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

2 – A. Foreword
Maintenance Manual Ottawa T2 4x2
• TRW Steering Components - www.trw.com
• Chelsea PTO - www.chelseaproduct.com
• Parker Hydraulic pump - www.parker.com
• Cab Tilt Pump - www.bucherhydraulics.com
• Denso Starter - www.densoheavyduty.com
• Remy Alternator - www.delcoremy.com
• Bostrom Seat - www.bostromseating.com
• Link Cab Suspension - www.linkmfg.com
• Ottawa Kalmar - www.ottawatrucksna.com

– B. Safety 3
Maintenance Manual Ottawa T2 4x2
mm mm mm mm mm mm
B. Safety
page– Hazardous Condition Signs
The following signs accompanied by an explanation are used
toadvisethe readerofthedegreeofhazardassociatedwiththe
procedure being described.
NOTE
Information that is important without being safety related.
Note is used to facilitate the work process, operation/handling
or to increase understanding of the information.
DANGER
A situation that may result in serious personal injury,
possibly death, if the instruction is not followed.
WARNING
A situation that may result in serious personal injury
if the instruction is not followed.
CAUTION
A situation that may result in damage to the product if
the instruction is not followed.

4 – B. Safety
Maintenance Manual Ottawa T2 4x2
page– Do’s and Dont’s
• Do use care when removing the radiator filler cap. When
the engine is hot, rotate the cap to the first detent, allow the
pressure to dissipate and then remove it.
• Do stay clear when lowering the cab.
• Do set the parking brake when parking the vehicle.
• Don't apply full throttle while the engine is cold.
• Don't allow sparks or flames near a charging battery.
• Don’t allow sparks or flames nearby when inspecting fuel,
fuel tank or filler-neck strainer.
• Don’t operate a vehicle in an enclosed area without ade-
quate ventilation.
• Don’toperatethevehiclewithinspectionplates, coverplate
or engine access doors removed or open.
• Don’t weld or flame cut frame rails or drill holes in rail
flanges.
• Don’tmodifythe vehicle orits equipmentwithout theadvice
and written consent of the Engineering department at
Kalmar.
• Don’t push start the vehicle.
• Don’t stand or work under a raised cab unless the safety
prop on the tilt cylinder is locked.
• Don’t jump start the vehicle using welding equipment.
• Don’t operate the vehicle with air pressure below 70 PSI.
• Don’t shift the transmission from neutral to driveor reverse
at engine speeds above idle.
WARNING
Always disconnect the batteries before welding on or
near the vehicle. Improper welding procedures may
damage the alternator or batteries. Failure to heed
this warning may result in serious personal injury or
property damage.

0.1 Lubrication Points – C. Preventive Maintenance 5
Maintenance Manual Ottawa T2 4x2
mm mm mm mm mm mm
C. Preventive
Maintenance
0.1 Lubrication Points
page–
Lubrication Points
Chassis Lubrication Diagram — Left-Hand Drive
1. Coolant/Antifreeze
2. Engine Oil
3. Slack Adjusters Brake Cam Pivot
4. Front Axle King Pins
5. Tie Rod Ends
6. Transmission Fluid
7. Diesel Fuel
8. Universal Joints
9. Rear Axle Differential
10. Driveline Slip Yoke
11. Hydraulic/Steering Fluid
12. Cab Suspension Latch
13. Diesel Exhaust Fluid
14. Front Wheel Bearings
15. Drag Link Ends
16. Steering Slip Joint
Boom and Fifth-Wheel Lubrication Diagram
17. Boom Pivot
18. Boom Cylinder Bearings
19. Fifth-Wheel Pivot
20. Fifth-Wheel Top Plate
21. Fifth-Wheel Jaws
Side Door Hinge (not shown) Optional
Rear Door Upper Rollers (not shown)
2
3
4
5
6
7
8
9
* BOTH SIDES
** BOTH SIDES FRONT AND REAR
10
11
12
13
14
15
16
*
*
**
*
1
17
* BOTH SIDES
*
OTT0002
18*
20 21
19*

6 0.2 Inspections – C. Preventive Maintenance
Maintenance Manual Ottawa T2 4x2
0.2 Inspections
page– Every Day
Perform the inspections listed in the Daily Inspection Checklist
on page 7 and page 8.
At each inspection, add fluids and lubricants as indicated. Re-
pair all leaks. Replace cracked, damaged or worn parts.
page–
Every 250 Hours of Operation
Perform the inspections listed incolumn Aofthe chart. Referto
the Preventive Maintenance Forms on page 10 and page 11.
These service procedures must be performed after every 250
hours of operation or every month, whichever occurs first.
page–
Every 500 Hours of Operation
Perform the inspections listed incolumn Bofthe chart. Referto
the Preventive Maintenance Forms on page 10 and page 11.
These service procedures must be performed after every 500
hours of operation, or every three months, whichever occurs
first.
page–
Every 1,000 Hours of Operation
Perform the inspections listed incolumn Cofthe chart. Referto
the Preventive Maintenance Forms on page 10 and page 11.
Theseservice proceduresmustbeperformedafter every 1,000
hours of operation.
page–
Every 2,000 Hours of Operation
Perform the inspections listed incolumn Dofthe chart. Referto
the Preventive Maintenance Forms on page 10, and page 11.
Theseservice proceduresmustbeperformedafter every 2,000
hours of operation.

0.3 Checklists – C. Preventive Maintenance 7
Maintenance Manual Ottawa T2 4x2
0.3 Checklists
page–
page– Daily Inspection Checklist
❒Fuel tank
❒Engine oil level (engine stopped)
❒Coolant level
❒Windshield washer fluid level (if applicable)
❒Fuel water separator
❒Transmission fluid level (engine running)
❒Hydraulic fluid level (boom full down)
❒Diesel exhaust fluid level
❒Front wheel hub oil level (if applicable)
❒Engine belt condition and tension
❒Steering system
❒Hoses and wiring
❒Exhaust system
❒Drain air tanks
❒Trailer lines, glad-hand seals and trailer cord
❒Catwalk, boom deck and grab handles
❒Lift cylinders
❒Cab doors and latches
❒Cab hold down latch
❒Fifth-Wheel, secondary lock, jaws and cylinder operation
❒Boom control lever operation
❒Tire condition
❒Transmission shift lever operation
❒Backup alarm operation
❒Windshield wiper and washer operation
❒Horn
❒Radio equipment
❒Gauges and dash lights
❒Dome lights
❒Turn signals
❒Hazard lights
❒Headlights
❒Marker lights
❒Backup lights
❒Brake lights
❒Strobe light (if applicable)
❒Auxiliary backup lights

8 0.3 Checklists – C. Preventive Maintenance
Maintenance Manual Ottawa T2 4x2
❒Clean the cab interior.
❒Clean the windows.
❒Clean and adjust the mirrors.

0.3 Checklists – C. Preventive Maintenance 9
Maintenance Manual Ottawa T2 4x2
Daily Inspection Form
DAILY INSPECTION FORM
TRUCK # ________________ DRIVER NAME __________________________________________ DATE _____________
PERFORM THE FOLLOWING
COMPLETE COMPLETE COMPLETE
LEVELLIOKNATCILUARDYHKCEHCLEVELTNALOOCENIGNEKCEHCLEVELLEUFKCEHC
CHECK ENGINE OIL LEVEL DRAIN WATER FROM AIR TANKS
CHECK AIR INTAKE DUCTS CHECK TRANSMISSION FLUID LEVEL
CHECK THE FOLLOWING ITEMS AND INDICATE IF “OK” OR “REPAIR NEEDED”. CIRCLE LOCATON ON DRAWINGS IF
NECESSARY. DESCRIBE PROBLEMS IN REMARKS AREA AT BOTTOM OF PAGE.
OK REPAIR
NEEDED OK REPAIR NEEDED OK REPAIR NEEDED
STHGILPUKCABGNIREETSSMROFTALP/SELDNAH/SPETS STHGILEKARBELTTORHTRETRATS )S(THGILDOOLFNOITAREPOMOOBTRATSLARTUEN 5MRALAPUKCAB TH WHEEL RELEASE STROBE LIGHT HCTAL/NOISNEPSUSBACSEKARBECIVRESRETSORFED/RETAEH SKAELDIULFEKARBKRAPSRORRIM SREDNEF/SPALFDUM)S(NROHSROOD SERITSENILRIARELIARTSWODNIW EGAMADDROCTHGILRELIARTSREPIW STHGILDAEHTAES STHGILLANGISTLEBTAES
REMARKS:

10 0.3 Checklists – C. Preventive Maintenance
Maintenance Manual Ottawa T2 4x2
page– Preventive Maintenance Forms
PreventativeMaintenanceForm–Non-SyntheticTransmission
Lubrication
KALMAR TERMINAL TRACTOR PREVENTATIVE MAINTENANCE FORM
NON-SYNTHETIC (NON – TES-295) LUBE USED IN THE TRANSMISSION
TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE
EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION.
√= SATISFACTORY 0= ADJUSTMENT NECESSARY Χ= 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 THROTTLE OPERATION TORQUE FRONT AXLE KING PIN DRAW KEY NUT(S)
CHECK HORN(S) OPERATION CHECK POWER STEERING PUMP
CHECK AIR SYSTEM – MINIMUM 120 PSI, MAXIMUM 130 PSI CHECK STARTER MOUNTING AND CONNECTIONS
CHECK AIR SYSTEM FOR LEAK DOWN CHECK ENGINE AND TRANSMISSION FOR LEAKS
CHECK OPERATION OF BACK UP ALARM CHANGE ENGINE OIL AND FILTER
CHECK HVAC SYSTEM CHANGE TRANSMISSION FILTERS
BLOWER MOTOR OPERATION CHANGE TRANSMISSION FLUID
TEMPERATURE CONTROL CHECK ENGINE AND TRANSMISSION MOUNTS
DEFROSTER OPERATION CHECK WHEEL SEALS FOR LEAKS
A/C OPERATION (IF APP.) CLEAN REAR AXLE BREATHER
AUXILIARY FAN(S) (IF APP.) CHECK DIFFERENTIAL FOR LEAKS
CHECK 5TH WHEEL UNLATCH CONTROL CHECK DIFFERENTIAL OIL LEVEL
CHECK OPERATION OF BOOM CHANGE DIFFERENTIAL OIL
CHECK OPERATION OF WINDOWS CHECK LIFT CYLINDERS FOR LEAKS
CHECK SEAT BELT SYSTEM PER 10-STEP INSPECTION TORQUE REAR AXLE MOUNTING BOLTS
CHECK OPERATION OF DOOR LATCHES CHASSIS
CHECK DOME LIGHT OPERATION CHECK FRONT WHEEL BEARINGS
CHECK ALL GLASS AND MIRRORS CHECK FRONT AXLE OIL LEVEL (IF APP.)
CHECK FIRE EXTINGUISHER CHARGE (IF APP.) REPACK FRONT WHEEL BEARINGS (IF APP.)
CAB DOWN – EXTERIOR CHECK BATTERY CABLES & HOLDDOWNS
CHECK SIDE DOOR HINGE (IFF APP.) CHECK BATTERIES FOR CRACKS OR DAMAGE
CHECK CAB ACCESS STEPS AND HANDLES CLEAN BATTERY CABLE CONNECTIONS
CLEAN HEATER / AC FILTER (IF APP.) CHECK BATTERY BOX COVER HOLDDOWNS
CHECK REAR DOOR ROLLERS / SLIDE ADJUSTMENT DRAIN WATER FROM AIR TANKS
CHECK GLADHAND SEALS AND TRAILER AIR LINES CHECK AND TORQUE ALL WHEEL NUTS
CHECK TRAILER LIGHT CORD CHECK WHEELS
CHECK HEADLIGHTS / MARKER LIGHTS CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION
CHECK TURN SIGNALS CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)
CHECK STROBE LIGHT (IF APP.) INSPECT PLATFORMS
CHECK SPOTLIGHTS CHECK FRAME FOR CRACKS
CHECK WIPER BLADES CHECK MUD FLAPS / FENDERS (IF APP.)
CHECK WINDSHIELD WASHER FLUID LEVEL CHANGE HYDRAULIC SYSTEM FILTER
CHECK TRANSMISSION FLUID LEVEL CHECK HYDRAULIC FLUID LEVEL
CHECK ENGINE OIL LEVEL CHANGE HYDRAULIC FLUID
CAB UP CLEAN HYDRAULIC TANK VENT
CHECK OPERATION OF CAB TILT PUMP CHECK CAB HINGE PINS AND BUSHINGS
CHECK CAB SAFETY PROP LUBRICATION
CHECK CAB SUSPENSION AND LATCH CHECK / LUBRICATE REAR DOOR ROLLERS
CHECK INTAKE DUCTING FOR LEAKS CHECK / LUBRICATE STEERING SLIP JOINT
CHECK RADIATOR FOR LEAKS CHECK / LUBRICATE STEERING U-JOINTS
CHECK RADIATOR MOUNTS CHECK / LUBRICATE ALL STEERING LUBE POINTS
CHECK COOLANT LEVEL AND CONCENTRATION CHECK / LUBRICATE SLACK ADJUSTERS
CHECK AND ADJUST COOLANT ADDITIVE (IF APP.) CHECK / LUBRICATE DRIVELINE U-JOINTS
CHANGE ENGINE COOLANT CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS
CHECK COOLANT HOSES AND CLAMPS CHECK AND LUBRICATE 5TH WHEEL TOP PLATE
CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS
CHECK ENGINE COOLING FAN FOR CRACKS CHECK AND LUBRICATE BOOM PIVOT BEARINGS
CHECK ENGINE BELT(S) AND TENSIONER CHECK AND LUBE BOOM CYLINDER BEARING
CHANGE ENGINE COOLANT FILTER (IF APP.) ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.)
CHECK ENGINE AND TRANSMISSION FOR LEAKS TEST DRIVE
DRAIN FUEL WATER SEPARATOR DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION
CHANGE FUEL FILTER / FUEL WATER SEPARATOR
CHECK AIR RESTRICTION GAUGE (IF APP.)
CHANGE AIR FILTER AS NEEDED
CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED
CHECK EXHAUST SYSTEM
CLEAN TRANSMISSION BREATHER

0.3 Checklists – C. Preventive Maintenance 11
Maintenance Manual Ottawa T2 4x2
Preventative Maintenance Form – Synthetic Transmission
Lubrication with High Capacity Filters
KALMAR TERMINAL TRACTOR PREVENTATIVE MAINTENANCE FORM
SYNTHETIC (TES-295) LUBE AND ALLISON HIGH-CAPACITY FILTERS USED IN THE TRANSMISSION
TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE
EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION.
√= SATISFACTORY 0= ADJUSTMENT NECESSARY Χ= 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 THROTTLE OPERATION TORQUE FRONT AXLE KING PIN DRAW KEY NUT(S)
CHECK HORN(S) OPERATION CHECK POWER STEERING PUMP
CHECK AIR SYSTEM – MINIMUM 120 PSI, MAXIMUM 130 PSI CHECK STARTER MOUNTING AND CONNECTIONS
CHECK AIR SYSTEM FOR LEAK DOWN CHECK ENGINE AND TRANSMISSION FOR LEAKS
CHECK OPERATION OF BACK UP ALARM CHANGE ENGINE OIL AND FILTER
CHECK HVAC SYSTEM CHANGE TRANSMISSION FILTERS 3000 HOURS
BLOWER MOTOR OPERATION CHANGE TRANSMISSION FLUID 6000 HOURS
TEMPERATURE CONTROL CHECK ENGINE AND TRANSMISSION MOUNTS
DEFROSTER OPERATION CHECK WHEEL SEALS FOR LEAKS
A/C OPERATION (IF APP.) CLEAN REAR AXLE BREATHER
AUXILIARY FAN(S) (IF APP.) CHECK DIFFERENTIAL FOR LEAKS
CHECK 5TH WHEEL UNLATCH CONTROL CHECK DIFFERENTIAL OIL LEVEL
CHECK OPERATION OF BOOM CHANGE DIFFERENTIAL OIL
CHECK OPERATION OF WINDOWS CHECK LIFT CYLINDERS FOR LEAKS
CHECK SEAT BELT SYSTEM PER 10-STEP INSPECTION TORQUE REAR AXLE MOUNTING BOLTS
CHECK OPERATION OF DOOR LATCHES CHASSIS
CHECK DOME LIGHT OPERATION CHECK FRONT WHEEL BEARINGS
CHECK ALL GLASS AND MIRRORS CHECK FRONT AXLE OIL LEVEL (IF APP.)
CHECK FIRE EXTINGUISHER CHARGE (IF APP.) REPACK FRONT WHEEL BEARINGS (IF APP.)
CAB DOWN – EXTERIOR CHECK BATTERY CABLES & HOLDDOWNS
CHECK SIDE DOOR HINGE (IFF APP.) CHECK BATTERIES FOR CRACKS OR DAMAGE
CHECK CAB ACCESS STEPS AND HANDLES CLEAN BATTERY CABLE CONNECTIONS
CLEAN HEATER / AC FILTER (IF APP.) CHECK BATTERY BOX COVER HOLDDOWNS
CHECK REAR DOOR ROLLERS / SLIDE ADJUSTMENT DRAIN WATER FROM AIR TANKS
CHECK GLADHAND SEALS AND TRAILER AIR LINES CHECK AND TORQUE ALL WHEEL NUTS
CHECK TRAILER LIGHT CORD CHECK WHEELS
CHECK HEADLIGHTS / MARKER LIGHTS CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION
CHECK TURN SIGNALS CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)
CHECK STROBE LIGHT (IF APP.) INSPECT PLATFORMS
CHECK SPOTLIGHTS CHECK FRAME FOR CRACKS
CHECK WIPER BLADES CHECK MUD FLAPS / FENDERS (IF APP.)
CHECK WINDSHIELD WASHER FLUID LEVEL CHANGE HYDRAULIC SYSTEM FILTER
CHECK TRANSMISSION FLUID LEVEL CHECK HYDRAULIC FLUID LEVEL
CHECK ENGINE OIL LEVEL CHANGE HYDRAULIC FLUID
CAB UP CLEAN HYDRAULIC TANK VENT
CHECK OPERATION OF CAB TILT PUMP CHECK CAB HINGE PINS AND BUSHINGS
CHECK CAB SAFETY PROP LUBRICATION
CHECK CAB SUSPENSION AND LATCH CHECK / LUBRICATE REAR DOOR ROLLERS
CHECK INTAKE DUCTING FOR LEAKS CHECK / LUBRICATE STEERING SLIP JOINT
CHECK RADIATOR FOR LEAKS CHECK / LUBRICATE STEERING U-JOINTS
CHECK RADIATOR MOUNTS CHECK / LUBRICATE ALL STEERING LUBE POINTS
CHECK COOLANT LEVEL AND CONCENTRATION CHECK / LUBRICATE SLACK ADJUSTERS
CHECK AND ADJUST COOLANT ADDITIVE (IF APP.) CHECK / LUBRICATE DRIVELINE U-JOINTS
CHANGE ENGINE COOLANT CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS
CHECK COOLANT HOSES AND CLAMPS CHECK AND LUBRICATE 5TH WHEEL TOP PLATE
CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS
CHECK ENGINE COOLING FAN FOR CRACKS CHECK AND LUBRICATE BOOM PIVOT BEARINGS
CHECK ENGINE BELT(S) AND TENSIONER CHECK AND LUBE BOOM CYLINDER BEARING
CHANGE ENGINE COOLANT FILTER (IF APP.) ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.)
CHECK ENGINE AND TRANSMISSION FOR LEAKS TEST DRIVE
DRAIN FUEL WATER SEPARATOR DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION
CHANGE FUEL FILTER / FUEL WATER SEPARATOR
CHECK AIR RESTRICTION GAUGE (IF APP.)
CHANGE AIR FILTER AS NEEDED
CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED
CHECK EXHAUST SYSTEM
CLEAN TRANSMISSION BREATHER