PREVENTIVE MAINTENANCE INSPECTION

For every task in Preventive Maintenance Inspection, the following safety task must be strictly enforced:

Comply with personal and environmental safety practices associated with clothing; eye protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/ materials in accordance with federal, state, and local regulations.

The tasks included in the Preventive Maintenance Inspection area are entry-level technician inspection tasks designed to introduce the student to correct procedures and practices of vehicle inspection in a teaching/learning environment. They are not intended to satisfy the Annual Federal Vehicle Inspection requirement as prescribed in the Federal Motor Carrier Safety Regulations, Part 396, Appendix G to Subchapter B, Minimum Periodic Inspection Standards.

The first task in Preventive Maintenance is to listen to and verify operator's concern, review past maintenance documents, and record condition on appropriate document.

VIII. PREVENTIVE MAINTENANCE INSPECTION

A. Engine System

1. Engine

1. Check engine starting/operation (including unusual noises, vibrations, exhaust smoke, etc.); record idle and governed rpm. P-1

2. Inspect vibration damper. P-1

3. Inspect belts, tensioners, and pulleys; check and adjust belt tension. P-1

4. Check engine oil level; check engine for oil, coolant, and fuel leaks (Engine Off). P-1

5. Inspect engine mounts for looseness and deterioration. P-1

6. Check engine for oil, coolant, air, and fuel leaks (Engine Running). P-1

7. Check electrical wiring, routing, and hold-down clamps, including Engine Control Module/Powertrain Control Module (ECM/PCM). P-1

2. Fuel System

1. Check fuel tanks, mountings, lines, caps, and vents. P-1

2. Inspect throttle linkages and return springs. P-1

3. Drain water from fuel system. P-1

4. Inspect water separator/fuel heater; replace fuel filter(s); prime and bleed fuel system. P-1

3. Air Induction and Exhaust System

1. Check exhaust system mountings for looseness and damage. P-1

2. Check engine exhaust system for leaks, proper routing, and damaged or missing components. P-1

3. Check air induction system: piping, charge air cooler, hoses, clamps, and mountings; check for air restrictions and leaks. P-1

4. Inspect turbocharger for leaks; check mountings and connections. P-1

5. Check operation of engine/exhaust brake. P-1

6. Service or replace air filter as needed; check and reset air filter restriction indicator. P-1

4. Cooling System

1. Check operation of fan clutch. P-1

2. Inspect radiator (including air flow restriction, leaks, and damage) and mountings. P-1

3. Inspect fan assembly and shroud. P-1

4. Pressure test cooling system and radiator cap. P-1

5. Inspect coolant hoses and clamps. P-1

6. Inspect coolant recovery system. P-1

7. Check coolant for contamination, supplemental coolant additives (SCA) concentration, and protection level (freeze point). P-1

8. Service coolant filter/conditioner. P-1

5. Lubrication System

1. Change engine oil and filters; visually check oil for coolant or fuel contamination; inspect and clean magnetic drain plugs. P-1

2. Take an engine oil sample. P-1

B. Cab and Hood

1. Instruments and Controls

1. Inspect key condition and operation of ignition switch. P-1

2. Check warning indicators. P-1

3. Check instruments; record oil pressure and system voltage. P-1

4. Check mechanical, electronic, and emergency shut down operation. P-1

5. Check mechanical and electronic engine speed controls. P-1

6. Check heater, ventilation, and air conditioning (HVAC) controls. P-1

7. Check operation of all accessories. P-1

8. Using diagnostic tool or on-board diagnostic system; extract engine monitoring information. P-1

2. Safety Equipment

1. Check operation of electric/air horns and back-up warning devices. P-1

2. Check condition and documentation of safety flares, spare fuses, triangles, fire extinguisher, and all required decals. P-1

3. Inspect seat belts and sleeper restraints. P-1

4. Inspect wiper blades and arms. P-1

3. Hardware

1. Check wiper and washer operation. P-1

2. Inspect windshield glass for cracks or discoloration; check sun visor. P-1

3. Check seat condition, operation, and mounting. P-1

4. Check door glass and window operation. P-1

5. Inspect steps and grab handles. P-1

6. Inspect mirrors, mountings, brackets, and glass. P-1

7. Record all observed physical damage. P-1

8. Lubricate all cab and hood grease fittings. P-1

9. Inspect and lubricate door and hood hinges, latches, strikers, lock cylinders, safety latches, linkages, and cables. P-1

10. Inspect cab mountings, hinges, latches, linkages and ride height; service as needed. P-1

11. Inspect tilt cab hydraulic pump, lines, and cylinders for leakage; inspect safety devices; service as needed. P-1

4. Heating, Ventilation, & Air Conditioning (HVAC)

1. Inspect A/C condenser and lines for condition and visible leaks; check mountings. P-1

2. Inspect A/C compressor and lines for condition and visible leaks; check mountings. P-1

3. Check A/C system condition and operation; check A/C monitoring system, if applicable. P-1

4. Check HVAC air inlet filters and ducts; service as needed. P-1

C. Electrical/Electronics

1. Battery and Starting Systems

1. Inspect battery box(es), cover(s), and mountings. P-1

2. Inspect battery hold-downs, connections, cables, and cable routing; service as needed. P-1

3. Check/record battery state-of-charge (open circuit voltage) and condition. P-1

4. Perform battery load test. P-1

5. Inspect starter, mounting, and connections. P-1

6. Engage starter; check for unusual noises, starter drag, and starting difficulty. P-1

2. Charging System

1. Inspect alternator, mountings, wiring and wiring routing; determine needed action. P-1

2. Perform alternator current output test. P-1

3. Perform alternator voltage output test. P-1

3. Lighting System

1. Check operation of interior lights; determine needed action. P-1

2. Check all exterior lights, lenses, and reflectors; check headlight alignment; determine needed action. P-1

3. Inspect and test tractor-to-trailer multi-wire connector(s), cable(s), and holder(s); determine needed action. P-1

D. Frame and Chassis

1. Air Brakes

1. Check parking brake operation. P-1

2. Record air governor cut-out setting (psi). P-1

3. Check air drier drain valve operation. P-1

4. Check air system for leaks (brakes released). P-1

5. Check air system for leaks (brakes applied). P-1

6. Test one-way and double-check valves. P-1

7. Check low air pressure warning devices. P-1

8. Check air governor cut-in pressure. P-1

9. Check spring brake inversion system, if applicable. P-1

10. Check tractor protection valve. P-1

11. Test air pressure build-up time. P-1

12. Inspect coupling air lines, holders, and gladhands. P-1

13. Check brake chambers and air lines for secure mounting and damage. P-1

14. Service air drier. P-1

15. Inspect and record brake lining/pad condition and thickness. P-1

16. Inspect and record condition of brake drums/rotors. P-1

17. Check operation of brake manual slack adjusters; adjust as needed. P-1

18. Check operation and adjustment of brake automatic slack adjusters. P-1

19. Lubricate all brake component grease fittings. P-1

20. Check camshaft and bushing condition. P-1

21. Check condition and operation of hand brake (trailer) control valve. P-1

22. Perform antilock brake system (ABS) operational system self-test. P-1

2. Hydraulic Brakes

1. Check master cylinder fluid level and condition. P-1

2. Inspect brake lines, fittings, flexible hoses, and valves for leaks and damage. P-1

3. Check parking brake operation; inspect parking brake application and holding devices. P-1

4. Check operation of hydraulic system: pedal travel, pedal effort, pedal feel (drift). P-1

5. Inspect wheel cylinders/calipers for leakage and damage. P-1

6. Inspect power brake booster(s), hoses; and check/control valves. P-1

7. Inspect and record brake lining/pad condition and thickness. P-1

8. Inspect and record condition of brake drums/rotors. P-1

9. Adjust drum brakes. P-1

3. Drive Train

1. Check operation of clutch, clutch brake, and gearshift. P-1

2. Check clutch linkage/cable for looseness or binding, if applicable. P-1

3. Check hydraulic clutch slave and master cylinders, lines, fittings, and hoses, if applicable. P-1

4. Check clutch adjustment. P-1

5. Check transmission case, seals, filter, hoses, and cooler for cracks and leaks. P-1

6. Inspect transmission breather. P-1

7. Inspect transmission mounts. P-1

8. Check transmission oil level, type, and condition. P-1

9. Inspect U-joints, yokes, drive lines, and center bearings for looseness, damage, and proper phasing. P-1

10. Inspect axle housing(s) for cracks and leaks. P-1

11. Inspect axle breather(s). P-1

12. Lubricate all drive train grease fittings. P-1

13. Check drive axle(s) oil level, type, and condition. P-1

14. Change drive axle(s) oil and filter; check and clean magnetic plugs. P-1

15. Check two-speed axle unit operation and oil level. P-1

16. Change transmission oil and filter; check and clean magnetic plugs. P-1

4. Suspension and Steering Systems

1. Check steering wheel operation for free play or binding. P-1

2. Check power steering pump, mounting, and hoses for leaks, condition, and routing; check fluid level. P-1

3. Change power steering fluid and filter. P-1

4. Inspect steering gear for leaks and secure mounting. P-1

5. Inspect steering shaft U-joints, pinch bolts, splines, pitman arm-to-steering sector shaft, tie rod ends, linkage, and linkage-assist power steering cylinders. P-1

6. Check king pin wear. P-1

7. Check wheel bearings for looseness and noise. P-1

8. Check oil level and condition in all non-drive hubs; check for leaks. P-1

9. Remove and inspect wheel bearings; reassemble and adjust. P-1

10. Inspect springs, hangers, shackles, spring U-bolts, and insulators. P-1

11. Inspect shock absorbers for leaks and secure mounting. P-1

12. Inspect air suspension springs, mounts, hoses, valves, linkage, and fittings for leaks and damage. P-1

13. Check and record suspension ride height. P-1

14. Lubricate all suspension and steering grease fittings. P-1

15. Check toe-in. P-1

16. Check tandem axle alignment and spacing. P-1

5. Tires and Wheels

1. Inspect tires for irregular wear patterns and proper mounting of directional tires. P-1

2. Inspect tires for cuts, cracks, bulges, and sidewall damage. P-1

3. Inspect valve caps and stems; replace as needed. P-1

4. Measure and record tread depth; probe for imbedded debris. P-1

5. Check and record air pressure. P-1

6. Check for loose lugs and/or slipped wheels; check mounting hardware condition; service as needed. P-1

7. Retorque lugs in accordance with manufacturer's specifications. P-1

8. Inspect wheels and spacers for cracks or damage. P-1

9. Check tire matching (diameter and tread) on dual tire installations. P-1

6. Frame and Fifth Wheel

1. Inspect fifth wheel mounting bolts, air lines, and locks. P-1

2. Test operation of fifth wheel locking device; adjust if necessary. P-1

3. Check mud flaps and brackets. P-1

4. Check pintle hook assembly and mounting. P-1

5. Lubricate all fifth wheel grease fittings and plate. P-1

6. Inspect frame and frame members for cracks and damage. P-1