Kalmar Ottawa, Operator'S Manual

Page: 53 / 59

52
Maintenance
Check Engine Belts and Tensioner – Inspect belt(s) for cracking and wear. Belt tensioner should be
checked for proper operation.
Change Engine Coolant Filter – Replace the engine coolant filter. A filter containing the proper
supplemental coolant additive should be used to maintain the SCA concentration level.
Check Engine and Transmission for Leaks – Perform a visual inspection of the engine and transmission
looking for any fluid leaks visible from above.
Drain Fuel / Water Separator – Open the drain valve on the fuel / water separator and allow water to
drain from the filter.
Change Fuel Filter / Fuel Water Separator
– Replace fuel filter following the instructions in the engine
operator’s manual.
Check Air Restriction Gauge (If Applicable) – Record reading on gauge, reset, start engine, run to high
idle and shut off engine. If reading remains on zero, the gauge may be defective or the intake piping has a
leak. The cause must be investigated and the gauge replaced and/or the piping repaired.
If the initial gauge reading indicates that the filter should be changed, do so at this time. See the next item
on the PM form.
Change Air Filter – The air filter should be changed as needed. If the truck is equipped with a restriction
gauge, replace the filter when the gauge indicates it is appropriate.
Change Air Dryer Desiccant (If Applicable) – The desiccant should be changed as needed. Change as
soon as water is evident when system air tanks are drained.
Check Exhaust System – Visually inspect all of the exhaust system components for leaks and / or damage.
Check Transmission Fluid Level
– With the engine running use the transmission dipstick to check the
fluid level per the guidelines in the transmission operator’s manual.
Clean Transmission Breather – Confirm that the breather, located on top of the transmission, is clean and
the passage is open. Do not spray directly with high pressure or cleaning solvents.
Torque Cab to Deck Mounting Bolts – Re-torque the four cab to deck fasteners .
Under Vehicle
Check Steering Gear
– Inspect steering gear for fluid leaks and excessive play. Inspect the steering
linkage for wear or looseness.
Check Brake Linings and Drums – Visually check linings and drums for wear and cracks. If the lining is
0.25” thick or less in any location the shoes should be replaced or relined.
Check Springs
– Inspect leaf springs for cracking or excessive deflection. Inspect spring pins and shackles
for wear.
Check Shock Absorbers (If Applicable) – Inspect shock absorbers for leaks.
Torque Front Axle Mounting Bolts – Re-torque front axle mounting bolts.
Torque King Pin Draw Key Nuts –
Re-torque steer axle king pin draw key nut(s).
Check Power Steering Pump – Inspect pump for fluid leaks.
KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES
Check Hydraulic Pump
–Inspect hydraulic pump for leaks.
Check Starter Mounting and Connections – Confirm that starter mounting bolts are tight. Inspect
electrical connections for good contact at starter terminals.
Check Engine and Transmission for leaks
- Perform a visual inspection of the engine and transmission
looking for any fluid leaks visible from below.
Change Engine Oil and Filter – Drain and replace engine oil. Use oil meeting, at least, the minimum
specifications provided in the engine operator’s manual. Replace the oil filter.
Change Transmission External Filter
– Replace external filter.
Change Transmission Fluid and Internal Filter – Drain and replace transmission fluid. Replace paper
filter located in transmission pan. If there is a stainless steel screen instead of a paper filter, clean and reuse
the stainless steel screen. Use fluid meeting, at least, the minimum specifications provided in the
transmission operator’s manual.
Check Engine and Transmission Mounts
– Re-torque engine and transmission mounts . Inspect isolator
material and replace if deteriorated.
Check Wheel Seals for Leaks – Inspect front and rear hubs for signs of oil leaks. Replace if leaking.
Clean Rear Axle Breather
– Insure that the rear axle vent turns freely.
Check Differential for Leaks – Inspect rear axle housing for signs of leaks. Repair as necessary.
Check Differential Oil Level – Check the differential oil level per the component manufacturer’s
instructions.
Change Differential Oil
– Drain and replace differential oil. Use oil meeting, at least, the minimum
specifications of the component manufacturer.
Check Lift Cylinders for Leaks – Inspect cylinders for signs leaking. Repair as necessary.
Check Otto-Ride Rubber Isolator
– Inspect the isolator for signs of cracking or loss of elasticity.
Replace as necessary.
Torque Rear Axle Mounting Bolts – Re-torque rear axle mounting bolts.
Chassis
Check Front Axle Oil Level (If Applicable) – Check oil level in front axle hubcaps. Fill to proper level
as necessary.
Repack Front Wheel Bearings (If Applicable) – Remove front hubs and repack the bearings using grease
meeting, at least, the minimum specifications of the component manufacturer.
Check Battery Cables and Holddowns – Inspect battery for signs of abrasion or breaking. Repair and
reroute as needed. Insure that batteries are properly secured.
Check Batteries for Cracks or Acid Damage – Inspect batteries for signs of damage. Replace as
necessary.
Clean Battery Cable Connections – Remove cable terminals from batteries, clean connections, reattach
cable terminals.