KALMAR PRESENTATION DRF PM_eng(V1)
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Transcript of KALMAR PRESENTATION DRF PM_eng(V1)
![Page 1: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/1.jpg)
Preventive Maintenance Manual - DRF
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What is Preventive Maintenance?
To perform proactive maintenance under a plan schedule to prevent unnecessary breakdown
Importance of Preventive Maintenance • prevent unplanned breakdown
• reduce maintenance cost
• increase machine reliability and availability
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Preventive Maintenance Schedule
• Plan A – 250 hrs
• Plan B – 500 hrs
• Plan C – 1000hrs
• Plan D – 2000hrs
* Remark: For new machine 50 hours machine warranty maintenance
to be carry out after handing over – according to Plan C and includedadjusting engine valve tappet clearance
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Preventive Maintenance Cycle
START
● ●1500hr
1000hr
500hr
250hr 250hr
250hr
250hr250hr
250hr
250hr
BB
●A
●A
●A
●A
●
●D
2000hr
C
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Before You Start the PM Job I
1. To ensure the truck is park in a safe working place – place safety cones and fence off area if necessary
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Before You Start the PM Job II
2. Walk around the machine and check for any damage and leakage
3. Carry out a function test on all function to check for defects
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Before You Start the PM Job III
4. Turn off the main electric power and remove the key
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Before You Start the PM Job IV
5. Use the wood block to secure the machine on a flat position
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Before You Start the PM Job V
6. Hang up “Machine Under Repair” signs on the machine (one on steering wheel and one on truck’s rear)
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Oils and Lubricants for PM Jobs With TWD1240 engine and TE32000 Transmission
Engine Oil: Both ACEA E3 and VDS-2 (SAE15W40)
Transmission Oil: Dexron III
Hydraulic Oil: (ISO-L HV68)
Drive Axle and Gear Oil: API-GL5 or MIL-L-2105B (SAE80W140)
Brake Oil: (ISO-L HV68)
Grease: Universal grease, type EP according to NLGI grade 2 with
3-5% molybdenum sulphide
Remarks: 1. For details please refer Section F of Maintenance Manual DFR400-450 2. ( ) above viscosity depends on the ambient temperature, please refer same Section F 3. For engine oil outside Europe market API : CE, CF, CF-4, CG-4, CH-4 (SAE15W40)
can be used BUT oil change every 250 hours or 12 months
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Oils and Lubricants for PM Jobs With TWD1031 engine and HR36000 Transmission
Engine Oil: API-CD (SAE15W40)
Transmission Oil: API-CD (SAE15W40)
Hydraulic Oil: (ISO-L HV68)
Drive Axle and Gear Oil: API-GL5 or MIL-L-2105B (SAE80W140)
Brake Oil: (ISO-L HV68)
Grease: Universal grease, type EP according to NLGI grade 2 with
3-5% molybdenum sulphide
Remarks: 1. For details please refer Section F of Maintenance Manual DFR400-450 2. ( ) above viscosity depends on the ambient temperature, please refer same Section F
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PM Plan A - Engine
1) Check Air Filter indicator
3) Replace Oil and Oil Filter
4) Replace Fuel Filter
5) Check Cooling Water
6) Clear Debris form Radiator Surface
7) Check Pulley and all Vee-belts
8) Check Starting, Stopping and Running
9) Check for Oil, Fuel and Water Leakage
10) Check Turbocharger and Exhaust for Leak
11) Replace Fuel / Water Separator Filter
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PM Plan A - Engine
1) Check Air Filter indicator
• Check the indicator when the engine is running. If it shows red, the main filter element is dirty and need to replace
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PM Plan A - Engine
3) Replace Oil and Filter
• Change it because to remove all the solid contaminants and sludge that collected by the filter, to reduce the restriction of oil flow
• Please Remember to Lubricate
the O-rings on the new filter
• Tighten to contact and then another half to three quarter turn by HAND
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PM Plan A - Engine
3) Replace Oil and Filter
OIL Filter
• Properties of engine oil will deteriorate due to heat and carbon contamination.
• Change filter because to remove
all the solid contaminants and sludge that collected by the filter, to reduce the restriction of oil flow
• Please Remember to Lubricate
the O-rings on the new filter
• Tighten to contact and then another half to three quarter turn by HAND
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PM Plan A - Engine
4) Replace Fuel Filter
• Change it because choke or dirty fuel filter may restrict fuel delivery to the injectors
• Cause fuel injector having
improper fuel spraying pattern into the combustion chamber. Thus affecting engine efficiency
• Please Remember to Lubricate the O-rings on the new filter
• Tighten to contact and then another half turn by HAND
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PM Plan A - Engine
4) Replace Fuel Filter (Fuel Pre-Filter)
• Change it because choke or dirty fuel filter may restrict fuel delivery to the injectors
• Disconnect the cabling from the
sensor water in fuel
• Please Remember to Lubricate the O-rings on the new filter
• Tighten to contact and then another half to three quarter turn by HAND
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PM Plan A - Engine
4) Replace Fuel Filter
• Change it because choke or dirty fuel filter may restrict fuel delivery to the injectors
• Cause fuel injector having
improper fuel spraying pattern into the combustion chamber. Thus affecting engine efficiency
• Please Remember to Lubricate the O-rings on the new filter
• Tighten to contact and then another half turn by HAND
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PM Plan A - Engine
5) Check Cooling Water Condition and
• Checked the coolant level to prevent engine overheat
Level
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PM Plan A - Engine
6) Clear Debris from Radiator Surface
• Check any debris form radiator surface to prevent engine overheat
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PM Plan A - Engine
7) Check Pulley and All Vee-belts
• Check the tension of belt, if it looses, tight it
• It should not be possible to
depress V-belt more than 10-12 mm mid-way between the pulleys
• If the belt still loose, after re-
tighten, replace a new belt • Loose belts may affect engine’s
cooling, air condition, and electrical performance
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PM Plan A - Engine
8) Check Starting, Stopping and Running
Starting
• Check all oil level (engine oil, gearbox oil, hydraulic fluid, axle and planetary gear oil)
• Bleed air out of fuel system • Turn the starter key to position
3(starting position) and release it when the engine has started
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PM Plan A - Engine
8) Check Starting, Stopping and Running Running
• Never race a cold engine, nor run the engine at critically low speed
• Run engine at 1400rpm till the
temperature gauge read about 80deg Celsius
• Warming up the engine oil is essential
so that it is circulating correctly before turbocharger works at high speed
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PM Plan A - Engine
9) Check for Oil, Fuel and Water Leakage
• Look under the truck to find any liquid leakages
• If find a leakage, please address
where the liquid from and shut down the machine immediately
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PM Plan A - Engine
10) Check Turbocharger and Exhaust fo
• Check that the oil line to and from the turbocharger do not leak
• Check that all connection between
the turbo and inter-cooler do not leak. Renew all broken gasket seals and studs to confirm gas tight between connection
• Pressure may build up in a blocked
crankcase vent. This may force oil into the inlet air system of the turbocharger and engine
r Leak
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PM Plan A - Engine
11) Replace Fuel / Water Filter
• Drain the filter and remove the filter from the top.
• Loose the bolts under the filter, to
clean the dirt from the trap
• Put the new filter in
• After that refuel inside the water/ fuel filter
• Replace the o-ring for the cover
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PM Plan A – Transmission & Propeller Shaft
16) Check and Top up Transmission Oil
17) Check Propeller Shaft Connection Bolts
18) Check Sensor on Propeller Shaft Flange
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PM Plan A – Transmission &
16) Check and Top up Transmission Oil
• Check the oil level with the engine at idling speed
• Fill it up until the oil up to FULL
mark
Propeller Shaft
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17) Check Propeller Shaft Connecting Bolt
• Loose bolt are prone to shear under load and vibration
• Re-tighten the bolt to 200 Nm on
transmission side and parking brake side
PM Plan A - Transmission & Propeller
Shaft![Page 30: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/30.jpg)
PM Plan A – Drive Axle & Brake
24) Check Tightness of Axle Mounting Bolts
25) Check for Oil Leak from Axle and WDB
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PM Plan A – Drive Axle
24) Check Tightness of Axle Mounting Bo
• Loose bolt are prone to shear under load and vibration
• Re-tighten the bolt to 2350Nm
& Brake
lts
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PM Plan A - Drive Axle &
25) Check for Oil Leak from Axle and W
• Check for oil leakage from filling point and drain plug
Brake
DB
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PM Plan A – Steering Axle
30) Check for Damage and Free Play in Linkage
31) Check Overload Protection Sensor
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PM Plan A – Steering
30) Check for Damage and Free Play
• Check for cracks on linkage area
• Check for any abnormal
movement
Axle
in Linkage
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PM Plan A – Steering A
31) Check Overload Protection Sensor
• Check any damage on sensor
xle
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PM Plan A - Spreader
36) Check Twistlock Pin and Mechanism
37) Check Sensor for Twistlock Indication
38) Check and Adjust 20/40 Chain and Stopper
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PM Plan A - Spreader
36) Check Twistlock Pin and Mechanism
• Check the twistlock function correctly
• Clean the twistlock from any dirt • Check the link arm, check pin and
lock nut • Press in the alignment pin so that
the head is flush with the spreader beam’s underside. Check the distance to sensor alignment, the distance should be 5 +/- 3mm
• Check the lock guide and lift pin can move freely
• Fit a pray bar between the lift pin and the lock guide and check the clearance, max clearance: 1-1.5mm
• Check wears of the lift pin. Change the pin if needed
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PM Plan A - Spreader
37) Check Sensor for Twistlock Indicatio • Check all sensor sensing light
(yellow) is lit up when contacting
n
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PM Plan A - Spreader
38) Check and Adjust 20/40 Chain an
• Run out the spreader to the 40-foot position
• Measure how much the chain can
be pressed in by the hole closest to the middle of the attachment. When the chain is pressed in with a force of 250N, it should move 20-40 mm from the resting position
• Adjust the chain if needed
d Stopper
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PM Plan A - Spreader
38) Check and Adjust 20/40 Chain an For 20’ position stopper
• Both protruding arms are to in contact with the stoppers at the same time and the distance between the spreader beam and spreader motor mounting is at least 3mm
• Adjust by switching the washers
between the left and right stopper • The distance between the right
and left twistlock should be 5853+/-3mm
d Stopper
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PM Plan A - Spreade
38) Check and Adjust 20/40 Chain For 40’ position stopper
• Both left and right side stoppers to be in contact at the same time. Each stopper is provided with an adjusting bolt.
• Adjust the chain tension if
needed • Distance between right and left
twistlock should be 11985+/-3mm
r
and Stopper
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PM Plan A – Telescopic Boom and Lift Cylinder
44) Check Boom Mounting Bracket & Pin
45) Check Lift Cylinder Mounting Bracket & Pin
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PM Plan A – Telescopic B
44) Check Boom Mounting Bracket and
• Loose pins are prone to shear under load and vibration
• Check any crack around bracket
area, dye test may needed for further testing
oom and Lift Cylinder Pin
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PM Plan A – Telescopic B
45) Check Lift Cylinder Bracket & Pin
• Loose pins are prone to shear under load and vibration
• Check any crack around bracket
area, dye test may needed for further testing
oom and Lift Cylinder
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PM Plan A - Hydraulic
57) Check Oil Level in Main and Brake Tank
58) Accumulator Minimum Pressure Check by Brake (20 Times)
59) Measure Oil Pressure per Hydraulic Plate a) Main Pressure b) Brake Pressure c) Servo Pressure d) Steering Pressure e) Charging Pressure
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PM Plan A - Hydraulic
57) Check Oil Level in Main and Brake Tank
• Ensure sufficient hydraulic and brake oil inside the tank by reading the oil level on sight glass
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PM Plan A - Hydraulic
58) Accumulator Minimum Pressure – Check by Brake (20 Times) • Start the engine and let it idle for
approx. 5 minutes (until the accumulator charging valve switches to cooling)
• Turn off the engine and turn the start key to position I
• Apply and release the brake several times, and count the number of times that applied on the brake before warning light is activated
(It should be apply the brake 20 times before the warning light for light brake pressure is activated)
• If warning light is activated before applied the brake 20 times, there’s probably a defect inside the system. A further inspection is needed
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PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraul (Main Pressure)
• Start the engine and allow it at idle • There are 4 measure points for
main oil pressure • All pressure should be the same
ic Plate
Test Point
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PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydra (Brake Pressure)
• Gives brake when testing brake pressure
• Find setting pressure in hydraulic
plate
ulic Plate
Test Point
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PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic Plate
Test Point
(Servo Pressure)
• Servo pressure should be around 35+/- 5 bars
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PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic P (Steering Pressure)
• Allow the engine to run in mid-speed range and turn the steering wheel to full lock in one direction.
late
Test Point
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PM Plan A - Hydraulic
59) Measure Oil Pressure per Hydraulic P (Charging Pressure)
• Allow the engine to run, release all the pressure from the accumulator
• Check the pressure after completed
re-charging (Maximum)
• Check the pressure when starts to re-charge (Starting)
late
Test Point
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PM Plan - Electrical
66) Check Battery Water and Top Up
67) Check All Work Light and Indication Light
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PM Plan - Electrical
66) Check Battery Water and Top up
• Check the battery voltage with the operating menu for electrical system.
• Engine off 23-25V, and engine at
max rpm 27-29V • Turn off the engine and the main
electrical power • Clean the battery area and grease
the battery terminal • Check the fluid level inside the cells,
top up with distilled water if needed
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PM Plan - Electrical
67) Check All Work Light and Indication Lamp
• Operate every lights to ensure functionally
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PM Plan - General
68) Check Tightness of Wheel Nut
69) Check Tyre Condition and Pressure
70) Check Horn, Reverse Alarm and Beacon
71) Grease Sliding Surface, Greasing Point and Chain
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PM Plan - General
68) Check Tightness of Wheel Nut
• Check tightness by re-torque all the nuts to 400Nm
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PM Plan - General
69) Check Tyre Condition and Pressur
• Check for cracks, dents and corrosion on rims
• Check for tyres pressure and
thread depth. Renew badly worn tyres
• Remove all foreign object
embedded in the tyres.
e
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PM Plan - General
70) Check Horn, Reverse Alarm and
• Operate each items to ensure proper function
Beacon
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PM Plan - General
71) Grease Sliding Surface, Greasin
Sliding Surface
• Scrap away the old grease • Apply grease only on the sliding
plate areas only
g Point and Chain
![Page 61: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/61.jpg)
PM Plan - General
71) Grease Sliding Surface, Greasing Point and Chain
Greasing Points
• Clean nipple heads before and injecting in new grease
• Pump new grease into the
nipples until the old grease is force out
• Remove all extra grease
![Page 62: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/62.jpg)
PM Plan – Function Test
72) Test Overload Protection System
73) Test Twistlock Safety Inter-lock System
74) Test All Hydraulic Function
75) Check for Any Leaks
![Page 63: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/63.jpg)
PM Plan – Function Tes
72) Test Overload Protection System
• Recommended to test with an operator
t
![Page 64: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/64.jpg)
PM Plan – Function Tes
74) Test All Hydraulic Function
• Test all the hydraulic function such as lifting, side shifting, spreader and tilt functions with operator to find anything that need to adjust
t
![Page 65: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/65.jpg)
PM Plan – Function Test
68) Check for All Leaks
• After testing the machine, walk around and find any possible leaking from the machine
![Page 66: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/66.jpg)
PM Plan B - Engine
01) Check Air Filter indicator
02) Replace Air Filter*
03) Replace Oil and Oil Filter
04) Replace Fuel Filter
05) Check Cooling Water
06) Clear Debris form Radiator Surface
07) Check Pulley and all Vee-belts
08) Check Starting, Stopping and Running
09) Check for Oil, Fuel and Water Leakage
10) Check Turbocharger and Exhaust for Leak
11) Replace Fuel / Water Separator Filter 12) Clean Oil Cleaner (Not Applicable for Volvo’s Engine)*
![Page 67: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/67.jpg)
PM Plan B - Engine
02) Replace Air Filter
• Dirty air filter could reduce the airflow and affect engine’s performance
• After removing the filter
cartridge, it recommends to clean the internal area with a clean cloth
• Safety filter element must not be
cleaned and reused
![Page 68: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/68.jpg)
PM Plan B – Transmission & Propeller Shaft
16) Check and Top up Transmission Oil
17) Check Propeller Shaft Connection Bolts
18) Check Sensor on Propeller Shaft Flange
19) Replace Transmission Oil Filter*
![Page 69: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/69.jpg)
PM Plan B – Transmission
19) Replace Transmission Oil Filter
• Choke filter would reduced oil required for engaging and lubrication of the gears
• Remove the filter with filter tool • Lubricate the o-ring with
transmission oil • Fit the new filters and then other
two-thirds turn
& Propeller Shaft
![Page 70: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/70.jpg)
PM Plan B – Transmission & Propeller Shaft
19) Replace Transmission Oil Filter
Transmission Oil Filter
• Choke filter would reduced oil required for engaging and lubrication of the gears
• Remove the filter with filter tool • Lubricate the o-ring with
transmission oil • Fit the new filters and then other
two-thirds turn
![Page 71: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/71.jpg)
PM Plan B – Drive Axle and Brake
24) Check Tightness of Axle Mounting Bolts
25) Check for Oil Leak from Axle and WDB
26) Check Differential and Hub Oil Level and Top up*
![Page 72: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/72.jpg)
PM Plan B – Drive Ax
26) Check differential and Hub Oil L
• Drive the truck forward so that the mark at the filling hole hub is horizontal (For wheel hub)
• Remove the level plug and
check the oil inside • Refill as necessary
le and Brake
evel and Top Up
![Page 73: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/73.jpg)
PM Plan B – Steering Axle
30) Check for Damage and Free Play in Linkage
31) Check Overload Protection Sensor
32) Check Wheel Alignment*
![Page 74: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/74.jpg)
PM Plan B – Steering A
32) Check Wheel Alignment
• All wheels should in the same direction
• Both rear wheels should parallel
with others • If both wheels are not align,
check steering axle
xle
![Page 75: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/75.jpg)
PM Plan B - Spreader
36) Check Twistlock Pin and Mechanism
37) Check Sensor for Twistlock Indication
38) Check and Adjust 20/40 Chain and Stopper
39) Check Planetary Gear Oil and Brake Oil*
![Page 76: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/76.jpg)
PM Plan B – Spre
39) Check Planetary Gear
• Check the level glass for hydraulic and gear oil
• Refill it if needed
ader
Oil and Brake Oil
![Page 77: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/77.jpg)
PM Plan B – Telescopic Boom & Lift Cylinder
44) Check Boom Mounting Bracket & Pin
45) Check Lift Cylinder Mounting Bracket and Pin
![Page 78: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/78.jpg)
PM Plan B - Hydraulic
57) Check Oil Level in Main and Brake Tank
58) Accumulator Minimum Pressure Check by Brake (20 Times)
59) Measure Oil Pressure per Hydraulic Plate a) Main Pressure b) Brake Pressure c) Servo Pressure d) Steering Pressure
e) Charging Pressure
![Page 79: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/79.jpg)
PM Plan C - Engine
01) Check Air Filter indicator
02) Replace Air Filter
03) Replace Oil and Oil Filter
04) Replace Fuel Filter
05) Check Cooling Water
06) Clear Debris form Radiator Surface
07) Check Pulley and all Vee-belts
08) Check Starting, Stopping and Running
09) Check for Oil, Fuel and Water Leakage
10) Check Turbocharger and Exhaust for Leak
11) Replace Fuel / Water Separator Filter
12) Clean Oil Cleaner (Not Applicable for Volvo’s Engine)
13) Replace Cooling Water Filter *
![Page 80: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/80.jpg)
PM Plan C - Engine 13) Replace Cooling Water Filter
• Close the shut-off valve on the filter bracket
• Remove the filter with filter tool • Lubricate the o-ring with oil • Tight the filter with half to three
quarter turn • Open the shut-off valve
![Page 81: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/81.jpg)
PM Plan C – Transmission & Propeller Shaft
16) Check and Top up Transmission Oil
17) Check Propeller Shaft Connection Bolts
18) Check Sensor on Propeller Shaft Flange
19) Replace Transmission Oil Filter 20) Replace Transmission Oil*
21) Check and Clean Magnetic Filter*
22) Clean the Breather*
![Page 82: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/82.jpg)
PM Plan C - Transmission & Propeller Shaft 20) Replace Transmission Oil
• Remove the drain plug and let the oil drain out to the container
• Check for metal particles in the
old oil for prediction of component damage in the gear box
• Refit the drain plug after the oil
has drain • Fill up with transmission oil to
the MIN mark on dipstick
• Run the engine until the oil has reached working temperature, check the oil level and top up to the MAX mark on dipstick
![Page 83: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/83.jpg)
PM Plan C - Transmission & Propeller Shaft
21) Check and Clean Magnetic Filter
• Check for metal particles on the filter for prediction of component damage in the gear box
![Page 84: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/84.jpg)
PM Plan C - Transmission & Propeller Shaft
22) Clean the Breather
• To allow free ventilation of vapour
• To prevent pressure built-up in
the gearbox
![Page 85: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/85.jpg)
PM Plan C – Drive Axle and Brake
24) Check Tightness of Axle Mounting Bolts
25) Check for Oil Leak from Axle and WDB
26) Check Differential and Hub Oil Level and Top up
27) Replace Differential and Hub Oil*
28) Clean the Breather*
29) Check the Parking Brake Pad and Function*
![Page 86: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/86.jpg)
PM Plan C – Drive Axle
27) Replace Differential and Hub O
• Drive the truck forward until the oil drain plug is at its lowest point of travel (For Differential)
• Drive the truck forward so that
the mark at the filling hole hub is horizontal (For wheel Hub)
• Remove the oil plug and drain
the oil and refit the plug • Repeat the procedure on the
other wheel
and Brake
il
![Page 87: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/87.jpg)
PM Plan C – Drive Axle
28) Clean the Breather
• To allow free ventilation of vapour
• To prevent pressure built-up in
the drive axle
and Brake
![Page 88: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/88.jpg)
PM Plan C – Drive Axl
29) Check the Parking Brake Pad
• Release the parking brake • Check the parking brake calliper
can move on the bracket • Check the clearance between
the brake pad and brake disc. The clearance should be approximately 1mm
• Adjust as needed
e and Brake
and Function
![Page 89: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/89.jpg)
PM Plan C – Steering Axle
30) Check for Damage and Free Play in Linkage
31) Check Overload Protection Sensor
32) Check Wheel Alignment
33) Check Steering Axle Rubber Mounting*
![Page 90: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/90.jpg)
PM Plan C – Steering Axle
33) Check Steering Axle Rubber Mounting
• Check the rubber element for damage
• Replace it if needed • Check surrounding area for any
cracks
![Page 91: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/91.jpg)
PM Plan C – Spreader
36) Check Twistlock Pin and Mechanism
37) Check Sensor for Twistlock Indication
38) Check and Adjust 20/40 Chain and Stopper
39) Check Planetary Gear Oil and Brake Oil
40) Replace Planetary Gear Oil and Brake Oil*
41) Check Rotator Mounting Bolt*
42) Check Sliding Plate on Beam and Yoke*
![Page 92: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/92.jpg)
PM Plan C – Spreader 40) Replace Planetary Gear Oil an
• Drain the hydraulic fluid in upper level and gear oil in lower level
d Brake Oil
![Page 93: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/93.jpg)
PM Plan C – Spreader
41) Check Rotator Mounting Bolt
• Re-torque all mast, spreader mounting bolts
![Page 94: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/94.jpg)
PM Plan C – Spreader
42 Check Sliding Plate on Beam
• Remove Cover Plate, spacer plate and glide plate
• Measure slide plate’s thickness
(Thickness should be at least 25mm)
• Check the slide plate clearance
by measuring the distance between the slide plate and the edge for the cover plate (The clearance should be 1mm)
• Fit or remove the spacer until
the distance is correct • Fit the cover plate
and Yoke
![Page 95: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/95.jpg)
PM Plan C – Spreader 42 Check Sliding Plate on Beam a
• Park the machine with the attachment as down as possible and let the spreader has a 40 cm remaining to the 20-foot position
• Remove the attaching bolts for the slide plate bracket
• Remove the slide plate’s guide pin
• Pull out the slide plate with space plate and bracket
• Measure the slide plate with a minimum 10mm thickness
• Place the slide plate in correct position and check the clearance between spreader beam and slide. Clearance should be maximum 1 mm with all slide plates mounted
nd Yoke
![Page 96: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/96.jpg)
PM Plan C – Telescopic Boom & Lift Cylinder
44) Check Boom Mounting Bracket & Pin
45) Check Lift Cylinder Mounting Bracket and Pin
46) Check Sliding Plate on Outer Boom*
![Page 97: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/97.jpg)
PM Plan C – Telescopic
46) Check Sliding Plate on Outer
• Remove Cover Plate, spacer plate and glide plate
• Measure slide plate’s thickness
(Thickness should be at least 25mm)
• Check the slide plate clearance
by measuring the distance between the slide plate and the edge for the cover plate (The clearance should be 1mm)
• Fit or remove the spacer until
the distance is correct • Fit the cover plate
Boom & Lift Cylinder
Boom
![Page 98: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/98.jpg)
PM Plan C - Hydraulic
57) Check Oil Level in Main and Brake Tank
58) Accumulator Minimum Pressure Check by Brake (20 Times)
59) Measure Oil Pressure per Hydraulic Plate a) Main Pressure b) Brake Pressure c) Servo Pressure d) Steering Pressure
e) Charging Pressure
60) Replace all high Pressure Filter* 61) Replace Servo Oil Filter * 62) Replace Brake Oil Cooling Filter *
![Page 99: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/99.jpg)
PM Plan C - Hydraulic
60) Replace all High Pressure Filter
• Choke filter will restrict the flow of oil supply
• A hydraulic system is sensitive
to impurities. A small damage to the piston rod chromium plating can cause leakage from seals
• Replace the o-ring between the filter head and the bowl, and other o-ring on adaptor
• Fit the bowl and tighten it to 140Nm
![Page 100: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/100.jpg)
PM Plan C - Hydraulic
61) Replace Servo Oil Filter
• Release the brake pressure • Choke filter will restrict the flow
of oil supply • Replace the o-ring on adaptor
![Page 101: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/101.jpg)
PM Plan C - Hydraulic
62) Replace Brake Oil Cooling Filter
• Release the brake pressure • Choke filter will restrict the flow
of oil supply • Replace the o-ring on adaptor
![Page 102: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/102.jpg)
PM Plan D - Engine
01) Check Air Filter indicator 02) Replace Air Filter 03) Replace Oil and Oil Filter 04) Replace Fuel Filter 05) Check Cooling Water 06) Clear Debris form Radiator Surface 07) Check Pulley and all Vee-belts 08) Check Starting, Stopping and Running 09) Check for Oil, Fuel and Water Leakage 10) Check Turbocharger and Exhaust for Leak 11) Replace Fuel / Water Separator Filter 12) Clean Oil Cleaner (Not Applicable for Volvo’s Engine) 13) Replace Cooling Water Filter (Not Applicable)
14) Check Mounting Bracket and Bolt* 15) Check and Adjust Valve Tappet Clearance*
![Page 103: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/103.jpg)
14) Check Mounting Bracket and Bolt
• Check all the mounting bolts • Re-tight it if needed
PM Plan D - Engine
![Page 104: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/104.jpg)
PM Plan D - Engine
15) Check and Adjust Valve Tap
• Turn the crankshaft in its normal direction until the inlet valve of No.6 cylinder has just opened and the exhaust valve has not yet closed fully
• Check the valve clearance on
No.1 and adjust as necessary • The sequence to check valve
clearance from no.1, 5,3,6,2,4 • The sequence to check inlet and
exhaust valve from no.6, 2,4,1,5,3
pet Clearance
![Page 105: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/105.jpg)
PM Plan D – Transmission & Propeller Shaft
16) Check and Top up Transmission Oil
17) Check Propeller Shaft Connection Bolts
18) Check Sensor on Propeller Shaft Flange
19) Replace Transmission Oil Filter 20) Replace Transmission Oil
21) Check and Clean Magnetic Filter
22) Clean the Breather
23) Check Mounting Bracket and Bolt*
![Page 106: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/106.jpg)
PM Plan D - Transmission
23) Check Mounting Bracket and Bolt • Check all the mounting bolts • Re-tight it if needed
& Propeller Shaft
![Page 107: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/107.jpg)
PM Plan D – Steering Axle
30) Check for Damage and Free Play in Linkage
31) Check Overload Protection Sensor
32) Check Wheel Alignment
33) Check Steering Axle Rubber Mounting
34) Check Wheel Hub Bearing and Lock Nut*
35) Check Knuckle Pin Bearing and Lock Nut*
![Page 108: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/108.jpg)
PM Plan D – Steering Axle 34) Check Wheel Hub Bearing and Lock Nut
• Remove the hub cover • Wipe grease off the wheel cover and
hub bearing • Bend up the lock washer’s tabs,
remove the lock nut and lock washer • Torque the nut with 250Nm • Rotate the hub with 10 revolutions • Re-torque the nut with 250 Nm • Check the spacer ring inside the
wheel hub is positioned up against the wheel spindle. If not, re-torque it by increasing 50 Nm.
• Fit the lock nut and tighten with 250Nm. Lock the bearing nut and lock nut with the lock washer
• Fill the bearing casing with grease and fit it
![Page 109: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/109.jpg)
PM Plan D – Steering
35) Check Knuckle Pin Bearing a
• Check that the knuckle pin rotates smoothly with a maximum free play of 0.25mm.
Axle
nd Lock Nut
![Page 110: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/110.jpg)
PM Plan D – Telescopic Boom & Lift Cylinder
48) Check Mast Mounting Bracket and Pin
49) Grease Greasing Point (Apply Jack First)
50) Check Alignment of Lifting Chain 51) Adjust the Slackness of Lifting Chain
52) Measure Chain Extension Over 25 Links a) Big Chain (left/right)
53) Check Mounting Bracket for Tilt Cylinder
54) Check Sliding Plate and Rollers on Carriage
55) Check Sliding Plate and Rollers on Mast 56) General Visual Inspection for Crack*
![Page 111: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/111.jpg)
PM Plan D – Telescopic B
56) General Visual Inspection for C
• Inspect the boom and lifting cylinder for damage or wear
• Run the function of boom and
lifting cylinder to listen any unusual sound
oom & Lift Cylinder
rack
![Page 112: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/112.jpg)
PM Plan D – Hydraulic
57) Check Oil Level in Main and Brake Tank 58) Accumulator Minimum Pressure
Check by Brake (20 Times) 59) Measure Oil Pressure per Hydraulic Plate
a) Main Pressure b) Brake Pressure c) Servo Pressure d) Steering Pressure
e) Charging Pressure
60) Replace all high Pressure Filter 61) Replace Servo Oil Filter 62) Replace Brake Oil Cooling Filter (Not Applicable) 63) Replace Main Hydraulic Oil and Brake Oil* 64) Replace Main and Brake Tank Breather Filter* 65) Replace Return Oil filter*
![Page 113: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/113.jpg)
PM Plan D – Hydraulic
63) Replace Main Hydraulic Oil and
• The oil qualities deteriorate over time due to contamination and heat.
• Deteriorated oil causes abnormal wear and corrosion in components like pumps and valve.
• Remove the bottom plug of the hydraulic tank and drain off the oil
• bleed air from all variable pumps before starting engine
Brake Oil
![Page 114: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/114.jpg)
PM Plan D - Hydraulic
64) Replace Main and Hydraulic Tank Breather Filter • Choke breather filter would
cause pressure built-up in tank
![Page 115: KALMAR PRESENTATION DRF PM_eng(V1)](https://reader030.fdocuments.us/reader030/viewer/2022033010/563dbb5a550346aa9aac6b45/html5/thumbnails/115.jpg)
PM Plan D - Hydraulic
65) Replace Return Oil Filter
• Choke filter will restrict the flow of oil supply
• This may cause over-
pressuring the pump delivery line causing hose rupture