Kalmar Ottawa Operator's Manual - page 49
48
Maintenance
KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM
QSB-155 – RDS TRANSMISSION WITH “TRANSYND” LUBE AND ALLISON FILTERS
TRUCK NUMBER
LOCATION
TECHNICIAN
HOURS
DATE
EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION.
= SATISFACTORY = ADJUSTMENT NECESSARY = REPAIRS NEEDED.
“A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVALS, “B” INSPECTIONS AT 500 HOUR INTERVALS, “C” INSPECTIONS AT 1000 HOUR
INTERVALS, AND “D” INSPECTIONS AT 2000 HOUR INTERVALS.
OPERATION
A B C D
OPERATION
A B C D
CAB – INTERIOR
UNDER VEHICLE
CHECK OPERATION OF NEUTRAL START
CHECK STEERING GEAR
CHECK OPERATION OF ALL GAUGES
CHECK BRAKE LININGS AND DRUMS
CHECK LOW AIR BUZZER AND LIGHT
CHECK SPRINGS
CHECK WINDSHIELD WIPER OPERATION
CHECK SHOCK ABSORBERS (IF APP.)
CHECK WINDSHIELD WASHER OPERATION (IF APP.)
TORQUE FRONT AXLE MOUNTING BOLTS
CHECK ACCELERATOR FOR FREE OPERATION
TORQUE KING PIN DRAW KEY NUT(S)
CHECK HORN(S) OPERATION
CHECK POWER STEERING PUMP
CHECK AIR SYSTEM FOR MAXIMUM 120 PSI
CHECK HYDRAULIC PUMP
CHECK AIR SYSTEM FOR LEAK DOWN
CHECK STARTER MOUNTING AND CONNECTIONS
CHECK OPERATION OF BACK UP ALARM
CHECK ENGINE AND TRANSMISSION FOR LEAKS
CHECK OPERATION OF SHIFT LOCK OUT
CHANGE ENGINE OIL AND FILTER
CHECK HVAC SYSTEM
CHANGE TRANSMISSION EXTERNAL FILTER
BLOWER MOTOR OPERATION
CHANGE TRANSMISSION FLUID
TEMPERATURE CONTROL
CHECK ENGINE AND TRANSMISSION MOUNTS
AUXILIARY FAN(S) (IF APP.)
CHECK WHEEL SEALS FOR LEAKS
A/C OPERATION (IF APP.)
CLEAN REAR AXLE BREATHER
DEFROSTER OPERATION
CHECK DIFFERENTIAL FOR LEAKS
CHECK OPERATION OF PTO CONTROL (IF APP.)
CHECK DIFFERENTIAL OIL LEVEL
CHECK 5
TH
WHEEL UNLATCH CONTROL
CHANGE DIFFERENTIAL OIL
CHECK OPERATION OF BOOM
CHECK LIFT CYLINDERS FOR LEAKS
CHECK FIRE EXTINGUISHER CHARGE (IF APP.)
CHECK OTTO-RIDE RUBBER ISOLATOR (IF APP.)
CHECK SEAT BELT OPERATION
TORQUE REAR AXLE MOUNTING BOLTS
CHECK SIDE DOOR LATCH OPERATION
CHASSIS
CHECK REAR DOOR LATCH OPERATION
CHECK FRONT AXLE OIL LEVEL (IF APP.)
CHECK DOME LIGHT OPERATION
REPACK FRONT WHEEL BEARINGS (IF APP.)
CHECK ALL GLASS AND MIRRORS
CHECK BATTERY CABLES & HOLDDOWNS
CHECK OPERATION OF WINDOWS
CHECK BATTERIES FOR CRACKS OR ACID DAMAGE
CAB DOWN – EXTERIOR
CLEAN BATTERY CABLE CONNECTIONS
CHECK CAB ACCESS STEPS AND HANDLES
CHECK BATTERY BOX COVER HOLDDOWNS
CLEAN HEATER / AC FILTER (IF APP.)
DRAIN WATER FROM AIR TANKS
CHECK REAR DOOR ROLLER / SLIDE ADJUSTMENT
CHECK AND TORQUE ALL WHEEL NUTS
CHECK GLADHAND SEALS AND TRAILER AIR LINES
CHECK WHEELS
CHECK TRAILER LIGHT CORD
CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION
CHECK HEADLIGHTS / MARKER LIGHTS
CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)
CHECK TURN SIGNALS
INSPECT CATWALK
CHECK STROBE LIGHT (IF APP.)
CHECK FRAME FOR CRACKS
CHECK SPOTLIGHTS
CHECK MUD FLAPS / FENDERS (IF APP.)
CHECK WIPER BLADES
CHANGE HYDRAULIC SYSTEM FILTER
CHECK WINDSHIELD WASHER FLUID LEVEL
CHECK HYDRAULIC FLUID LEVEL
CAB UP
CHANGE HYDRAULIC FLUID
CHECK OPERATION OF CAB TILT PUMP
CLEAN HYDRAULIC TANK VENT
CHECK CAB SAFETY PROP
LUBRICATION
CHECK CAB SUSPENSION AND LATCH
CHECK / LUBRICATE SIDE DOOR HINGES
CHECK INTAKE DUCTING FOR LEAKS
CHECK / LUBRICATE REAR DOOR ROLLERS
CHECK RADIATOR FOR LEAKS
CHECK / LUBRICATE CAB HINGE PINS
CHECK RADIATOR MOUNTS
CHECK / LUBRICATE HOOD HINGE
CHECK COOLANT LEVEL AND CONCENTRATION
CHECK / LUBRICATE STEERING SLIP JOINT
CHECK AND ADJUST COOLANT ADDITIVE (IF APP.)
CHECK / LUBRICATE STEERING U-JOINTS
CHANGE ENGINE COOLANT
CHECK / LUBRICATE THROTTLE SHAFT
CHECK COOLANT HOSES AND CLAMPS
CHECK / LUBRICATE KING PINS AND TIE ROD ENDS
CHECK FAN CLUTCH FOR OPERATION (IF APP.)
CHECK / LUBRICATE DRAG LINK
CHECK ENGINE COOLING FAN FOR CRACKS
CHECK / LUBRICATE SLACK ADJUSTERS
CHECK ENGINE BELT(S) AND TENSIONER
CHECK / LUBRICATE SPRING PINS AND BUSHINGS
CHANGE ENGINE COOLANT FILTER (IF APP.)
CHECK / LUBRICATE DRIVELINE U-JOINTS
CHECK ENGINE AND TRANSMISSION FOR LEAKS
CHECK AND LUBE LOWER BOOM CYLINDER BEARING
DRAIN FUEL WATER SEPARATOR
CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)
CHANGE FUEL FILTER / FUEL WATER SEPARATOR
ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.)
CHECK AIR RESTRICTION GAUGE (IF APP.)
CLEAN, CHECK, ADJUST AND LUBE 5
TH
WHEEL JAWS
CHANGE AIR FILTER
AS NEEDED
CHECK AND LUBRICATE 5
TH
WHEEL TOP PLATE
CHANGE AIR DRYER DESICCANT (IF APP.)
AS NEEDED
CHECK AND LUBRICATE 5
TH
WHEEL PIVOT PINS
CHECK EXHAUST SYSTEM
CHECK AND LUBRICATE BOOM PIVOT BEARINGS
CHECK TRANSMISSION FLUID LEVEL
CHECK AND LUBE UPPER BOOM CYLINDER BEARING
CLEAN TRANSMISSION BREATHER
CHECK AND LUBRICATE HYDRAULIC PUMP DRIVE
TORQUE CAB TO DECK MOUNTING BOLTS
TEST DRIVE
DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION
Cab Interior
Check Operation of Neutral Start – Move the gear selector to any position other than “N” and attempt to
start the engine. The engine should not crank with the selector in any position other than “N”.
Check Operation of All Gauges – With the engine is running verify that all gauges are functional.
Check Low Air Buzzer and Light – Apply and release the brake pedal until air pressure drops below 90
PSI. At that point, the low air buzzer and dash warning light should come on.
Check Windshield Wiper Operation – Turn on the windshield wiper on and confirm full and smooth
travel of the wiper arm. Listen for any noises that might indicate a worn wiper motor.
Check Windshield Washer Operation (If Applicable) – Depress the washer button and confirm the flow
and pattern of the washer fluid.
Check Accelerator for free operation – Depress and release the foot throttle and check for binding and
ease of operation.
Check Horn(s) Operation – Sound electric and air horns (if applicable) to confirm proper operation.
Check Air System for Maximum 120 PSI – Start engine and run at fast idle. Governor should limit
system air pressure to 120 psi.
Check Air System for Leak Down – Disconnect the gladhands from any trailer. Run engine at fast idle
and allow air pressure to stabilize at 120 psi for at least one minute. Shut off engine and observe dash
gauge(s) for 2 minutes. The drop in pressure should not exceed 2 psi over the two-minute period.
Check Operation of Back Up Alarm – With engine running, move the gear selector to reverse and listen
for back up alarm.
Check Operation of Shift Lock Out – With engine running, air pressure above 90 psi, and the parking
brake set, attempt to move the gear selector from any drive gear to reverse without depressing the brake
pedal. You should not be able to select reverse.
Check HVAC System
Blower Motor Operation – With the key on, insure that the blower motor operates at each
position of the blower speed switch.
Temperature Control – Confirm proper operation of the temperature control switch.
Auxiliary Fan(s) (If Applicable) – With the key on turn on the auxiliary fans and confirm
operation.
Air Conditioner Operation – With the engine running and the air conditioner control turned on,
confirm cooled airflow from the defroster vents.
Defroster Operation – With the engine running and the defroster control turned on, confirm
airflow from the defroster vents.
Check Operation of PTO Control (If Applicable) – With the truck running apply the parking brake and
move the gear selector to any drive gear. Confirm that the PTO engages and disengages when the dash
control is activated.
Check 5
th
Wheel Unlatch Control – With system air pressure above 100 psi confirm that the 5
th
wheel
jaws unlatch when the dash control is activated.