Kalmar Ottawa t2 User manual

Maintenance Manual Ottawa T2 4x2
A. Foreword ........................................................................................................................... 1
About this manual ................................................................................................... 1
Additional Information ............................................................................................. 1
B. Safety ................................................................................................................................3
Hazardous Condition Signs .................................................................................... 3
Do’s and Dont’s ...................................................................................................... 4
C. Preventive Maintenance .................................................................................................. 5
Lubrication Points .............................................................................................................. 5
Lubrication Points .............................................................................................. 5
Inspections ........................................................................................................................6
Every Day .......................................................................................................... 6
Every 250 Hours of Operation ........................................................................... 6
Every 500 Hours of Operation ........................................................................... 6
Every 1,000 Hours of Operation ........................................................................ 6
Every 2,000 Hours of Operation ........................................................................ 6
Checklists .......................................................................................................................... 7
Daily Inspection Checklist ................................................................................. 7
Preventive Maintenance Forms ....................................................................... 10
Preventive Maintenance Technique ................................................................................ 12
General ........................................................................................................... 12
Fuel, Filters, Fluids and Lubricants ............................................................................. 12
Maintenance ............................................................................................... 12
Cab Interior .................................................................................................................13
Maintenance ............................................................................................... 13
Seat Belt System ........................................................................................ 14
Cab Down — Exterior ................................................................................................. 15
Maintenance ............................................................................................... 15
Cab Up ........................................................................................................................16
Maintenance ............................................................................................... 16
Under Vehicle ............................................................................................................. 18
Maintenance ............................................................................................... 18
Chassis .......................................................................................................................19
Maintenance ............................................................................................... 19
Lubrication ..................................................................................................................20
Maintenance ............................................................................................... 20
Test Drive ................................................................................................................... 21
Maintenance ............................................................................................... 21
0. Machine Complete .......................................................................................................... 23
The Ottawa T2 Terminal Tractor .....................................................................................23
Description ...................................................................................................... 23
Diesel Fuel Requirements ............................................................................................... 24
Precautions ..................................................................................................... 24
Emergency Starting ......................................................................................................... 26
Precautions ..................................................................................................... 26
Jump Starting Instructions ............................................................................... 26
Vehicle Towing ................................................................................................................28
Precautions ..................................................................................................... 28
Front End Towing (Front Wheels Off the Ground) .......................................... 28
Front End Towing (All Wheels On the Ground) ............................................... 29
Rear End Towing ............................................................................................ 29
Vehicle Modifications ......................................................................................................30
Approval .......................................................................................................... 30
Vehicle Identification .......................................................................................................31
Identification Plate ........................................................................................... 31
Certification Label ........................................................................................... 31

Maintenance Manual Ottawa T2 4x2
Vehicle Serial Number ..................................................................................... 32
Engine Serial Number ..................................................................................... 32
Component Location .......................................................................................................33
Chassis/Cab, Left Side ...............................................................................................33
Ottawa T2, Left Side (4x2 HHD chassis shown) ........................................ 33
Chassis/Cab, Right Side .............................................................................................34
Ottawa T2, Right Side (4x2 HHD chassis shown) ...................................... 34
Chassis/Cab, Front/Rear ............................................................................................35
Ottawa T2, Front/Rear (4x2 HHD chassis shown) ..................................... 35
Chassis, Plan View .....................................................................................................36
Ottawa T2 Plan View (4x2 HHD chassis shown) ....................................... 36
Electrical Instruments ......................................................................................................37
Guide to Troubleshooting ................................................................................ 37
Basic Gauge Cluster Diagnostic Procedure .................................................... 37
Engine ..................................................................................................................................39
Description ............................................................................................................ 39
Controls and Instruments ................................................................................................40
Fuel Gauge .................................................................................................................40
Diagnosis .................................................................................................... 40
Fuel System ...................................................................................................................41
Fuel Tank ....................................................................................................................41
Description ................................................................................................. 41
Sensor, Fuel Level ......................................................................................................41
Description ................................................................................................. 41
Pipes and Hoses .........................................................................................................41
Description ................................................................................................. 41
Diesel Exhaust Fluid (DEF) .............................................................................................42
DEF Tank and Pump ..................................................................................................42
Description ................................................................................................. 42
Sensor, Low DEF Level ..............................................................................................42
Description ................................................................................................. 42
DEF Hose Lines ..........................................................................................................42
Description ................................................................................................. 42
Start/Stop ........................................................................................................................43
Diagnosis (Starting and Charging Diagnosis) ................................................. 43
Transmission ......................................................................................................................45
Description ............................................................................................................ 45
Driveline/Axle ......................................................................................................................47
Description ............................................................................................................ 47
Brakes ..................................................................................................................................49
Controls and Instruments ................................................................................................49
Foot Pedal (Treadle Valve) .........................................................................................49
Description ................................................................................................. 49
Air Control Valves .......................................................................................................49
Description ................................................................................................. 49
Brake System ..................................................................................................................50
Description ...................................................................................................... 50
Air Compressor and Governor ....................................................................................51
Description ................................................................................................. 51
Air Reservoir ...............................................................................................................51
Description ................................................................................................. 51
Stop Light Switch ........................................................................................................51
Description ................................................................................................. 51
Brakes .........................................................................................................................52
Description ................................................................................................. 52

Maintenance Manual Ottawa T2 4x2
Trailer Brake Air Lines ................................................................................................ 53
Description ................................................................................................. 53
Anti-lock Brake System (Optional) ..............................................................................53
Description ................................................................................................. 53
Automatic Traction Control (Optional) ........................................................................ 54
Description ................................................................................................. 54
Manually Releasing Tractor Spring Brakes (Caging) .................................................. 54
Description ................................................................................................. 54
Diagnosis (Mechanical) ................................................................................................... 56
Brakes ............................................................................................................. 56
Steering ...............................................................................................................................59
Steering System .............................................................................................................. 59
Description (Power Steering Components) ..................................................... 59
Description (Optional Hydrostatic Steering Components) ............................... 59
Diagnosis (Power Steering) ............................................................................................ 60
Power Steering ................................................................................................ 60
Hydraulic Pump with Priority Valve Test – Power Steering Testing ................ 60
Tools Needed .................................................................................................. 61
Diagnosis (Hydrostatic Steering) ..................................................................................... 63
Hydrostatic Steering ........................................................................................ 63
Suspension ......................................................................................................................... 65
Description (Vehicle Suspension) ........................................................................ 65
Front Springs ................................................................................................................... 66
Repair (Springs Removal) ............................................................................... 66
Repair (Springs Installation) ............................................................................ 66
Load Handling ..................................................................................................................... 67
Lift and Lower ..................................................................................................................67
Description (Boom Components) .................................................................... 67
Hydraulic Pump .......................................................................................................... 67
Description ................................................................................................. 67
Control Valve .............................................................................................................. 67
Description ................................................................................................. 67
Boom Lift Cylinders ..................................................................................................... 68
Description ................................................................................................. 68
Diagnosis (Boom) ............................................................................................................ 69
Diagnosis ........................................................................................................ 69
Hydraulic Pump with Priority Valve Tests – Boom .......................................... 70
Control System ................................................................................................................... 73
Introduction - General Information ........................................................................ 73
Frame, Body, Cab and Accessories ..................................................................................75
Controls and Instruments ................................................................................................ 75
Description ...................................................................................................... 77
Low Air Warning ......................................................................................................... 81
Diagnosis ................................................................................................... 81
Hourmeter .................................................................................................................. 81
Diagnosis ................................................................................................... 81
Speedometer .............................................................................................................. 82
Diagnosis ................................................................................................... 82
Voltmeter .................................................................................................................... 83
Diagnosis ................................................................................................... 83
Seating ............................................................................................................................84
Description ...................................................................................................... 84
Heating, Ventilation and Air Conditioning ........................................................................ 85
Description ...................................................................................................... 85
Wiping and Cleaning of Windows ................................................................................... 86

Maintenance Manual Ottawa T2 4x2
Windshield Wipers ......................................................................................................86
Description ................................................................................................. 86
Diagnosis .................................................................................................... 86
Windshield Washer .....................................................................................................87
Description ................................................................................................. 87
Diagnosis .................................................................................................... 87
Lighting System ...............................................................................................................88
Description ...................................................................................................... 88
Headlights ...................................................................................................................88
Diagnosis .................................................................................................... 88
Clearance, Marker and Tail Lights ..............................................................................89
Diagnosis .................................................................................................... 89
Brake Lights ................................................................................................................90
Diagnosis .................................................................................................... 90
Backup Light ...............................................................................................................91
Diagnosis .................................................................................................... 91
Turn Signal ..................................................................................................................92
Diagnosis .................................................................................................... 92
Beacon Light ...............................................................................................................93
Diagnosis .................................................................................................... 93
Dome Light ..................................................................................................................93
Diagnosis .................................................................................................... 93
Daytime Running Lights ..............................................................................................94
Diagnosis .................................................................................................... 94
Trailer Auxiliary Power ................................................................................................94
Diagnosis .................................................................................................... 94
Transmission Shifter/Fifth-Wheel Control and Panel Lighting ....................................95
Diagnosis .................................................................................................... 95
Signal System .................................................................................................................96
Horn ............................................................................................................................96
Diagnosis .................................................................................................... 96
Emergency Flasher ....................................................................................................96
Diagnosis .................................................................................................... 96
Backup Alarm ..............................................................................................................97
Diagnosis .................................................................................................... 97
Maintenance and Communication ...................................................................................98
Radio ...........................................................................................................................98
Description ................................................................................................. 98
Diagnosis .................................................................................................... 98
Glass/Window/Mirrors .....................................................................................................99
Description ...................................................................................................... 99
Rear-View Mirror .........................................................................................................99
Description ................................................................................................. 99
Construction and Suspension of Cab/Deck ...................................................................100
Cab Frame ...............................................................................................................100
Description ............................................................................................... 100
Door ..........................................................................................................................101
Description ............................................................................................... 101
Repair (Rear Door Adjustment) ................................................................ 101
Roof and Door Mouldings .........................................................................................102
Description ............................................................................................... 102
Cab Tilting ................................................................................................................102
Description ............................................................................................... 102
Cab Tilt (Hydraulic) Components ............................................................. 104
Diagnosis (Cab Tilt) .................................................................................. 105

Maintenance Manual Ottawa T2 4x2
Cab Tilt Pump and Motor .......................................................................................... 106
Diagnosis (Cab Tilt Pump) ....................................................................... 106
Repair (Pump and Motor Removal) ......................................................... 106
Repair (Pump and Motor Installation) ...................................................... 107
Repair [Relief Pressure Adjustment] ........................................................ 107
Cab Tilt Cylinder ....................................................................................................... 109
Repair (Cylinder Removal) ....................................................................... 109
Repair (Cylinder Installation) .................................................................... 110
Cab Pivot Bushing .................................................................................................... 111
Repair (Pivot Bushing Removal) .............................................................. 111
Repair (Pivot Bushing Installation) ........................................................... 113
Cab Mounting and Suspension ................................................................................ 113
Description ............................................................................................... 113
Diagnosis (Cab Air Suspension) .............................................................. 114
Air Ride Suspension (Three-Point) ...........................................................................114
Repair (Cab Suspension Assembly Removal) ......................................... 114
Repair (Cab Suspension Assembly Installation) ...................................... 115
Repair (Air Ride Level Adjustment) .......................................................... 116
Leveling Valve .......................................................................................................... 116
Repair (Valve Operation Check) .............................................................. 116
Shock Absorbers ......................................................................................................117
Repair (Shock Removal) .......................................................................... 117
Repair (Shock Installation) ....................................................................... 118
Cab Latch Bar Plate ..................................................................................................118
Repair (Latch Bar Plate Adjustment) ........................................................ 118
Chassis .........................................................................................................................119
Description .................................................................................................... 119
Diagnosis (Chassis) ...................................................................................... 120
Repair (Frame Damage Analysis) ................................................................. 123
Repair (Making Reinforcements, General Information) ................................. 123
Repair (Making Reinforcements, Attachment) .............................................. 124
Repair (Cracks in Steel Rails or Cross Members) ......................................... 124
Bodywork ......................................................................................................................126
Footstep .................................................................................................................... 126
Description ............................................................................................... 126
Accessories and Options .............................................................................................. 127
Accessory Relay ....................................................................................................... 127
Diagnosis ................................................................................................. 127
Heater/Air Conditioning (Optional) ............................................................................127
Diagnosis ................................................................................................. 127
Mirrors (Heated/Motorized) ....................................................................................... 128
Diagnosis ................................................................................................. 128
Common Hydraulics ......................................................................................................... 131
System Description ............................................................................................ 131
Tanks and Accumulators .............................................................................................. 131
Reservoir ..................................................................................................................131
Description ............................................................................................... 131
Temperature Control, Cleaning and Hydraulic Oil ........................................................ 132
Return Filter .............................................................................................................. 132
Description ............................................................................................... 132
Common Electric .............................................................................................................. 133
Controls and Instruments .............................................................................................. 133
Description (Wiring Harness) ........................................................................ 133
Safety ............................................................................................................................134
Fuses, Relays and Circuit Breakers .........................................................................134
Description ............................................................................................... 134

Maintenance Manual Ottawa T2 4x2
Common Pneumatics .......................................................................................................137
Air System and Brakes .................................................................................................137
Description .................................................................................................... 137
Diagnosis ..................................................................................................................137
Brakes — Air System ............................................................................... 137
Valves ............................................................................................................................142
Tractor Protection Valves .............................................................................. 142
Proportioning Relay (Bobtail) Valve (Optional) .............................................. 142
Quick Release Valves ................................................................................... 142
Anti-Compounding Valve (Optional) .............................................................. 142
Double (Two-Way) Check Valves ................................................................. 142
Air Dryer ........................................................................................................................143
Description .................................................................................................... 143
Diagnosis ....................................................................................................... 143
D. Error Codes ..................................................................................................................145
Description .................................................................................................... 145
E. Schematics ...................................................................................................................147
Air System Circuits ........................................................................................................147
Air Brakes ................................................................................................................147
Components ............................................................................................. 147
Air Brake System with Split Brakes ............................................................... 147
On-Highway Air System ................................................................................ 148
On-Highway Air System Circuit ..................................................................... 150
Off-Highway Air System ................................................................................ 152
Off-Highway Air System Circuit ..................................................................... 154
Cab Seating .............................................................................................................156
Air Lines — Driver's Seat ......................................................................... 156
Cab Suspension .......................................................................................................156
Air Lines — Cab Suspension ................................................................... 156
Fifth-Wheel Coupling ...............................................................................................157
Air Lines — Fifth-Wheel Latch .................................................................. 157
5th Wheel Interlock Option Circuit ............................................................ 159
Tractor/Trailer Park Brake ........................................................................................160
Air Lines — Tractor/Trailer Park Brake Option ......................................... 160
Tractor/Trailer Park Brake Valve Option Circuit ....................................... 161
Quick Trailer Air/R14 Valve ......................................................................................162
Air Lines — Quick Trailer Air/R14 Valve Option ....................................... 162
Quick Trailer Air/R14 Valve Option Circuit ............................................... 163
Trailer Hand Brake ...................................................................................................163
Air Lines — Trailer Hand Brake Option .................................................... 163
Trailer Hand Brake Option Circuit ............................................................ 164
Trailer Hose Connection Coiled Air Lines Circuit ..................................... 164
Trailer Hose Connection Glad Hands Both Ends Coiled Air Lines Circuit 165
Trailer Hose Connection Straight Rubber Air Lines Circuit....................... 165
Air Horn .....................................................................................................................166
Air Lines — Air Horn Option ..................................................................... 166
Air Horn Option Circuit ............................................................................. 166
Inter Axle Lock ..........................................................................................................167
Air Lines — Inter Axle Option ................................................................... 167
Inter Axle Lock Option Circuit ................................................................... 167
Grease Jockey Lube Pump .......................................................................................168
Air Lines — Grease Jockey Lube Pump Option ....................................... 168
Grease Jockey Lube Pump Option Circuit ............................................... 168
Differential Axle Lock ...............................................................................................169
Air Lines — Differential Axle Lock Option ................................................ 169

Maintenance Manual Ottawa T2 4x2
Differential Axle Lock Option Circuit ......................................................... 169
Additional 7.35 cu. in. Air Reservoir ......................................................................... 170
Air Lines — Additional 7.35 cu. in. Air Reservoir Option .......................... 170
Additional 7.35 cu. in. Air Reservoir Option ............................................. 170
Air Dryer ................................................................................................................... 171
Air Lines — Air Dryer Option .................................................................... 171
Air Dryer Option ....................................................................................... 172
ABS Brakes ............................................................................................................. 173
Air Lines — ABS Brakes Option – On-Highway Only .............................. 173
ABS Brake Option Circuit ......................................................................... 174
Traction Control ....................................................................................................... 175
Air Lines — Traction Control Option for ABS Brakes – On-Highway Only 175
Traction Control Option for Use With ABS Brake Option Circuit .............. 176
3rd Air Tank .............................................................................................................. 177
Air Lines — 3rd Air Tank Option – Off-Highway Only .............................. 177
3rd Air Tank Option Circuit ....................................................................... 177
Hydraulic System Circuits ............................................................................................. 178
Hydraulic Systems ......................................................................................... 178
Cab Tilt ....................................................................................................................178
Hydraulic Lines — Cab Tilt ....................................................................... 178
Fifth-Wheel Boom ....................................................................................................179
Hydraulic Lines — Fifth-Wheel Boom ...................................................... 179
Power Steering ........................................................................................................ 180
Hydraulic Lines — Power Steering .......................................................... 180
Optional Hydrostatic Steering .................................................................................. 181
Hydraulic Lines — Hydrostatic Steering ................................................... 181
Electrical System Circuits ..............................................................................................182
Starting and Charging .............................................................................................. 182
Starting and Charging Circuit ................................................................... 182
Cab Accessory Components ...................................................................................183
Wire Color Codes ..................................................................................... 183
Anti-lock Braking System (ABS) ............................................................... 183
Heater and Air Conditioning ..................................................................... 184
Horn ......................................................................................................... 185
Mirrors ...................................................................................................... 186
Radio (Optional) ....................................................................................... 188
Radio Circuit — Hot Wire ......................................................................... 189
Windshield Washer (Optional) ................................................................. 190
Windshield Wiper ..................................................................................... 191
Cab Power Board ..................................................................................... 192
Cab Interior Engine Wiring ....................................................................... 193
Cab Instrumentation ................................................................................................195
Air Pressure Gauge Lighting .................................................................... 195
Engine Hourmeter .................................................................................... 196
Fuel Gauge .............................................................................................. 197
Low Air Warning Alarm ............................................................................ 200
Speedometer ............................................................................................ 201
Voltmeter .................................................................................................. 202
Gauge Cluster Wiring ............................................................................... 203
Chassis Circuits ....................................................................................................... 209
Chassis Power Board ............................................................................... 209
Air Dryer (Optional) .................................................................................. 210
Cab Tilt Pump .......................................................................................... 211
Cab Exterior/Front Chassis Wiring ........................................................... 212
Chassis Wiring ......................................................................................... 215

Maintenance Manual Ottawa T2 4x2
Air System Tank Pressure Senders ......................................................... 218
Battery Power Distribution ........................................................................ 219
Cab Tilt System Control Wiring ................................................................ 221
Lighting Circuits (Cab and Chassis) .........................................................................224
Backup Light and Alarm ........................................................................... 224
Beacon/Strobe Light (Optional) ................................................................ 225
Clearance Lights (Optional) ...................................................................... 226
Daytime Running Lights (Optional) .......................................................... 227
Dome Light ............................................................................................... 228
Fifth-Wheel Control .................................................................................. 228
Flood Light ................................................................................................ 229
Headlights ................................................................................................ 230
Marker Lights ............................................................................................ 230
Panel Lighting ........................................................................................... 230
Strobe Light .............................................................................................. 230
Tail Lights ................................................................................................. 231
Trailer Auxiliary Power ............................................................................. 231
Transmission Shifter, Fifth-Wheel Control and Panel Lighting ................. 232
Turn Signal, Tail, Brake Lights and Emergency Flasher .......................... 233
Upper Cab Harness .................................................................................. 235
Headlight/Dimmer Switch Wiring .............................................................. 236
Auxiliary Lighting and Air Horn ................................................................. 238
Tail Light/Backup Light Wiring .................................................................. 239
Engine Controls ........................................................................................................241
Throttle Pedal (TPS) Wiring ..................................................................... 241
Engine Wiring ........................................................................................... 242
Exhaust .....................................................................................................................245
Aftertreatment Wiring ............................................................................... 245
F. Technical Data ..............................................................................................................247
Standard Vehicle Data ..................................................................................................247
Ottawa T2 Series Terminal Tractor ............................................................... 247
Hydraulic System ..........................................................................................................249
Ottawa T2 Series 4x2 .................................................................................... 249
Fluids, Lubricants and Sealants ....................................................................................250
Ottawa T2 Series 4x2 .................................................................................... 250
Fastener Torque Values ................................................................................................251
Ottawa T2 Series 4x2 .................................................................................... 251
G. Appendix .......................................................................................................................253

– A. Foreword 1
Maintenance Manual Ottawa T2 4x2
mm mm mm mm mm mm
A. Foreword
page– About this manual
This service manual covers the Ottawa T2 4x2 and 6x4 termi-
nal (yard) tractors produced by Kalmar Solutions LLC, Kalmar
Terminal Tractors. You will find here descriptions of the fea-
tures, location and operation of the components. Diagnostic
and repair procedures are included along with schematic dia-
gramsofthe electric, pneumaticandhydrauliccircuits. There is
a table of specifications and a schedule for preventive mainte-
nance.
Basic information, diagnostic and repair procedures are provid-
ed for the uniquely Ottawa T2 features and components. De-
signed to provide the owners and operators of Ottawa T2 4x2
and 6x4 terminal tractors with the information necessary to ser-
vice and maintain their vehicles properly, this manual presents
the information in seven sections.
For the major components, such as engine, transmission and
axles,followtheserviceinstructionsandguidelinesprovidedby
the component manufacturer. This applies also to lesser com-
ponents, such as the steering gear, ABS controllers and other
system components, that are produced by quality manufactur-
ers and supplied to Kalmar for production of Ottawa T2 vehi-
cles.
It is our hope that this manual will help you to realize maximum
utility, efficiency, reliability and durability from your Ottawa T2
tractor.
For more in-depth information on individual components, ser-
vice and/or maintenance manuals are available on the internet.
Below is a list of websites where component manuals can be
found.
Additional Information
• Cummins Engine - www.cummins.com
• Allison Transmission - www.allisontransmisson.com
• Meritor Axle - www.meritor.com
• Sisu Axle - www.sisuaxles.com
• Bendix Brake System - www.bendix.com
• Haldex Slack Adjusters - www.hbsna.com
• Holland 5th Wheels - www.safholland.com
• Fontaine Armor 5th Wheels -
www.fontainecouplingsolutions.com
• Sheppard Steering Systems - www.rhsheppard.com