Kalmar Ottawa, Operator'S Manual

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Page 2: ...e time of publication Contents of this manual are subject to change at publishers discretion DO NOT REMOVE THIS MANUAL FROM THE VEHICLE STUDY THIS MANUAL READ AND COMPLY WITH ALL WARNINGS IN THIS MANU...

Page 3: ...annot 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 con gured truck For information on some major compo...

Page 4: ...FETY 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 Steering 7 Suspension 7 Transmission 8 Wheels 8 ADDITI...

Page 5: ...portant information on the use of Warnings Cautions and Notes that are found throughout this manual This sec tion also contains important safety and service support information The second section Oper...

Page 6: ...following areas NOTE If the vehicle is used in a severe application such as a rail yard operation or in 24 hour operations a more frequent schedule may be required When parts or service are required...

Page 7: ...while operating the vehicle and after the engine is shut off A minimum air pressure of 70 PSI is required to operate this vehicle 4 Visually check hoses and pneumatic lines for damage and chaf ng 5 Ch...

Page 8: ...should operate smooth and with minimal effort Always replace damaged throttle compo nents with factory replacement parts PROPELLER SHAFT Check universal joints for wear If propel ler shaft vibrations...

Page 9: ...ration of this vehicle ADDITIONAL MANUALS AND SAFETY INFORMATION OTTO Shows and Tells booklet Do not forget to read your safety booklet that is provided with your Kalmar tractor This little manual is...

Page 10: ...er for proper operation ________ Check steering system for any binding Make sure steering effort is smooth and light ________ Check accelerator for proper operation Should operate smoothly and without...

Page 11: ...t the time of manufacture f the tractor frame has not been modi ed by welding on cutting into or drilling into the original structure The repair or replacement of defective parts or workmanship under...

Page 12: ...ice replacements The KALMAR warranty does not cover towing charges or rental replacements A Warranty Registration form is mailed for every tractor It is the obligation of the purchaser to complete and...

Page 13: ...ation 17 Control and Display Description 18 STARTING THE VEHICLE 22 Ignition Switches 22 Key Type Ignition 22 Push Button Starter 22 PARKING THE VEHICLE 23 AIR BRAKE SYSTEM 23 Low Air Pressure Indicat...

Page 14: ...Operation 31 Fifth Wheel Unlatch Control Valve 32 BASIC TRAILER SPOTTING STEPS 32 TOWING THE VEHICLE 34 Towing vehicle with front wheels suspended 34 Towing vehicle with rear wheels suspended 35 AXLES...

Page 15: ...Use extra care during bad weather especially when steps and handholds may be icy or wet INTRODUCTION The following section on OPERATION should be read carefully It covers im portant information that...

Page 16: ...he vehicle or to the decal located on the seat base Your local Kalmar dealer can assist with any questions Adjust the seat to the comfortable position for the operator to have full control of all cab...

Page 17: ...16 Operation...

Page 18: ...SIGNAL IND LT INDICATOR LIGHT HEATER FAN CONTROL INDICATOR LIGHT TRANS TEMP IND LIGHT BRAKE AIR INDICATOR LT WIPER SWITCH GAUGE STANDARD AIR GAUGE 2nd AIR GAUGE TRACTOR PARK CONTROL GAUGE TRAILER PAR...

Page 19: ...ndshield Wiper Control 17 Windshield Washer 17 Air conditioner Switch 20 Air Pressure Gauge 21 Beacon Switch optional 17 Boom Control Lever 21 Coolant Temperature Gauge 19 Engine Oil Pressure Gauge 19...

Page 20: ...es the level of fuel in the fuel tank in 1 4 increments 4 Engine Oil Pressure Gauge Indicates the engine oil pressure in P S I 5 Coolant Temperature Gauge Indicates the temperature of the engine coola...

Page 21: ...Tachometer Optional Indicates engine R P M 14 Speedometer Optional Indicates vehicle speed in M P H or K P H This gauge may also come with an odom eter feature built in 15 Heater Air Conditioner Duct...

Page 22: ...Lever C Emergency Flasher Switch The column mounted control on the Kalmar tractor has three functions It is located on the left hand side of the steer ing column Fig 1 1 Moving the lever Fig 1 B forw...

Page 23: ...e functions like the standard key type with OFF ACCESSORY and RUN positions The button engages the starter when the switch is in the RUN position only The two position switch has only the OFF and RUN...

Page 24: ...eadle valve or foot pedal in the cab Fig 1 page 24 CAUTION If the engine does not start within 30 seconds release the starter switch and wait 3 minutes to allow the starter motor to cool If after 3 re...

Page 25: ...ce brakes should not be rapidly pumped NOTE Air brakes do not respond like the brakes in a car and pumping them in an emergency stop is not advised Rapidly pumping the brakes is more likely to use up...

Page 26: ...ca tor light on the dash will illuminate While the engine is running the air compressor replenishes the brake system air supply This air supply provides the pressure necessary to operate the service b...

Page 27: ...inated PARKING BRAKE Otttawa tractors are equipped with spring brakes of parking The parking system is operated manually by a cab mounted parking brake control valve Fig 1 Also see page 21 Items 6 and...

Page 28: ...e nut 3 00 inches Type 2430 and 3030 Chambers 4 00 inches Type 3036 and 3636 Chambers parking brakes will apply automatically To release the spring brakes the air pressure must be returned to 70 P S I...

Page 29: ...ally increased Without the trailer service brakes working jack kni ng and loss of vehicle control is much more likely during heavy braking WARNING Always connect both trailer air lines when towing a t...

Page 30: ...repeat ed attempts to start the engine STARTING THE ENGINE See page 22 Starting the Vehicle WARNING Always set parking brake and place shifter in neutral before attempting to start en gine Failure to...

Page 31: ...ion are controlled by the ECM ENGINE SHUT DOWN Diesel engines generate large amounts of heat Internal engine parts on any diesel engine need to cool down before the en gine is shut off The operator sh...

Page 32: ...osition 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...

Page 33: ...the right of the shifter See page 21 2 Line the tractor up to the front of the trailer by centering the fth wheel to the center line of the trailer Make sure that the tail of the fth wheel is BELOW th...

Page 34: ...the ground 13 Disconnect and STORE the air lines and electrical cable 14 DEPRESS and HOLD the fth wheel unlatch control valve as you slowly pull away from the trailer Once the fth wheel is completely...

Page 35: ...e wheels are properly blocked If the wheels are not blocked the vehicle could move suddenly when the spring brakes are released and cause sever injury WARNING Never tow a trailer above the minimum hei...

Page 36: ...ntact your Kalmar dealer for assistance on operating and maintaining this differential WARNING If the disabled vehicle is connected to a tow vehicle before the spring brakes are released make sure tha...

Page 37: ...Under power assist the cab can be tilted to 45 degrees At 45 degrees the safety prop is automatically engaged The cab can be tilted MANUALLY TO 90 degrees if needed This requires that the tilt cylind...

Page 38: ...2 7 Make sure that the Safety Prop is resting properly on top of the Tilt Cylinder Pull on the Safety Prop Release Cable and ensure that the safety prop is secure it should not move with the weight of...

Page 39: ...39 Fig 1 Trucks equipped with an electronic engine will have an additional relay panel located directly above the main fuse panel The relay panel can be accessed by removing the rst dash panel The fus...

Page 40: ...39 Figure 1a Standard fuse con guration Figure 1b QSB fuse con guration Figure 2 Relay Location Operation...

Page 41: ...ic 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 LUBRI...

Page 42: ...ventive Maintenance Form INTRODUCTION The key to safe and dependable op eration of your Kalmar tractor is proper maintenance Yard tractors are used in very abusive operations Moving trailers through r...

Page 43: ...al covers the speci c transmission in your vehicle Re fer to thisTransmission Operator s Manual for transmission uid requirements and service intervals CAUTION Kalmar Industries Corporation requires t...

Page 44: ...e Operator s Manual with your new Kalmar 50 Water Coolant system additive must be aluminum compatible Proper level of ll for the cooling system is indicated by the presence of coolant in the sight gla...

Page 45: ...exceed the maximum time inter vals Doing so may lead to vehicle damage and void the vehicle and component war ranties ENGINE OIL All Kalmar tractors come with an Engine Operator s Manual provided by t...

Page 46: ...CID DAMAGE CAB DOWN EXTERIOR CLEAN BATTERY CABLE CONNECTIONS CHECK CAB ACCESS STEPS AND HANDLES CHECK BATTERY BOX COVER HOLDDOWNS CLEAN HEATER AC FILTER IF APP DRAIN WATER FROM AIR TANKS CHECK REAR DO...

Page 47: ...CLEAN BATTERY CABLE CONNECTIONS CHECK CAB ACCESS STEPS AND HANDLES CHECK BATTERY BOX COVER HOLDDOWNS CLEAN HEATER AC FILTER IF APP DRAIN WATER FROM AIR TANKS CHECK REAR DOOR ROLLER SLIDE ADJUSTMENT CH...

Page 48: ...KS OR ACID DAMAGE CAB DOWN EXTERIOR CLEAN BATTERY CABLE CONNECTIONS CHECK CAB ACCESS STEPS AND HANDLES CHECK BATTERY BOX COVER HOLDDOWNS CLEAN HEATER AC FILTER IF APP DRAIN WATER FROM AIR TANKS CHECK...

Page 49: ...XTERIOR CLEAN BATTERY CABLE CONNECTIONS CHECK CAB ACCESS STEPS AND HANDLES CHECK BATTERY BOX COVER HOLDDOWNS CLEAN HEATER AC FILTER IF APP DRAIN WATER FROM AIR TANKS CHECK REAR DOOR ROLLER SLIDE ADJUS...

Page 50: ...ne minute Shut off engine and observe dash gauge s for 2 minutes The drop in pressure should not exceed 2 psi over the two minute period Check Operation of Back Up Alarm With engine running move the g...

Page 51: ...eration of Windows Confirm that all regulated and sliding windows open and close fully Cab Down Exterior Check Cab Access Steps and Handles Inspect all steps and grab handles for proper mounting and t...

Page 52: ...ct the air bag for leaks or signs of abrasion Inspect the lock jaw for excessive wear and proper operation Check Intake Ducting for Leaks Inspect all engine clean air tubes and hoses for leaks All cla...

Page 53: ...indicates it is appropriate Change Air Dryer Desiccant If Applicable The desiccant should be changed as needed Change as soon as water is evident when system air tanks are drained Check Exhaust Syste...

Page 54: ...e Breather Insure that the rear axle vent turns freely Check Differential for Leaks Inspect rear axle housing for signs of leaks Repair as necessary Check Differential Oil Level Check the differential...

Page 55: ...raulic filter Check Hydraulic Fluid Level Start engine raise and lower the boom two to three times to insure that system components are filled Lower boom to full down position shut off engine and chec...

Page 56: ...ervoir If the vehicle is equipped with an automatic lubrication system inspect all lubrication points for sufficient grease Fill the system s reservoir with the proper type and quantity of grease per...

Page 57: ...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: ...l No 2 9 Universal Joints Lithium Grease 10 Rear Axle Differential EP 85 140 11 Drive Line Slip Yoke Lithium Grease 12 Spring Shackle Pins Lithium Grease 13 Throttle Linkage Lithium Grease 14 Front Wh...

Page 59: ...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 Yoke NI Rear Door Rollers Silicone Spray...