FIRST ECHELON PREVENTIVE MAINTENANCE SERVICES
Paragraph
Purpose 14
Before‐operation service 15
During‐operation service 16
At‐halt service 17
After‐operation and weekly service 18
14. PURPOSE.
=a.= To insure mechanical efficiency it is necessary that the vehicle
be systematically inspected at intervals each day it is operated and
weekly, so that defects may be discovered and corrected before they
result in serious damage or failure. Certain scheduled maintenance
services will be performed at these designated intervals. The services
set forth in this section are those performed by driver or crew before
operation, during operation, at halt, after operation, and weekly.
=b.= Driver preventive maintenance services are listed on the back of
“Driver’s Trip Ticket and Preventive Maintenance Service Record,” W.D.
Form No. 48, to cover vehicles of all types and models. Items peculiar
to specific vehicles, but not listed on W.D. Form No. 48, are covered
in manual procedures under the items to which they are related. Certain
items listed on the form that do not pertain to the vehicle involved
are eliminated from the procedures as written into the manual. Every
organization must thoroughly school each driver in performing the
maintenance procedures set forth in manuals, whether or not they are
listed specifically on W.D. Form No. 48.
=c.= The items listed on W.D. Form No. 48 that apply to this vehicle
are expanded in this manual to provide specific procedures for
accomplishment of the inspections and services. These services are
arranged to facilitate inspection and conserve the time of the driver,
and are not necessarily in the same numerical order as shown on W.D.
Form No. 48. The item numbers, however, are identical with those shown
on that form.
=d.= The general inspection of each item applies also to any supporting
member or connection, and generally includes a check to see whether the
item is in good condition, correctly assembled, secure, or excessively
worn.
(1) The inspection for “good condition” is usually an external visual
inspection to determine whether the unit is damaged beyond safe or
serviceable limits. The term “good condition” is explained further by
the following: not bent or twisted, not chafed or burned, not broken
or cracked, not bare or frayed, not dented or collapsed, not torn or
cut.
(2) The inspection of a unit to see that it is “correctly assembled”
is usually an external visual inspection to see whether it is in its
normal assembled position in the vehicle.
(3) The inspection of a unit to determine if it is “secure” is usually
an external visual examination, a hand‐feel, or a pry‐bar check for
looseness. Such an inspection should include any brackets, lock
washers, lock nuts, locking wires, or cotter pins used in assembly.
(4) “Excessively worn” will be understood to mean worn close to, or
beyond, serviceable limits, and likely to result in a failure if not
replaced before the next scheduled inspection.
=e.= Any defects or unsatisfactory operating characteristics beyond
the scope of first echelon to correct must be reported at the earliest
opportunity to the designated individual in authority.
15. BEFORE‐OPERATION SERVICE.
=a.= This inspection schedule is designed primarily as a check to see
that the vehicle has not been tampered with, or sabotaged since the
After‐operation Service was performed. Various combat conditions may
have rendered the vehicle unsafe for operation and it is the duty of
the driver to determine whether or not the vehicle is in condition to
carry out any mission to which it is assigned. This operation will not
be entirely omitted, even in extreme tactical situations.
=b. Procedures.= Before‐operation Service consists of inspecting
items listed below according to the procedure described, and correcting
or reporting any deficiencies. Upon completion of the service, results
should be reported promptly to the designated individual in authority.
(1) ITEM 1, TAMPERING AND DAMAGE. Look for any injury to vehicle in
general, its accessories or equipment, that may have been caused by
tampering, sabotage, collision, falling debris, or shell fire since
parking vehicle. Look for loosened or damaged accessories, loose fuel
or oil lines, or any disconnected linkage.
(2) ITEM 3, FUEL AND OIL. Inspect tanks for fuel and oil levels, add
oil and fuel as necessary. Any appreciable change in levels since
performing After‐operation Service should be investigated and reported
to designated authority.
(3) ITEM 4, ACCESSORIES AND DRIVES. Examine all accessories such
as carburetor, air cleaner, generator, and cut‐out relay for loose
connections, loose mountings, or leaks. Examine rear chain (final
drive) for free up‐and‐down movement (slack), midway between sprockets.
Total up‐and‐down movement must not be more than 1 inch, nor less than
1/2 inch. Inspect rear chain for adequate lubrication.
(4) ITEM 6, LEAKS, GENERAL. Examine vehicle and ground under vehicle
for indications of fuel or oil leaks. Normally a few drops of waste oil
from chains may be expected to drop from skid plate.
(5) ITEM 11, GLASS. Clean glass on instruments; clean and adjust rear
view mirror; inspect glass for breakage.
(6) ITEM 12, LAMPS. If tactical situation permits, observe whether
blackout and service lights operate with switch in its respective
positions, and go out when switched off. Also see that lights are
secure, and that lenses are clean and not broken. Observe whether both
filaments of service headlight operate when dimmer switch on left
handle bar is moved to its respective positions.
(7) ITEM 13, WHEELS, AXLE NUTS AND SCREWS. Examine rear wheel mounting
socket screws, front and rear axle nuts, and front fork rocker stud
nuts for tightness. Observe rear chain adjusting screws for secure
locking. Inspect spokes for good condition and tightness.
(8) ITEM 14, TIRES. Examine tires for cuts or imbedded objects in
treads or carcass. If time permits, check air pressure, which should be
18 pounds front, and 20 pounds rear (tires cold). Inspect valve caps
for presence and secure mounting.
(9) ITEM 15, SPRINGS AND SUSPENSION. Examine front fork springs for
secure mounting and good condition. Push down rear of saddle to test
for full action of saddle post spring.
(10) ITEM 16, STEERING AND HANDLE BAR CONTROLS. Test steering head
bearing adjustment by exerting strong upward pull at handle bar grips,
and observing whether or not there is any noticeable play in bearing.
Operate steering damper lever and observe that damper is compressed
before lever reaches right‐side position, and is fully released with
lever in left‐side position. Test handle bar grip controls for full,
free action; also test for complete opening and closing of throttle,
and full advance and retard of timer.
(11) ITEM 17, FENDERS (MUDGUARDS), LUGGAGE CARRIER, SAFETY GUARDS, AND
STANDS. Examine these items for good condition and secure mounting.
(12) ITEM 21, TOOLS AND EQUIPMENT. Inspect tools and equipment for
presence, serviceability, and proper stowage. (See tool list in par.
21.)
(13) ITEM 7, ENGINE WARM‐UP. Start engine, noting any tendency toward
hard starting, or improper action of foot starter crank. Set throttle
to moderate idle speed. Listen for unusual noises. Watch instrument
indications and engine performance, such as misfiring. CAUTION: _Do not
idle engine longer than 1 minute with vehicle standing_.
(14) ITEM 8, CHOKE. During idling of engine, reset choke as required to
prevent excessive choking and dilution of engine oil.
(15) ITEM 9, INSTRUMENTS. When switch is turned on and engine is idling
at moderate speed both red light (indicating oil pressure) and green
light (indicating generator action) should be out. At lower operating
speeds generator‐indicating light may flicker. CAUTION: _Do not operate
engine with red light on (no oil pressure)_.
(16) ITEM 10, HORN. Tactical situation permitting, test horn.
(17) ITEM 22, ENGINE OPERATION. Engine should idle smoothly. Accelerate
and decelerate, listening for any unusual noises that may indicate
compression or exhaust leaks, worn, damaged, loose, or inadequately
lubricated engine parts, or accessories. Note any unusual smoke from
exhaust.
(18) ITEM 23, DRIVER’S PERMIT, ACCIDENT REPORT FORM NO. 26, AND VEHICLE
MANUAL. These items must be present on vehicle and safely stowed.
(19) ITEM 25, DURING‐OPERATION SERVICE. The During‐operation Service
should start immediately after vehicle is put in motion, in the nature
of a road test.
16. DURING‐OPERATION SERVICE.
=a.= While vehicle is in motion, listen for any sounds such as rattles,
knocks, squeals, or hums that may indicate trouble. Be alert to detect
any odor of overheated components or units such as generator, brakes,
or clutch, fuel vapor from a leak in fuel system, exhaust gas, or other
signs of trouble. Any time the brakes are used, gears shifted, or
vehicle turned, consider this a test and notice any unsatisfactory or
unusual performance. Watch the instruments constantly. Notice promptly
any unusual instrument indication that may signify possible trouble in
system to which the instrument applies.
=b. Procedures.= During‐operation Service consists of observing
items listed below according to the procedures following each item,
and investigating any indications of serious trouble. Notice minor
deficiencies to be corrected or reported at earliest opportunity,
usually at next scheduled halt.
(1) ITEM 27, FOOT AND HAND BRAKES. The foot brake should operate
smoothly and effectively, leaving reserve pedal travel of 1 inch.
Normal free play before operation is 1 inch. Test hand brake lever for
free play, which should be 1/4 of total handle travel. Test for ease and
smoothness of operation.
(2) ITEM 28, CLUTCH. Inspect clutch for disengagement at about 1/2 pedal
travel. Clutch should not chatter, squeal, or slip.
(3) ITEM 29, TRANSMISSION. Gears should shift smoothly, operate
quietly, and not jump out of mesh during operation. If transmission
jumps out of mesh in any gear, this indicates need of shifter control
adjustment.
(4) ITEM 31, ENGINE AND CONTROLS. Be alert for deficiency in engine
performance such as lack of usual power, misfiring, unusual noise,
stalling, indication of engine overheating, or unusual exhaust smoke.
Notice whether engine responds to controls satisfactorily, whether
controls appear to be in proper adjustment and are sufficiently tight.
(5) ITEM 32, INSTRUMENTS. Observe instruments for indication of normal
functioning of systems to which they apply.
(_a_) _Speedometer and Odometer._ Speedometer should indicate vehicle
speed without excessive noise or fluctuation. Odometer should record
trip and total mileage.
(_b_) _Oil Pressure Signal Light._ Red light should be off during
operation. If light goes on, stop vehicle and investigate for oil
pressure failure.
(_c_) _Generator Signal Light._ Green light should be off above 20
miles per hour. Battery discharge is indicated by green light being on.
(6) ITEM 33, STEERING. Adjust steering damper to desired steering
friction. Observe vehicle steering for wander, shimmy, leading to one
side, or wheel hop.
(7) ITEM 34, RUNNING GEAR. Listen for any unusual noises from wheels,
axles, or suspension parts that might indicate looseness or damage.
(8) ITEM 35, CHASSIS. Be alert for noises that might indicate loose
accessories, controls, attachments, or equipment.
17. AT‐HALT SERVICE.
=a.= At‐halt Service may be regarded as minimum maintenance procedures
and should be performed under all tactical conditions, even though more
extensive maintenance services must be slighted or omitted altogether.
=b. Procedures.= At‐halt Service consists of investigating any
deficiencies noted during operation, inspecting items listed below
according to the procedures following the items, and correcting any
deficiencies found. Deficiencies not corrected should be reported
promptly to the designated individual in authority.
(1) ITEM 38, FUEL AND OIL. Replenish fuel and oil as may be required to
reach next refilling point. CAUTION: _Left tank is for fuel; right tank
is for oil. Filler caps should not be interchanged, as only fuel tank
cap is vented._
(2) ITEM 39, TEMPERATURES. Hand‐feel wheel hubs and brake drums for
overheating.
(3) ITEM 40, VENTS. Make sure that crankcase breather outlet and rear
chain oil feed pipe are clear. Make sure grease drains in front and
rear brake side covers are open and clean.
(4) ITEM 42, SPRINGS AND SUSPENSIONS. Look for broken springs in fork.
(5) ITEM 43, STEERING. Investigate any difficulty developed during
riding.
(6) ITEM 44, WHEELS AND MOUNTING SCREWS. Inspect wheels for broken,
bent, or loose spokes. Also, look for loose axle nuts or rear wheel
mounting screws. Inspect wheel rims for good condition.
(7) ITEM 45, TIRES. Examine tires for low pressure or damage. Remove
foreign matter from tire treads; inspect for cuts.
(8) ITEM 46, LEAKS, GENERAL. Inspect vehicle for indication of fuel,
oil, or battery leaks.
(9) ITEM 47, ACCESSORIES AND CHAIN. Examine accessories for loose
connections, loose mountings, or damage. Examine rear drive chain
for broken rollers, broken link side plates, and broken or missing
connecting link spring clips. Inspect chain for adequate lubrication.
(10) ITEM 48, AIR CLEANER. Air cleaner must be secure, with air
passages in good condition and clean. When operating under extremely
dusty or sandy conditions, inspect air cleaner frequently and service
as required.
(11) ITEM 49, FENDERS (MUDGUARDS), LUGGAGE CARRIER, SAFETY GUARDS, AND
STANDS. Inspect these items for looseness or damage.
(12) ITEM 52, APPEARANCE AND GLASS. Clean windshield, rear view mirror,
and light lenses; inspect for good condition, secure attachment, and
broken glass.
18. AFTER‐OPERATION AND WEEKLY SERVICE.
=a.= After‐operation Service is particularly important, because at this
time the driver inspects his vehicle to detect any deficiencies that
may have developed, and corrects those he is permitted to handle. He
should report promptly, to the designated individual in authority, the
results of his inspection. If this schedule is performed thoroughly,
the vehicle should be ready to roll again on a moment’s notice. The
Before‐operation Service, with a few exceptions, is then necessary
only to ascertain whether the vehicle is in the same condition in
which it was left upon completion of the After‐operation Service. The
After‐operation Service should never be entirely omitted, even in
extreme tactical situations, but may be reduced to the bare fundamental
services outlined for the At‐halt Service, if necessary.
=b. Procedures.= When performing the After‐operation Service, the
driver must remember and consider any irregularities noticed during
the day in the Before‐operation. During‐operation, and At‐halt
Services. The After‐operation Service consists of inspecting and
servicing the following items. Those items of the After‐operation
Services that are marked with an asterisk (*) require additional Weekly
services, the procedures for which are indicated in step (_b_) of each
applicable item.
(1) ITEM 54, FUEL AND OIL. Fill fuel and oil tanks; fill oil tank
within 1 inch of top; be sure to put oil in right tank and fuel in left
tank; do not interchange caps. CAUTION: _When operating under extremely
dusty conditions, drain engine oil tank and refill with fresh oil as
frequently as excessive contamination of the oil occurs_.
(2) ITEM 55, ENGINE OPERATION. Test for satisfactory engine idle
without stalling. Accelerate and decelerate engine, noting any tendency
to miss or backfire, unusual noises, or vibration that may indicate
worn parts, loose mounting, incorrect fuel mixture, or faulty ignition.
Investigate any unsatisfactory engine operating characteristics noted
during operation. Learn to recognize noise caused by loose primary
(front) drive chain. Slack in excess of 1/2 inch total up‐and‐down
motion can cause excessive noise which sounds like engine knock. Remove
inspection cover for examination of chain.
(3) ITEM 57, HORN. If tactical situation permits, test horn.
(4) ITEM 59, LIGHTS. If tactical situation permits, observe whether
blackout and service lights operate with switch in its respective
positions, and go out when switched off. Also see that lights are
secure, and lenses clean and not broken. Observe whether both filaments
of service headlight operate when dimmer switch on left handle bar is
moved to its respective positions.
(5) ITEM 56, INSTRUMENTS. Before stopping engine, inspect instruments
to see that indicator lights are still out. Stop engine. After 30
seconds, turn on switch to see that oil pressure and generator signal
lights turn on. CAUTION: _Be sure to turn off ignition switch after
this test_.
(6) ITEM 58, GLASS. Clean rear view mirror, windshield, instrument, and
light glass. Examine for secure mounting and breakage.
(7) ITEM 62, *BATTERY.
(_a_) Inspect battery carrier for good condition and secure mounting.
Inspect electrolyte level (should be 5/16 inch above plates). Inspect
for any signs of leakage of electrolyte indicating battery has been
overfilled, poorly sealed, or damaged. CAUTION: _Do not add water
unless actually needed_.
(_b_) _Weekly._ Clean dirt from top of battery, remove battery caps,
bring electrolyte level to 5/16 inch above plates, using clean,
drinkable water. Clean terminals or posts if corroded; be sure felt
washers are on terminals and properly oiled; tighten terminal bolts
cautiously, if loose. Clean and paint battery carrier if corroded.
(8) ITEM 63, *ACCESSORIES AND CHAIN.
(_a_) Inspect carburetor, air cleaner, generator, and cut‐out relay
for loose connections, mountings, or damage. Examine rear drive chain
for broken rollers, broken link side plates, and broken or missing
connecting link spring clips. Examine rear chain (final drive) for free
up‐and‐down movement (slack) midway between sprockets; maximum total
allowable deflection is 1 inch, minimum, 1/2 inch.
(_b_) _Weekly._ Tighten any accessory connections found loose. Wipe
excess dirt from rear chain. Check front chain for adjustment, and
inspect for proper lubrication.
(9) ITEM 65, *AIR CLEANER.
(_a_) Examine oil cup for excessive dirt and correct oil level. If air
cleaner is excessively dirty, clean elements in dry‐cleaning solvent,
refill cup with fresh oil. Dip elements in oil in oil cup, replacing
elements and attaching oil cup immediately. If gaskets are damaged,
replace. Under extremely dusty or sandy conditions it may be necessary
to clean and refill the air cleaner more than once daily. Inspect hose
for leaks.
(_b_) _Weekly._ Inspect air cleaner for proper oil level and
excessively dirty oil. Clean and service air cleaner, tighten mounting
and hose clamps. NOTE: _Early‐type, round air cleaner does not have
removable filter elements. Complete cleaner must be removed to wash
element._
(10) ITEM 66, *FUEL FILTER (GASOLINE STRAINER).
(_a_) Clean cap and screen of fuel filter.
(_b_) _Weekly._ Clean cap and screen of fuel filter, remove carburetor
bowl drain plug, and drain off water and dirt. Be sure to replace plug,
being careful to avoid cross threading.
(11) ITEM 67, ENGINE CONTROLS. Examine throttle and spark controls
for damage to wires or for disconnected linkage. Observe for lack of
lubrication.
(12) ITEM 68, *TIRES.
(_a_) Remove foreign matter such as nails, glass, or stones from tire
treads. Inspect tires for abnormal tread wear, cuts, or bruises: also
for presence and tightness of valve caps. Inflate tires to 18 pounds
front, 20 pounds rear, with tires cool.
(_b_) _Weekly._ Replace badly worn or otherwise unserviceable tires.
(13) ITEM 69, *SPRINGS AND SUSPENSION.
(_a_) Inspect front fork for broken or sagged springs, loose bolts,
studs, and nuts.
(_b_) _Weekly._ Tighten wheel axle nuts and rear brake sleeve nut. Also
tighten rear wheel mounting socket screws very securely.
(14) ITEM 70, STEERING. Inspect steering head for proper adjustment of
bearings. Examine steering damper for correct adjustment.
(15) ITEM 72, *VENTS.
(_a_) Make sure that crankcase breather outlet and rear chain oil
supply pipe are clear. Make sure grease drains in front and rear brake
side covers are open and clean.
(_b_) _Weekly._ Clean crankcase breather outlet, rear chain oil supply
pipe, and grease drains in front and rear brake side covers.
(16) ITEM 73, LEAKS, GENERAL. Look around mechanism and beneath vehicle
for indication of fuel, oil, and grease leaks. Examine around brake
drums for evidence of grease in drums or on linings. Normally a few
drops of oil may be expected to drip from skid plate.
(17) ITEM 74, GEAR OIL LEVELS. Inspect transmission oil level with
vehicle standing on rear stand (not jiffy stand); refill, if required,
to level of filler plug opening with engine oil. CAUTION: _Do not use
gear oil_.
(18) ITEM 76, FENDERS (MUDGUARDS), LUGGAGE CARRIER, SAFETY GUARDS, AND
STANDS. Examine these items for good condition and secure mounting.
(19) ITEM 82, *TIGHTEN.
(_a_) Inspect all frame and assembly nuts, bolts, and cap screws for
tightness.
(_b_) _Weekly._ Tighten all vehicle assembly or mounting nuts. Driver
is cautioned not to tamper with or tighten screws or nuts about the
circuit breaker, as doing so may disturb ignition timing.
(20) ITEM 83, *LUBRICATE AS NEEDED.
(_a_) Lubricate all parts where inspection reveals need for
lubrication: wipe all dirt from fittings before applying lubricant.
Report any missing fittings.
(_b_) _Weekly._ When vehicle has been driven a sufficient number
of miles so that it is due for a regularly scheduled lubrication,
lubricate according to Lubrication Guide in manual and current
lubrication directives. Refrain from overlubricating wheel bearings,
front brake side cover bushing, and front and rear brake operating
lever camshafts.
(21) ITEM 84, *CLEAN ENGINE AND VEHICLE.
(_a_) Clean dirt and trash from vehicle and remove excess grease.
(_b_) _Weekly._ Wash vehicle if possible. If not, wipe off thoroughly.
Do not rub lustreless paint enough to cause shine. If vehicle is washed
in a stream, care should be taken that water or dirt does not get
into bearings, breather valve, or brakes. CAUTION: _It is extremely
important that high‐pressure streams or steam should not be directed
against wheel hubs, brakes, carburetor, air cleaner, or electrical
units_.
(12) ITEM 64, *ELECTRICAL WIRING.
(_a_) Inspect all ignition wiring to see that it is securely connected,
clean, and not damaged.
(_b_) _Weekly._ Inspect all wiring to see that it is securely connected
and supported, that insulation is not cracked or chafed, that loom,
shielding, and condensers are in good condition and securely attached.
Clean as required. Tighten any loose connections carefully. Radio
shielding or bonding defects, except cleaning or tightening, must be
referred to signal corps personnel.
(23) ITEM 85, *TOOLS AND EQUIPMENT.
(_a_) See that all tools and equipment assigned to vehicle are present,
in good condition, and properly stowed.
(_b_) _Weekly._ Check tools and equipment assigned to vehicle with
vehicle stowage list (par. 21) to see that they are present. Inspect
tools for good condition and proper stowage. Report missing or
unserviceable items to designated authority.