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Kalmar Ottawa Operator's Manual

Manual is about: Kalmar Ottawa Truck Operator's manual  

Summary of Ottawa

  • Page 2: Kalmar

    1 kalmar operator’s manual section title page prefix owner information..................................................4 operation....................................................................12 maintenance..............................................................40 note the information in...

  • Page 3: From Kalmar

    2 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 to refer to the ...

  • Page 4: Contents

    3 contents section “a” introduction ...............................................................................................4 cautions and warnings ............................................................................4 notes ................................................................

  • Page 5: Cautions &

    4 cautions & warnings throughout this manual you will find warnings and cautions: danger - warning will indicate a potentially hazardous situation that could lead to serious injury of death. Warning - failure of the operator of this vehicle to read and be aware of all the warnings published in this ...

  • Page 6: Safety-Checks

    5 owner information safety-checks and precautions all spotting applications are demanding on the vehicle. Maintenance is critical for the continued safe performance of your tractor. Before operating your kalmar it is extremely important that the vehicle is in proper and safe working condition. The f...

  • Page 7

    6 owner information axle-front maintaining correct front axle alignment is critical and should be performed by a qualified mechanic. Check to ensure that the axle mounting bolts are securely tightened. Regularly check the front axle for damage, binding or worn parts, and adequate lubrication. Pay spe...

  • Page 8

    7 owner information seat belts - check entire seat belt system for wear and proper operation. Make sure anchor mountings are tight. Electrical horn - operate steering wheel mounted horn to check operation. (check optional air horns if equipped) instruments - check operation of all in- struments and ...

  • Page 9: Additional

    8 owner information on all mounting bolts and nuts. Check springs and replace broken or distorted springs. Transmission follow transmission manufacturer’s guide- lines for proper maintenance. Wheels check condition and maintain specified torque on all wheel mounting nuts. Re- place missing or broken ...

  • Page 10

    9 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 ___...

  • Page 11: Kalmar Terminal Tractor

    10 kalmar terminal tractor north american warranty policy kalmar industries corp (hereafter kalmar) warrants to the original owner that each new kalmar terminal tractor will be free from defects in material or workmanship under normal use and service for a period not to exceed three hundred sixty fi...

  • Page 12

    11 excluded from this warranty are engines, transmissions, tires and batteries or ant other components which have warranties covered by their manufactures. The provisions of this warranty do not apply to the prime product or any com- ponent part thereof, which has been subject to misuse, or damaged ...

  • Page 13: Contents

    12 contents section “b” introduction ...............................................................................................14 vehicle entry and exit ................................................................................ 14 occupant restraint system ...................................

  • Page 14

    13 engine .........................................................................................................28 starting the engine ................................................................................29 starting procedure ......................................................... .....

  • Page 15: Vehicle Entry

    14 vehicle entry and exit the kalmar tractor is designed for easy entry and exit. The walkways, steps, and handholds are designed with operator safety in mind. As with any vehicle of this type, care must be taken when climbing in or out of your kalmar tractor. Remember, be careful! Warning - never r...

  • Page 16: Occupant

    15 occupant restraint system the kalmar tractor is equipped with seat belts. They should be used whenever the vehicle is in operation. Seat belt operation the seat belt system used on kalmar tractors is a lap type restraint with an automatic retractor. Before fastening the seat belt, be sure to adju...

  • Page 17

    16 operation.

  • Page 18

    17 pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42-52 53 54 55 56 57 58 59 60 61 62 63 65 66 name water temp gauge tachometer oil pressure gauge speedometer fuel gauge air diffuser headlight switch panel lts dimmer indicator li...

  • Page 19

    18 ignition switch ..........................17 indicator light strip...................20 optional gauges.......................17 optional controls.....................17 optional switches.....................17 parking brake control................21 speedometer (optional).............20 tachomet...

  • Page 20: Panels 1 and 2

    19 panels 1 and 2 1. Dash panel light dimmer 2. Headlight/running light control this switch controls headlights and run- ning lights on the tractor and trailer. This switch also activates the interior dash and gauge lights when either the headlights or the running lights are on. The switch has three...

  • Page 21

    20 8. Heater control this lever controls the heater temperature. The full down position shuts off the heater. The lever can be adjusted to provide the desired amount of heat by moving it up from the off position. 9. Fan speed on/off switch the switch has four positions. Full coun- terclockwise is th...

  • Page 22: Panels 4 and 5

    21 1. Standard air gauge indicates air pressure in the air system in p.S.I. 2. 2nd air gauge indicates air pressure in the air system in p.S.I. 3. Transmission shift selector this control selects the operating range of the transmission. (see page 30, trans- mission) 4. Boom control lever this contro...

  • Page 23: Starting The

    22 key type ignition there are three positions; off, acces- sory and run/start. The full left (counterclockwise) position is the off position. The second position to the right (clockwise) is the accessory position. The third position to the right (clockwise) is the run/start position. The run/start ...

  • Page 24: Air Brake System

    23 ing it in gear. Always place the transmission shifter selector in the “neutral” position. 3. Never park a tractor trailer com- bination unless the trailer parking brakes are operational and applied. Note - if the vehicle is parked in gear, the vehicle will not start. Air brake system danger - bra...

  • Page 25

    24 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. If the low air indicator l...

  • Page 26

    25 braking ability of the tractor trailer combination and creates a serious hazard. This increases the possibil- ity of an accident and could result in serious injury or death. Warning - never oper- ate the vehicle when system air pressure is below 70 p.S.I. There may not be enough air in the system...

  • Page 27: Parking Brake

    26 trouble-shooting or clearing fault codes is performed at the ec module mounted in the left front wheel well. Traction control automatic traction control (a.T.C.) is available as an option on trucks equipped with the antilock braking system. When activated, the a.T.C. Active/warning lamp will be o...

  • Page 28

    27 1. Shut the engine off and remove the key. 2. Block all wheels front and rear to prevent the vehicle from rolling forward and backwards. 3. Determine whether the chamber has an internal (figure 1) or external (figure 2) caging tool. Proceed to step 4 with an externally mounted tool. Step 8 for in...

  • Page 29: Trailer Brakes

    28 caution - never use an impact wrench to tighten the nut onto the release bolt. Never exceed the above lengths and never exceed 50 lbs-ft. Of torque on the release nut or the chamber may be damaged. Trailer brakes kalmar tractors are designed to use the trailer’s brakes when towing trailers. All k...

  • Page 30

    29 to start a vehicle equipped with the standard electrical starting system, follow these steps: starting procedure note - all kalmar tractors are designed to start in neutral only. The starter should not operate if the vehicle is in any other gear. 1. Set the parking brake. 2. Place the transmissio...

  • Page 31: Transmission

    30 engine oil always refer to the engine operation man- ual for complete information on engine oil requirements. Service intervals, oil types and refill quantities are all covered in the engine operation manual. Read it! Transmission standard tractors are equipped with an allison automatic transmissi...

  • Page 32: Hydraulic Fifth

    31 is located on the console to the right of the seat and next to the shift lever (page 21). Figure 1 a - fifth wheel plate b - boom danger - never raise or lower the boom while the tractor and trailer combina- tion are moving. Raising the boom while the tractor and trailer are moving creates a “rol...

  • Page 33: Basic Trailer

    32 marked on the boom operating lever, low- ers the boom and fifth wheel. To increase the rate of travel of the boom, the engine may be idled higher while the vehicle is in neutral only. Standard configuration of the boom allows both power up and down capability. Fifth wheel unlatch control valve the ...

  • Page 34

    33 raised too high. 8. Once proper trailer height is reached, apply the tractor parking brake. Now hook both the trailer emergency and service airlines to the trailer (blue & red airlines) and plug in the trailer electrical cable. 9. With the brake treadle fully applied, push in both the parking bra...

  • Page 35: Towing The

    34 towing vehicle with front wheels suspended it is not recommended to tow a vehicle with the front wheels lifted and the rear drive wheels on the road. This practice may result in serious vehicle damage. Pay close attention to the following rules to prevent vehicle damage if you must tow your kalma...

  • Page 36: Axles

    35 fahrenheit (37 deg. Celsius) above ambi- ent temperature. Operating temperatures above 230 deg. F significantly increase the rate of lubricant oxidation and short- ens the effective life of the lubricant. This makes more frequent changes necessary. Rear axles with locking differentials kalmar trac...

  • Page 37: Cab Tilting

    36 to fully extend the cylinder past 45 degrees can cause pump and mo- tor damage. Check cab tilt cylin- der and bracket mounting bolt for proper torque and for wear! Figure 1 a - cab tilt control switch b - safety prop release cable to tilt cab in most cases, the cab tilt control switch is located ...

  • Page 38

    37 the cab and make sure to properly maintain this important safety sys- tem. 1. Locate the cab tilt control switch and safety prop release cable. 2. Pull the safety prop release cable and hold the cable to the rear. 3. While holding the cable to the rear move the tilt control switch to the “up” pos...

  • Page 39: Electrical

    38 electrical electrical 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 leaves the factory, contact your kalmar dealer first...

  • Page 40

    39 figure 1a - standard fuse configuration figure 1b - qsb fuse configuration figure 2 - relay location operation.

  • Page 41: Contents

    40 contents section “c” introduction ...........................................................................................41 lubrication and fluids .........................................................................41 automatic transmission fluid ............................................

  • Page 42: Introduction

    41 danger - a vehicle that has not been properly maintained, may not be safe to operate. The opera- tor of an kalmar must be satisfied that his/her vehicle has been prop- erly maintained and is in safe work- ing condition, before operating that vehicle. Operating an improperly maintained vehicle may ...

  • Page 43

    42 (see page 45) indicates services that need to be performed at every 250, 500, 1000 and 2000 hour interval. The chart also indicates the type of lu- bricant or fluid required or indicates the page number where that information can be found. Caution - the mainte- nance and service intervals in this ...

  • Page 44

    43 caution - the coolant should be tested every 250 hours and replaced every 2000 hours at the very minimum. Exceeding these intervals may damage the cooling system. Note - a coolant mixture below 30% does not provide adequate corrosion protection and may lead to radiator damage. A coolant mixture a...

  • Page 45

    44 note - the fluid in the hydraulic system and the filter must both be replaced at least once a year at the very minimum. Never exceed this interval. Multi-purpose grease the following fluids are recommended: 1. Api grade 1 2. Any high quality lithium based grease that has extreme pressure properties,...

  • Page 46

    45 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. = satis...

  • Page 47

    46 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 neces...

  • Page 48

    47 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 no...

  • Page 49

    48 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

    49 maintenance 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”. Check operation of all gauges – with the engine is running verify that a...

  • Page 51

    50 maintenance 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. Check seat belt ...

  • Page 52

    51 maintenance 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. Check seat belt ...

  • Page 53

    52 maintenance 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 th...

  • Page 54

    53 maintenance 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 th...

  • Page 55

    54 maintenance 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. Check and torque all wheel nuts – inspect all whe...

  • Page 56

    55 maintenance 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. Check and torque all wheel nuts – inspect all whe...

  • Page 57: Chassis

    56 maintenance 1 2 3** 4* 5* 7 8 9 10 11 16 6 12* 13 14* 15 17 18 chassis lubrication diagram * both sides ** both sides front and rear (left hand drive chassis shown).

  • Page 58: Lubrication Chart

    57 maintenance key no. Part / description lubricant used / note 1 coolant/antifreeze 50/50 ethyl-glycol / water 2 engine oil sae 15w-40 3 slack adjusters brake cam pivot lithium grease 4 front axle king pins lithium grease 5 tie rod ends lithium grease 6 cab suspension latch lithium grease 7 transmi...

  • Page 59: Boom And Fifth Wheel

    58 key no. Part / description lubricant used / note 18 boom pivot lithium grease #1 19 cylinder bearings lithium grease #1 20 fifth wheel pivot lithium grease #1 21 fifth wheel top plate lithium grease #1 22 fifth wheel jaws lithium grease #1 ni cab door hinge silicone spray ni steering column slip ...