Major service - rigid truck, prime mover and heavy vehicle
Estimated duration: 6 - 10 hours • Frequency: every 100,000 km (or per manufacturer schedule)
Vehicle Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 15,000 km) | ||||
| 1 | Replace fuel filter (primary and secondary) | REPLACE | ☐ | |
| 2 | Replace air filter (outer and inner elements) | REPLACE | ☐ | |
| 3 | Drain, flush and replace coolant (full system) | FLUSH/FILL | ☐ | |
| 4 | Replace fan belts (accessory and drive) | REPLACE | ☐ | |
| 5 | Inspect turbocharger (shaft play, oil seals, boost pressure) | INSPECT | ☐ | |
| 6 | Check and adjust valve clearance | ADJUST | ☐ | |
| 7 | Inspect fuel injectors (test or send for reconditioning) | INSPECT | ☐ | |
| 8 | Full DPF service (forced regen, check ash load) | INSPECT | ☐ | |
| Drivetrain (additional to 15,000 km) | ||||
| 9 | Drain and replace transmission oil + filter (auto) or gearbox oil (manual) | DRAIN/FILL | ☐ | |
| 10 | Drain and replace differential oil (all diffs) | DRAIN/FILL | ☐ | |
| 11 | Replace power steering fluid (flush) | FLUSH/FILL | ☐ | |
| Brakes (additional to 15,000 km) | ||||
| 12 | Full brake reline (reline drums/replace pads if below spec) | REPLACE | ☐ | |
| 13 | Inspect brake drums/discs (measure and record thickness) | MEASURE | ☐ | |
| Wheels and Bearings (additional to 15,000 km) | ||||
| 14 | Repack or replace wheel bearings (all positions) | REPLACE | ☐ | |
| Steering and Suspension | ||||
| 15 | Full steering inspection (drag link, tie rods, pitman arm, steering box) | INSPECT | ☐ | |
| 16 | Inspect suspension bushes, shackles, U-bolts and spring packs | INSPECT | ☐ | |
| Chassis and Structural | ||||
| 17 | Inspect chassis rails for cracks (visual and dye penetrant if needed) | INSPECT | ☐ | |
| 18 | Inspect 5th wheel and jaws (prime mover) | INSPECT | ☐ | |
| Air System | ||||
| 19 | Service air dryer (replace desiccant cartridge) | REPLACE | ☐ | |
| 20 | Test air system (governor, safety valve, tank drain) | TEST | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 or 10W-40 CI-4/CK-4 | 20 - 40 L |
| Coolant | 50/50 ethylene glycol | 30 - 50 L (full system) |
| Transmission oil | Allison TES 295 or 80W-90 manual | 15 - 30 L (system) |
| Diff oil | 80W-140 or 85W-140 GL-5 | 8 - 15 L per diff |
| Power steering | ATF | 3 - 5 L |
| AdBlue / DEF | ISO 22241 | As required |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical rigid trucks and prime movers. Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by engine and drivetrain configuration.
Parts / Consumables Required (additional to 15,000 km service)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Fuel filters (primary + secondary) | 1 set | ☐ | |
| 2 | Air filters (inner + outer) | 1 set | ☐ | |
| 3 | Coolant (full system flush and refill) | 30-50 L | ☐ | |
| 4 | Transmission oil + filter | 15-30 L | ☐ | |
| 5 | Differential oil | 8-15 L/diff | ☐ | |
| 6 | Power steering fluid | 3-5 L | ☐ | |
| 7 | Brake linings / pads | 1 set | ☐ | |
| 8 | Wheel bearing kits | As req. | ☐ | |
| 9 | Fan belts (accessory + drive) | 1 set | ☐ | |
| 10 | Air dryer desiccant cartridge | 1 | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager