Truckmount Preventative Maintenance Guide

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This is a basic Truckmount Preventative Maintenance Guide that attempts to cover all makes and models and is a reference guide only. refer to your owners manual or call our service technicians for more information.

1 - Maintenance Logs

Initiation of a planned preventative maintenance program will ensure that your truckmount has optimum performance, a long operating life, and a minimal amount of down time. This maintenance checklist is designed to be performed once every three months in addition to daily weekly and monthly preventative maintenance. The number of running hours will change depending on the amount of work the machine is doing. The frequency of service intervals should be changed accordingly. A log book should be kept of daily weekly and monthly services. An example of daily weekly and monthly service log is attached. 

2 - General Inspection

Wiring

Check the condition of the machines wiring and wiring looms. Ensure that all wiring is secured. Secure any loose wiring with automotive ties. Replace any chafed wiring. Ensure all spade connectors are tight. Replace any loose spade connectors.

Nuts and bolts

Inspect all nuts and bolts. Ensure they are tight. Replace any nuts and bolts that are rusted or damaged.

Garden hose screen

Remove garden hose connector from water connector. Remove garden hose screen and clean out any debris. Replace garden hose screen if damaged.

Chemical system

Remove clear plastic chemical hose from 20 litre chemical jug. Ensure filter screen is clear. Insert clear plastic hose into one litre bottle of vinegar. Connect truckmount to fresh water. Turn truckmount ignition key to on but do not start the machine. Set chemical flow meter to maximum. Open truckmount mix tank drain valve. Flush system until vinegar is exhausted. Completely drain mix tank then flush the vinegar from the chemical system by repeating the above process with one litre of water.

Y filter screen and control orifice

Remove the filter screen from the Y filter in front of control orifice. Clean the filter screen and remove any build up of debris. Replace the filter screen if damaged. Remove control orifice assembly and remove orifice control set screw. Visually inspect for blockage or excessive wear. Carefully remove any blockages. Replace the control orifice set screw if worn.

Bypass valve

Brass Control Knob

Unscrew bypass valve control knob. Remove the spring, thrust plate and piston plate. Inspect piston plate seals for damage. Replace seals with seal kit if necessary. Apply rubber grease to piston plate and thrust plate. Reassemble the bypass valve.

Plastic Control Knob

This part does not need to be internally serviced. Remove plastic knob clean with cloth and apply a spray lubricant

3 - Vacuum Tank

Safety Equipment Required– Rubber Gloves, Mask, Eye Protection

Vacuum tank bag

Remove vacuum tank filter bag. Empty contents. Rinse bag clean. Check bag for holes or tears. If the bag has any holes, repair or replace the bag.

Vacuum tank basket

Remove vacuum tank filter basket. Empty contents. Rinse basket clean. Check bag for holes,  repair or replace the bag if nessesary

Auto Pump Out System

Drop in Style

Drain vacuum tank. Dispose of wastewater in the appropriate location. Disconnect the auto pump out electrical wiring and waste hose and remove pump from vacuum tank. Remove auto pump out screens and wash with warm soapy water. Clean auto pump out housing with warm soapy water. Any build up of scale can be removed with scotch pad.

Belt Driven Style or External APO

This part does not need to be internally serviced. Keeping the tank clean will ensure longevity. The rubber impeller inside will need to be replaced periodically.

Vacuum tank Remove stainless steal air intake filter and clean thoroughly. Don’t clean with pressure washer as this may damage the filter. Inspect the filter for damage. Replace if necessary. Thoroughly clean vacuum tank of all scale and fine soils with high-pressure washer and scotch pad. Drain the waste tank and dispose of waste in appropriate location. Check trim lock seal to ensure adequate vacuum seal is maintained. If damaged replace seals. Clean and inspect high water and auto pump out float switches.

Vacuum relief valve

Ensure vacuum relief valve adjustment nuts are tight and relief valve spring is in good condition and working. Clean thoroughly and spray with blower lubricant.

4 - Wand and Hoses

Wand

Wash the wand with warm soapy water, paying particular attention to the underside of the wand head and the jet manifold. Inspect for clogged jets and debris in vacuum slot. Ensure handle is tightly secured. Clean all inline filters. Brass jets on wand should be replaced every 6 months. Stainless steel jets should be replaced every 12 months.

Wand valve

Remove and cap spring and piston from high-pressure valve. Inspect o-rings for wear and tear. Replace with valve kit if necessary. Apply a small amount of rubber grease to valve piston and reassemble wand valve.

Vacuum and solution hoses

Check vacuum hoses vacuum hoses for holes. Replacing vacuum hoses as they become worn and shabby looking is recommended. Run solution hoses through a rag dipped in warm soapy water to remove any build up of cleaning solutions. Check hoses for chafing. Replace chafed hoses. Check quick connector for damage. Replace worn quick connectors.

5 - Engine

This section does not apply to CDS units

Fuel line and fuel filter

Check fuel supply line. Start from the engine carburetor working your way back to the fuel tank. Ensure that there are no leaks and that the fuel line is in good condition. Disconnect quick connect coupling at the through floor hookup and check o-rings. Check fuel line under vehicle. Ensure that the fuel line is secured with cable ties. Check the fuel filter. Replace if needed.

Battery

Remove the plastic top of battery box. Check the water level in the battery and ensure that the water is covering the platelets. If the water level is low, poor in enough distilled water to cover the battery platelets. Check the battery connections for scale. Remove the battery connections and remove scale with a wire brush if necessary. Ensue battery cables are secured with cable ties.

Engine oil and filter

Remove the engine oil drain cap and drain engine oil whilst engine is still warm. Dispose of the engine oil in an appropriate location. Replace the drain cap. Remove the oil filter. Replace the oil filter with genuine Briggs and Stratton oil filter. Lubricate the gasket on the oil filter with a small amount of clean engine oil and screw into place until gasket contacts filter adaptor. Then tighten a further ½ to ¾ of a turn. Top up the engine with the required amount of SAE30 grade engine oil. Check the oil level with the oil dipstick. Don’t over fill. The dipstick must be screwed all the way in for an accurate reading.

Engine air filter

Remove the top of the air filter housing. Remove the foam pre-filter and wash in warm soapy water. Squeeze out the excess water. Then squeeze out any additional moisture by placing the pre filter inside a clean dry cloth and squeezing. Saturate the pre-filter in clean engine oil and then wrap in a clean absorbent cloth to remove the excess oil. Remove the cartridge filter and tap on a clean surface to shake loose any dust. Do not use compressed air to clean or dry the paper cartridge. Replace any air cleaner gaskets and mounting gaskets that are worn or damaged. Wipe the filter housing clean with a cloth and replace the air filter and foam pre-filter.

Engine cooling system

Air cooled

Remove front grill of the machine. Inject compressed air to dislodge any build up of debris. If excessive debris is present you may have to remove the cooling system cowling to get access. If necessary remove the cowling and clean the debris away from the engine cooling fins.

Liquid Cooled

Check fluid level in coolant reservoir, top up as necessary, drain and flush cooling system and add new coolant as required

Spark plugs

Remove spark plug leads check for wear and tear. Replace if necessary. Remove spark plugs. Replace spark plugs if electrodes are burnt away, or porcelain is cracked. Clean spark plugs by carefully scraping or brushing with a wire brush and washing in a solvent. Set spark plug gap at 0.76mm.

6 - Blower & Pump

Vacuum blower

Oil Bath & Grease

Remove the blower oil drain cap and drain oil. Dispose of the oil in an appropriate location. Replace the drain cap. Remove the blower filler lug and blower oil level overflow lug. Fill with industrial blower lubricant 220 grade into the fill hole until oil seeps out of the overflow hole. Replace fill lug and over flow lug. Do not over tighten. Locate blower grease nipple. Give three to for good pumps on you grease gun with premium petroleum based high temperature and moisture resistant grease into blower bearing. Wipe away the excess grease. Check the blower leveling; drive alignment and tightness of all mounting bolts. Manually turn blower to ensure that blower turns freely and impellers rotate with out bumping or rubbing at any point. (check manual for the correct grade of lubricant, Lubricants in small quantities can be ordered from CCW on 1800 68 68 69.

Oil Bath Both Ends

This blower has an oil bath on both ends and does not need to be greased. Remove the blower oil drain cap and drain oil from both ends. Dispose of the oil in an appropriate location. Replace the drain cap. Fill with industrial blower lubricant into the fill hole until oil just covers the lubricate sight glass. Replace fill lug and over flow lug. Do not over tighten. Check the blower leveling; drive alignment and tightness of all mounting bolts. Manually turn blower to ensure that blower turns freely and impellers rotate with out bumping or rubbing at any point. (check manual for the correct grade of lubricant, Lubricants in small quantities can be ordered from CCW on 1800 68 68 69.

Solution pump

Remove the pump oil drain cap and drain oil. Dispose of the oil in an appropriate location. Replace the drain cap. Remove the pump filler lug. Fill with premium grade engine oil 15w40 until oil reaches half way up the sight glass. Replace fill lug. Manually turn pump to ensure that the pump turns freely.

Drive coupling and belts

Slide in units

Check drive coupler for wear and tear. Replace coupler element or coupler plugs if necessary. Check belts and pulleys for wear and tear. Inspect for contaminants such as oil or grease. Remove contaminants with warm soapy water. If belts have a slick glazed look, belts are slipping. Check the belt tension. Check to ensure that belts are as near to perfect alignment as possible.

CDS units

The clutch under drivers seat does not need to be serviced. Check belts and pulleys for wear and tear. Inspect for contaminants such as oil or grease. Remove contaminants with warm soapy water. If belts have a slick glazed look, belts are slipping. Check the belt tension. Check to ensure that belts are as near to perfect alignment as possible. Locate grease nipples at both ends of the shaft. Give two ot three good pumps on you grease gun with premium petroleum based high temperature and moisture resistant grease into blower bearing. Wipe away the excess grease.

7 - Heat Exchange System

Heat exchangers

No service necessary. Wipe over with a damp cloth.

Exhaust diverter

Manual diverter

Spay exposed metal surfaces with spray lubricant and work the diverter back and forth to ensure it is moving freely

Automatic diverter control (ADC)

Spay cylinder ram with spray lubricant with the machine running on idle turn the diverter switch on and of a number of times. Inspect the diverter to ensure that it is moving freely

8 - Testing & Cleaning

Testing

Hook up machine to garden hose and turn on the garden hose. Turn the ignition on and listen to the fuel pump. Ensure fuel pump starts quickly then slows down as fuel pressure builds up. Set the engine throttle to the minimum setting and start the engine. Pull out choke if required. Run the engine for approximately 20 seconds. Stop the engine and check the oil levels of the engine, pump and blower. Add oil or drain off oil if necessary. Start engine again set on low revs. Spray blower lubricant into blower lube port for approximately 15 seconds. Check truckmount fail-safes are working. Cut off fresh water to the machine and open the mix tank drain. The machine should stop before the mix tank is completely empty. Open vacuum tank and lift high water shut off float. The machine should shut down. Turn machine up to high revs. Check battery to ensue that it is fully charged and that the rectifier is working. Check that the vacuum pressure relief valve is set at 12-12.5Hg. Attach a high-pressure lance to the solution line. Turn the pump pressure to maximum. Ensure that there is a constant flow of water with out pulsating or cavitations. Run the machine for approximately 2 minutes then restrict the vacuum inlet on the vacuum tank to put the machine under load. Run the machine until the machines is up to temperature and dumping into the waste tank. Check the temperature of the water. Ensure that the temperature is at the optimum dump temperature for your unit.

Cleaning

Clean all cleanable surfaces with warm soapy water and dry with a soft cloth. Apply car polish to painted surfaces and buff shine.

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