Kalmar Ottawa, Operator'S Manual

Page: 55 / 59

54
Maintenance
Check Battery Box Cover Holddowns
– Check bolts or rubber latches to insure that the battery box cover
is secured.
Drain Water from Air Tanks – With air system charged, open each manual drains until all moisture is
removed from system.
Check and Torque All Wheel Nuts
– Inspect all wheel nuts for signs of wear or damage. Loosen outer
nuts on dual wheels before tightening inner nuts. Re-torque all nuts to 450 – 500 ft/lbs.
Check Wheels – Inspect all wheels for signs of damage including oversized holes and cracks.
Check Tire Pressure, Tread Depth and Condition – Inspect tires for damage and wear. Adjust to the
proper air pressure.
Check Rear Axle Planetary Fluid Level (If Applicable) – Check and adjust lubricant level in planetary
housings per the component manufacturer’s instructions.
Inspect Catwalk - Inspect catwalk for proper mounting and the absence of cracks and trip points.
Check Frame for Cracks
– Inspect frame rails and crossmembers for cracks and bending.
Check Mud Flaps / Fenders (If Applicable) – If equipped with mud flaps and or fender, inspect these
items for proper mounting and damage.
Change Hydraulic System Filter
– Remove and replace the external hydraulic filter.
Check Hydraulic Fluid Level – Start engine, raise and lower the boom two to three times to insure that
system components are filled. Lower boom to full down position, shut off engine and check fluid level on
tank gauge. Fill as necessary.
Change Hydraulic Fluid
– Drain hydraulic tank and refill with Dexron III automatic transmission fluid.
Clean Hydraulic Tank Vent – Remove any dirt collecting around vent and insure that vent is clear.
Lubrication
Check / Lubricate Side Door Hinges
– Inspect door hinge for wear and damage. Lubricate.
Check / Lubricate Rear Door Rollers – Inspect upper and lower (if applicable) rollers. Replace if
binding or damaged. Lubricate.
Check / Lubricate Cab Hinge Pins
– Inspect pins for wear or damage. Lubricate with lithium grease.
Check / Lubricate Hood Hinge - Inspect hood hinge for wear and damage. Lubricate.
Check / Lubricate Steering Slip Joint - Inspect slip joint for wear or damage. Lubricate with lithium
grease.
Check / Lubricate Steering U-Joints
- Inspect u-joints for wear or damage. Lubricate with lithium
grease.
Check / Lubricate Throttle Shaft – Mechanical engines only. Inspect shaft from pump to pedal for wear
or damage. Lubricate with lithium grease.
Check / Lubricate Throttle Shaft
– Mechanical engines only. Inspect shaft from pump to pedal for wear
or damage. Lubricate with lithium grease.
KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES
Check / Lubricate King Pins and Tie Rod Ends – Inspect king pins and tie rod ends for wear or damage.
Lubricate with lithium grease.
Check / Lubricate Drag Link – Inspect king pins and tie rod ends for wear or damage. Lubricate with
lithium grease.
Check / Lubricate Slack Adjusters – Inspect brake slack adjusters for wear or damage. Measure the
brake actuator stroke. If this measurement exceeds the component manufacturer’s recommendation check
brake lining and adjuster to determine which is the cause of the excessive stroke and repair as necessary.
Check / Lubricate Spring Pins and Bushings – Inspect spring pins, hangers and pin bushings for wear or
damage. Lubricate with lithium grease.
Check / Lubricate Driveline U-Joints – Inspect driveline and u-joints for wear or damage. Lubricate with
lithium grease.
Check / Lubricate Lower Boom Cylinder Bearings
– Inspect lower boom cylinder bearings for wear or
damage. Lubricate with lithium grease.
Check / Lubricate Otto-Ride Pivot Points – If applicable. Inspect all Otto-Ride pivot points for wear or
damage. On Otto-Ride systems equipped with a single point lube system inspect lube lines to insure
delivery of lubricant to all points. Depending on the type of lube system lubricate single point or each
pivot point with lithium grease.
Add Grease to Autolube Reservoir – If the vehicle is equipped with an automatic lubrication system
inspect all lubrication points for sufficient grease. Fill the system’s reservoir with the proper type and
quantity of grease per the component manufacturer’s recommendation.
Clean, Check and Adjust 5
th
Wheel Jaws
– Remove dirt and excessive grease from the 5
th
wheel jaws.
Using a 5
th
wheel jaw gauge measure the free play. If free play exceeds 1/8” determine the cause of the
excessive play and either repair or replace the jaws per the component manufacturer’s recommendation.
Check / Lubricate 5
th
Wheel Top Plate – Clean and inspect the 5
th
wheel top plate for cracks or other
damage. Apply lithium grease to the surface of the top plate.
Check / Lubricate 5
th
Wheel Pivot Pins
- Inspect 5
th
wheel pivot pins for wear or damage. Lubricate with
lithium grease.
Check / Lubricate Boom Pivot Bearings – Inspect boom pivot bearings for wear or damage. Lubricate
with lithium grease.
Check / Lubricate Upper Boom Cylinder Bearing
– Inspect upper boom cylinder bearings for wear or
damage. Lubricate with lithium grease.
Check / Lubricate Hydraulic Pump Drive – Remove the hydraulic pump from the PTO. Inspect splined
coupling shaft for wear. On units equipped with external grease zerk grease on the PTO removal of the
PTO is not necessary. Lubricate with NLGI #2 Coupling Grease.
Test Drive
Drive Vehicle to Check for Overall Operation – Start and drive vehicle. Test the operation of all
systems and components.