hand - Latch when activated

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Test emergency steering system as per Komatsu 930E O&M Manual. Engine running, hit emergency stop button, Key on, Wheels must turn lock to lock and back to center

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check PLM strut pressures via dash panel.
  Record strut pressures:
  Front = 2930 kPa (425 psi +/- 43psi)
  Rear = 1296 kPA (188 psi +/- 18psi)

• LH Front - Psi

• Adjusted To

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  Sign

• Out of Spec - Readjust

• Add signature

  Sign

• RH Front - Psi

• Adjusted To

• Add signature

  Sign

• Out of Spec - Readjust

• Add signature

  Sign

• LH Rear - Psi

• Adjusted To

• Add signature

  Sign

• Out of Spec - Readjust

• Add signature

  Sign

• RH Rear - Psi

• Adjusted To

• Add signature

  Sign

• Out of Spec - Readjust

• Add signature

  Sign

• Check operation of grease pump and cycle times via
  manual operation. (Override switch)
  - Pressure to build up to 2000 psi in less than 120 sec.
  - With grease under pressure check all injector pins
  (should be retracted into body).
  - Pump shut off between 2350 - 2500 psi.
  - With no pressure all injector pins should be visible

• Pressure 2000 psi in less than 120 sec

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• All Injector Pins Retracted

  Select Yes No

  • Yes
  • No

• Add signature

  Sign

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Pump Shutoff 2350 - 2500 psi

• Adjusted To

• Out of Spec - Readjust

• Add signature

  Sign

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  Sign

• No Grease Press Injector Pins Visible

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Non-Tech:
  Take the Scheduled Oil Samples (SOS) using KOWA
  sample bottles.
  - Ensure Machine is at Operating Temperature prior to
  Live sampling.
  - Complete Live sampling where possible.

• Non-Tech: Take KOWA Diesel Engine Oil sample

  Sign

• Non-Tech: Take KOWA Hydraulic Oil sample

  Sign

• Non-Tech: Take KOWA LH Wheel Motor Oil sample

  Sign

• Non-Tech: Take KOWA RH Wheel Motor Oil sample

  Sign

Mechanical Engine Checks

• Position truck and isolate, as per BCO Isolation Procedure – Before Performing
  Maintenance (Sec 3-12). Ensure all accumulators are bled down

• Non-Tech: Attach Kidney machine to LH wheel motor (Duration 4hrs - kidney loop through component) Refer to Manual FM40440 for installation and operation

  Date

• Attached by

  Sign

• Time finished

  Date

• Detached by

  Sign

• Non-Tech: Attach Kidney machine to RH wheel motor (Duration 4hrs - kidney loop through component) Refer to Manual FM40440 for installation and operation

  Date

• Attached by

  Sign

• Time finished

  Date

• Detached by

  Sign

• Non-Tech: Change Engine Oil in Sump and ROS Tank.

  Sign

• Non-Tech: Change primary fuel filters. (2 x FF5782NN) Change fuel water seperator filter (1 x FS53014) if fitted.

  Sign

• Non-Tech: Check radiator coolant level and top-up if required.

  Sign

• Inspect crankcase breathers for damage and breather tubes for damage and restrictions.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Inspect Alternator belt condition, no cracks or misalignment. Belt tensioner working correctly.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check engine fan belt for condition and alignment and Tensioner working correctly.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• CHECK the fan clutch for leaks and mounting bolts for integrity. Check fan spider for cracks and loose hardware.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Inspect engine for fuel, oil and water leaks. Remove any oil/rags/build up of material.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Check water pump for tell-tale coolant leakage. No leaks or weeps

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check all engine area hoses for general condition (damage, leaks, chaffing, security)

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check cooling system hoses for damage and signs of leaks and deterioration.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check condition of radiator (Check mounts, upper radiator stabilisers, lower radiator stabilizers and shroud bumpers, clamps, fan, guard for damage and tightness. Check radiator cap, relief valve operation).

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Check all guards for damage and security.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check engine mounts for wear and security. Check Engine "seats" in the middle of mounts.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• undefined

• Add signature

  Sign

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  Sign

• Non-Tech: Manually grease front engine mount trunnion

  Sign

• Check exhaust component system for leaks: - turbochargers - exhaust manifolds - exhaust pipe work - mufflers Report any leakage to your supervisor

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Non-Tech: Check Turbo & Exhaust component Lagging for damage, condition and security – Report defects to your Supervisor

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Inspect Turbo Feed & Drain Lines for chaffing, rubbing, general condition, orientation away from lagging and security. Inspect clamps and fasteners are in place and secure.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check engine air intake mounting hardware, joints and connections. Ensure that there are no air leaks and all tubes, hoses and clamps are secure and air tight to prevent dirt entry.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• ROS System, HPI Engines Only Examine all hoses, including those on the reserve tank and the ones leading to and from the engine. Check for leaks, cracks or other damage. Check all fittings for tightness, leakage or damage.

  Select Pass Fail A B C D N/A

  • Pass
  • Fail
  • A
  • B
  • C
  • D
  • N/A

• Details

• Add signature

  Sign

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  Sign

• Check all fuel tank and all fuel lines for damage, wear and security.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check fuel tank mounts for loose or broken bolts, as well as for cracks around mounting areas.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

Mechanical Air Conditioning System

• Non-Tech: Replace A/C filters (Cab Air & Recirc). (1x P/N PB7001; 1x P/N EM0055). Clean cab air conditioner filter mesh. Check and clean evaporator condensation drain.

  Sign

• Inspect A/C compressor for any leaks and for loose or broken mounting bolts and no cracks or damage to brackets / guards. No leaks or weeps. Clamps are in place and secure. Hose / Pipes are not chaffing or rubbing.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Check A/C compressor belts for condition, cracking and wear.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check / Wash A/C condenser with a low pressure hose, ensure no dirt build-up and leaks. Ensure the Air/Con cab drains are clear of any obstructions.

  Sign

• Inspect all A/C and heater hoses for damage, wear, and leaks, and loose or missing hold down clamps. Check for rubbing or chaffing of hoses.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Inspect door strikers, door seals and windows for any damage and wear.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

Mechanical Hydraulics

• Non-Tech: Change hydraulic tank breathers. (2x P/N PB5556) Check area around breathers is clean and free of debris.

  Sign

• Non-Tech: Change hoist high-pressure filter element, O-Ring and Back-Up Ring. (2x P/N 58E-60-00040; 2x P/N BF2196; 2x P/N 07000- 13115)

  Sign

• Non-Tech: Change steering high-pressure filter element. (1x P/N AK3572; 1x P/N 07000-03092)

  Sign

• Non-Tech: MCRS machines only Change steering/brake filter elements(2x P/N AK3568)

  Sign

• Non-Tech: Change hydraulic filter O-ring (1x P/N TL3995LP)

  Sign

• Non-Tech: Grease hydraulic pump drive shaft universal joints. Add one or two applications of grease to each grease fitting. Hand grease gun only Non - Moly grease only. Shell GADUS S3 V220C 2

  Sign

• Check hydraulic system for leaks. - Check tanks, tap / valves fully operational (open / close) - Check pumps for leaks and damage. - Check condition of hoses for rubbing, chaffing, orientation and leaks. - Check security of hose clamps and fasteners.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

  Sign

• Check all cylinders condition for (Leaks, Weeping,
  Chrome Pitting, Scored or Rod Damage)

• RH Steer :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• LH Steer :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• RH Hoist :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• LH Hoist :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• Pos 1 Strut :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• Pos 2 Strut :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• Pos 3 Strut :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• Pos 4 Strut :

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Comment:

• Add media

  Media

• Add signature

  Sign

• Add signature

  Sign

• Check hydraulic tank and mounts for wear, damage and security. Check tank sight glass is clean

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Non-Tech: Check hydraulic oil level, and top-up if required.

  Sign

Mechanical Steering System

• 

• Check torque on the pin retaining nuts located on the steering linkages. Re-torque steering pin retainer nuts – 1017 Nm (750 +/- 75lb ft) (item 1 in figure), x 6 in Image 5

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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• Check complete steering systems for leaks. - Visually inspect all steering hoses for damage and condition. - Ensure all hoses are secure, all clamps are installed and in good condition. - Check tank, valves and pumps.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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Mechanical Brake System

• Check front and rear brake hubs for oil leaks, damaged hoses and pipes. - Clamps are in place and secure. - Hose / Pipes are not chaffing or rubbing

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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• Measure the amount of disc wear on both parking brake
  assemblies as follows:
  Measure park brake wear with park brake applied as per
  the workshop manual.
  a. Insert a depth micrometre through each piston hole
  and record measurement depths.
  b. Add the three measurements and divide the total by
  3 to determine the average.
  c.I f the resulting measurement is equal to or greater
  than 24mm the parking brake assembly must be
  removed and rebuilt.
  d. If the result is equal to or greater than 23mm fill
  out RTS to replace at next service.
  Notify Supervisor Immediately if :
  Average measurement >24mm = remove and rebuild
  assembly.
  Park Brake Rebuild Kit P/N: 58F-BK-AK060 (#173595)
  Dowel Park Brake P/N: VG7407 (#174087)

• Record measurements in mm

• LHS 1

• LHS 2

• LHS 3:

• LH Average mm (L1+L2+L3)/3

• Complete an RTS to have changed at next service. Code as PASS - B

• LH Park Brake Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

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• Park Brake is U/S. Must be replaced. Code as FAIL - A

• LH Park Brake Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

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• In Spec

• LH Park Brake Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• RHS 1:

• RHS 2:

• RHS 3:

• RH Average mm (R1+R2+R3)/3

• Complete an RTS to have changed at next service. Code as PASS - B

• RH Park Brake Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

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• Park Brake is U/S. Must be replaced. Code as FAIL - A

• RH Park Brake Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

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• In Spec

• RH Park Brake Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Add signature

  Sign

• Check complete brake system for leaks. - Inspect all hoses and piping, valves and pumps. - No leaks or weeps, clamps and hardware in place and secure.

  Sign

Mechanical Wheel Motors, Axle Box, Spindle and Tyres

• Non-Tech:
  Remove and inspect front wheel hub magnetic plugs.
  Record contamination rating as per attached
  MAGNETIC PLUG INSPECTIONS sheet:
  Notify Supervisor if abnormal amount of material is
  found on any plugs (and record condition by taking
  a photo).
  Clean plugs prior to reinstalling.

  

• LHF Contamination Rating:

  Select 1 2 3 4

  • 1
  • 2
  • 3
  • 4

• Add signature

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• Non-Tech:
  Remove and inspect front wheel hub magnetic plugs.
  Record contamination rating as per attached
  MAGNETIC PLUG INSPECTIONS sheet:
  Notify Supervisor if abnormal amount of material is
  found on any plugs (and record condition by taking
  a photo).
  Clean plugs prior to reinstalling.

  

• RHF Contamination Rating:

  Select 1 2 3 4

  • 1
  • 2
  • 3
  • 4

• Add signature

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• Add media

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• Non-Tech:
  Remove and inspect wheel motor gear case mag plugs.
  Record contamination rating as per attached
  MAGNETIC PLUG INSPECTIONS sheet:
  Notify Supervisor if abnormal amount of material is
  found on any plugs (and record condition by taking
  a photo).
  Clean plugs prior to reinstalling.

  

• LH WM Contamination Rating:

  Select 1 2 3 4

  • 1
  • 2
  • 3
  • 4

• Add signature

  Sign

• Add media

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• Non-Tech:
  Remove and inspect front wheel hub magnetic plugs.
  Record contamination rating as per attached
  MAGNETIC PLUG INSPECTIONS sheet:
  Notify Supervisor if abnormal amount of material is
  found on any plugs (and record condition by taking
  a photo).
  Clean plugs prior to reinstalling.

  

• RH WM Contamination Rating:

  Select 1 2 3 4

  • 1
  • 2
  • 3
  • 4

• Add signature

  Sign

• Add media

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• Non-Tech: Check oil level in LH and RH wheel motor gear cases (After Kidney Loop process is complete.) Shell Omala S4 GXV 680

  Sign

• Non-Tech: Replace LH and RH Wheel Motor Breather elements

  Sign

• Visually check for broken or missing bolts. No missing or broken bolts on Axle mounting box.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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• Check for oil leaks around Duo seals and mounting plates. No leaks or weeps

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• undefined

• Add signature

  Sign

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• Check axle box for grease or oil leakage

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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  Sign

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• Visual Inspection of axle box, check for cracking or damage.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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• Check front wheels for loose damaged or missing nuts and studs. Use a Torch and mirror on a long rod to inspect all inner and outer wheel mounting nuts and studs

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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• Inspect nose cone for signs of cracking or excessive movement. Report any defect immediately.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

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Mechanical Fire Control System

• Non-Tech:
  Check condition of all fire extinguisher and support
  brackets.
  - Check test tags (within 6 months inspection).
  - Check pressure gauges are in the operating range on
  all fire extinguishers.
  - Test Tags Date:

• Test Tags Date:

  Date

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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  Sign

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• Non-Tech:
  Check fire suppression bottles and bracket mounts are
  in place and secure.
  - Check pressure gauges are in the operating range on
  all fire suppression bottles.
  - Record bottle pressure test date

• Bottle Pressure Test Date

  Date

• Serviceability

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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• Check fire suppression Hoses / Pipework: - No cuts, abrasions, burns, corrosion, are in good condition and securely fastened. - Discharge Nozzles are aligned & securely fastened. - Fit nozzle caps as required.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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• Check condition of fire system actuators. Ensure safety pins and anti-tamper pins are intact on actuators

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

Mechanical Lubrication Service

• 

• Non-Tech: Check Grease Pump Housing Oil Level and top-up if required (SAE 30).

  Sign

• Non-Tech: Check all grease hoses from the injectors to lube points. Check all grease supply line hoses from the pump to Injectors Pay particular attention to : a) Rear suspension struts top and bottom pins and dog bone pins and bushes. b) Front suspension struts top and bottom pins and steering linkages pins and bushes. c) Nose cone pin and bearing d) Body hinge pin Inspect all bearing points for a bead of grease around the bearing seal

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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Mechanical Gerneral Other

• Non-Tech: Check ladder oil level and inspect for leaks. Top-up oil if required (CX30). Ensure that breather is upright, and no kinks in hoses.

  Sign

• Non-Tech: Clean, Grease Ladder pivot shaft bearing. - Check for any cracking, loose or missing hardware - Check landing bolts are secure (4 on front mount 2 on rear). - Check for build up of dirt/mud that could affect ladder operation.

  Sign

• Non-Tech:<br>Inspect Ladder information label is in place and legible<br>(located at top landing).

  Pass

  Fail

• Details

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• Non-Tech:
  Ensure Tamper Tag is installed on Emergency Ladder
  Release valve

• Tamper tag and Manual Release Valve in place

  Select Pass Fail

  • Pass
  • Fail

• Details

• Add signature

  Sign

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• Inspect and record any worn or failed emergency ladder components (hinge, latch bolt, spring, roll pin). Check for bent or misaligned structures.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

• Add signature

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• Non-Tech: Use drylube spray Lubricate brake and throttle pedal roller and hinge pins. - Lift the boot from the mounting plate and apply a few drops of oil between the mounting plate and the plunger. - Lubricate door latch, strikers and hinges.

  Sign

• Non-Tech: Inspect all mirrors for damage and security

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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• Check ROPS/FOPS and mounts for damage, cracks, corrosion or missing/loose bolts.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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• Inspect cab mounts and bolts. Check for signs of wear / loose bolts.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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• Check rock ejectors and mounts for wear. No excessive side way movement and 100 mm gap to wheel hub.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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• Inspect chassis and tray pivot for wear, damage or cracking.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add media

  Media

• Add signature

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• Check dump body pads, shims and mounting hardware for wear, damage, cracking and tension. Pads are equally loaded / worn. Rear pads have a approx. 1.9mm gap

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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  Sign

• Check front suspension heights.
  Spec 229+/-10 mm (9.0")

  

• Pos 1 - mm

• Add signature

  Sign

• Adjusted to

• Out of Spec - Readjust

• Add signature

  Sign

• Check front suspension heights.
  Spec 229+/-10 mm (9.0")

  

• Pos 2 - mm

• Add signature

  Sign

• Adjusted to

• Out of Spec - Readjust

• Add signature

  Sign

• Check Rear suspension heights.
  Spec Rear 218+/-13mm

  

• Pos 3 - mm

• Add signature

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• Adjusted to

• Out of Spec - Readjust

• Add signature

  Sign

• Check Rear suspension heights.
  Spec Rear 218+/-13mm

  

• Pos 4 - mm

• Add signature

  Sign

• Adjusted to

• Out of Spec - Readjust

• Add signature

  Sign

• Inspect struts for security and missing hardware. Check that all strut covers and dust skirts are fitted and free of damage. Check PLM sensors/cabling for damage

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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• Non-Tech: Check all handrails from ground to top deck for any damage, cracks or missing or broken nuts and bolts. Check non slip step treads.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

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• Check cab deck structure from underneath for cracks.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

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• Check left and right wing section and centre platform section for cracks to platform and support structure.

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add signature

  Sign

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• Check mounting point on top of horse collar for cracks

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add media

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• 

• Inspect engine module frame for cracking

  Select Pass Fail A B C D

  • Pass
  • Fail
  • A
  • B
  • C
  • D

• Details

• Add media

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Return To Work Checklist

• Before starting machine, check machine is free from oil and fuel spillage.

  Sign

• Check Hyd tank tap lock plates are in place. Taps are open and locked

  Sign

• Check all fluid levels.

  Sign

• Start machine and test all operations and functions.

  Sign

• Re-check fluid levels, top up as required.

  Sign

• If any work has been performed on the brake system carry out brake testing as per procedure.

  Sign

• Check for water, fuel & oil leaks.

  Sign

• Non-Tech: Ensure cab is clean & machine is free from rag, paper or waste material

  Sign

• Non-Tech: Wash machine down after servicing, cleaning around all serviced areas of oil, fuel and grease.

  Sign

• Non-Tech: Clean windows & mirrors. Fill washer bottle.

  Sign

• Check operation of Slow Mode system including illuminated switch and external blue cab light

  Sign

• Test drive truck in Slow Mode to ensure speed is limited to 20 klms

  Sign

• Perform CLEAN TRUCK TARE

  Sign
RTS form to be completed/attached for all Outstanding Work (All Code B)

• Details of RTS attached to sheet

• Items identified as requiring an RTS have been completed and are attached to this service sheet and photos taken?

  Yes

  No

• Add signature

  Sign
Completed Repairs

• Details of defects rectified during service

• Add signature

  Sign

• If you believe that any part of this Task Instruction should be altered, expanded, rearranged, or omitted, please inform your supervisor. Make a note in the table and indicate the section that you think needs to be modified.

Continuous Improvement

• Yes

  No

• Task

• Description of Improvement

• Submitter

  Sign

• Service Completed - create action for the Supervisor to signoff sheet.

  Yes

  No

• Detail why service is not complete

• Create the Action, Add this sheet "Document Number" (930E500 .....) in the header, Select the Supervisor by clicking on the assignee and then user list,

• Click the "Complete Inspection" button to send for Supervisor approval

Supervisor Signoff

• Add signature

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