i. Tubing and Hose. Check all hose surfaces for broken or frayed fabric. Check for breaks caused by sharp
kinks or rubbing against other parts. Inspect fitting threads for damage. Replace any part found defective. Check for
j. Electrical Parts. Inspect all wiring harnesses for chafed or burned insulation. Inspect all terminal connectors
for loose connections and broken parts.
a. Work Required. Remove only those parts needing repair or replacement. Do not disassemble component
any further than needed.
b. Preparation. Before removing any part of electrical or hydraulic system, make certain system is not energized
or pressurized. Disconnect battery cables. Make sure all controls are off before starting any removal procedure.
c. Lifting. Always use chain hoist, jack, or other aid when lifting heavy parts. Make certain load limit of lifting
device exceeds weight being lifted. Position and rig lifting device before disconnecting part for removal.
d. Identification. Tag or mark all similar parts, such as electrical leads, before disconnecting and removing.
This will make proper assembly easier. Be sure to identify mating ends of electric and hydraulic lines as they are
a. Electrical Parts. Replace all broken, worn, or burned electrical wiring. Wires with several broken strands
must be replaced. Broken strands will increase resistance of wire and impair efficiency of electrical components,
especially ignition system.
b. Hoses. Replace all broken, frayed, crimped, or soft flexible lines and hoses. Replace stripped or damaged
fittings. Replace entire flexible hose if fittings are damaged. Make sure hose clamps do not crimp hoses.
c. Fasteners. Replace any bolt, screw, nut, or fitting with damaged threads. Inspect tapped holes for thread
damage. If cross-threading or galling is evident, retap holes for next oversize screw or stud. When retapping will weaken
part, or when cost of part makes retapping impractical, replace damaged part. Chasing threads with proper size tap or
die may often be enough.
a. Cleanliness. Work area must be kept as clean as possible to prevent contamination of internal parts. This is
especially true for valves, cylinders, pumps, and motors. Dirt or grit will damage machined surfaces and will result in
leakage or premature motor failure.
b. Mandatory Replacement Parts. All gaskets, O-rings, packings, and seals removed must be discarded and
replaced with new parts. These items are usually damaged during removal. All lockwire, cotter pins, and like items must
c. Removing Seals. When removing gaskets, packings, or seals, do not use metal tool that will scratch surfaces
next to these items.