Leighton International Limited

SITE Unit No :

Preventive Maintenance Service - Volvo A35E Dump Truck Articulated 35T- 1000 HRS
Job Supervisor by : Date created :

Superintendent : Planner :

Date Scheduled : Priority :

Location of job : Workshop Field

WORK ORDER SPECIAL INSTRUCTION :

2000 HR SERVICE = 14 HRS Target

1000 HR SERVICE = 10 HRS Target
500 HR SERVICE = 6 HRS Target
250 HR SERVICE = 4 HRS Target

Clean unit before carry out PM SERVICE

Make sure the Unit Backlog file should be attached on this sheet.

DOWN TIME INFORMATION

Date equipment down Time : Date

Date equipment up Time : Supervisor

Service Meter Reading ( SMR ) Hrs. Signature

Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA

Procedures and Safety Instructions (Prosedure dan Instruksi Keselamatan)

I PRE STOP CHECK (Pengecekan sebelum unit di Parkir)

1 CHECK FOR EXCESIVE PLAY & OR WEAR IN ALL STEERING PIN & BUSH JOINTS.
Periksa kalau ada pergerakan dari semau pin & bush di steering linkage2
2 CHECK FOR EXCESSIVE SIDE PLAY & OR WEAR IN THE BODY PIVOT PINS & BUSHES
Periksa kalau ada pergerakan dari body pivot pin & bush atau side play besar
3 CHECK FOR WEAR IN THE HOIST CYLINDER PINS & BUSHES
Periksa kalau ada keausan dari hoist cylinder pin2 & bush2
4 INSPECT HYD RODS IN FULLY EXTENDED POSITION FOR SCRATCHES & OR DAMAGE.
Periksa semua hyd cylinder rods utk kerusakan atau skratch, rod dipanjangkan penuh.

II SAFETY (Keselamatan Kerja)

1 Park Truck on Level Surface

Parkir terpisah dan Pada Permukaan Rata
2 Place Wheel Chocks Behind/Front of Wheels
Ganjal Roda depan dan roda belakang
3 Lift Dump Body and Attach Safety Pin
Angkat Dump Body dan Pasang Pin Pengaman
4 Isolate Machine and Fit "Personal & Out of Service Tag"
Unit pisahkan dan Letakkan " Pribadi dan Unit Rusak" tag pada tempat switch start

# " Fuel/Oil Leaked or Spilled onto hot Surfaces or Electrical Components Can cause a FIRE. Clean up fuel
spills Immediately"
# Bahan bakar/Oli yang bocor atau tertumpah ke permukaan komponen yang panas atau elektrik
componen Dapat menyebabkan kebakaran
Oleh sebab itu Bersihkan TUMPAHAN fuel SEGERA.

III LUBRICATION AND SERVICE

CAUTION:
The Person who drains the Oil is Responsible to Refilling the Compartment
YANG DITUNJUK UNTUK MELAKUKAN PENGURASAN OLI HARUS BERTANGGUNG JAWAB
UNTUK PENGISIAN OLI KEMBALI.
OILS AND LIQUIDS IN ALL COMPARTMENTS MAYBE HOT AND CAUSE SERIOUS INJURY
OLI DAN CAIRAN DIDALAM SEMUA KOMPARTEMEN MUNGKIN PANAS DAN DAPAT MENYEBABKAN
KECELAKAAN FATAL
TAKE CARE WHEN DRAINING ANY COMPARTMENT
BERHATI - HATILAH SAAT MENGURAS KOMPARTEMEN
* CONSULT MAINTENANCE GUIDE FOR LUBE POINTS and PROCEDURES
LIHAT PETUNJUK PERAWATAN UNTUK TITIK PELUMASAN DAN PROSEDUR
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
SERVICE (PM CLINIC) and LUBRICATIONS (Manual Hand Grease Pump)

Engine
1 Clean Air Cleaner Box ( Housing ) and Air Filter Dust indicator
Bersihkan perumahan saringan udara dan Dust indicator
2 Change Element Outer Air Cleaner
Ganti Element Outer Air Cleaner
3 Change Element Inner Air Cleaner
Ganti Element Inner Air Cleaner
4 Check Air intake lines is Complete without Damage or Cracks
Periksa jalur Air intake jika ada keretakan/Kerusakan
5 Check coolant level and "Do not Open Rad Cap" if engin is hot
Periksa Level Coolant dan "Jangan buka Rad Cap" jika mesin panas
6 Take SOS Sample of Engine Oil (Infra Red on New Machine up to 6000Hrs)
Ambil Sampel SOS Dari Oli Mesin (Infra Red untuk Unit Baru sampai dgn 6000Hrs)
7 Change Oil Engine = 49 Liters Oil
Ganti Oli Mesin
8 Change Filter - Oil Engine
Ganti Filter - Oli Mesin
9 Clean Breathers - Engine Crankcase
Bersihkan Breather Mesin
10 Change Filter - Primary Fuel (Fuel-Water Separator)
Ganti Screen Primary Fuel (Fuel-Water Separator)
11 Change Filter - Secondary Fuel
Ganti Filter Fuel Secondary
12 Lubricate Fan Pulley Radiator (by Hand grease pump only)
Gemuki Pulli Kipas Radiator (dengan pompa grease tangan)
13 Lubricate Tension Pulley
Gemuki Tension Pulli
Others Cabin Area
14 Check Air Con Operation (If Fitted)
Periksa Pengoperasian Pendingin Ruangan (AC) - bila tersedia
15 Clean Cabin Filter
Bersihkan Cabin Filter
16 Check Battery Electrolyte Level
Periksa Ketinggian Air Aki
17 Fill Wind Screen Washer Tank
Isi tangki air wipper
Transmission
18 Take SOS Sample of Oil Transmission & Torque Converter
Ambil Sampel SOS Dari Oli Transmission & Torque Converter
19 Change Filter - Oil Transmission (1000hrs)
Ganti Filter - Oli Transmisi
19 Change Oil - Transmission = 34 Liters Oil
Ganti Oli Transmisi
20 Check Level Oil - Drop Box
Periksa Level Oli Drop Box
21 Clean Strainer PTO Suction (1000hrs)
Bersihkan Strainer PTO Suction
22 Clean Strainer Suction Transmission and Magnetic
Bersihkan Strainer Suction and Magnit
23 Change Breather of Oil Transmission
Ganti Breather of Oil Transmission
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
Hydraulic System
24 Take SOS Sample of Oil Hydraulic System
Ambil Sampel SOS Dari Oli Hydraulic System
25 Check Level Oil - Hydraulic System
Periksa Level Oli Hydraulic System
Frame Joint Bearing & Pivot Shaft
26 Check Level Oil - Frame Joint Bearing
Periksa Level Oli Frame Joint Bearing
27 Check Oil Level of Pivot Shat
Periksa Level Pivot Shaft
Brakes
28 Change Oil - Brake Cooling = 210 Liters Oil
Ganti Oli Brake Cooling
29 Clean Brake Cooling Magnetic Rods
Bersihkan Brake Cooling Magnetic Rods
30 Change Filter Return Brake System
Ganti Filter Return Brake System
Oscillating Hitch
31 Check Level Oil Oscilating Hitch
Periksa Level Oil Oscilating Hitch
32 Lubricate Hitch Bearing 2 points
Lubricate Hitch Bearing 2 points
33 Lubricate Hitch Pins 2 points
Lubricate Hitch Pins 2 points
Dump body and Hoist Cylinder Area.
34 Lubricate Dump Control Linkage
Gemuki Hoist control linkage
35 Lubricate Dump body hinge pin (Pivot Bearing) LH/RH
Gemuki ensel pin body ( kiri dan kanan )
36 Lubricate Hoist Cylinder pin LH/RH
Gemuki pin silinder dump ( kiri dan kanan )
Tailgate & Cylinder (If Equipped)
37 Lubricate Tailgate - ( left and right : 2 points each )
Gemuki Tailgate - ( kiri dan kanan masing - masing 1 tempat )
38 Lubricate Tailgate Cylinder - Lubricate 2 Points
Gemuki Tailgate silinder - 2 Tempat
Drive Shaft
39 Lubricate Drive Shaft Universal Joints
Gemuki Shaft Universal Joint
Axles (Differential and Final Drive)
40 Clean all Axle Breathers
Bersihkan seluruh Breather Axel
41 Take SOS Sample of Oil Front Final Drive
Ambil Sampel SOS Dari Oli Front Final Drive
42 Check Level Oil - Front Final Drive
Periksa Level Oli Axel Depan Final Drive
43 Take SOS Sample of Oil Center Final Drive
Ambil Sampel SOS Dari Oli CenterFinal Drive
44 Check Level Oil - Center Final Drive
Periksa Level Oli Axel Tengah Final Drive
45 Take SOS Sample of Oil RearFinal Drive
Ambil Sampel SOS Dari Oli Rear Final Drive
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
46 Check Level Oil - Rear Final Drive
Periksa Level Oli Axel Belakang Final Drive
47 Inspection and Clean Grams in all Magnetic Plug Axle
Periksa dan Inspeksi gram-gram pada seluruh Magnetic Plug (Differential/Final Drive)

IV MECHANICAL CHECK AND INSPECTIONS

1. Cabin / Kabin
1 Check Operator Access-Step/Hand Holds
Periksa jalan masuk Operator-Pijakan/Tempat pegangan
2 Record Hour Meter Reading
SMR
Catat Pembacaan Meter Jam Kerja
3 Check Door Latches and window catches.
Periksa kunci pintu dan Jendela
4 Check Operator Seat Belt
Periksa Sabuk Pengaman Pengemudi
5 Check Operator Seat and Adjustment Control
Periksa Kursi dan Pengatur Kursi (Adjustment Control)
6 Check operation of Windscreen Wipers and inspect Rubber condition
Periksa fungsi pembersih kaca cabin dan wipper, periksa kondisi karet wipper
8 Check if any Oil/Fluids Leaks onto Cabin
Periksa jika ada Oli/Cairan yang bocor didalam cabin
9 Check operations: Steering,brakes,transmission,implements,emergency steering.
Periksa Operasi dan control: Kemudi,Rem,Transmisi,Implement dan Kemudi Darurat
10 Check the ROPS, Cabin, Platform for Craks,damage,wear and Loose Bolts.
Periksa ROPS, cabin, & platformnya utk ratak2, kerusakan & keausan
11 Check door and window seal condition.
Periksa kondisi seal pada pintu dan jendela
12 Check condition of all windows for cracks, chips.
Periksa kondisi semua jendela dari keretakan, tercuil atau terpotong.
13 Check all gauges, dials, internal lights, warning lamps/lights are operational.
Pastikan semua gauges, dials, internal lights, dan warning lamps/light beroperasi dengan baik
14 Remove, clean & replace when dry, air conditioner filter.
Lepaskan filter air conditioner, bersihkan & ganti ketika kering
Others outside Cabin (Lain Lain)
15 Check pressure gauge fire extingusher.
Periksa tekanan pemadam kebakaran
16 Check Fire Extinguizer Bracket for loose bolt or cracks
Periksa Tabung Pemadam bracket pada keretakan dan bolts yang longgar.
2. Electrical system - Bagian Elektrik
Air Condition
17 Inspect AC for leaks & or Rubbing hoses or Pipes
Periksa hose2 yg kebocoran & atau bergesek
18 Check Brackets and Loose bolts for AC
Periksa baut-baut yg kendor & bracket pada AC
Lamps, Horn, Back-up Alarm, Battery and Fuses/CB
19 Check Battery Terminals and Cables
Periksa terminal-terminal Aki, (+) dan (-), beserta kabel-kabelnya
20 Tighten Battery Hold Down Clamps
Kencangkan Klem-klem Aki
21 Check Fuses and Circuit Breakers
Periksa semua sekering dan permutus rangkaian
22 Check Horn and Back-up Alarm
Periksa semua klakson dan alarm back-up
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
23 Check Operation Of All lights & Warning Indicators.
Periksa Operasi Semua Lampu Dan Indicator.
Radio Communications
20 Check function Of 2 way radio communications
Periksa Radio komunikasi berfungsi dengan baik
21 Check all aplications switch
Periksa semua fungsi tombol
22 Check LCD Screen radio communications
Periksa layar LCD radio komunikasi
23 Check Cabel and Microphone radio Communication
Periksa kabel dan mikrophone radio komunikasi
24 Check Mounting and Antena radio Communication
Periksa mounting dan antena komunikasi
3. Engine Area - Bagian Mesin
Engine
25 Check Radiator Mounting
Periksa fisik radiator mountingnya
26 Check condition of water lines and radiator core clean if required
Periksa kondisi jalur air dan fisik radiator cuci bila diperlukan
27 Check fan guard are in place and secure
Periksa pelindung fan agar tetap ditempatnya dan aman
28 Check fan hub and jockey pulley bearings
Periksa bearing fan hub dan pulley
29 Check Conditions & Tension of Engine V-Belts
Periksa Mesin V-Belts ( Kondisin dan Kekencangannya )
30 Check Conditions & Tension of Air Concition V-Belts
Periksa Air Concition V - Belts ( Kondisin dan Kekencangannya )
31 Check Engine Mounting for Wear and Bolt Tension
Periksa mounting Mesin terhadap keausan dan kekencangan baut
32 Check and Inspection for any Leaks Oil, Fluids, Fuel onto Engine area.
Periksa dan Inspeksi pada Engine area jika terdapat kebocoran Oli, Fuel dan Cairan lainnya..
33 Check for exhaust system for leaks & bolts loose
Periksa kalau ada kebocoran pada sistim exhaust & kelonggaran bolt
34 Check for Leaks or Loose bolt at Air Compressors
Periksa kebocoran & atau baut kendor dari air compressor
35 Check all Engine wiring harnesses, ensure no rubbing or damage can occure
Periksa semua cable electrik di engine, tidak bergesek atau kerusakan bisa terjadi
36 Check Alternator Cables, Starter Motor Cables and Mounting Bolts and Brackets.
Periksa starter motor & alternator cable electrik & baut / bracket mountingnya
37 Check Fuel Lines for any Leaks.
Periksa jalur pipa/selang bahan bakar pada kebocoran.
5. Transmission
38 Check for external oil leaks around transmission
Periksa kebocoran sekitar Transmisi
39 Check Transmission Mounting for Damage or Loose Bolts
Periksa Mounting Transmissi untuk kerusakan dan baut yang longgar.
6. Steering System
40 Check for External oil Leaks around LH & RH Steering Cylinders
Periksa kebocoran oli di sekitar steering cylinder
41 Check for External oil Leaks around Orbital Steering Valve
Periksa kebocoran oli di sekitar steering orbitrol valve
42 Test Secondary/Emergency Steering
Test Secondary/Emergency Steering
7. Hydraulic System
43 Check for External oil Leaks around LH & RH Hoist Cylinders
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
Periksa kebocoran oli disekitar hoist cylinder
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
44 Check Hydraulic Cylinder for Damage or Loose Bolts.
Periksa hyd cylinder cylinder kerusakan & atau baut yg kendor
45 Inspect all Hydraulic Hoses & Tubes for Leaks - Retorque suction lines clamps.
Periksa kalau ada kebocoran pada semua hose & pipa hyd, retorque clamp2 hose suction
46 Check Hyd Control Valves for loose bolts, cracked bracket and Leaks
Periksa kalau ada baut kendor, bracket yg ratak pada hyd control valves dan kebocoran
47 Check Hyd Pump for loose mounting bolts/clamps or leaks.
Periksa baut mounting, hosenya ,klemnya & kebocoran oli pada hyd pump
8. Wheels and Brakes
48 Check wheel Front,Center & Rear for retaining bolts and clamps are in place
Periksa baut pengencang roda depan/tengah/belakang dan klem ada ditempatnya
49 Check for External oil Leaks around Front/Center/Rear Brakes
Periksa kebocoran oli di sekitar brake depan/tengah/belakang
50 Check Park Brake in the On & Off position for air Leaks.
Periksa park brake di posisi 'on' & juga 'off' dari kebocoran angin
51 Check Service Brake in the On & Off position for air Leaks.
Periksa Service brake di posisi 'on' & juga 'off' dari kebocoran angin
52 Check Retarder in the On & Off position for air Leaks.
Periksa Retarder di posisi 'on' & juga 'off' dari kebocoran angin
53 Check brake accumulator precharge pressure for service and parking brake
Periksa tekanan akumulator untuk service dan parking brake
54 Check
Periksaand Adjust
/ adjust Parking
parking Brake:
brake, ukurMeasurement
ketebalan padnya
55 Check Parking Brake Assy for Wear/Damage/Loose Bolts and inspect the Disc.
Periksa parking brake assy dari keausan/kerusakan/baut kendor, periksa disknya
56 Brake performance test all functions below
Test performa rem untuk semua fungsi berikut
RPM
COMMENT
SERVICE PARKING EMERGENCY RETARDER

57 Check all tyres pressure and conditions

Check semua tekanan dan kondisi ban

TYRE POSITION
Pos 1 Pos 2 Pos 3 Pos 4 Pos 5 Pos 6

9. Drive Shaft & Oscilating Hitch

58 Inspect front, center and rear Driveshaft for worn spiders or loose bolts.
Periksa driveshaft depan, tengah dan belakang utk spider yg aus & atau baut yg kendor
10. Suspensions
59 Check all Suspension Cylinder for Leaks.
Periksa seluruh suspensi dari kebocoran
11. Frame, Dump Body
Frame.
60 Check that all protective guards are in place: Belly guard/Radiator Grill/Engine cover etc.
Periksa apakah semua pelindung ada ditempatnya: Pelindung Radiator dan Mesin
61 Check Front & Rear Frame for cracks
Periksa kerangka depan dan belakang dari keretakan
62 Check A frame ball stud mounting for loose bolts or movement
Periksa dudukan stud ball kerangka dari baut yang longgar atau goyang
Dump Body
63 Check tray mounts for loose bolts or pins and tray pads are in good condition
Periksa dudukan body truck dari baut atau pin yang longgar
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
dan kondisi harus baik pada body truck
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
64 Check condition of tray - cracks/worn liners/damage etc
Periksa kondisi - retak / liner yang aus/rusak dsb
65 Inspect Body Kick out Bracket for Damage
Periksa kondisi body kick out dari kerusakan

V COMPLETION

1 Remove Body Safety Pin and Lower Hoist

Lepaskan Pin Pengaman dan Turunkan Hoist(Dump)
2 Remove Wheel Cocks Behind/Front of Wheels
Lepaskan Pengganjal Roda depan dan roda belakang
3 Check all Compartement OIL Levels " BEFORE STARTING THE MACHINE"
Periksa semua Level Oli "SEBELUM UNIT DI JALANKAN"
4 Test Drive, Check Brakes, Steering and Unusual Noises
Uji Jalankan Truk, Periksa Rem, Kemudi dan Bunyi-Bunyi Yang Mengganggu
5 Remove "Personal & Out of Service Tag" Tag
Lepaskan Label " Pribadi dan Unit Rusak"
6 Hold all Filters (on new machines up to 6000Hrs) at time of 1000HRS Service.For TU Inspection.
Simpan semua filters (pd unit baru hingga 6000Hrs) saat service 1000Hrs untuk TU inspeksi.

Task Special Instruction..

PLEASE Report any DEFECT or unusual findings to Foreman Supervisor or Superintendent
FOREMAN must be fill in the DEFECT Report if any.

List of Serviceman or DONE BY

Name of Personnel Signature
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Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA
Task Details Volvo A35E Dump Truck Articulated 35T- 1000 HRS.
Done: Not Done: Repairs or Adjustments Done: R Work Order or Further Work Required: W
INITIAL/
TICK NAMA

ADDITIONAL ITEMS FOR BACKLOG

Unit ID

Priority
HRS TO PARTS
ITEM

DESCRIPTION OF DEFECT COMPL

Model A35E ETE IN STOCK LOCATION

1
2
3
4
5

LIL-P&E-FM-019F(01)
VOLVO A35E - Service Kit

Filter Kit

Description Part Number 250 500 1000 2000

FILTER OIL ENGINE
FILTER FUEL SECONDARY 477556 1 1 1 1
FILTER FUEL PRIMARY 478736 2 2 2 2
FUEL FILTER 20976003 1 1 1 1
AIR FILTER 11110217 1 1
SAFETY FILTER 11110218 1
PRIMARY FILTER (WATER SEPARATOR) 11110683 1 1 1

* If equipped
Oil Kit

Compartment Type 250/750 500 1000 2000 6000

ENGINE SAE 15W-40 49 49 49 49 49
TRANSMISSION ATF Dextron IID 34 34 34
FRONT AXLE (FRONT DIFF) 40 40 40
FRONT BOGIE AXLE (CENTRE DIFF) 40 40 40
REAR BOGIE AXLE (REAR DIFF) 40 40 40
BRAKE 210 210
DROP BOX 8.5 8.5
FRAME JOINT BEARING 3 3
HYDRAULIC SAE 30 245 245
RADIATOR PRE-MIX
COOLANT 90