SERVICE PACKAGE

PRE-START SAFETY ACTIVITIES

OFF HIGWAY TRUCK 773E
Service guide(Service manual,sis,part
book,IK,SOP,)
Personal Protective Equipment Sign Mandatory
Wash machine Properly
Operational test (Kimper/Simper Required)
House keeping /Contamination control
Walk arround Inspection
Isolation energy
(Mekanikal,Hydraulic,Electric,Pneumatic,Kimia)
Running and test Prosudure
Park Unit Service area/ Ground level
Switch Parking Brake Active & Transmisison lever
transmission in Netral Position
Check Dump Body For Carry Back (Material) And
Safety pin dump body
Turn Off Engine & Main Battery Switch to OFF
Position 773E
Fit Personal Danger Tag & Out of Service Tag
All unauthorized person should be kept from the
machine when Pm Is Being
 Good Good
DESCRIPTION x Bad xBad
Inspection guidelines X Backlog XBacklog
PRE PM PERFORMANCE Before Remarks Name After Remarks Name

SMU, Downtime / Delay Record

Interview Operator & Record any Ensure & Update History
problem/Issue
Backlog validasi and execution Follow backlog list
Repetitive Issue Check history
Follow up SOS Check history,issue
Engine System Test performance,work properly
Power train System Test performance & Adjust
Hydraulic System Test performance & Adjust
Steering System Test performance & Adjust
Electric System Test performance,work properly
Air Conditoner Test performance & Adjust
Autolube System Test performance,work properly
Fire System Test performance,work properly
Chasis Test performance,work properly
Tyre Test performance,work properly
Low idle test =700 +/- 30 Rpm Test performance,work properly Actual = Actual =
High idle test = 2240+/- 30 rpm Test performance,work properly Actual = Actual =
Stall test = 1805 +/- 65 rpm Test performance,work properly Actual = Actual =
Parking brake = > 1200 rpm Test performance,work properly Actual = Actual =
Service Brake = > 1200 rpm Test performance,work properly Actual = Actual =
Retarder Holding = > 1200 rpm Test performance,work properly Actual = Actual =
Secondary brake = > 1200 rpm Test performance,work properly Actual = Actual =
Cut In Air compressor = 655 Kpa Test performance & Adjust Actual = Actual =
Cut Out Air compressor = 830 Kpa Test performance & Adjust Actual = Actual =
Parking brake Release Prsessure =
Test performance & Adjust Actual =
650-750 Psi Actual =
Service brake Pressure = 630 - 790 Psi Test performance,work properly Actual =
Actual =
Retarder = 627-825 Psi Test performance & Adjust Actual = Actual =
Front brake = 2185-2875 Psi Test performance,work properly Actual = Actual =
Residual brake pressure Rear Max 18
Test performance,work properly Actual =
Psi Actual =
Residual brake pressure Front Max 18
Test performance,work properly Actual =
Psi Actual =
Steering Cycle time 7-9 Sec Test performance,work properly Actual = Actual =
Hoist Cycle time 18-20 Sec Test performance & Adjust Actual = Actual =
Data Electronic (PSRPT) Download,data,cut out cylinder

Frame and Handril,Ladder,walk way Inpect, loose,broken,cracked

Steering Wheel,Lingkage,Horn,Switch
Test performance,work properly
multifunction,Wipper,Alrm

Secondary Steering,& ARC System Test performance,work properly

Shock Abshorber,Cussion seat, Test performance,work properly

Seat belt,back rest,adjustment and

Test performance,work properly
mounting seat Gp

All gauge panel,Switch & Power

Test performance,work properly
windows
AC system Test performance,work properly
Payload system Test performance,Calibrated
Handle door LH/RH,Seal,mirror Test performance,work properly
Autolube and fire system Test performance,work properly
 SERVICE PACKAGE
Mark Pm type Item to be serviced PM TYPE Result
 Actio
Action n Remarks Name
MAINTENANCE SCOPE 250 500 1000 2000 x Not
Action

PCR Update schedule & Componen

Backlog Update backlog Status part
Repetitive Issue Check History
Follow up SOS Check History SOS

Engine System
(Coolant,fuel,lubrication,air intake & Inspect,service maintenance
Exhaust))
Powertrain System Inspect,service maintenance
Hydraulic System Inspect,service maintenance
Electric System Inspect,service maintenance
Air Conditoner system Inspect,service maintenance
Autolube System Inspect,service maintenance
Fire System Inspect,service maintenance
Chasis Inspect,service maintenance
Tyre Inspect,service maintenance
All Ball stud,center arm and all lines greaseInspect condition
A-Frame,pin,bolt,cracked and grease
Inspect condition
lines
Hoist RH/LH,Bearing lower,Upper and
Inspect condition
Grease lines
Front Suspenssion RH/LH,Grease,and
Inspect condition
crhome,level
Rear Suspenssion RH/LH,Bearing
Inspect condition
Upper/Lower and level
Pivot Dump RH/LH Side shims,Grease lines Inspect condition
Lateral rod inner/Outer bearing and
Inspect condition
grease lines
Pedestal RH/LH and Pad Dump
Inspect condition
body,lock pin
Main drive shaft and PTO Shaft Inspect condition
All Lining brake Inspect condition
Engine Oil Take Oil sample & tag
Transmission Oil Take Oil sample & tag
Hydraulic Oil Take Oil sample & tag
Steering Oil Take Oil sample & tag
Coolant Take sample & tag
Oil Front wheel RH/LH,Plug foto Take Oil sample & tag
Oil Final Drive RH/LH,Plug foto Take Oil sample & tag
Oil Differential,Plug foto Take Oil sample & tag
Breather engine Service,Clean up
Air filter and pre cleaner Service,Clean up
Primary fuel filter Service,Clean up
Screen Transnission Inspect,foto
Drain sendiment Air tank Drain,service
Drain sendiment fuel tank / Water
Inspect,Drain
separator
Grease Tank Fill Up,Service,Inspect
Fan Drive and tensioner Greasing,Torque
Mounting Alternator V-Belt Inspect,Adjust,Torque
Mounting Refrigrant AC Compressoe
Inspect,Adjust,Torque
V-Belt
Mounting Fan Drive V-belt Inspect,Adjust,Torque
Mounting Diff and Transmission Inspect,Torque
Mounting Starting motor Inspect,Torque
All Clamp Hose Extender Inspect,Torque
Terminal Battery and Bracket Inspect,Level,Torque
Payload Calibrated
Disconnect switch Inspect,Torque
Engine Oil filter Replace,filter cut,foto
Hydraulic,TM,Axle (Kidney Loop) Kidney Loop system

Fuel filter primary and secondary filter Replace,filter cut,foto

Steering Oil filter Replace,filter cut,foto

Hydraulic Oil Filter Replace,filter cut,foto
Transmission Oil filter Replace,filter cut,foto
Parking brake Oil filter Replace,filter cut,foto
Brake wear Test & Record
Engine Oil Change,Check level
Air Filter Cabin in and Outter Replace,Service
Screen Torque conventer Check,Service
Steering Oil Change,Check level
 SERVICE PACKAGE
Mark Pm type Item to be serviced PM TYPE Result
 Actio
Action n Remarks Name
MAINTENANCE SCOPE 250 500 1000 2000 x Not
Action

Oil Front Wheel RH/LH Change,Check level

Technical analysis II Test,Adjust and Record

Test Cracked A-Frame and mounting Test & Record

Breather fuel tank and Hydraulic Replace

Dessicant air dryers Recondition
Primary and secondary air filter Replace
Coolant and additive Change,Check level
Oil Transmission Change,Check level
Oil Hydraulic Change,Check level
Oil Differential Change,Check level
End play turbo (0.08mm-0.025mm) Inspect,record,replace
Pressurized cooling system Inspect,Repair record
Air Intake and exhaust system Inspect,Repair record
Valve Clearance Inspect,adjust record
All Suspenssion Flushing adjust
Craked Main spider Shaft Inspect,record,replace

Inspect planetary gear Final drive RH/LH Inspect,record

Differential thrust pin Inspect,adjust record
MACHINE INSPECTION AND BACKLOG Result  Good x Bad X Backlog Name
VALIDATION
 xdevice,Lines,Bearing,Harness
Check : Frame Structure,Fastener,All system,Safety X
From : Abnormal condition,Fail
Cracked,Bent,Incident,Noisy,Discolor
scratch,Fatigue,Leaks,Oil,Coolant,Ga
ss,Nitrogen
Friction,bracket,Clamp,Bolt
loose,Missing,Lack lubrication
Shaky,Worn out,Open
Cabin
Engine System
Powertrain System
Hydraulic System
Brake system
Steering system
Electric System
Air Conditoner system
Autolube System
Fire System
Chasis/Frame
Tyre
CABIN Name

ROPS / FOPS and Mounting Bolts

All Warning Tags/Safety Labels Fitted
& Clear
Floor Deck condition
Mirror and bracket
Switch Multifunction and blade wiper
Handle Door RH/LH
Seal Door and floor mat
Seat belt and bracket
Adjustment seat operator
Shock Abshorber & Cussion seat
Mounting seat operator
Payload Display
Pedal brake,accelerator and secondar
brake

Steering Wheel,Lingkage,Horn,Switch
multifunction,Wipper,Alrm

Panel instrument and All switch

Dome lamp And Warning indicator
Fire and Autolube controller
Ac controller
Panel breaker and fuse
Switch parking brake
Lever transmission
Power windows
Lever Hoist
Cabin glass
 SERVICE PACKAGE
ENGINE (COOLANT,FUEL,LUBRICATION,AIR INTAKE & EXHAUST SYSTEM) Name

Radiator,Cap And Relief valve

Radiator
(Gauge,Core,tube,hose,clamp,bracket)
Fan and guard Radiator
Coolant temprature sensor and wiring
harness
Regulator housing,Tube,and Lines

Refrigrant AC
Compressor,bracket,guard and V-Belt

Fan Drive,Pulley and V-Belt and

mounting
Auxiliary water pump and Lines
Main Water pump,switch and wiring and
lines

Aftercooler,hose extender and sensor

Boonet Cooler,Bracket
Oil pan,Dipstick,bracket and cap
Engine ECM,Cover valve,Front cover
and Rear
Cylinder Head
Lines oil filter and bracket
Filter base engine oil filter,switch oil
level and wiring
Sensor Atmospheric pressure and
Crankcase
Adapter oil pump Engine
Turbo charger RH/LH,lines,bracket,and
clamp
Sensor air inlet and exhaust
Speed Timming sensor,EOS sensor

Engine oil
cooler,Hydraulic,Transmission,Hose,and
bracket
HEUI Pump and lines
Air filter and Precleaner housing and
Mounting
Indicator Air Filter
Fuel tank and Mounting
Fuel Transfer
pump,regulator,lines,tube,sensor
Fuel filter base,switch and wiring
harness
Fuel Sender,Guard and Fast fill
Regulator fuel,Tube,Bracket and clamp
Breather fuel tank
POWERTRAIN AND HYDRAULIC SYSTEM Name

Hydraulic Tank,Transmission Tank and

Mounting
Implememt pump Mounting Lines and
Clamp

Control valve hoist,Actuator,Solenoid

and Harness
Housing,Bracket filter Hydraulic
PTO shaft and Guard
Hose extender Hydraulic,tube,bracket
and clamp
Towing valve and hose
Hoist Cylinder RH/LH Bracket and Lines
Cooler Hydrauic Mounting and Lines

Torque converter,Lock up
valve,Harness,Soleniod
Torque converter Valve (T/C Inlet
/Outlet )
Parking brake release filter,Lines and
wiring harness
Scavange pump mounting and Lines
 SERVICE PACKAGE
Cooler Transmission mounting and Lines

Sensor brake cooling

Temprature,harness and clamp
Main drive shaft,Bearing and Guard
Mounting gp Transmission & Cover
transmission
Down and Up Shift solenoid and
Harness
Transmission Output Sensor,Guard and
Wiring
Transmission Charging Pump,Screen
and Lines
Brake module RH/LH,Tube
lines,sensor,and wiring
Transmission,pump,Solenoid,harness,an
d hose lines
Differential Mounting
Wheel speed sensor and harness
Spindel Mounting RH/LH
BRAKE AND STEERING SYSTEM Name

Air Tank Primary And Secondary

Drain sendiment Air tank
Rear Brake Chamber Mounting and lines

Front Brake Chamber Mounting and

Lines
Make Up tank and Lines
Linning Brake,Disc RH/LH
Harness and sensor brake and TCS

Brake relay Front,Rear,ARC And

Inverter valve
Parking brake release Pump Mounting
And Lines
Filter brake,Mounting And Lines
Control Valve Parking brake release
Brake oil cooler
Diverter valve Brake
Valve AETA,Sensor and wiring
Slack adjuster and Lines
Brake module,Spindle RH/LH and Tube
Wheel Speed Sensor,Guard Harness
RH/LH
Automatic Traction Control
System,Sensor,Harness
Pedal service and secondary brake
Handle And Retarder Valve
Steering Tank Mounting and Lines
HMU Steering,Bracket,lines and Clamp

Steering Pump,Mounting And Lines

Reliefe Valve,Fill Cap oil And sigh Glass

steering
Control valve Steering
Steering wheel and lingkage
Cylinder steering,Lines,clamp and
Bracket RH/LH
Secondary steering Motor,lines,harness
switch
Relay secondary steering wiring and
clamp
Lingkage/Tie Rod Steering
Bleeding brake system
AIR CONDITIONER DAN ACCESSORIES Name

Air Conditioning Operation & Control

Air filter Cabin In/Outter
Pressure system AC
Low : High :

Pully,Clutch,and Mounting Ac
Voltage Supply To Clutch :

Refrigrant V-Belt,Rod Adjusment,Guard

and Mounting
AC Condenser,Evaporator
Thermostat
 SERVICE PACKAGE
Reciever dryer,Accumulator
Harnes and Pressure Switch AC
Lines,Fitting high and low Pressure
System
Louver and Speed Blower AC
Lines Drain AC system
Expantion Valve
Clean Up Cabin Area
Heater valve and lines
ELECTRIC DAN ELECTRONIC SYSTEM Name

Box Battrey and Cover

Battery Condition,Load & Electrolyte
Level Battery
Terminal Battery and bracket hold down

Master key on/off and all Panel

instrument
Monitor (CMS,POD)
Indicator Test Switch
Engine Coolant Temperature Gauge
Hydraulic Oil Temperature Gauge
Fuel Level Gauge
Tachometer
All Alert Indicator Lights
Warning Buzzer/Alarm
Digital Display Windows ( Some
Application )

Ground level shutdown,service switch

Measure voltage battery :

Voltage Dropped battery :
Battery No.1 = V Battery No.1 =
V
Battery No.2 = V Battery No.2 = V

Alternator Output Voltage = V

Disconnect Switch = V

Alternator and drive Pully,belt and rod

adjustment

Individual Check Starting Motor

Operation/Condition wiring and mounting

Ground & Positive Cable,Disconnect

switch,battery,ECM,Starting,Alternator

Secondary steering,relay,cable and

bracket

Wiring
harness,Connector,Relay,Fuse,circuit
Breaker,Terminal,Front and rear Cabin

Wiring harness,Connector,ECM,All
Sensor,Terminal,Engine Area
Wiring harness,Connector,ECM,All
Sensor,Terminal,Chasis
Wiring harness,Connector,ECM,All
Sensor,Terminal,Brake
Wiring harness,Connector,ECM,All
Sensor,Termial,POD

Wiring harness,Connector,Terminal,All
work lamp

Panel Instrument (Dash Panel Light)

Front Floodlights,Sign lamp,Head

beam,Rotary lamp,tail lamp and hazard

Rear Floodlights,Sign lamp rear,brake

lamp and tail lamp and hazard
Radio Communication
Fatique alarm
All work lamp,back up alrm,sign lamp
hazard,brake dan tail lamp
 SERVICE PACKAGE
Remove,Clean & Check All Connection
to Switches,Solenoids & Sensors
AUTOLUBE AND FIRE SYSTEM Name

Fill up grease tank

Timer grease and cycle time pump
Check Pressure switch and solenoid
Pressure Grease system
Lubricated pump head
Lines Pump and Wiring Grease system
Injector RH Bank
Injector LH Bank
Injector Rear Bank
Hose Grease RH/LH Hoist cylinder
upper and lower
Hose Grease RH/LH Dump body pivot
pin
Hose Grease RH/LH Suspension
cylinder lower,Upper
Hose Grease Lateral rod inner and
outer bearing
Hose Grease Pivot pin "A" frame
Hose Grease RH/LH Center,Head front
suspenssion
Hose Grease RH/LH Rod end,Head end
of steering cylinder
Hose Grease Center arm
Hose Grease Fan Drive and Pully
Tenssioner
Pressure Fire Extinguisher
Fire Suppression System-If Equipped

Fire Extinguisher Ensure Lock Out

System
Lines and Harness Fire System
Mounting and Bracket Tank Fire
Gauge Fire,Hensor and Harness
Connection Wire and Harnness fire
Auto lube and Fire Control
CHASIS/FRAME Name

1. Rear cross tube

2. Tail casting - right
3. Tail cooling - left
4. Side rail - right
5. Side rail - left
6. Center tube
7. Hoist support - right
8. Hoist support - left
9. Front strut support - right
10. Front strut support - left
11. Bumper
12. Upper superstructure - right
13. Upper superstructure - left
14. Front side rails - right
15. Front side rails - left
16. Support steering
17. Support fore - left
18. Support fore - right
19. Front mounting hydraulic tank
20. Rear mounting hydraulic tank
21. Front mounting fuel tank
22. Rear mounting fuel tank
23. Radiator mounting - Left
24. Radiator mounting - Right
25. Beam
26. Pin bore for control rod
27. Rear suspension - Left
27. Rear suspension - Right
 SERVICE PACKAGE
28. Hole & Pin Padestal LH RH
A.Area Top,Buttom and Nose A-Frame

B.Rear axle housing at suspension

cylinder mount and top of housing

A.Front strut Area

B.Engine Mounting and steering box
C.Upper Cross Member
D.Side Rails main frame
F.Super Structure area
G.Upper cross member
H.Rear Casting area
K.Torque Tube area
L.Radiator Mounting area
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