400 Hour Service Checklist

INSPECT THE TOP PLATE FOR DAMAGE/CRACKS

• FIFTH WHEEL HAS NO VISIBLE DAMAGE

• FIFTH WHEEL IS DAMAGED

CHECK THE FIFTH WHEEL ADJUSTMENT WITH THE TEST TOOL. CHECK THAT THE YOKE TIPS DO NOT EXTEND PAST THE JAWS MORE THAN 1/2"

• FIFTH WHEEL IS IN ADJUSTMENT AND WITHIN SPEC

• FIFTH WHEEL NEEDS ADJUSTMENT

• FIFTH WHEEL REQUIRES REBUILD

CHECK FIFTH WHEEL PIVOT PINS AND BUSHINGS

• PIVOT PINS AND BUSHINGS ARE WITHIN SPEC

• PIVOT PINS AND BUSHINGS REQUIRE REPLACEMENT

CHECK FIFTH WHEEL SLIDER, SLIDER LOCK CYLINDER

• FIFTH WHEEL SLIDER LOCKS AND CYLINDER ARE WITHIN SPEC

• FIFTH WHEEL SLIDER LOCKS HAVE PLAY

• FIFTH WHEEL SLIDER CYLINDER DOES NOT MOVE

• FIFTH WHEEL SLIDER CYLINDER LEAKS AIR

CHECK AND MEASURE BRAKE SHOE/PAD LININGS

• BRAKE SHOE/PAD LININGS AND HARDWARE ARE WITHIN SPEC

• BRAKE LININGS CONTAMINATED

• BRAKE LININGS CRACKED OR DAMAGED

• BRAKE SHOES PROTRUDING FROM DRUM

• BRAKE LINING HARDWARE MISSING OR DAMAGED

• BRAKE DRUM/ROTOR CRACKED OR DAMAGED

CHECK CLEVIS PINS ON ALL SLACK ADJUSTERS

• CLEVIS PINS ARE ALL PRESENT, FREE AND SECURE

• CLEVIS PINS SEIZED

• CLEVIS PINS MISSING

• CLEVIS PIN COTTER PINS MISSING

• CLEVIS PINS WORN

• WRONG CLEVIS PINS OR CLEVIS

ANCHOR PIN AND BUSHING

• ANCHOR PINS AND BUSHINGS ARE SECURE AND NOT WORN

• ANCHOR PINS AND/OR BUSHIGS WORN

• LOOSE OR MISSING ANCHOR PINS

• SLACK ADJUSTER INDICATOR NOT IN THE NOTCH WHEN BRAKES ARE RELEASED

BACK OFF BRAKE CALIPERS

• BRAKES BACKED OF WITHOUT BREAKING SHEAR ADAPTER

• SHEAR ADJUSTER BROKE MORE THAN ONCE (IF MORE THAN 1 SHEAR ADAPTER BREAKS THE CALIPER IS DEFECTIVE)

BRAKE CALIPER SLIDE PIN BOOTS

• NO DAMAGE OBSERVED IN THE SLIDE PIN BOOTS

• TORN SLIDE PIN BOOT(S)

WITH THE BRAKE CALIPERS BACKED OFF CHECK THE SLIDE PINS FOR EXCESSIVE PLAY

• NO EXCESS PLAY FOUND IN THE PINS

• PLAY FOUND IN THE SLIDE PINS

BRAKE PAD HOLD DOWN HARDWARE

• ALL HARDWARE IS PRESENT AND THE BRAKE PADS ARE SECURE

• LOOSE OR MISSING BRAKE PAD HARDWARE

REMOVE THE DUST PLUG IF APPLICABLE

• DUST PLUG PRESENT AND BRAKE SPRING HAS NO VISIBLE DEFECTS

• MISSING DUST PLUG

• BRAKE CHAMBER FULL OF DEBRIS (FAIL)

• PARK BRAKE SPRING BROKEN (FAIL)

• UNABLE TO CAGE BRAKE CHAMBER (FAIL)

• DAMAGED BRAKE CHAMBER ASSEMBLY OR MOUNTING (FAIL)

CHECK FOR AIR LEAKS

• NO AIR LEAKS HEARD, NO PRESSURE DROP OBSERVED ON GAUGES

• AUDIBLE AIR LEAK OR PRESSURE DROP OBSERVED

WITH THE PARK BRAKE RELEASED APPLY THE SERVICE BRAKES

• NO AIR LOSS HEARD OR OBSERVED ON GAUGES

• AUDIBLE AIR LEAK OR PRESSURE DROP OBSERVED ON GAUGES

BRAKE PUSH ROD MEASUREMENT AND ABILITY TO TRAVEL

• BRAKE STROKE WITHIN SPEC FOR BRAKE CHAMBER TYPE

• BRAKE PUSHROD STROKE BEYOND SPEC OR BEYOND 90 DEGREES

• BRAKES PUSHROD SLOW TO RETRACT INTO BRAKE CHAMBER

• BRAKE PUSHROD ANGLE INCORRECT (WEARING INTO BRAKE CHAMBER)

• BRAKE CHAMBER MOUNTED IN WRONG MOUNTING HOLES (TOP HOLES FOR 5", DIAGONAL FOR 5.5" AND BOTTOM HOLES FOR 6" SLACK ADJUSTER LENGTH)

BRAKE CHAMBER HARDWARE AND CLEVIS

• BRAKE CHAMBER HARDWARE IS CORRECT AND SECURE

• BRAKE CHAMBER MOUNTING HARDWARE IS LOOSE, MISSING OR DAMAGED

• CLEVIS IS NOT SECURED (JAM NUT BACKED OFF OR MISSING)

S-CAM HARDWARE

• ALL HARDWARE IS CORRECT AND SECURE

• INCORRECT S-CAM/ADJUSTER SHIMMING

• INCORRECT OR MISSING SNAP-RING(S)

• SLACK ADJUSTER MISALIGNED TO BRAKE CHAMBER PUSH ROD

ENSURE EACH UNIT HAS ENOUGH CAGING BOLTS

• ENOUGH CAGING BOLTS PRESENT ON UNIT TO CAGE ALL BRAKE CHAMBERS

• MISSING CAGING BOLTS

CHECK AIR LINES AND FITTINGS

• NO ABRASIONS OR DAMAGED FITTINGS. HOSES SECURED

• LOOSE HOSES THAT NEED TO BE SECURED

• DAMAGED FITTINGS

• HOSES OR FITTINGS THAT ARE NOT DOT COMPLIANT

CHECK ENTIRE UNIT FOR ANY FLUID LEAKS

• NO FLUID LEAKS FOUND

• COOLANT LEAK

• ENGINE OIL LEAK

• TRANSMISSION OIL LEAK

• POWER STEERING LEAK

• HYDRAULIC LEAK

• DIFFERENTIAL LEAK

• AXLE SHAFT OR HUBCAP LEAK

• PRODUCT PUMP/PIPING LEAK

• WASHER FLUID LEAK

• A/C SYSTEM OIL LEAK

• FUEL SYSTEM LEAKS

EXHAUST LEAKS

• NO EXHAUST LEAKS

• LEAKING EXHAUST MANIFOLD

• LEAKING EXHAUST PIPING

• BROKEN EXHAUST CLAMPS

• BROKEN OR STACK MOUNTS

• BROKEN OR LOOSE EXHAUST MOUNTS

• EXHAUST FUMES IN CAB

• ALL WIRING IS SECURED

• WIRES RUBBING

• MISSING LOOM OR PROTECTIVE COVERINGS

• CORRODED CONNECTIONS

• IMPROPER WIRE ROUTING

ENGINE OIL LEVEL

• Pass
• Flag
• Fail

TRANSMISSION OIL LEVEL

• Pass
• Flag
• Fail

COOLANT LEVEL AND CONDITION

• Pass
• Flag
• Fail

CHECK POWER STEERING FLUID LEVEL AND CONDITION

• Pass
• Flag
• Fail

CHECK HYDRAULIC FLUID LEVEL AND CONDITION

• Pass
• Flag
• Fail

WHEEL HUB OIL LEVEL/CONDITION

• Pass
• Flag
• Fail

PLUG SWAP ALL AXLE HOUSINGS TO CHECK FOR DEBRIS

• Pass
• Flag
• Fail

DIFFERENTIAL FLUID LEVEL

• Pass
• Flag
• Fail

TREAD DEPTH AND CONDITION

• Pass
• Flag
• Fail

SIDE WALL INSPECTION

• Pass
• Flag
• Fail

DUAL MATCHING (TIRE TREAD DEPTH, PRESSURE AND HEIGHT SHOULD MATCH)

• Pass
• Flag
• Fail

TIRE PRESSURES

• Pass
• Flag
• Fail

ALL WHEEL NUTS PRESENT AND TIGHT

• Pass
• Flag
• Fail

SIGNS OF WHEELS CLOCKING (HOLES BECOMING OBLONG)

• Pass
• Flag
• Fail

CRACKED WHEELS ANYWHERE ON THE WHEELS

• Pass
• Flag
• Fail

SKID INDICATORS PRESENT ON TRAILERS

• Pass
• Flag
• Fail

AIR TANK CHECK VALVES (DRAIN PRIMARY TANK AND CHECK IF SECONDARY DRAINS AS WELL, FILL SYSTEM AND REPEAT TEST BUT DRAIN SECONDARY AND SEE IF PRIMARY SYSTEM DRAINS)

• Pass
• Flag
• Fail

TRACTOR PROTECTION VALVE (OBSERVE BLUE GLADHAND AND WITHOUT RELEASING THE TRAILER BRAKE PERFORM A SERVICE BRAKE APPLICATION AND SEE IF AIR COMES OUT OF THE BLUE OR RED GLADHANDS)

• Pass
• Flag
• Fail

ENSURE THE LOW AIR ALARM IS WORKING

• Pass
• Flag
• Fail

RELEASE THE TRUCK PARKING BRAKES AND DRAIN THE AIR SYSTEM, NOTE WHERE THE PRESSURE IS AT WHEN THE YELLOW BUTTON POPS OUT

• Pass
• Flag
• Fail

CHECK THE AIR COMPRESSOR CUT-OUT PRESSURE

• Pass
• Flag
• Fail

WITH THE TRUCK RUNNING FILL THE AIR SYSTEM UNTIL CUT-OUT PRESSURE HAS BEEN REACHED, APPLY THE SERVICE BRAKE A FEW TIMES AND NOTE THE PRESSURE WHEN THE AIR COMPRESSOR STARTS BUILDING AIR AGAIN (CUT-IN PRESSURE)

• Pass
• Flag
• Fail

AIR COMPRESSOR BUILD TIME IS WITHIN SPEC

• Pass
• Flag
• Fail

FOG LIGHTS (IF APPLICABLE) (SHOULD ONLY WORK WITH LOW BEAMS)

• Pass
• Flag
• Fail

DRIVING LIGHTS (IF APPLICABLE)(SHOULD ONLY WORK WITH HIGH BEAMS)

• Pass
• Flag
• Fail

SIGNAL LIGHTS

• Pass
• Flag
• Fail

STOP LIGHTS

• Pass
• Flag
• Fail

REVERSE LIGHTS

• Pass
• Flag
• Fail

LICENCE PLATE LIGHT (IF APPLICABLE)

• Pass
• Flag
• Fail

MARKER/CLEARANCE LIGHTS

• Pass
• Flag
• Fail

WORK LIGHTS/AUX LIGHTING

• Pass
• Flag
• Fail

DOME LIGHTS

• Pass
• Flag
• Fail

DASH/GAUGE LIGHTS

• Pass
• Flag
• Fail

CHECK THE TRAILER CORD FOR ALL FUNCTIONS

• Pass
• Flag
• Fail

ABS LIGHT ILLUMINATED

• Pass
• Flag
• Fail

CHECK ENGINE LIGHT ILLUMINATED

• Pass
• Flag
• Fail

SEAT BELT LIGHT

• Pass
• Flag
• Fail

CHECK GAUGES TO MAKE SURE ALL ARE WORKING

• Pass
• Flag
• Fail

ELECTRIC (CITY) HORN

• Pass
• Flag
• Fail

AIR HORN

• Pass
• Flag
• Fail

HEADLIGHTS (HIGH BEAM AND LOW BEAM)

• Pass
• Flag
• Fail

CLUTCH PEDAL LINKAGE IS IN SPEC

• Pass
• Flag
• Fail

CLUTCH BRAKE

• Pass
• Flag
• Fail

CLUTCH BRAKE GAP

• Pass
• Flag
• Fail

INSPECTION COVER IS PRESENT AND SECURE

• Pass
• Flag
• Fail

FREEPLAY

• Pass
• Flag
• Fail

LIFT AXLE AND RELEASE BRAKES (TRAILER) TO CHECK WHEEL BEARINGS

• Pass
• Flag
• Fail

HUB CAP VENT PLUGS, WINDOWS AND GASKETS

• Pass
• Flag
• Fail

WHEEL SEAL LEAKS

• Pass
• Flag
• Fail

LEAF SPRING PINS

• Pass
• Flag
• Fail

TIE ROD AND DRAG LINKS

• Pass
• Flag
• Fail

STEERING SHAFT AND U-JOINTS

• Pass
• Flag
• Fail

KING PINS

• Pass
• Flag
• Fail

HAZARD KIT (MUST BE COMPLETE, CHECK EACH FLARE TO MAKE SURE THEY ARE NOT BROKEN AND ARE FUNCTIONAL)

• Pass
• Flag
• Fail

FIRE EXTINGUISHER AND MOUNTING (MUST BE ACCESSABLE)

• Pass
• Flag
• Fail

ESD SYSTEMS (TRAILER)

• Pass
• Flag
• Fail

GROUND CABLES

• Pass
• Flag
• Fail

STATIC STRAPS

• Pass
• Flag
• Fail

POSITIVE AIR SHUT DOWN

• Pass
• Flag
• Fail

FENDERS SECURE AND UNDAMAGED

• Pass
• Flag
• Fail

CAB MOUNTS

• Pass
• Flag
• Fail

CAB SHOCKS

• Pass
• Flag
• Fail

CAB AIRBAGS

• Pass
• Flag
• Fail

DOOR LATCHES AND HANDLES

• Pass
• Flag
• Fail

HOOD HINGES, LATCHES AND SPRINGS

• Pass
• Flag
• Fail

SIDE WINDOWS ROLL UP AND DOWN

• Pass
• Flag
• Fail

WINDSHIELD(S) CONDITION

• Pass
• Flag
• Fail

SEATBELTS

• Pass
• Flag
• Fail

SEATS

• Pass
• Flag
• Fail

GRAB HANDLES AND STEPS

• Pass
• Flag
• Fail

MUDFLAPS PRESENT AND IN GOOD CONDITION

• Pass
• Flag
• Fail

RADIATOR MOUNTS

• Pass
• Flag
• Fail

FAN SHROUD AND BLADE

• Pass
• Flag
• Fail

BELTS, PULLEYS AND TENSIONERS

• Pass
• Flag
• Fail

AIR CLEANER MOUNTING

• Pass
• Flag
• Fail

AIR-TO-AIR HOSES AND CLAMPS

• Pass
• Flag
• Fail

COOLANT HOSE CLAMPS

• Pass
• Flag
• Fail

ALTERNATOR (CHECK CONNECTIONS AND MOUNTING HARDWARE)

• Pass
• Flag
• Fail

OI FILLER CAP AND COOLANT CAPS PRESENT AND TIGHT

• Pass
• Flag
• Fail

ENGINE MOUNTS

• Pass
• Flag
• Fail

PHYSICAL CONDITION OF BATTERIES (LEAKING, CRACKED OR BLOATED CASES)

• Pass
• Flag
• Fail

DISCONNECT THE BATTERIES (NEGATIVE SIDE FIRST) AND CLEAN ALL THE CONNECTIONS WITH A WIRE WHEEL

• Pass
• Flag
• Fail

INDIVIDUALLY CHECK EACH BATTERY WITH A DIGITAL CONDUCTANCE TESTER

• Pass
• Flag
• Fail

CONNECT THE BATTERIES (POSITIVE FIRST), SPRAY WITH PROTECTIVE COATING

• Pass
• Flag
• Fail

BATTERY HOLD DOWNS PRESENT AND TIGHT

• Pass
• Flag
• Fail

• DRAIN THE ENGINE OIL

• REMOVE THE FILTER(S)

• CLEAN THE OIL FILTER CAPS OR MOUNTING SURFACES

• MAKE SURE OLD SEALS AND O-RINGS CAME OFF WITH THE OLD FILTERS

• INSTALL NEW FILTERS, USE LUBRIPLATE ON MOUNTING SEALS/SURFACES

• FILL WITH CLEAN ENGINE OIL

• RUN THE ENGINE FOR ABOUT 20-30 SECONDS AND SHUT DOWN

• AFTER 2-3 MINUTES CHECK AND ADJUST THE OIL PRESSURE (DO NOT OVER FILL)

• RUN THE ENGINE FOR ABOUT 5 MINUTES

OIL PRESSURE AFTER OIL CHANGE

CHECK OIL PRESSURE AND LEVEL BEFORE CHANGING THE OIL AND NOTE THE PRESSURE

CHECK AND REPAIR ALL FITTINGS AND ENSURE PROPER FITTINGS ON TRUCK

• Pass
• Flag
• Fail

CHECK SEALS ON PRODUCT PUMP

• Pass
• Flag
• Fail

CHECK GREASE LINES/FITTINGS ON PRODUCT PUMP

• Pass
• Flag
• Fail

CHECK AND REPAIR ALL LOAD HOSES

• Pass
• Flag
• Fail