Kalmar Ottawa Operator's Manual
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Kalmar Ottawa Operator's Manual

Kalmar ottawa truck operator's manual
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  • Page 2: Owner Information

    DO NOT REMOVE THIS MANUAL FROM THE VEHICLE. STUDY THIS MANUAL. READ AND COMPLY WITH ALL WARNINGS IN THIS MANUAL. IF THE VEHICLE IS SOLD, GIVE THIS MANUAL TO THE NEW OWNER. Kalmar Industries Corp. 415 East Dundee Street Ottawa, Kansas USA (785) 242-2200 Fax (785) 242-6177...
  • Page 3 FROM KALMAR TO THE OWNER: The manufacturer of these trucks cannot create a single manual that would cover every option available. We have tried to cover all the information that would be included in a normally configured truck. For information on some major components you will need...

  • Page 4: Table Of Contents

    Owner Information CONTENTS Section “A” INTRODUCTION ....................4 CAUTIONS AND WARNINGS ................4 NOTES ........................4 SERVICE ASSISTANCE ..................4 VEHICLE MODIFICATIONS ................5 SAFETY CHECKS AND PRECAUTIONS ...............5 Axle - Front ....................6 Axle -Rear ....................6 Brake System ..................6 Cab ......................6 Electrical ....................7 Exhaust System ..................7 Frame .....................7 Fuel System ....................7 Propeller Shaft ..................7...

  • Page 5: Introduction

    Kalmar dealer for assistance. Kalmar Industries Corp. has an established dealer network throughout the country. NOTE — The Kalmar tractor may also be Whenever assistance is needed contact referred to throughout this manual as “vehicle” local dealer first. For the number of your “the vehicle”.

  • Page 6: Vehicle Modifications

    ID plate inside of the cab. All spotting applications are demanding on the vehicle. Maintenance is critical for Kalmar is proud to have been the leader in the continued SAFE performance of your the Port and Terminal Tractor Industry for tractor.

  • Page 7: Axle-Front

    Owner Information AXLE-FRONT of 70 PSI is required to operate this vehicle. Maintaining correct front axle alignment 4. Visually check hoses and pneumatic is critical and should be performed by a lines for damage and chaffing. qualified mechanic. 5. Check the operation of both the service Check to ensure that the axle mounting and parking brake systems.

  • Page 8: Electrical

    Contact your dealer for instructions on ken, damaged, worn, or non OEM frame repair. Do not weld on frame rails steering system components. unless directed to do so by your Kalmar dealer or by the factory. SUSPENSION FUEL SYSTEM Check condition of front and optional rear...

  • Page 9: Transmission

    Kalmar Industries Corp. directly. NOTE - Because of the many options available on Kalmar tractors, it is critical that the owner be aware of all options that may affect the safe operation of the vehicle and take appropriate measures to maintain his/her specific vehicle.

  • Page 10: Sample Pre-Operation Safety Checklist

    SAMPLE PRE-OPERATION CHECKLIST (Walk Around Inspection) ________ Check tires for damage and proper inflation ________ Check cab hold down latch (air suspension unit) for proper latching ________ Check all fluid levels: engine oil, hydraulic, and coolant ________ Drain any moisture from air tanks ________ Check cab doors and latches for proper operation ________...

  • Page 11: Vehicle Warranty

    first 182 days of service and if the prepaid returned parts are judged by KALMAR to be faulty or defective. If the de- fect occurs between 183 and 365 days of service KALMAR or KALMAR Terminal Tractor authorized Parts and Service Dealer will repair or replace parts only and will not reimburse for any labor charges.
  • Page 12 ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, OF ANY KIND OR NATURE WHATSOEVER. KALMAR reserves the right, at any time, to make changes in the design, mate- rial, and/or specification of this product, or accessories thereof, without thereby becoming liable to make similar changes in such equipment or accessories previously manufactured.

  • Page 13: Operation

    Operation CONTENTS Section “B” INTRODUCTION ....................14 VEHICLE ENTRY AND EXIT ................14 OCCUPANT RESTRAINT SYSTEM ..............14 Seat Belt Operation ................15 Suspension Type Seats ................15 Seat Adjustment ..................15 INSTRUMENT PANELS AND CONTROLS ............16 Control and Display Location ...............17 Control and Display Description ............18 STARTING THE VEHICLE ................22 Ignition Switches ................22 Key Type Ignition ..............
  • Page 14 Operation ENGINE ......................28 Starting the Engine ................29 Starting Procedure ............29 Engine Shut Down ................30 Shut Down Procedure ............30 Engine Oil ................30 TRANSMISSION ...................30 Parking with an Automatic Transmission ..........31 HYDRAULIC FIFTH WHEEL LIFTING SYSTEM ..........31 Hydraulic Boom Operation ...............31 Fifth Wheel Unlatch Control Valve .............32 BASIC TRAILER SPOTTING STEPS ..............32 TOWING THE VEHICLE ...................34...

  • Page 15: Introduction

    This manual is intended to cover the stan- or out of your Kalmar tractor. Remember, dard Kalmar tractor and some of the most be careful! common options. Not all of the customer ordered optional equipment or systems are covered in this manual.

  • Page 16: Occupant Restraint System

    WITH SEAT BELTS. THEY SHOULD BE the decal located on the seat base. Your USED WHENEVER THE VEHICLE IS IN local Kalmar dealer can assist with any OPERATION. questions. Adjust the seat to the comfortable position...

  • Page 17: Instrument Panels And Controls

    Operation...

  • Page 18: Control And Display Location

    Operation s=standard a=assigned options u=unassigned options n=not available CUMMINGS CATERPILLAR DETROIT NAME OFF HWY ISB/ISC 3126 DIESEL S40 E WATER TEMP GAUGE TACHOMETER OIL PRESSURE GAUGE SPEEDOMETER FUEL GAUGE AIR DIFFUSER HEADLIGHT SWITCH PANEL LTS DIMMER INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT...

  • Page 19: Control And Display Description

    Operation CONTROL AND DISPLAY DESCRIPTION Ignition Switch ......17 Air-conditioner Switch ....20 Indicator Light Strip....20 Air Pressure Gauge....21 Optional Gauges.......17 Beacon Switch (optional)..17 Optional Controls.....17 Boom Control Lever....21 Optional Switches.....17 Coolant Temperature Gauge..19 Parking Brake Control....21 Engine Oil Pressure Gauge..19 Speedometer (optional).....20 Emergency 4 Way Flasher..21 Tachometer (optional)....20 Fan Control...
  • Page 20 Operation PANELS 1 and 2 4. Engine Oil Pressure Gauge 1. Dash Panel Light Dimmer Indicates the engine oil pressure in P.S.I. 2. Headlight/Running Light Control 5. Coolant Temperature Gauge This switch controls headlights and run- Indicates the temperature of the engine ning lights on the tractor and trailer.
  • Page 21 Operation 8. Heater Control Indicator Light Strip This lever controls the heater temperature. The full down position shuts off the heater. The indicator lights are located along the The lever can be adjusted to provide the top of dash panels 1 and 2. These panels desired amount of heat by moving it up contain the 5 STANDARD indicators and from the OFF position.
  • Page 22 2. 2nd Air Gauge Indicates air pressure in the air system The column mounted control on the in P.S.I. Kalmar tractor has three functions. It is located on the left hand side of the steer- 3. Transmission Shift Selector ing column (Fig. 1).

  • Page 23: Starting The Vehicle

    The three position type functions like the The standard ignition switch on the standard key type with OFF, ACCESSORY Kalmar tractor is a key type, similar to the and RUN positions. The button engages kind found on automobiles. Push button...

  • Page 24: Parking The Vehicle

    NOTE - Some vehicles may be equipped with be kept in proper work- optional shut down systems or optional starter ing condition. Operating a switches. Contact your Kalmar dealer if you vehicle with poorly main- have any questions regarding the operation tained, brakes or worn out brakes of any optional starter switches or shut down systems.

  • Page 25: Low Air Pressure Indicators

    Operation air pressure in the system. The warning buzzer will shut off after air pressure has reached 70 P.S.I.. (See page 21) If the warning light and buzzer do not shut off at least 5 minutes after start-up, shut the engine down and determine why the air system is not charging.

  • Page 26: Abs

    Trucks should not be operated if the in- is stopped or slowed completely. dicator light is on. Contact your nearest This could result in serious injury or Kalmar dealer for qualified service on the death. A.B.S. system. Trucks built with A.B.S. after March of...

  • Page 27: Traction Control

    Operation WARNING-Never apply Trouble-shooting or clearing fault codes the parking brake during is performed at the EC module mounted normal driving. Doing this in the left front wheel well. will lock the rear wheels, possibly causing an uncontrolled stop. TRACTION CONTROL PARKING BRAKE AND TRAILER Automatic traction control (A.T.C.) is AIR SUPPLY CONTROLS...
  • Page 28 It should lease the standard brake chambers used extend approximately 3” out of the nut. on most Kalmar tractors. If your vehicle is equipped with other optional brake 3.00 inches - Type 2430 and 3030 Chambers chambers, refer to that manufacturer’s...

  • Page 29: Trailer Brakes

    This increases the possibility of an accident and could TRAILER BRAKES result in serious injury of death. Kalmar tractors are designed to use the ENGINE trailer’s brakes when towing trailers. All Kalmar tractors are equipped with a trailer...

  • Page 30: Starting The Engine

    Failure to do so may cause NOTE - All Kalmar tractors are designed to the vehicle to move suddenly and start in NEUTRAL ONLY. The starter should not unexpectedly when the starter is operate if the vehicle is in any other gear.

  • Page 31: Engine Shut Down

    NOTE - Always refer to the engine operation manual for complete information on engine Allison Transmission operator’s manual is shut down procedures. provided with every Kalmar. This manual provides important information on opera- SHUT DOWN PROCEDURE tion of the RDS series transmissions.

  • Page 32: Parking With An Automatic Transmission

    The Allison RDS series transmissions do not have a “PARK” position like an auto- mobile transmission. For information on how to properly park your Kalmar, see the following sections in this manual: Page 23, Parking the Vehicle Pages 26 thru 28, Parking Brake...

  • Page 33: Fifth Wheel Unlatch Control Valve

    FIFTH WHEEL UNLATCH plate. CONTROL VALVE 4. With your foot firmly on the brake The Kalmar tractor comes standard with treadle and the tractor shift lever in an air operated fifth wheel unlatch cylin- NEUTRAL, move the boom control lever der.
  • Page 34 Operation raised too high. the fifth wheel unlatch control and go the next trailer. 8. Once proper trailer height is reached, WARNING - When the trac- apply the tractor parking brake. Now tor is operated on public hook BOTH the trailer emergency and streets or highways, the service airlines to the trailer (blue &...

  • Page 35: Towing The Vehicle

    Kalmar. Using a chain or cable to tow the vehicle is not recommended. The best way to tow a Kalmar tractor is with the rear wheels lifted off the road. 2. Always disconnect the drive line This prevents any possible damage to the to the rear drive axle(s), or remove transmission and drivetrain.

  • Page 36: Towing Vehicle With Rear Wheels Suspended

    (See page 26, on Kalmar tractors. If you do not know if Manually Releasing Spring Brakes). your vehicle is equipped with a special axle and differential, contact your Kalmar dealer.

  • Page 37: Cab Tilting And Lowering

    Operation to fully extend the cylinder past 45 CAB TILTING degrees can cause pump and mo- tor damage. Check cab tilt cylin- AND LOWERING der and bracket mounting bolt for proper torque and for wear! The tractor comes equipped with an electrically operated cab tilt system as standard equipment.

  • Page 38: To Lower Cab

    Operation the cab and make sure to properly until the safety prop is free from the top of the tilt cylinder. maintain this important safety sys- tem. 2. Pull the safety prop release cable to the rear and hold in the rearward 1.

  • Page 39: Electrical

    CAB SAFETY PROP IS NOT ELECTRICAL ENGAGED CORRECTLY ACCESSORY CONNECTIONS The wiring harness in the Kalmar is designed to support many vehicle options. These options may or may not already be on your vehicle. If any electrical equip- ment is installed on the vehicle after it...
  • Page 40 Operation Figure 1a - Standard fuse configuration Figure 1b - QSB fuse configuration Figure 2 - Relay Location...
  • Page 41 Maintenance CONTENTS Section “C” INTRODUCTION ...................41 LUBRICATION AND FLUIDS .................41 Automatic Transmission Fluid ............42 Axle Lubricant ...................42 Coolant / Anti-freeze .................42 Fuel ....................43 Engine Oil ..................44 Hydraulic System Fluid ..............44 Mulit-purpose Grease ................44 FILTERS ......................44 MAINTENANCE ..................... 45 CHASSIS LUBRICATION DIAGRAM ..............56 LUBRICATION CHART ...................57 BOOM AND FIFTH WHEEL LUBRICATION DIAGRAM .........58...

  • Page 42: Introduction

    The key to safe and dependable op- safe to operate. The opera- eration of your Kalmar tractor is proper tor of an Kalmar must be satisfied maintenance. Yard tractors are used in that his/her vehicle has been prop- very abusive operations.

  • Page 43: Automatic Transmission Fluid

    NOTE - Synthetic gear lubricant is available as is currently being used. Mixing of difference an option. Contact your Kalmar dealer if you lubricant and fluid grades or types should need more information.

  • Page 44: Fuel

    FUEL Manual before changing the factory recommended anti-freeze to water ratio in the coolant mixture. Some engine All Kalmar tractors come with an Engine manufacturers have specific coolant Operator’s Manual provided by the en- mixture requirements needed to satisfy gine manufacturer. This manual is for the engine warranty requirements.

  • Page 45: Engine Oil

    FILTERS severe engine damage. Contact your Kalmar dealer if you did not Refer to your Kalmar Parts Manual for the receive and Engine Operator’s required part numbers. Remember, your Manual with your new Kalmar.

  • Page 46: Maintenance

    Maintenance KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM ELECTRONIC ENGINES (Except QSB-155) – RDS TRANSMISSION WITH NON-SYNTHETIC LUBE TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION. � = SATISFACTORY �...
  • Page 47 Maintenance KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM QSB-155 – RDS TRANSMISSION WITH NON-SYNTHETIC LUBE TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION. � = SATISFACTORY � = ADJUSTMENT NECESSARY �...
  • Page 48 Maintenance KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM ELECTRONIC ENGINES (Except QSB-155) – RDS TRANSMISSION WITH “TRANSYND” LUBE AND ALLISON FILTERS TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION.
  • Page 49 Maintenance KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM QSB-155 – RDS TRANSMISSION WITH “TRANSYND” LUBE AND ALLISON FILTERS TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION. � = SATISFACTORY �...
  • Page 50 Maintenance KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES Cab Interior Check Operation of Neutral Start – Move the gear selector to any position other than “N” and attempt to start the engine. The engine should not crank with the selector in any position other than “N”.
  • Page 51 Maintenance KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES Check Operation of Boom – With the engine running at fast idle activate the boom control and insure full extension and retraction. Check Fire Extinguisher Charge (If Applicable) – If the vehicle is equipped with a fire extinguisher confirm that it is properly charged.
  • Page 52 Maintenance KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES Check Trailer Light Cord – Inspect light cord for cuts and abrasions. As the lights of the truck are checked confirm that a trailer connected with the light cord also has lights. This can be done either with a trailer connected or with a “test box”.
  • Page 53 Maintenance KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES Check Engine Belts and Tensioner – Inspect belt(s) for cracking and wear. Belt tensioner should be checked for proper operation. Change Engine Coolant Filter – Replace the engine coolant filter. A filter containing the proper supplemental coolant additive should be used to maintain the SCA concentration level.
  • Page 54 Maintenance KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES Check Hydraulic Pump –Inspect hydraulic pump for leaks. Check Starter Mounting and Connections – Confirm that starter mounting bolts are tight. Inspect electrical connections for good contact at starter terminals. Check Engine and Transmission for leaks - Perform a visual inspection of the engine and transmission looking for any fluid leaks visible from below.
  • Page 55 Maintenance KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES Check Battery Box Cover Holddowns – Check bolts or rubber latches to insure that the battery box cover is secured. Drain Water from Air Tanks – With air system charged, open each manual drains until all moisture is removed from system.
  • Page 56 Maintenance KALMAR INDUSTRIES PREVENTATIVE MAINTENANCE GUIDLINES Check / Lubricate King Pins and Tie Rod Ends – Inspect king pins and tie rod ends for wear or damage. Lubricate with lithium grease. Check / Lubricate Drag Link – Inspect king pins and tie rod ends for wear or damage. Lubricate with lithium grease.

  • Page 57: Chassis Lubrication Diagram

    Maintenance BOTH SIDES CHASSIS BOTH SIDES FRONT AND REAR LUBRICATION DIAGRAM (Left hand drive chassis shown)

  • Page 58: Lubrication Chart

    Maintenance LUBRICATION CHART PART / DESCRIPTION Lubricant Used / Note Coolant/Antifreeze 50/50 Ethyl-Glycol / Water Engine Oil SAE 15W-40 See Engine Operator Manual Slack Adjusters Brake Cam Pivot Lithium Grease Front Axle King Pins Lithium Grease Tie Rod Ends Lithium Grease Cab Suspension Latch Lithium Grease Transmission Fluid...

  • Page 59: Boom And Fifth Wheel Lubrication Diagram

    Maintenance BOOM AND FIFTH WHEEL LUBRICATION DIAGRAM * Both Sides NI = Not Illustrated PART / DESCRIPTION Lubricant Used / Note Boom Pivot Lithium Grease #1 Cylinder Bearings Lithium Grease #1 Fifth Wheel Pivot Lithium Grease #1 Fifth Wheel Top Plate Lithium Grease #1 Fifth Wheel Jaws Lithium Grease #1...

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