TICO Pro-Spotter PM MANUAL - TICO TICO
TICO Pro-Spotter PM MANUALESykes@ticotractors.comTICO ManufacturingTICO, July 2015
1-1. GENERALA permanent record of the services, repairs, and modifications made to these vehicles must be recorded. Insureyou document all maintenance and repair that you perform on the TICO Work Requests.1-2. CLEANING INSTRUCTIONSa. Cleaning is an after operation service performed by operations personnel to keep the vehicle in a state ofreadiness. Facilities and material available to operators for vehicle cleaning can vary greatly in differingoperating conditions. However, vehicles must be maintained in as clean a condition as available cleaningequipment, materials, and operational situations permit. Pressure wash if possible.WARNING -Mineral Spirits are flammable and will not be usednear an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in wellventilated places. Failure to do this may result in injury to personnel and/or damage to equipment.WARNING -Protective gloves, clothing, and/or respiratoryequipment must be worn whenever caustic, toxic, or flammable cleaning solutions are used. Failure todo this may result in injury to personnel and/or damage to equipment.CAUTION -Do not allow caustic or flammable cleaningcompounds to come into contact with rubber, leather, vinyl, fiberglass cabs or canvas materials.Damage to equipment will result.CAUTION - Do not use compressed air when cleaning vehicleinteriors. Damage to equipment will result.CAUTION - Do not allow water to enter air cleaner assembly airintake weather cap. Damage to engine will occur.NOTICE -Remember to clean windshield wipers of debris on aregular basis to ensure proper vision.ii
1-3. PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)a. Designated Intervals.1.2.3.4.PM Service interval for TICO tractors is 500 hours.Certain areas, due to the conditions, will have service intervals lessened as neededNew tractors or vehicles with new engines installed will have a 50-hour “Initial” service performed.Also during the initial service on the new tractors ensure that all attaching hardware is physicallychecked for tightness.NOTICE -Designated intervals are performed under usualoperating conditions. PM intervals must be performed more frequently, as determined by themaintenance manager, when operating under unusual conditions.b. Procedures.1. For troubleshooting malfunctions, refer to your supervisor.2. Malfunctions are to be reported to the maintenance supervisor at once.3. Wiping cloths are needed to remove dirt or grease during inspections and maintenance.c. Trouble spots.1. Check all bolts, nuts and screws. If loose, bent, broken, or missing, tighten or report conditions tomaintenance personnel.2. Look for loose, chipped paint, rust and cracks at welds. Remove rust and or loose paint; spot paint asrequired. If a cracked weld is found, report the situation to maintenance personnel.3. Inspect electrical wires and connectors for cracked or broken insulation. Also look for bare wires, andloose or broken connections. Tighten loose connections. Report other problems to maintenancepersonnel.4. Check hoses and fluid lines for wear, damage and leaks. Ensure clamps and fittings are tight. (Referto Para. 1-4 for information on leaks.)5. Check pivot points for security and operation.6. Check data, caution, and warning plates/decals for security and legibility.Not Ready/AvailableIf a vehicle is not able to perform the mission, equipment will be reported as not serviceabled. Correct Assembly or Stowage.1. Check each component for installation as an assembly, in the right place, and with no missing orDirt, grease, oil, and debris may cover up a seriousdamage.problem. Clean as you check. Following precautions printed on container, use Mineral Spirits on allmetal surfaces. On rubber or plastic material, use soap and water.NOTICE -TICO, July 2015
1-4. FLUID LEAKAGEWetness around seals, gaskets, fittings, or connections indicates a leakage. A stain also denotes leakage. If afitting or connector is loose, tighten it. If broken or defective, report it.CAUTION -No tractor will be operated with a fuel leak. WHENIN DOUBT, NOTIFY YOUR SUPERVISOR. All leaks must be reported immediately to your supervisoror to maintenance personnel. Failure to do this will result in damage to vehicle and/or components.1-5. LUBRICATION REQUIREMENTSFor lubrication requirements and procedures SEE TICO LUBRICATION ORDER in the Operator’s Manual.WARNING REVIEWSWARNING - EXHAUST GASES CAN KILLBrain damage or death can result from heavy exposure. Precautions must be followed to ensurepersonal safety when the engine of any vehicle is operated for any purpose.1. Do not operate vehicle engine in enclosed areas.2. Do not idle vehicle engine with vehicle windows closed.3. Be alert at all times for exhaust odors.4. You must be alert for exhaust poisoning symptoms. They are: Headache Dizziness Sleepiness Loss of muscular control5. If you see another person with exhaust poisoning symptoms: Remove person from area Expose to open air Keep person warm Do not permit physical exercise Administer artificial respiration, if necessary Notify medical personnel.THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION.WARNING REVIEWSWARNING -Do not perform fuel or battery system checks,inspections, or maintenance while smoking, near sparks or open flames. Fuel may ignite andbatteries may explode causing damage to vehicle and injury or death to personnel.iv
WARNING REVIEWSWARNING -Mineral spirits is flammable and will not be usednear an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in wellventilated places. Failure to do this may result in injury to personnel and/or damage to equipmentWARNING -Avoid using a fire extinguisher in unventilatedareas. Prolonged inhalation/exposure to extinguishing agent or fumes from burning material maycause injury to personnel. Using fire extinguisher in a windy area will cause rapid dispersal ofextinguishing agent and reduce effectiveness in fire control.WARNING -Vehicle operation in snow is a hazardous condition.Operator must travel at reduced speeds and be prepared to meet sudden changes in road conditions.Apply brakes gradually when stopping vehicle on ice or snow. Sudden braking will cause wheels tolock and vehicle to slide out of control causing damage to vehicle and injury or death to personnel.WARNING - Do not rely on wet service brakes. Keep applyingbrakes until they dry out and uneven braking ceases. Failure to do this may cause damage to vehicleand injury or death to personnelWARNING -Exhaust components are hot after prolongedvehicle use. Ensure exhaust system components are cool before removing/installing exhaustassembly. Failure to do this will result in injury to personnel.WARNING -Chock blocks shall be used when parking a vehiclewith inoperative parking brakes, when operating in extreme cold conditions, when parking on inclines,or whenever and wherever maintenance is being performed. Failure to do so may result in injury topersonnel or damage to equipment.WARNING -Vehicle speed must be reduced consistent withweather and road/terrain conditions. Obstacles such as stumps, potholes and boulders must beavoided. Failure to use basic safe driving techniques/skills may result in injury or death to personneland damage to equipment.TICO, July 2015
TICO TRACTORSPREVENTATIVE MAINTENANCE CHECKS AND SERVICES“A” P.M. Every 500 HoursDRIVE IN CHECKSITEM TO CHECK:WHAT TO LOOK FOR:NOT READY IF:1DRIVERS SEAT OPERATION –CONDITIONInsure that all seat adjustments operate correctly. Check seat forair leaks. Check that seat back, cushion and arm (if equipped) aresecure and that no rips or tears exist. Lubricate all hinge points onseat frame with spray silicone or equivalent. Insure seat stops arein place. Insure seat restraints are in place and serviceableSeat will not adjust,seat base cracked orunserviceable.Restraints missing orunserviceable.2SEAT BELT OPERATION –CONDITIONCheck that belt is in good condition, no fraying or cuts. Insurethat the belt is securely fastened to the seat frame. Checkoperation of belt latch. Buckle belt across seat bottom whenfinished.Seat belt missing,damaged ordefective.3HORN OPERATIONPress the horn button on the floor to check operation. Check bypass horn (If equipped) by turning the ignition key to the runposition and depressing by-pass button. The warning horn shouldsound. Check both horns for secure mounting. The city horn (Ifequipped) can be checked by pressing the center button of thesteering wheel.Either horn isdefective.Floor switchPull cable4WINDSHIELD WIPEROPERATIONCheck that windshield wiper works when ignition switch is turnedon and works in both high and low positions. Insure wiper doesnot hit the molding on either side of the windshield. Check motor,arm and wiper blade for secure mounting and serviceability.Check mounting of the switch into the dash as well as the knobmounting to the switch to ensure they are secure. Insure the wiper“parks” in the proper position.5DOME LIGHTCheck light for operation. Check that the wiring is mountedcorrectly and secure. Check the lens for serviceability.-1–TICO, July 2015Windshield wipersinoperative.
ITEM TO CHECK:WHAT TO LOOK FOR:6DEFROSTER FAN AND HEATERCheck fan operation. Check that fan wiring and mounting aresecure. Check that the heater fan operates on both high and lowspeeds, check that the coolant control valve is on and check theheater core for leaks. Check that heater wiring and mounting issecure. Check that the vent hoses are in place and serviceable.Check the air intake screen for cleanliness and serviceability.Check operation of AC (If equipped)7DASH LIGHTSCheck that all dash lights are operational when the light switch isturned “ON”8ALL GAUGES AND VEHICLECONTROLSCheck that all gauges are operational. Insure that all controlsoperate properly: brake pedal, 5th wheel release valve, boomcontrol, park and trailer brake air valves and knobs. All lightswitches are secure and operational. On mechanical enginesadjust air throttle to 60PSI pedal depressed. Trucks equipped withelectronic engines and transmissions will have warning and shutdown lights that come on and go off.WARNING -Ifgauges, instruments, or instrument lights areinoperable or not within ranges described in thesechecks, immediately shut off engine and notifysupervisor. Continued operation of vehicle may resultin injury or damage to equipment.NOT READY IF:Defroster or heaterinoperative.Air intake screenunserviceable.Heater core leaking.AC inoperative.NOTE:Check at idle atoperatingtemperature.Oil Pressure:Below 12 PSIVoltmeter:Above 15 VDC orBelow 12 VDCTemperature:Above 220 DegreesAir Pressure:Above 125 PSIBelow 90 PSIAny control valvesticking or leaking.Engine, transmissionlight stays on.9HEAD LINER AND FLOOR MATCheck that the insulation material is secured to the ceiling of thecab. Floor mat is in place and serviceable.10INTERIOR FOR LOOSE ORMISSING SCREWS ANDHARDWAREInsure that all dash screws, wiring loom clamps, screws and anyother interior clamps are in place and secure. Tighten all hardwareand fasteners that were found loose.11GLASS AND LATCHASSEMBLIESNo cracked or missing glass. Latches in place and secure. Sidewindow tracks in place and holding glass firmly.Any glass missing,broken, or notmounted properly.12CAB DOORAir operated door should operate smoothly. Lubricate upperbushings with spray silicone or a light weight lubricant such asWD40. Lower bushings should be greased via zerk fittings.Panels should not be so cloudy as to obstruct vision.Door panels cloudyor damaged.Door is stiff, hard toopen or close.Door slams open orclose.2
ITEM TO CHECK:WHAT TO LOOK FOR:NOT READY IF:With the parking brakes released and full air pressure, chock thewheels to prevent the tractor from rolling and listen for air leakswhile walking around the vehicle. Observe the air gauge forpressure drops. With full air pressure (120 PSI) apply servicebrakes and listen for air leaks, also observe the air gauge for adrop in operating pressure.Any air leaks orvehicle fails tomaintain air pressure.13AIR LEAKS – PARK BRAKERELEASED14PARKING BRAKE OPERATIONAfter checking for air leaks with the engine off, pump the brakesand observe the air pressure. At approximately 60 PSI the parkingbrakes should apply and the vehicle should not move forward orback.Parking brakes do notengage whenpressure drops.Parking brakes fail tohold vehicle.15BOOM OPERATIONRaise boom to highest level and back down again. This processshould be done several times to insure the boom operates properly.Boom fails to operateproperly.WARNING -Donot place any part of your body into a pinch positionbetween the boom assembly and frame. Severe injuryor death may occur. Always use the boom safety barwhen working under boom assembly.16STEERING WHEEL ANDCOLUMNInsure the column is secure. Check that steering wheel is secureand no cracks are present. Insure the steering mounting bolts aretight and the column does not move up or down.3Steering column isnot secure.Steering wheel isunserviceable if aspoke missing orcracked.
ITEM TO CHECK:WHAT TO LOOK FOR:NOT READY IF:17STEERING OPERATIONSteering should operate right and left smoothly. There should beno vibration or hard spots in the steeringSteering binds orsticks.Excessive play insteering.18TRANSMISSION OPERATIONCheck operation of shift control into forward and reverse. Checkfor excessive play in the shifter. No slipping should be evident inforward or reverse. Insure the engine starts only in the neutralposition.ELECTRONIC TRANSMISSION: Check shift pad for crackedcover, transmission should only shift into drive or reverse whenthe brakes are applied.Excessive play in theshifter.Engine starts in (D)or (R).Electronictransmission goesinto drive or reversewithout applyingbrakes.EXTERNAL CAB CHECKS19ALL LIGHTS – OPERATIONSCheck all lights. All lights should be in working order. All wiringwill be secure in wire looms and any splices/repairs will have heatshrink on them to protect from arcing and corrosion.Any lights inoperableor any bare wires.20CAB PROTECTION BARCheck for loose mounting bolts, cracked welds or accidentdamage.Any cracks oraccident damageevident21CAB CONDITIONCheck for cracks in the cab, loose mounting bolts, or accidentdamage.22MIRRORS AND BRACKETSInsure mirrors and bracket mounts are secure. No broken or loosemirrors.Cracks or holes thatwould allow water toenter into cab.Mirror missing orloose4
ITEM TO CHECK:WHAT TO LOOK FOR:NOT READY IF:23BUMPER AND FENDERCheck that bumper bolts /welds are secure. Bumper notexcessively bent to the point of making the vehicle unsafe. Checkfender for damage and secure mounting. Make sure there are nosharp edges or extrusions that could be a potential hazard.Bumper or fenderexcessivelybent/damaged.24GLAD HANDS, HOSES &HANGERSCheck glad hands for damage. Insure that rubber washers are inserviceable condition. Hoses should not have any cracks or tearsin the casing. If tractor is equipped with hose hangers insure theyare fastened to the rail on the cab protection bar. Some units areequipped with a basket type holder.Glad hands damaged.If rubber washers aremissing orunserviceable.Hoses are cracked.ENGINE COMPARTMENTCHECKS25AIR CLEANER DUCTWORKInspect the air inlet piping including all joints, clamps, hoses andconnections to insure they are tight. That there are no holes ortears in the system. Be sure to check the supports for the air intakepipe making sure they are not broken or loose.Any looseconnections or worncomponents.Any cracks oropenings between theair cleaner and theturbocharger.Support bracket looseor broken.26AIR FILTERCheck the air filter restriction indicator. If red replace the airfilter. Record the date changed on the filter with a Yellow PaintMarker. If the air restriction indicator is green check the date onthe air filter, if the date is over six months replace the air filter.Always insure the air filter cap is tight. Insure the air restrictionindicator is serviceable.Air restrictionindicator is red or airfilter date is over sixmonths old.RESET THE AIR FILTER RESTRICTION INDICATORLOCATED ON THE FILTER HOUSINGAir FilterChange Every Six Months OrWhen Unserviceable.NOTE:(WRITE DATE ON FILTER)5
ITEM TO CHECK:WHAT TO LOOK FOR:NOT READY IF:27ALTERNATORCheck alternator and insure that all mounting bolts and bracketsare secure and that no cracks are present. Inspect pulley for cracksand/or damage. Insure that all wiring is tight and secured out ofthe way. Check for broken wires.Any cracks.Any hardwaremissing or anybroken wires.28WATER PUMPInspect the water pump for any signs of leakage.Any leakage ofcoolant.29FAN, FAN CLUTCH, FAN HUB &IDLERCheck fan hub for noise or vibration. Inspect the fan clutch (Ifequipped) for operation. Inspect fan for broken or bent blades.Inspect the idler pulley. Inspect the fan shroud for serviceability.Any noise orvibration.Bent or brokenblades.Worn idler pulley.Fan clutch isinoperative.30BELTS – CONDITION &TENSIONCheck that all belts have adequate tension. Inspect the belts forcracks or excessive wear on the drive side.Belt not adjustedproperly.Any cracks orexcessive wear.31EXHAUST SYSTEMCheck the exhaust manifold and all piping for cracks, holes, or anyleaks. Insure that all clamps are tight. Check condition of themuffler. Insure that the muffler guard is secure.Any cracks, holes orexhaust leaks.Any loose mountinghardware.32TURBOCHARGERInspect the turbocharger for any cracks, exhaust or oil leakage.Check that all clamps and mounting hardware are secure. Checkturbo oil supply line and drain tube for any leaks, chaffing orabrasions.Any cracks, holes,exhaust or oil leaksfound.Any loose mountinghardware.Any lines or tubesrubbing.6
ITEM TO CHECK:33RADIATOR & TRANSMISSIONCOOLERWHAT TO LOOK FOR:NOT READY IF:Check all mounting bolts (Self-locking only) for the radiator andtransmission cooler. Insure the fan shroud is in place and secure.Inspect all lines and hoses for leaks, abrasions, chaffing andproper mounting (To include all clamps are in place). Inspect theradiator and transmission oil cooler for leaks. Insure thetransmission oil cooler is properly mounted. Inspect the overflowbottle; insuring that it will hold fluid and that the cap and line arein place. If equipped with CAC, insure it is mounted properly andno leaks present.Any leaks found.Any mountinghardware missing orimproperly mounted.Overflow bottleunserviceable.NOTICE - Tightenmounting bolts of the radiator just enough to compressthe rubber mounting cushions. Over-torqueing willcause damage due to excessive vibration.34REVERSE BLOW THERADIATORUsing shop air pressure (No more than 40-50 lbs) with properblow gun attachment carefully blow out the radiator (DO NOTTOUCH THE RADIATOR FINS WITH THE BLOW GUN) Dothis in the opposite direction of the normal air flow. If the radiatorhas been oil fouled you will have to steam clean the unit to clearthe radiator.NOTICE -Improperairflow will cause the vehicle to run hot and shut down.Continued use in this condition can result inengine/transmission damage35STARTERCheck the mounting of the starter. Insure that all mount bolts arein place and tight. Inspect the cables for chaffing or abrasions.Insure that cable connections to the starter posts are tight andclean. Once cleaned be sure to spray with battery terminal sealer.Any mountinghardware loose ormissing.Any cables worn orchaffed.36HYDRAULIC PUMP & PTOCheck to insure the mounting bolts are in place and secure. Checkall gaskets and hoses to insure there are no leaks.Any mountinghardware missing orloose.Any leaks at the PTOpump or hoses.PTO Type Pump Mounted OnTransmission7
ITEM TO CHECK:WHAT TO LOOK FOR:NOT READY IF:37HYDRAULIC TANKInspect the hydraulic tank for secure mounting, damage or leaks.Insure that both return and suction ball valves located at thebottom of the tank are wired in the open position (THE VALVEHANDLE IN
4 WINDSHIELD WIPER OPERATION . control, park and trailer brake air valves and knobs. All light switches are secure and operational. On mechanical engines . Air operated door should operate smoothly. Lubricate upper bushings with spray silicone or a light weight lubricant such as WD40. Lower bushings should be greased via zerk fittings.
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