Kalmar Ottawa t2 Manuals

Kalmar Ottawa t2 Manuals

Manuals and User Guides for Kalmar Ottawa t2. We have 2 Kalmar Ottawa t2 manuals available for free PDF download: Maintenance Manual, Operator's Manual

Kalmar Ottawa t2 Maintenance Manual

Kalmar Ottawa t2 Maintenance Manual (262 pages)

Brand: Kalmar | Category: Tractor | Size: 15 MB

Table of Contents

Table of Contents
2
Foreword

10
- About this Manual
  10
- Additional Information
  10
Safety

12
- Hazardous Condition Signs
  12
- Do's and Dont's
  13
Preventive Maintenance

14
- Lubrication Points
  14
- Inspections
  15
  - Every Day
    15
  - Every 250 Hours of Operation
    15
  - Every 500 Hours of Operation
    15
  - Every 1,000 Hours of Operation
    15
  - Every 2,000 Hours of Operation
    15
- Checklists
  16
  - Daily Inspection Checklist
    16
  - Preventive Maintenance Forms
    19
- Preventive Maintenance Technique
  21
  - General
    21
  - Fuel, Filters, Fluids and Lubricants
    21
    
    Maintenance
    21
  - Cab Interior
    22
    
    Maintenance
    22
    
    Seat Belt System
    23
  - Cab down - Exterior
    24
    
    Maintenance
    24
  - Cab up
    25
    
    Maintenance
    25
  - Under Vehicle
    27
    
    Maintenance
    27
  - Chassis
    28
    
    Maintenance
    28
  - Lubrication
    29
    
    Maintenance
    29
  - Test Drive
    30
    
    Maintenance
    30
Machine Complete

32
- The Ottawa T2 Terminal Tractor
  32
  - Description
    32
- Diesel Fuel Requirements
  33
  - Precautions
    33
- Emergency Starting
  35
  - Precautions
    35
  - Jump Starting Instructions
    35
- Vehicle Towing
  37
- Vehicle Modifications
  39
  - Approval
    39
- Vehicle Identification
  40
  - Identification Plate
    40
  - Certification Label
    40
    
    Engine Serial Number
    41
    
    Vehicle Serial Number
    41
- Component Location
  42
  - Chassis/Cab, Left Side
    42
    
    Ottawa T2, Left Side (4X2 HHD Chassis Shown)
    42
    
    Chassis/Cab, Right Side
    43
    
    Ottawa T2, Right Side (4X2 HHD Chassis Shown)
    43
    
    Chassis/Cab, Front/Rear
    44
    
    Ottawa T2, Front/Rear (4X2 HHD Chassis Shown)
    44
    
    Chassis, Plan View
    45
    
    Ottawa T2 Plan View (4X2 HHD Chassis Shown)
    45
- Electrical Instruments
  46
  - Guide to Troubleshooting
    46
  - Basic Gauge Cluster Diagnostic Procedure
    46
Engine

48
- Description
  48
- Controls and Instruments
  49
  - Fuel Gauge
    49
    
    Diagnosis
    49
  - Fuel System
    50
    
    Description
    50
    
    Fuel Tank
    50
    
    Pipes and Hoses
    50
    
    Sensor, Fuel Level
    50
- Diesel Exhaust Fluid (DEF)
  51
  - DEF Tank and Pump
    51
    
    DEF Hose Lines
    51
    
    Description
    51
    
    Sensor, Low DEF Level
    51
- Start/Stop
  52
  - Diagnosis (Starting and Charging Diagnosis)
    52
Transmission

54
- Description
  54
Driveline/Axle

56
- Description
  56
Brakes

58
- Controls and Instruments
  58
  - Foot Pedal (Treadle Valve)
    58
    
    Air Control Valves
    58
    
    Description
    58
- Brake System
  59
  - Description
    59
  - Air Compressor and Governor
    60
    
    Air Reservoir
    60
    
    Description
    60
    
    Stop Light Switch
    60
    
    Brakes
    61
    
    Description
    61
  - Trailer Brake Air Lines
    62
    
    Description
    62
  - Anti-Lock Brake System (Optional)
    62
  - Automatic Traction Control (Optional)
    63
    
    Description
    63
  - Manually Releasing Tractor Spring Brakes (Caging)
    63
- Diagnosis (Mechanical)
  65
  - Brakes
    65
Steering

68
Suspension

74
- Description (Vehicle Suspension)
  74
- Front Springs
  75
  - Repair (Springs Removal)
    75
  - Repair (Springs Installation)
    75
Load Handling

76
- Lift and Lower
  76
  - Description (Boom Components)
    76
  - Hydraulic Pump
    76
    
    Description
    76
  - Control Valve
    76
  - Boom Lift Cylinders
    77
    
    Description
    77
- Diagnosis (Boom)
  78
  - Diagnosis
    78
  - Hydraulic Pump with Priority Valve Tests - Boom
    79
Control System

82
- Introduction - General Information
  82
Frame, Body, Cab and Accessories

84
- Controls and Instruments
  84
  - Description
    86
  - Low Air Warning
    90
    
    Diagnosis
    90
    
    Hourmeter
    90
  - Speedometer
    91
    
    Diagnosis
    91
  - Voltmeter
    92
    
    Diagnosis
    92
- Seating
  93
  - Description
    93
- Heating, Ventilation and Air Conditioning
  94
  - Description
    94
- Wiping and Cleaning of Windows
  95
- Windshield Wipers
  95
  - Description
    95
  - Diagnosis
    95
- Windshield Washer
  96
  - Description
    96
  - Diagnosis
    96
- Lighting System
  97
  - Description
    97
  - Headlights
    97
    
    Diagnosis
    97
  - Clearance, Marker and Tail Lights
    98
    
    Diagnosis
    98
  - Brake Lights
    99
    
    Diagnosis
    99
  - Backup Light
    100
    
    Diagnosis
    100
  - Turn Signal
    101
    
    Diagnosis
    101
  - Beacon Light
    102
    
    Diagnosis
    102
  - Dome Light
    102
  - Daytime Running Lights
    103
    
    Diagnosis
    103
  - Trailer Auxiliary Power
    103
  - Transmission Shifter/Fifth-Wheel Control and Panel Lighting
    104
    
    Diagnosis
    104
- Signal System
  105
  - Horn
    105
    
    Diagnosis
    105
    
    Emergency Flasher
    105
  - Backup Alarm
    106
    
    Diagnosis
    106
- Maintenance and Communication
  107
  - Radio
    107
    
    Description
    107
    
    Diagnosis
    107
- Glass/Window/Mirrors
  108
  - Description
    108
  - Rear-View Mirror
    108
- Construction and Suspension of Cab/Deck
  109
  - Cab Frame
    109
    
    Description
    109
  - Door
    110
    
    Description
    110
    
    Repair (Rear Door Adjustment)
    110
  - Roof and Door Mouldings
    111
    
    Cab Tilting
    111
    
    Description
    111
    
    Cab Tilt (Hydraulic) Components
    113
    
    Diagnosis (Cab Tilt)
    114
    
    Cab Tilt Pump and Motor
    115
    
    Diagnosis (Cab Tilt Pump)
    115
    
    Repair (Pump and Motor Removal)
    115
    
    Repair (Pump and Motor Installation)
    116
    
    Repair [Relief Pressure Adjustment]
    116
    
    Cab Tilt Cylinder
    118
    
    Repair (Cylinder Removal)
    118
    
    Repair (Cylinder Installation)
    119
    
    Cab Pivot Bushing
    120
    
    Repair (Pivot Bushing Removal)
    120
    
    Cab Mounting and Suspension
    122
    
    Description
    122
    
    Repair (Pivot Bushing Installation)
    122
    
    Air Ride Suspension (Three-Point)
    123
    
    Diagnosis (Cab Air Suspension)
    123
    
    Repair (Cab Suspension Assembly Removal)
    123
    
    Repair (Cab Suspension Assembly Installation)
    124
    
    Leveling Valve
    125
    
    Repair (Air Ride Level Adjustment)
    125
    
    Repair (Valve Operation Check)
    125
    
    Repair (Shock Removal)
    126
    
    Shock Absorbers
    126
    
    Cab Latch Bar Plate
    127
    
    Repair (Latch Bar Plate Adjustment)
    127
    
    Repair (Shock Installation)
    127
  - Chassis
    128
    
    Description
    128
    
    Diagnosis (Chassis)
    129
    
    Repair (Frame Damage Analysis)
    132
    
    Repair (Making Reinforcements, General Information)
    132
    
    Repair (Cracks in Steel Rails or Cross Members)
    133
    
    Repair (Making Reinforcements, Attachment)
    133
  - Bodywork
    135
    
    Description
    135
    
    Footstep
    135
  - Accessories and Options
    136
    
    Accessory Relay
    136
    
    Diagnosis
    136
    
    Heater/Air Conditioning (Optional)
    136
    
    Diagnosis
    137
    
    Mirrors (Heated/Motorized)
    137
10 Common Hydraulics

140
- System Description
  140
- Tanks and Accumulators
  140
  - Reservoir
    140
    
    Description
    140
- Temperature Control, Cleaning and Hydraulic Oil
  141
  - Return Filter
    141
    
    Description
    141
11 Common Electric

142
- Controls and Instruments
  142
  - Description (Wiring Harness)
    142
- Safety
  143
  - Fuses, Relays and Circuit Breakers
    143
    
    Description
    143
12 Common Pneumatics

146
- Air System and Brakes
  146
  - Description
    146
  - Diagnosis
    146
    
    Brakes - Air System
    146
- Valves
  151
  - Tractor Protection Valves
    151
  - Proportioning Relay (Bobtail) Valve (Optional)
    151
  - Quick Release Valves
    151
  - Anti-Compounding Valve (Optional)
    151
  - Double (Two-Way) Check Valves
    151
- Air Dryer
  152
  - Description
    152
  - Diagnosis
    152
Error Codes

154
- Description
  154
Schematics

156
- Air System Circuits
  156
  - Air Brakes
    156
    
    Air Brake System with Split Brakes
    156
    
    Components
    156
    
    On-Highway Air System
    157
    
    On-Highway Air System Circuit
    159
    
    Off-Highway Air System
    161
    
    Off-Highway Air System Circuit
    163
    
    Air Lines - Cab Suspension
    165
    
    Air Lines - Driver's Seat
    165
    
    Cab Seating
    165
    
    Cab Suspension
    165
    
    Air Lines - Fifth-Wheel Latch
    166
    
    Fifth-Wheel Coupling
    166
    
    5Th Wheel Interlock Option Circuit
    168
    
    Air Lines - Tractor/Trailer Park Brake Option
    169
    
    Tractor/Trailer Park Brake
    169
    
    Tractor/Trailer Park Brake Valve Option Circuit
    170
    
    Air Lines - Quick Trailer Air/R14 Valve Option
    171
    
    Quick Trailer Air/R14 Valve
    171
    
    Air Lines - Trailer Hand Brake Option
    172
    
    Quick Trailer Air/R14 Valve Option Circuit
    172
    
    Trailer Hand Brake
    172
    
    Trailer Hand Brake Option Circuit
    173
    
    Trailer Hose Connection Coiled Air Lines Circuit
    173
    
    Trailer Hose Connection Glad Hands both Ends Coiled Air Lines Circuit
    174
    
    Trailer Hose Connection Straight Rubber Air Lines Circuit
    174
    
    Air Horn
    175
    
    Air Horn Option Circuit
    175
    
    Air Lines - Air Horn Option
    175
    
    Air Lines - Inter Axle Option
    176
    
    Inter Axle Lock
    176
    
    Inter Axle Lock Option Circuit
    176
    
    Air Lines - Grease Jockey Lube Pump Option
    177
    
    Grease Jockey Lube Pump
    177
    
    Grease Jockey Lube Pump Option Circuit
    177
    
    Air Lines - Differential Axle Lock Option
    178
    
    Differential Axle Lock
    178
    
    Differential Axle Lock Option Circuit
    178
    
    Additional 7.35 Cu. In. Air Reservoir
    179
    
    Additional 7.35 Cu. In. Air Reservoir Option
    179
    
    Air Lines - Additional 7.35 Cu. In. Air Reservoir Option
    179
    
    Air Dryer
    180
    
    Air Lines - Air Dryer Option
    180
    
    Air Dryer Option
    181
    
    ABS Brakes
    182
    
    Air Lines - ABS Brakes Option - On-Highway Only
    182
    
    ABS Brake Option Circuit
    183
    
    Air Lines - Traction Control Option for ABS Brakes - On-Highway Only
    184
    
    Traction Control
    184
    
    Traction Control Option for Use with ABS Brake Option Circuit
    185
  - 3Rd Air Tank
    186
    
    3Rd Air Tank Option Circuit
    186
    
    Air Lines - 3Rd Air Tank Option - Off-Highway Only
    186
- Hydraulic System Circuits
  187
  - Hydraulic Systems
    187
  - Cab Tilt
    187
    
    Hydraulic Lines - Cab Tilt
    187
    
    Fifth-Wheel Boom
    188
    
    Hydraulic Lines - Fifth-Wheel Boom
    188
    
    Hydraulic Lines - Power Steering
    189
    
    Power Steering
    189
    
    Hydraulic Lines - Hydrostatic Steering
    190
    
    Optional Hydrostatic Steering
    190
- Electrical System Circuits
  191
  - Starting and Charging
    191
    
    Starting and Charging Circuit
    191
    
    Anti-Lock Braking System (ABS)
    192
    
    Cab Accessory Components
    192
    
    Wire Color Codes
    192
    
    Heater and Air Conditioning
    193
    
    Horn
    194
    
    Mirrors
    195
    
    Radio (Optional)
    197
    
    Radio Circuit Hot Wire
    198
    
    Windshield Washer (Optional)
    199
    
    Windshield Wiper
    200
    
    Cab Power Board
    201
    
    Cab Interior Engine Wiring
    202
    
    Air Pressure Gauge Lighting
    204
    
    Cab Instrumentation
    204
    
    Engine Hourmeter
    205
    
    Fuel Gauge
    206
    
    Low Air Warning Alarm
    209
    
    Speedometer
    210
    
    Voltmeter
    211
    
    Gauge Cluster Wiring
    212
    
    Chassis Circuits
    218
    
    Chassis Power Board
    218
    
    Air Dryer (Optional)
    219
    
    Cab Tilt Pump
    220
    
    Cab Exterior/Front Chassis Wiring
    221
    
    Chassis Wiring
    224
    
    Air System Tank Pressure Senders
    227
    
    Battery Power Distribution
    228
    
    Cab Tilt System Control Wiring
    230
    
    Backup Light and Alarm
    233
    
    Lighting Circuits (Cab and Chassis)
    233
    
    Beacon/Strobe Light (Optional)
    234
    
    Clearance Lights (Optional)
    235
    
    Daytime Running Lights (Optional)
    236
    
    Dome Light
    237
    
    Fifth-Wheel Control
    237
    
    Flood Light
    238
    
    Headlights
    239
    
    Marker Lights
    239
    
    Panel Lighting
    239
    
    Strobe Light
    239
    
    Tail Lights
    240
    
    Trailer Auxiliary Power
    240
    
    Transmission Shifter, Fifth-Wheel Control and Panel Lighting
    241
    
    Turn Signal, Tail, Brake Lights and Emergency Flasher
    242
    
    Upper Cab Harness
    244
    
    Headlight/Dimmer Switch Wiring
    245
    
    Auxiliary Lighting and Air Horn
    247
    
    Tail Light/Backup Light Wiring
    248
  - Engine Controls
    250
    
    Throttle Pedal (TPS) Wiring
    250
    
    Engine Wiring
    251
  - Exhaust
    254
    
    Aftertreatment Wiring
    254
Technical Data

256
- Standard Vehicle Data
  256
  - Ottawa T2 Series Terminal Tractor
    256
- Hydraulic System
  258
  - Ottawa T2 Series 4X2
    258
- Fluids, Lubricants and Sealants
  259
  - Ottawa T2 Series 4X2
    259
- Fastener Torque Values
  260
  - Ottawa T2 Series 4X2
    260
Appendix

262

Advertisement

Kalmar Ottawa t2 Operator's Manual

Kalmar Ottawa t2 Operator's Manual (79 pages)

Brand: Kalmar | Category: Trucks | Size: 6 MB

Table of Contents

Table of Contents
5
Foreword
7
- From Kalmar to the Owner
  7
- About the Operator's Manual
  7
1 Introduction

8
- Safety Summary
  8
  - CAUTIONS and WARNINGS
    8
  - Notices
    8
- Vehicle Towing
  8
  - Towing Vehicle with Front Wheels Suspended
    9
  - Towing Vehicle with Rear Wheels Suspended
    9
- Vehicle Modifications
  10
- Safety Checks and Precautions
  10
  - Inspection
    10
    
    Axle - Front
    11
    
    Axle - Rear
    11
    
    Brake System
    11
    
    Cab
    12
    
    Seat Belt System
    12
    
    Electrical
    13
    
    Exhaust System
    14
    
    Frame
    14
    
    Fuel System
    14
    
    Propeller Shaft
    14
    
    Steering
    14
    
    Suspension
    15
    
    Transmission
    15
    
    Wheels/Tires
    15
- Additional Manuals and Safety Information
  17
- Service Assistance
  18
3 Description and Operation

19
- Cab/Deck
  19
  - Vehicle Entry and Exit
    19
  - Cab Tilting
    20
    
    To Tilt Cab
    21
    
    To Lower Cab
    22
  - Seating
    23
    
    Seat Adjustment
    23
    
    Suspension-Type Seats
    23
  - Instrument Panel Gauges, Controls and Indicators
    24
    
    Instrument Panel Overview
    24
  - Electrical Equipment
    32
    
    Accessory Connections
    32
    
    Relays/Breakers/Fuses
    32
  - Occupant Restraint System
    35
    
    Seat Belt Operation
    35
- Chassis
  35
  - Powertrain
    35
    
    Engine
    35
    
    Axles
    38
    
    Transmission
    38
  - Air System and Brakes
    39
    
    Low Air Pressure Indicators
    40
    
    Service Brakes
    41
    
    Abs
    42
    
    Traction Control
    42
    
    Parking Brake
    43
    
    Parking Brake and Trailer Air Supply Controls
    43
    
    Parking the Vehicle
    43
    
    Manually Releasing Tractor Spring Brakes (Caging)
    44
    
    Trailer Air Lines
    45
    
    Trailer Brakes
    45
  - Hydraulic System
    46
    
    Fifth Wheel Unlatch Control Valve
    46
    
    Hydraulic Boom Operation
    46
    
    Hydraulic Fifth Wheel Lifting System
    46
    
    Basic Trailer Spotting Steps
    47
  - Exhaust System - DOT/EPA-Approved Engines
    49
    
    Diesel Particulate Filter (DPF) Regeneration
    49
    
    Exhaust-Related Engine Indicator Lamps
    51
6 Scheduled Maintenance

53
- General Maintenance Program
  53
- Checklists
  54
- Chassis Lubrication Diagram
  54
  - Boom and Fifth Wheel Lubrication Diagram
    55
  - Lubrication and Fluids
    58
    
    Automatic Transmission Fluid
    59
    
    Axle Differential Lubricant
    59
    
    Coolant/Anti-Freeze
    59
    
    Fuel
    60
    
    Diesel Exhaust Fluid (DEF)
    61
    
    Engine Oil
    61
    
    Filters
    62
    
    Hydraulic System Fluid
    62
    
    Multi-Purpose Grease
    62
    
    Cab Interior
    63
    
    Preventative Maintenance Guidelines
    63
    
    Check HVAC System
    64
    
    Seat Belt System
    65
    
    Cab down - Exterior
    66
    
    Cab up
    67
    
    Under Vehicle
    69
    
    Chassis
    70
    
    Lubrication
    71
    
    Test Drive
    72
7 Environment

73
- General
  73
- Environmental Policy
  73
- Environmental Awareness
  74
- Environmental Problems
  74
- Laws and Regulations
  74
- Use of Materials and Energy
  75
- Effects of Exhaust Gases
  75
- Recycling
  76
- Complete Overhaul or Disposal
  76
- Problem Waste
  77
- Oils and Fluids
  77
- Air Conditioning
  77
- Occupational Health and Safety
  78
- Working in an Environment that Is Hazardous to the Health
  78
- Remember
  78
- Standards
  79
  - Vibration Affecting the Hands
    79
  - Vibration Affecting the Whole Body
    79
  - Noise Levels
    79
  - CE Marking
    79
  - Exhaust Gas Emissions
    79

Advertisement

Related Products

Kalmar Categories

Forklifts Trucks Tractor Industrial Equipment

More Kalmar Manuals