Kalmar Ottawa t2 Maintenance Manual Download

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0.3 Electrical System Circuits – E. Schematics

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Maintenance Manual Ottawa T2 4x2

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Gauge Cluster Wiring (Cummins QSB 6.7 T3 Engine) – Part A

Summary of Contents for Ottawa t2

Page 1: ......

Page 2: ... 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 Starti...

Page 3: ...trols 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...

Page 4: ...ing 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 7...

Page 5: ...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...

Page 6: ...bers 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 Ac...

Page 7: ...ifth 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...

Page 8: ...aulic 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...

Page 9: ... 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 ...

Page 10: ...ons For the major components such as engine transmission and axles follow the service instructions and guidelines provided by 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 ...

Page 11: ...lsea 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 ...

Page 12: ...ion 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...

Page 13: ... inspection plates cover plate or engine access doors removed or open Don t weld or flame cut frame rails or drill holes in rail flanges Don t modify the vehicle or its equipment without the advice 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...

Page 14: ... 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 Option...

Page 15: ... occurs first page Every 500 Hours of Operation Perform the inspections listed in column B of the chart Refer to 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 in column C of the chart Refer to the Pre...

Page 16: ...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 a...

Page 17: ...8 0 3 Checklists C Preventive Maintenance Maintenance Manual Ottawa T2 4x2 Clean the cab interior Clean the windows Clean and adjust the mirrors ...

Page 18: ...ON ON DRAWINGS IF NECESSARY DESCRIBE PROBLEMS IN REMARKS AREA AT BOTTOM OF PAGE OK REPAIR NEEDED OK REPAIR NEEDED OK REPAIR NEEDED S T H G I L P U K C A B G N I R E E T S S M R O F T A L P S E L D N A H S P E T S S T H G I L E K A R B E L T T O R H T R E T R A T S S T H G I L D O O L F N O I T A R E P O M O O B T R A T S L A R T U E N 5 M R A L A P U K C A B TH WHEEL RELEASE STROBE LIGHT H C T A L...

Page 19: ...VEL 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 C...

Page 20: ... 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 WATE...

Page 21: ...g use the same fluid as is in the reservoir If the fluid is unknown drain and re place it according to specification Use only the fuel coolant coolant additives diesel exhaust flu id and lubricants specified by the engine manufacturer Follow the engine manufacturer s specification for the coolant and water ratio or maintain engine coolant freeze protection at approximately 34 F 37 C Determine the ...

Page 22: ...e washer fluid Check Throttle Operation Depress and release the foot throttle and check for binding and ease of operation Check Horn s Operation Sound electric and air horns if applicable to confirm proper operation Check Air System Minimum 120 PSI 8 27 bar Maxi mum 130 PSI 8 96 bar Start the engine and run at fast idle Maximum system pressure should be limited to a min imum of 120 P S I 8 27 bar ...

Page 23: ...he side door latch from inside and outside the cab to en sure proper operation Check Dome Light Operation With key on turn on cab dome light and confirm operation Check all Glass and Mirrors Inspect all glass and mir rors for cracks and breaks Check Fire Extinguisher Charge if applicable If the vehicle is equipped with a fire extinguisher confirm that it is properly charged page Seat Belt System I...

Page 24: ...mounting hardware on both sides of seat Hard ware should be tight Hardware must not be missing rust ed corroded or damaged If necessary replace defective or missing hardware with authorized parts and or tighten hardware Inspect tethers for cuts fraying extreme or unusual wear Tethers must also be inspected for proper attachment and or adjustment If necessary replace defective tethers Tighten and o...

Page 25: ...nsmission Fluid Level With the engine run ning use the transmission dipstick to check the fluid level per the guidelines in the Transmission Operator s Manual 0 4 4 Cab Up page Maintenance Check Operation of Cab Tilt Pump Pull safety prop re lease cable and activate cab tilt switch The cab should rise Check Cab Safety Prop Inspect the cab safety prop that encloses the cab lift cylinder It should d...

Page 26: ...king for any fluid leaks visible from above Drain Fuel Water Separator Open the drain valve on the fuel water separator and allow water to drain from the filter Change Fuel Water Separator Replace the fuel filter following the instructions in the engine operator s manual Check Air Restriction Gauge if applicable Record reading on gauge reset start engine run to high idle and shut off engine If rea...

Page 27: ...starter mounting bolts are tight Inspect electrical con nections 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 Change Engine Oil and Filter Drain and replace engine oil Use oil meeting at least the minimum specifications provided in the engine operator s manual ...

Page 28: ...ns of the component man ufacturer Check Battery Cables and Holddowns Inspect battery cables for signs of abrasion or breaking Repair and reroute as needed Ensure that batteries are properly secured Check Batteries for Cracks or Acid Damage Inspect batteries for signs of damage Replace as necessary Clean Battery Cable Connections Remove cable ter minals from batteries clean connections reattach cab...

Page 29: ...Lubrication page Maintenance Check Lubricate Rear Door Rollers Inspect upper roll ers Replace if binding or damaged Lubricate Check Lubricate Steering Slip Joint Inspect slip joint for wear or damage Lubricate with lithium grease Check Lubricate Steering U Joints Inspect U joints for wear or damage Lubricate with lithium grease Check Lubricate All Steering Lube Points Inspect king pins tie rod end...

Page 30: ... boom pivot bearings for wear or damage Lubricate with lithium grease Check Lubricate Upper Cylinder Bearings Inspect upper boom cylinder bearings for wear or damage Lubri cate with lithium grease Add Grease to Autolube Reservoir If the vehicle is equipped with an automatic lubrication system inspect all lubrication points for sufficient grease Fill the system s res ervoir with the proper type and...

Page 31: ...22 0 4 Preventive Maintenance Technique C Preventive Maintenance Maintenance Manual Ottawa T2 4x2 ...

Page 32: ... to all operator controls are some of the fea tures of the efficiently designed cab The trailer air lines and electrical connections are easily acces sible through the rear door Perforated decking allows the op erator to move from cab to trailer comfortably and easily A hydraulically powered boom under the fifth wheel raises a trail er high enough to allow it to be moved without raising and low er...

Page 33: ...us personal inju ry and property damage CAUTION Do NOT add anything but diesel fuel to the fuel tank Drain the entire fuel system and fill with the correct fu el Failure to heed this caution may result in serious property damage WARNING Do not allow Diesel Exhaust Fluid to contact the eyes In case of contact immediately flood eyes with large amounts of water for a minimum of 15 minutes Avoid prolo...

Page 34: ...ollowing are other common names used for DEF Urea AUS 32 Aqueous Urea Solution 32 AdBlue NOx Reduction Agent Catalyst Solution Regardless of what the Diesel Exhaust Fluid is called the Die sel Exhaust Fluid must meet the engine manufacturer s speci fication See your engine operator s manual ...

Page 35: ...ignition switch and all lights and accessories in both vehicles 4 Make sure the cable clamps do not touch other metal parts Clamp one end of the first jumper cable to the positive ter minal on one battery and the other end to the positive ter minal on the other battery NEVER connect positive to negative 5 Clamp one end of the second cable to the negative terminal of the charged battery and the oth...

Page 36: ...enerate levels of electrical current high enough to cause burns To reduce the risk of personal injury when working near a battery WEAR SAFETY GLASSES and avoid leaning over a battery whenever possible Do NOT expose a battery to open flames or sparks Ensure that batteries with fill caps are properly filled with fluid Do NOT allow battery acid to contact eyes or skin Flush any contacted area thoroug...

Page 37: ...r s Manual or the sec tion on caging the brakes in this manual if there is no air pressure in the system 3 Disconnect the propeller shaft at the axle Secure the pro peller shaft to the frame or cross member 4 Remove the axle shafts if there is damage or suspected damage to the axle s 5 Cover the hub openings to prevent loss of lubricant or entry of dirt or foreign objects CAUTION Do NOT connect to...

Page 38: ... vehicle may be towed with all wheels on the ground provid ed the steering system is operating normally Remember that the steering will not have power assist and the vehicle will not have brakes A tow bar must be used between the towing and the disabled vehicle To relocate a disabled vehicle by towing with all wheels on the ground follow the procedure described above for towing with front wheels o...

Page 39: ...e Maintenance Manual Ottawa T2 4x2 0 5 Vehicle Modifications page Approval Do not modify your Ottawa T2 tractor without approval in writing from Kalmar Solutions LLC Kalmar Terminal Tractors Unau thorized modifications may void the vehicle warranty ...

Page 40: ...s plate shows the model serial number and manufactured date for this vehicle Certification Label The certification label is supplied only for vehicles qualified un der EPA DOT regulations It is located inside the cab on the post behind the driver s door The certification label shows the vehicle type and date of manufacture Also shown are the Ve hicle Identification Number VIN gross vehicle weight ...

Page 41: ... is located on top of the left frame rail inboard of the cab air spring above the rear spring hanger and also on the identification plate See page 31 Always refer to this num ber when ordering parts or requesting field service assistance Engine Serial Number Cummins serial numbers are located on the top of the valve cover ...

Page 42: ...wa T2 Left Side 4x2 HHD chassis shown 1 Cab Air Ride Air Spring 2 Height Control Valve Assembly 3 Cab Tilt Switch 4 Boom Lift Cylinder Upper Mount 5 Fifth Wheel Pivot 6 Boom Lift Cylinder Lower Mount 7 Cab Tilt Lanyard 8 Battery Box 9 Fuel Filter 10 Cab Air Ride Shock Absorber 11 Cab Tilt Cylinder Safety Bar 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 43: ...ok 13 Fuel Tank 0 7 2 Chassis Cab Right Side page Ottawa T2 Right Side 4x2 HHD chassis shown 1 Fifth Wheel Pivot 2 Boom Lift Cylinder Upper Mount 3 Vertical Muffler and Exhaust Pipe 4 Tow Hook 5 Cab Tilt Pump 6 Hydraulic Fluid Tank 7 Hydraulic Fluid Filter 8 Boom Lift Cylinder Lower Mount ...

Page 44: ...ance Manual Ottawa T2 4x2 0 7 3 Chassis Cab Front Rear page Ottawa T2 Front Rear 4x2 HHD chassis shown 1 Front Panel Removable 2 Rear Door 3 Glad Hands Air Brake 4 Trailer Electrical Connector 7 pin 5 Air Brake Chambers 6 Fifth Wheel 7 Front Leaf Springs ...

Page 45: ...th Wheel Boom 2 Hydraulic Fluid Tank 3 Hydraulic Fluid Filter 4 Air Tank Service Air Brakes 5 Battery Box 6 Boom Pivot 7 Fuel Filter 8 Cab Lift Cylinder 9 Radiator Charge Air Cooler 10 Cab Pivots 11 Engine Oil Dipstick 12 Air Cleaner 13 Transmission Fluid Dipstick 14 Air Tank Supply Air Brakes 15 Fuel Tank 16 Fifth Wheel 1 2 3 5 6 7 8 9 10 11 12 13 15 16 ...

Page 46: ...ed and match the voltage in the vehicle 12 VDC or 24 VDC 2 Inspect the wiring between the gauge cluster and sender Wiring should be intact and tightly connected Tighten and replace wiring as required 3 If the gauge cluster still does not work ensure that the steel housing of the sender is properly seated Grounded Sender Test Attach the sender wire from the gauge to an established chassis ground Mo...

Page 47: ...38 0 8 Electrical Instruments 0 Machine Complete Maintenance Manual Ottawa T2 4x2 ...

Page 48: ...marily found in fire engines dump trucks and refuse haulers Engine options are provided for OFF HIGHWAY and DOT EPA certified applications with a choice of power ratings available from several engine manufac turers For service and maintenance information consult the manuals included with your vehicle contact the Kalmar dealer or the manufacturer of the component installed in your vehicle ...

Page 49: ...it Headlight Switch Ignition Switch Panel Dimmer Switch Optional Fuel Gauge Circuit Diagnosis Observation Cause Action Zero reading Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Open circuit loose connection Test Repair as needed Defective gauge cluster Test Replace as needed Defective alternator Test Replace as needed Inaccurate gauge Defective gauge cluster...

Page 50: ...plate is fastened to the side of the tank where it can easily be seen 1 2 6 Sensor Fuel Level page Description The tank is fitted with a fuel level sending unit and a vent plug A float riding on the surface of the fuel causes current changes which are transmitted via the sending unit to the instrument panel gauge 1 2 8 Pipes and Hoses page Description Fuel hoses are constructed of rubber and braid...

Page 51: ...The level sensor uses an ultrasonic transducer to sense the fluid level The instrument panel will illuminate the Low DEF warning lamp when fluid level falls below the preset amount 1 3 8 DEF Hose Lines page Description The DEF system coolant lines between the DEF multifunction head unit and coolant system are reinforced synthetic rubber secured with worm gear clamps The DEF suction and return line...

Page 52: ...servation Cause Action Battery charge low discharged Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Defective battery Replace as needed Defective alternator Repair or replace as needed Engine does not crank Battery charge low discharged See above Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Defective relay Replac...

Page 53: ...44 1 11 Start Stop 1 Engine Maintenance Manual Ottawa T2 4x2 ...

Page 54: ...m 2 Transmission page Description The standard transmission is an automatic Allison RDS series For service and maintenance information consult the manuals included with your vehicle contact the Kalmar dealer or the manufacturer of the component installed in your vehicle ...

Page 55: ...46 2 Transmission Maintenance Manual Ottawa T2 4x2 ...

Page 56: ...an ufacturer s rear axles Special features such as a locking or a No Spin differential are optional Contact your Kalmar dealer if you do not know whether your vehicle contains these fea tures For service and maintenance information consult the manuals included with your vehicle contact the Kalmar dealer or the manufacturer of the component installed in your vehicle ...

Page 57: ...48 3 Driveline Axle Maintenance Manual Ottawa T2 4x2 ...

Page 58: ... driven via air pressure by the first stage If air is lost to the first stage the sec ond stage is driven mechanically by the first stage 4 1 9 Air Control Valves page Description Instrument Panel 4 Trailer Air Supply and Tractor Parking Control Knobs There are two air control valves on the instrument panel The tractor parking brake has a yellow knob The trailer air supply knob is red Normal vehic...

Page 59: ...Valves Slack Adjusters Stop Light Switch Tractor Protection Valves Trailer Brake Air Lines Within the system are two separate air distribution circuits These operate the rear primary and front secondary founda tion brakes Air flow within the two circuits is controlled through a series of valves which supply or release air to the chambers in response to the driver s command The parking brakes are s...

Page 60: ... times called the wet tank It supplies air to the other two reser voirs independently A pressure relief valve in the primary tank protects the system from excessive pressure One of the two secondary reservoirs supplies air to the front brakes and the other to the rear brakes Check valves prevent air from returning to the compressor when it is not running This arrangement allows one set of brakes t...

Page 61: ...vides the parking brake action When system air pressure falls below 43 PSI the springs acti vate the push rods and apply the foundation brakes When sys tem air pressure rises above the set point it overcomes the spring pressure and releases the brakes For service the springs can be released manually if the engine cannot be started or if air pressure cannot be restored to the system Slack Adjuster ...

Page 62: ...ol unit mounted in the left front wheel well The anti lock modulator valve in conjunction with the EC 60 electronic control unit responds to the signals from the sensors to control the air pressure at the individual wheel brakes As a wheel s speed approaches 0 rpm locked up air pressure to that brake is repeatedly released and reapplied The process continues until all wheel speeds are equal Brakin...

Page 63: ...one side may cause loss of driver control 4 3 16 Manually Releasing Tractor Spring Brakes Caging page Description When air pressure in the system drops below approximately 43 psi the spring parking brakes will apply automatically To re lease the spring brakes the air pressure must be returned to 70 psi If the system cannot be recharged and the vehicle must be moved the spring parking brakes can be...

Page 64: ...lug from the brake canister 5 Insert the caging tool into the access hole T end first 6 Turn the caging tool 1 4 turn to engage with the slot on the pressure plate 7 Try to pull the caging tool out it should not pull out If it does repeat steps 5 and 6 External Caging Tool 8 Thread the nut and washer down onto the threaded end of the caging tool all the way to the canister 9 Tighten the nut until ...

Page 65: ...as need ed Insufficient braking power Low air system pressure Inspect for leaks Repair or replace as necessary Poor adjustment poor lubrication or worn brake linings Inspect Adjust lubricate and repair as needed Defective components e g slack adjusters push rods cams Inspect Repair or replace as need ed Air line s restricted Inspect Repair or replace as need ed Slow application Poor adjustment or ...

Page 66: ...Valve exhaust ports e g treadle quick release relay plugged Inspect Repair or replace as need ed Brakes grab Grease or oil on linings Determine source of grease or oil Repair as needed Clean drums and replace shoes Drum out of round Inspect Repair or replace as need ed Defective valves Inspect Repair or replace as need ed Actuating linkages e g slack ad justers push rods bind Inspect Repair or rep...

Page 67: ...buildup Refer to Brake Air System Diagno sis table Low air pressure warning Pressure drops quickly engine stopped brakes applied Pressure drops engine stopped brakes applied Pressure does not reach normal Pressure builds too slowly Pressure too high No brakes Observation Cause Action ...

Page 68: ... in moving the rack piston axially through the cylinder bore The rack piston then turns the sector shaft to steer the vehicle page Description Optional Hydrostatic Steering Components Hydrostatic steering consists of an orbital control valve a hy draulic pump either engine mounted or mounted via a PTO on the transmission steering cylinders a reservoir and fluid lines The orbital control valve has ...

Page 69: ...rom pump to steering gear box a Install a steering analyzer or flow meter between the pump and the steering gear box and record the flow ________ GPM b The steering gear box needs 4 1 2 to 5 GPM of flow to op erate correctly Observation Cause Action Hard steering Overloaded axle Review GAWR specifications Reload as needed Underinflated tires Inflate correctly Front end misaligned Align front end W...

Page 70: ...instructions in the next step 2 To clean the priority valve follow these instructions a Remove priority spool plug and the priority valve spring will be exposed and can be removed b After the spring is removed place your hand over the spool bore in the valve body and turn the valve body over The priority flow orifice will drop out in your hand c With the spool bore side of valve body down tap the ...

Page 71: ...62 5 3 Diagnosis Power Steering 5 Steering Maintenance Manual Ottawa T2 4x2 1 2 end wrench Allen wrench 5 16 ...

Page 72: ...ls Hydrostatic Steering Diagnosis Observation Cause Action Hard steering Overloaded axle Review GAWR specifications Re load as needed Underinflated tires Inflate correctly Front end misaligned Align front end Worn linkages Replace as needed Damaged king pins or cylinder con nections Repair or replace as needed Steering column binding Repair as needed Weak fluid flow rate Review the manufacturer s ...

Page 73: ...64 5 4 Diagnosis Hydrostatic Steering 5 Steering Maintenance Manual Ottawa T2 4x2 ...

Page 74: ...e front spring anchors and tow hooks are parts of special components welded to the front ends of the rails Another weld ment provides attachment for the rear spring hanger on each side Rear Spring Slipper Spring slippers retain the rear leaf springs at the rear mounting brackets The standard vehicle is equipped with a rear axle or axles at tached directly to the frame rails without any suspension ...

Page 75: ... remove the nuts washers and bolts securing the bump stop spring assembly and spacer to the front axle 7 Remove the bump stop spring assembly and spacer 8 Repeat steps 4 through 7 to remove the spring assembly at the opposite side Repair Springs Installation 1 Place the spacer spring assembly and bump stop in posi tion on the front axle and install the mounting bolts wash ers and nuts to secure th...

Page 76: ...the transmission 7 2 1 Hydraulic Pump page Description On a standard chassis the hydraulic pump is a fixed positive displacement gear type The pump is rated at 10 gallons 38 li ter per minute at high idle approximately 1200 rpm A relief valve in the lift control valve limits operating pressure 7 2 3 Control Valve page Description The valve housing is a one piece mono block casting The A and B work...

Page 77: ...guration utilizes two 4 inch 100 mm diam eter lift cylinders with a capacity of 48 500 pounds 22 000 kg and a lifting height of 17 7 inches 450 mm The cylinders are double acting in that they are hydraulically powered up and down Restrictor fittings are threaded into the base end work ports to better control downward lowering speed ...

Page 78: ...ave knife like characteristics Failure to heed this warning could result in severe personal injury Observation Cause Action Cylinders leak down Damaged seals or cylinder wall Replace cylinder Optional Install seal kits Worn control valve Replace Optional Install seal kits Drops slightly momentarily before lifting Load check seat or control valve spring malfunction Clean or replace as needed Lifts ...

Page 79: ...ockwise To de crease the pressure turn the adjusting screw counter clockwise 3 If the pressure reading is at 2000 psi install a steering analyzer or flow meter between the pump and control valve and record the maximum flow at engine idle as the boom is raised and lowered __________GPM The flow should be 3 1 2 to 5 GPM at engine idle and 23 25 GPM at maximum engine RPMS Valve actuating cable lever ...

Page 80: ... for full movement of control valve lever 3 Install a flow meter or steering analyzer between the pump and the control valve and record flow _______ GPM A maximum engine RPM there should be 23 25 GPM of flow If you are unable to get the required GPM of flow replace the pump If replacing the pump check the splines on the pump shaft and the splines inside the PTO for wear ...

Page 81: ...72 7 11 Diagnosis Boom 7 Load Handling Maintenance Manual Ottawa T2 4x2 ...

Page 82: ... 8 Control System 73 Maintenance Manual Ottawa T2 4x2 mm mm mm mm mm mm 8 Control System page Introduction General Information Not available ...

Page 83: ...74 8 Control System Maintenance Manual Ottawa T2 4x2 ...

Page 84: ...Body Cab and Accessories 75 Maintenance Manual Ottawa T2 4x2 mm mm mm mm mm mm 9 Frame Body Cab and Accessories 9 1 Controls and Instruments page 4 30 32 31 33 1 2 3 5 6 7 9 10 11 12 8 22 25 27 13 14 14 21 29 23 24 28 26 18 17 16 15 20 19 ...

Page 85: ... Push Button Start A A 11 Air Diffuser S S 12 Dome Light S S 13 Air Horn A A 14 Option Switches U U 15 Heater Control S S 16 Heater Control S S 17 Heater Control S S 18 Heater Control S S 19 Front Floodlight S S 20 Rear Floodlight S S 21 Trailer Air Supply S S 22 Parking Brake Control S S 23 Transmission Shifter S S 24 5th Wheel Control S S 25 5th Wheel Latch Control S S 26 Power Outlet A A 27 Opt...

Page 86: ...Panel are backlight when the headlights are on Left Dash Panel Displays the following gauges controls and indicators along with an air diffuser for the heating and op tional air conditioning system Headlight Switch Dimmer Switch optional Front Wiper Switch Rear Wiper Switch optional Radio optional Ignition Switch Push Button Starter optional with or without use of key Lower Left Dash Panel Provide...

Page 87: ... Indicator Lights The indicator lights are arranged in three sections along the top of the main gauge panel Left Side Indicator Lights Left Turn Signal Charger Water in fuel ATC Trailer ABS Tractor ABS Center Section Indicator Lights Low DEF Level High Beam Brake Air Low Fuel Malfunction Indicator Lamp MIL Check Engine Stop Engine Check Transmission Right Side Indicator Lights Wait to Start Seat B...

Page 88: ...Selector Temperature Control Air Recirculation Switch Air Conditioner Switch Optional Front Floodlights Rear Floodlight Dome Light Air Horn Optional Switches Right Dash Panel Displays the following gauges controls and indicators Controls Trailer Air Supply Parking Brake Control Transmission Shift Selector Boom Control Lever Fifth Wheel Unlatch Control Power Outlet Optional Switches Power Studs Air...

Page 89: ...lled Differential Lock Driver Controlled Differential Lock If equipped the Driver Controlled Differential Lock control rock er switch is located on the right dash panel Turn Signal High Beam and Emergency Flasher Control A multifunction switch is also provided on the stalk on the left side of the steering wheel ...

Page 90: ... Low Air Pressure Switch Indicator Panel Dimmer Switch Optional Low Air Warning Circuit Diagnosis 9 1 38 Hourmeter page Diagnosis Components Cab Accessory Fuse Gauge Cluster Ignition Switch Hourmeter Circuit Diagnosis Observation Cause Action Inoperative light and buzzer Circuit breaker open Reset Replace as needed Short circuit Test Repair as needed Switch grounded Test Repair as needed Defective...

Page 91: ... for kinks and breaks Repair or replace as needed Mislocated wiring Inspect routing Relocate wires or isolate terminals as needed Runs unevenly or fast or slow Defective gauge cluster Replace Observation Cause Action Observation Cause Action Panel lamp does not light Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires ...

Page 92: ...ive dimmer switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Inaccurate Defective gauge cluster Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Inoperative Circuit breaker open Reset Repair short as needed Re pla...

Page 93: ...w Seat height adjusts by changing the air pressure A switch on the side of the seat controls the air pressure Seat height is fixed by adjusting the tethers attached to each seat belt anchor The seat position can be adjusted fore and aft The position of the seat cushion can be adjusted fore and aft independently of the seat position A fore and aft isolator is included for snubbing undesirable chugg...

Page 94: ...ter is standard equipment Air conditioning is optional Air diffusion is provided through ducts in the instrument panel near the side window and underneath the instrument panel near the center of the cab Air flow can also be directed to the windshield and side windows Instrument panel controls give the driver several air handling options including fan speed and cab air temperature ...

Page 95: ...s Circuit Diagnosis Observation Cause Action Inoperative No power Turn on ignition switch Linkage binding Repair or replace as needed Defective switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective relay Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Operate slowly Linkage binding Repair or re...

Page 96: ... Washer Motor Windshield Washer Switch Windshield Washer Circuit Diagnosis Defective switch Replace Defective motor Replace Observation Cause Action Observation Cause Action Inoperative No power Turn on ignition switch No fluid Add fluid as needed Hose or nozzle plugged Clean as needed Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective relay Replace Defe...

Page 97: ...eadlight Switch Headlight Switch Circuit Breaker High Beam Indicator Light Headlight Circuit Diagnosis Observation Cause Action LH or RH headlight inoperative high or low beam Defective lamp Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Both headlights inoperative Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed...

Page 98: ...er 15A Trailer Lights Relay Cab Clearance and Marker Light Circuit Diagnosis Trailer Clearance Marker and Tail Light Circuit Diagnosis Observation Cause Action Individual light inoperative Defective lamp Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed All lights inoperative Defective light switch Replace Circuit breaker open Reset Repair short as ne...

Page 99: ... Test circuits Repair or replace as needed Observation Cause Action Observation Cause Action Inoperative light Defective lamp Replace Defective turn signal switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Inoperative brake lights Defective lamp Replace Defecti...

Page 100: ...uit Diagnosis Flood Light Circuit Diagnosis Observation Cause Action Inoperative backup light Defective lamp Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective backup relay Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Observation Cause Action Inoperative Defective lamp Replace Defective light sw...

Page 101: ...on Cause Action Inoperative light Defective lamp Replace Defective turn signal switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Inoperative turn signal Defective turn signal flasher Replace Defective turn signal switch Replace Circuit breaker open Reset Repair...

Page 102: ...sory Circuit Breaker Dome Light Dome Light Circuit Diagnosis Observation Cause Action Inoperative Defective beacon lamp Replace Defective switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Observation Cause Action Inoperative Defective lamp Replace Defective dom...

Page 103: ...lay Ignition Switch Trailer Auxiliary Switch Trailer Circuit Breaker 15A Trailer Wiring Disconnect Trailer Auxiliary Circuit Diagnosis Observation Cause Action Inoperative Defective lamp Replace Defective fuse Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Defective daytime running light module Replace Observation Cause Action No power at connector...

Page 104: ...s pinched so that the two pan els come in contact a short is created EL lamps require an inverter to change direct current to high cy cle alternating current and increase the voltage A shorted EL lamp will cause the inverter to shut down To isolate the defec tive lamp disconnect one lead to each lamp and reconnect one at a time A good lamp lights when connected Transmission Shifter Fifth Wheel Con...

Page 105: ...gnal Flasher Turn Signal Switch Turn Stop Light Lamps Emergency Flasher Circuit Diagnosis Observation Cause Action Inoperative horn Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Defective horn button switch Replace Defective horn relay Replace Defective horn Replace Dimin...

Page 106: ...5A Ignition Switch Reverse Switch Backup Alarm Circuit Diagnosis Defective turn signal switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Observation Cause Action Observation Cause Action Inoperative alarm Circuit breaker open Reset Repair short as needed Re pla...

Page 107: ... Observation Cause Action Inoperative radio Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective relay Replace Defective speakers Repair or replace Defective radio Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Poor performance Defective antenna Repair or replace Defective speakers Repair or replace Defecti...

Page 108: ...window in the side panel moves up and down via a regulator handle on the door A fixed window ahead of the side panel window permits a full view on that side A solid window on the opposite wall allows an unob structed view in that direction 9 9 5 Rear View Mirror page Description Mirrors Heated and heated motorized outside rear view mir rors are optional equipment ...

Page 109: ...re are E coat primered and powder coated The roof front panel and brow are constructed of ABS plastic The headliner is made of a fiber reinforced composite The floorplate is made of 3 mm steel The cab frame is a ful ly welded Roll Over Protective Structure ROPS constructed of 2 x 2 x 1 4 wall square tubing The deck provides the floor inside the cab and the walkway outside the cab The floor and wal...

Page 110: ...68427 1 32 inch 0 8 mm 2 With the door closed adjust the top of the door to obtain a 5 8 inch 16 mm gap between the front of the door and the back of the door frame on the cab 2 Adjust by loosening the roller attachment bolts A to move the door fore and aft 3 With the door closed adjust the rear door guide assembly to obtain a 5 8 inch 16 mm gap between the door and the cab at the bottom of the do...

Page 111: ...he cab can be tilted to 90 degrees if needed by pro viding a suitable hoist to carry the weight and disconnecting the lift cylinder Cab Tilt Cylinder and Safety Prop A hydraulic cylinder mounted between the deck and the frame at a front corner raises and lowers the cab The hydraulic pump is actuated by a well marked switch on the outside of the rail near the rear axle Also provided is a lanyard by...

Page 112: ... and Lanyard A Cab Tilt Control Switch B Safety Prop Release Cable The cab tilt control switch and lanyard are located on the rail between the hydraulic fluid tank and the rear wheel Tilt action stops when the switch is released or when the cab reaches full up or full down position Cab Suspension Latching Bar After the cab reaches the full down position the latching mechanism makes a loud sound Th...

Page 113: ...s a return path for oil from the tilt cylin der A one way check valve blocks oil returning from the relief valve and pump inlet and directs it through the valve passage It goes through a restriction which is pressure compensated and then back to the pump inlet and on to the reservoir When the solenoid operated control valve is de energized a simple spring load returns it to the blocked position Th...

Page 114: ...lid arm locking the hydraulic tilt cylinder in the extended cab tilted position It is cable operated from the tilt operation station where the control switch is located page Diagnosis Cab Tilt Components Stop Tilt Circuit Breaker 20A Tilt Pump Control Switch Tilt Pump Motor Tilt Solenoid Cab Tilt Diagnosis A B DANGER Do NOT work under the raised cab before ensuring that the cab safety prop is lock...

Page 115: ...lt pump control switch Replace Defective tilt pump solenoid Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Raised cab does not return Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective tilt pump control switch Replace Defective tilt pump valve Replace Motor operates cab does not rise Refer to Hydraulic se...

Page 116: ...ncap the hose end and connect the hydraulic line to the pump 3 Connect the two wires to the solenoid under the pump motor 4 Connect the battery cable to the pump motor 5 Check the fluid level in the hydraulic tank 6 Connect the negative cables from the batteries 7 Using the cab tilt switch raise and lower the cab to bleed all air from the system the system is self bleeding 8 Check all hoses and fi...

Page 117: ...c pressure gauge 7 Turn the adjusting screw in or out as required to reach the specified relief pressure For settings see Hydraulic System in the Technical Data section 8 Using an Allen wrench hold the adjusting screw in place and tighten the jam nut securely 9 Disconnect the hydraulic gauge and remove the T fitting from the supply line reconnect the supply line 10 Check the supply line hose and f...

Page 118: ...k and the frame in a manner that prohibits the safety bar from slip ping 3 Using the cab tilt switch or overhead hoist if necessary lower the cab until it rests on the safety bar and all pressure is removed from the cylinder 4 Clean the area around the hose fitting on the pump with compressed air to reduce the possibility of contamination 5 Position a catch can under the fitting to prevent spills ...

Page 119: ...in stalling the locknuts and bolts to attach the rear end of the cylinder to the mounting bracket on the frame rail Tighten the locknuts and bolts to 200 ft lbs 271 Nm 3 Attach the front end of the cylinder to the mounting bracket on the frame as follows 2000 year model and newer trucks Install an adjust able collar around the cylinder and through the mounting bracket and cylinder eye 1999 year mo...

Page 120: ...n of Cab Deck 9 Frame Body Cab and Accessories 111 Maintenance Manual Ottawa T2 4x2 9 10 8 Cab Pivot Bushing page Repair Pivot Bushing Removal WARNING Make sure all safety devices are in place while the cab is in the raised position ...

Page 121: ...ia and side skirts 9 Place 4x4x6 inch blocks on the top of the frame rails to sup port the cab then lower the cab onto the blocks This will help stabilize the cab while removing the cab bushings NOTE The blocks should be of sufficient thickness to fill the space between the frame rails cab deck channels and pivot brackets This will support the cab in the ride level position when the pivot pins are...

Page 122: ... cross member 9 Install the SNAPTRAC bolts at the front left corner of the frame cross member and from the bottom of the cab channel 10 Lower the cab and check for hose routing issues 9 10 10 Cab Mounting and Suspension page Description Cab Air Suspension and Latching System Three point suspension means that the cab is attached at two points in front by a pivot on each rail and latches to an air s...

Page 123: ...tilt switch to the DOWN position This will evacuate extra fluid from the cylinder 4 Disconnect and cap the hydraulic lines 1 connected to the latch at the top of the suspension assembly 5 Disconnect the air line 2 from the leveling valve on the suspension assembly 6 Remove the four mounting bolts 3 4 securing the suspen sion assembly to the frame rail driver s side Observation Cause Action Cab lev...

Page 124: ...all four mounting bolts and nuts 3 4 to 220 ft lbs 298 Nm 5 Reconnect the hydraulic lines to the latch at the top of the assembly 6 Reconnect the air line to the suspension leveling valve 7 Secure all hydraulic lines away from moving parts 8 Loosen the cab latch bar plate on the bottom of the cab deck 9 Lower the cab slowly until the cab latch bar plate makes contact with the air suspension latch ...

Page 125: ...d from the serrated portion of its upper sleeve 1 To raise ride level Decrease the rod 4 length by plac ing the rod deeper into the upper sleeve 1 To lower ride level Increase the rod length by reducing the insertion of the rod in the sleeve NOTE One inch 25 4 mm of clearance is required between the stop bumpers on the air suspension assembly and the channel at the bottom of the cab deck for prope...

Page 126: ... too bouncy under normal operating conditions 1 Raise the cab and lock it in the full tilt position 2 Remove the nuts 1 from the 7 16 inch mounting bolts se curing the shock absorber in the top and bottom mounting brackets at one side of the suspension assembly 3 Remove the bolts and remove the shock absorber from the assembly 4 Repeat the procedure to remove the second shock absorb er at the oppo...

Page 127: ...The position of the cab latch bar plate is important When prop erly positioned it relieves stress on the cab deck assembly To properly position the cab latch bar plate use this procedure 1 Raise the cab and loosen all four nuts 1 2 securing the cab latch bar plate to the bottom of the cab deck 2 With the plate loosened lower the cab slowly ensuring the latch bar properly seats in the hold down lat...

Page 128: ...ront Crossmember Weldment 2 Front Spring Hanger and Bumper Mount Weldment with Two Hook 2 3 Main Rail 2 4 Fifth Wheel Boom Pivot 5 Inverted L Channel Rail Reinforcement 2 when equipped 6 Boom Cylinder Lower Support Axle Mounting Bracket 2 7 Skid Ramp Rear Crossmember Mounting Bracket 2 8 Skid Ramp Weldment 9 Rear Tie Bar Angle 10 Rear Crossmember Weldment ...

Page 129: ...forcements and aligned with holes in the rails page Diagnosis Chassis Components Frame NOTE Frame rails are not serviceable For repair or replacement contact Kalmar service department Frame rails that are out of shape must be straightened and properly aligned to restore the vehicle to maximum capacity and safe performance If the cause of misshapen rails is overloading continuing safely in such hea...

Page 130: ...or repairing cracked rails elsewhere in this manual Reinforce rail Sagging rails Overloading Straighten reinforce and align the rails or replace the frame as needed Uneven loading Holes in rail flange Too many rail web holes Rail web holes too close together Four or more rail web holes aligned vertically Welds on flange No filler blocks Rail web holes cut with torch Straighten reinforce and align ...

Page 131: ...spring These conditions may give the appearance of misaligned rails Inspect Repair as needed Vehicle collision Straighten reinforce and align the rails or replace the frame as needed Towing load attached to one rail Operating over rough terrain Improper tracking Improper front end alignment Align the front end Misaligned rails Straighten reinforce and align the rails or replace the frame as needed...

Page 132: ...loading improper weight distribution or misapplication of the vehicle Excessive bending moment dam age will occur at different areas on various types of vehicles The effects of excessive bending moment will vary by type of vehicle page Repair Making Reinforcements General Information In general when making reinforcements of any type observe the following practices 1 Contact the Kalmar Engineering ...

Page 133: ...isting in the frame 5 No more than three holes should be on a vertical line of the web 6 Holes should be at least 3 4 inch 19 0 mm apart 7 Holes in a reinforcement plate should be at least two times the material thickness from the edge of the plate page Repair Cracks in Steel Rails or Cross Members Type of Cracks The straight crack and the sunburst crack are the two common types The straight crack...

Page 134: ...h access to the crack 2 Locate the extreme end of the crack and drill a 1 2 inch 12 7 mm hole 3 V grind the entire length of the crack from the starting point to the hole at the extreme end The angle of the V will de pend on the welding process used 4 The bottom of the crack should be opened up 1 16 inch 1 6 mm to allow good penetration of the weld A hacksaw blade may be used for this 5 Weld with ...

Page 135: ...door In addition three steps made from 10 gauge perforated steel are mounted on the battery box for access to the frame decking and the rear door Grab handles designed to accommodate en try to either door are attached to the rear cab wall Perforated decking made from 10 gauge steel is attached across the frame rails at the rear of the cab Additional perforat ed decking extends toward the fifth whe...

Page 136: ...on Switch Heater Air Conditioning Circuit Diagnosis Observation Cause Action One accessory inoperative Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed All accessories inoperative Defective relay Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Observation Cause Action Inoperative blower Circuit breaker open Reset ...

Page 137: ... switch Replace Observation Cause Action Observation Cause Action Inoperative heater Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective heater switch Replace Defective mirror Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Observation Cause Action Inoperative heater Circuit breaker open Reset Repair short ...

Page 138: ...es and Options 9 Frame Body Cab and Accessories 129 Maintenance Manual Ottawa T2 4x2 Inoperative motor Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Observation Cause Action ...

Page 139: ...130 9 16 Accessories and Options 9 Frame Body Cab and Accessories Maintenance Manual Ottawa T2 4x2 ...

Page 140: ...au lic oil flows continuously through the center of the control valve even while the steering wheel is not moving Power steering and the boom systems use the same hydraulic pump The pump is equipped with a priority valve that directs the first four gallons per minute of flow to the steering circuit 10 3 Tanks and Accumulators 10 3 1 Reservoir page Description The standard hydraulic reservoir has a...

Page 141: ...ntenance Manual Ottawa T2 4x2 10 6 Temperature Control Cleaning and Hydraulic Oil 10 6 8 Return Filter page Description The return filter is located in the hydraulic tank where it is con tinuously filtering fluid that is used in all three subsystems boom cab tilt and power steering ...

Page 142: ...a T2 4x2 mm mm mm mm mm mm 11 Common Electric 11 1 Controls and Instruments page Description Wiring Harness The wiring harness can accommodate several items of optional equipment Contact your dealer for information about any equipment installed after the vehicle left the factory ...

Page 143: ...age Description Fuses Relays and Circuit Breakers The Kalmar tractor is equipped with two power boards One power board is located in the cab under the center panel of the dash The second pow er board is located in the chassis over the transmission on the left side See following figures for fuse breaker and relay loca tions ...

Page 144: ...LUBE_IGN WIPE WASH_15 HVAC_30 TRLR_LIGHTS_30 PARK_LIGHTS_10 EXT_LIGHTS_25 RADIO ACCY_15 MIRRORS_15 FOGLIGHTS_10 CAB_LIGHT_10 PARK_LPS_10 DIAG_10 HEADLIGHTS_15 HORN_10 STOPLAMPS_20 LUBE_BAT FLASHER_30 RADIO_BATT_15 J2 J1 ACCY IGN HIGHBEAM MAIN_BATT DRL BATTERY_UNFUSED IGNITION_UNFUSED SWITCH_15 STD DRL1 J3 FLASHER HORN MAIN_GND GND PNL TAIL ACCY2 ...

Page 145: ...136 11 2 Safety 11 Common Electric Maintenance Manual Ottawa T2 4x2 Chassis Power Board ...

Page 146: ...out 12 1 1 Diagnosis page Brakes Air System A DOT EPA system includes three reservoirs primary front and rear Components Air Compressor Air Control Valve Air Dryer Optional Antilock Modulator Valve Optional Automatic Slack Adjusters Bobtail Proportioning Relay Valve Optional Brake Valve treadle Check Valve Double Check Valve Front Brake Chambers Governor Low Pressure Indicator Pressure Protection ...

Page 147: ...use Action Frequent air dryer purging cycling Excessive system leakage Inspect system connections and valves Repair or replace as need ed Defective internal check valve Test Replace as needed Defective governor Test Adjust or replace as needed Purge valve leaks Test Replace as needed Compressor unloader leaks Slight leakage permitted Uncover inlet cavity and inspect piston Repair or replace unload...

Page 148: ...tions Repair or replace as needed No pressure buildup continuous exhaust at dryer purge valve Purge valve leaking Inspect Repair or replace air dryer as needed Refer to Medium Duty Truck Unit Repair Manual Defective governor Test Adjust or replace as needed Purge control line connected to reservoir or governor exhaust port Connect to governor unloader port Defective electrical circuitry Test Repai...

Page 149: ...omponents as needed System failed Inspect for leaks Repair or replace failed components as needed Defective governor Test Adjust or replace as needed Defective compressor Inspect Repair or replace as needed Excessive air system leakage Inspect system connections and valves Repair or replace as needed Pressure drops quickly engine stopped brakes applied Treadle valve leak Inspect Repair or replace ...

Page 150: ...air or replace as needed Pressure builds too slowly Engine idle too slow Inspect Repair or replace as needed Excessive system leakage Inspect system connections and valves Repair or replace as needed Defective air compressor Inspect Repair or replace as needed Pressure too high Defective air pressure gauge Inspect Repair or replace as needed Poor governor adjustment Inspect Adjust repair or replac...

Page 151: ...sent and the trailer supply valve is opened a portion of the trailer supply air enters the proportioning valve through its control port The valve restores its internal pistons to their original positions Air passes normally through the valve to the rear and trailer brakes page Quick Release Valves Each brake chamber connects to its own quick release valve nearby This valve responds to the release ...

Page 152: ...es water vapor from the air It also removes any oil va por that may blow by the compressor page Diagnosis Components Ignition Circuit Breaker 30A Ignition Switch Air Dryer Circuit Diagnosis Observation Cause Action Inoperative heater Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective ignition switch Replace Defective wiring Inspect connections and wires ...

Page 153: ...144 12 5 Air Dryer 12 Common Pneumatics Maintenance Manual Ottawa T2 4x2 ...

Page 154: ...Manual Ottawa T2 4x2 mm mm mm mm mm mm D Error Codes page Description This section is not applicable for this vehicle NOTE Error codes for the engine and transmission can be found in the Engine and Transmission manufacturer s manuals ...

Page 155: ...146 D Error Codes Maintenance Manual Ottawa T2 4x2 ...

Page 156: ... Valve Two Way Check and Quick Release Valves Vehicles intended for road use conform to Federal Motor Vehi cle Safety Standard FMVSS 121 This standard specifies test requirements for air brake systems Semi trailer tractors must be equipped with an anti lock brake system ABS and meet stopping distance requirements under normal and emergency conditions ABS is optional on tractors that do not use the...

Page 157: ...KEY LUBE PUMP OPTION 3 8 BK 3 8 VL 5 8 OE 5 8 GN 5 8 OE 3 8 GN 1 2 OE 1 2 GN 3 8 GN 3 8 OE 3 8 RD 3 8 VL 3 8 BK 3 8 YW 3 8 GN 3 8 OE 3 8 YW 3 8 BK 3 8 VL 3 8 RD 5 8 OE 5 8 GN 5 8 OE 3 8 GN 5 8 OE 5 8 OE 5 8 OE 1 2 OE 1 2 OE 3 8 OE 3 8 GN 3 8 BK 3 8 YW 3 8 BK 3 8 VL 3 8 RD 1 2 OE 1 2 GN 3 8 RD 3 8 BL 1 2 GN 1 2 OE 3 8 RD 3 8 YW 3 8 BK 3 8 BL 3 8 RD 3 8 BL 3 8 VL FRONT BRAKES REAR BRAKES DEL DEL SUP...

Page 158: ...QR 1C BP R1 PR 4 AIR DRYER OPTION 7 35 CU IN RESERVOIR OPTION DIFF LOCK OPTION INTER AXLE LOCK OPTION 1 2 GN 1 2 GN 3 8 YW 3 8 YW 3 8 GN 5 8 GN 3 8 YW 3 8 RD 3 8 GN 5 8 GN 5 8 OE 5 8 OE 5 8 GN 5 8 BK 1 4 BK 3 8 VL 1 4 VL 3 8 VL 3 8 VL 5 8 OE 5 8 GN 3 8 GN 3 8 YW 3 8 RD 3 8 BK 1 4 BL 5TH WHEEL UNLATCH CYLINDER SER SUP CON DEL DEL AIR COMP RESV UNL SPRING SERVICE SPRING SERVICE ...

Page 159: ...ighway Air System Circuit On Highway Air System Circuit Part A TRACTOR TRAILER PARK BRAKE VALVE OPTION ABS FRONT BRAKES OPTION 5TH WHEEL INTERLOCK OPTION GREASE JOCKEY LUBE PUMP OPTION AIR HORN OPTION AIR DRYER OPTION 1 2 2 0 1 2 1 2 11 2 12 1 2 3 4 1 2 3 1 2 3 22 21 11 12 4 PSI ...

Page 160: ...y Air System Circuit Part B QUICK TRAILER AIR R14 VALVE OPTION TRAILER HAND BRAKE OPTION TRACTION CONTROL OPTION ABS REAR BRAKES OPTION 7 35 CU IN RESERVOIR OPTION TRAILER HOSE CONNECTION DIFF LOCK OPTION 42 41 1 2 1 2 1 2 0 150 PSI 0 150 PSI 11 2 12 23 11 12 24 1 4 21 22 4 PSI 4 PSI ...

Page 161: ...N GREASE JOCKEY LUBE PUMP OPTION 3 8 VL 3 8 BK 5 8 GN 5 8 OE 5 8 GN 5 8 OE 5 8 OE 5 8 GN 5 8 OE 5 8 GN 5 8 OE 1 2 OE 1 2 GN 3 8 GN 3 8 OE 3 8 VL 3 8 VL 3 8 BK 3 8 BK 3 8 VL 3 8 YW 3 8 GN 3 8 OE 3 8 YW 5 8 OE 1 2 OE 1 2 OE 5 8 OE 3 8 RD 3 8 BL 3 8 RD 1 2 GN 1 2 OE 1 2 OE 1 2 GN 3 8 YW 3 8 BL 3 8 BK 3 8 BL 3 8 RD 3 8 BK 3 8 OE 3 8 GN 3 8 YW 3 8 BK 3 8 VL FRONT BRAKES REAR BRAKES DEL DEL SUP DEL DEL ...

Page 162: ...AKES RESERVOIR CAB AIR SUSPENSION DIFF LOCK OPTION 3RD AIR TANK OPTION AIR DRYER OPTION 7 35 CU IN RESERVOIR OPTION INTER AXLE LOCK OPTION 5 8 OE 5 8 GN 5 8 GN 3 8 YW 1 2 GN 1 2 GN 3 8 YW 3 8 YW 5 8 GN 5 8 OE 1 4 VL 3 8 VL 3 8 VL 5 8 BK 1 4 BK 3 8 VL 3 8 VL 1 4 BL 3 8 BK 5 8 OE 5 8 GN 5 8 GN 3 8 YW 5TH WHEEL UNLATCH CYLINDER AIR COMP RESV UNL SPRING SERVICE SPRING SERVICE ...

Page 163: ...ff Highway Air System Circuit Off Highway Air System Circuit Part A 5TH WHEEL INTERLOCK OPTION TRACTOR TRAILER PARK BRAKE VALVE OPTION GREASE JOCKEY LUBE PUMP OPTION 3RD AIR TANK OPTION AIR HORN OPTION AIR DRYER OPTION 22 21 11 12 1 2 3 1 2 3 1 2 3 4 2 0 11 2 12 1 2 1 2 4 PSI ...

Page 164: ...nual Ottawa T2 4x2 Off Highway Air System Circuit Part B TRAILER HOSE CONNECTION QUICK TRAILER AIR R14 VALVE OPTION TRAILER HAND BRAKE OPTION 7 35 CU IN RESERVOIR OPTION DIFF LOCK OPTION 1 2 4 PSI 23 11 12 24 1 4 21 22 1 2 1 2 0 150 PSI 0 150 PSI 1 2 4 PSI ...

Page 165: ...e mounted on each side below and in back of the seat cushion Refer to the main air system schematics in 0 1 1 Air Brakes for driver s seat air lines 0 1 3 Cab Suspension page Air Lines Cab Suspension Components Air Spring Height Control Valve Latch Shock Absorbers Ride level is adjustable and automatically maintained Two shock absorbers react with the air spring to maintain a soft smooth ride A ru...

Page 166: ... on the instrument panel opens the latch The button is spring loaded and normally closed Once opened the latch remains open until closed by a trailer king pin OTT0049 BRAKE TREADLE DELIVERY SUPPLY TO BRAKE SYSTEM 3 8 YW 3 8 YW 3 8 BK 3 8 BK 5TH WHEEL AND BOOM TO TRACTOR PARK YELLOW TO TRACTOR PARK RED PLUG PLUGS MANIFOLD 8 PORT TO BRAKE TANK AIR LINES FIFTH WHEEL 5TH WHEEL UNLATCH 5TH WHEEL UNLATC...

Page 167: ...158 0 1 Air System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Air Lines Fifth Wheel Unlatch TR 3 3 8 BK 3 8 VL 3 8 VL 3 8 BL 3 8 RD 3 8 RD SUP DEL 5TH WHEEL UNLATCH SUP DEL CON ...

Page 168: ...0 1 Air System Circuits E Schematics 159 Maintenance Manual Ottawa T2 4x2 5th Wheel Interlock Option Circuit 5th Wheel Interlock Option 5TH WHEEL INTERLOCK OPTION 1 2 3 3 2 1 4 ...

Page 169: ...nance Manual Ottawa T2 4x2 0 1 5 Tractor Trailer Park Brake page Air Lines Tractor Trailer Park Brake Option Air Lines Tractor Trailer Park Brake Option 3 8 BL 3 8 RD 3 8 YW 3 8 GN 3 8 OE TRAILER PARK RED DEL SUP EXH SUP DEL TRACTOR PARK YELLOW MV 3 ...

Page 170: ... System Circuits E Schematics 161 Maintenance Manual Ottawa T2 4x2 Tractor Trailer Park Brake Valve Option Circuit Tractor Trailer Park Brake Valve Option TRACTOR TRAILER PARK BRAKE VALVE OPTION 12 11 3 21 22 ...

Page 171: ...awa T2 4x2 0 1 6 Quick Trailer Air R14 Valve page Air Lines Quick Trailer Air R14 Valve Option Air Lines Quick Trailer Air R14 Valve Option TP 3DC DC 4 QUICK TRAILER AIR R14 VALVE OPTION 5 8 OE 5 8 GN 3 8 RD 3 8 RD 5 8 RD 5 8 OE 5 8 GN 5 8 GN 5 8 OE VALVE FOOT 1 2 ...

Page 172: ...alve Option 0 1 7 Trailer Hand Brake page Air Lines Trailer Hand Brake Option Air Lines Trailer Hand Brake Option QUICK TRAILER AIR R14 VALVE OPTION FROM SUPPLY SIDE OF TREADLE 11 2 12 41 42 1 2 23 11 12 24 1 4 21 22 TP 3DC DC 4 TC 2 TRAILER HAND BRAKE OPTION 1 2 OE 1 2 OE 3 8 OE 1 2 OE 3 8 OE 3 8 BL 3 8 VL 3 8 VL VALVE FOOT 1 2 SUP DEL EXH ...

Page 173: ...aintenance Manual Ottawa T2 4x2 Trailer Hand Brake Option Circuit Trailer Hand Brake Option Trailer Hose Connection Coiled Air Lines Circuit Trailer Hose Connection Coiled Air Lines TRAILER HAND BRAKE OPTION 3 1 11 2 12 TRAILER HOSE CONNECTION ...

Page 174: ...d Hands Both Ends Coiled Air Lines Circuit Trailer Hose Connection Glad Hands Both Ends Coiled Air Lines Trailer Hose Connection Straight Rubber Air Lines Circuit Trailer Hose Connection Straight Rubber Air Lines TRAILER HOSE CONNECTION GLAD HAND CONNECTORS TRAILER HOSE CONNECTION STRAIGHT RUBBER HOSE ...

Page 175: ... System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 0 1 8 Air Horn page Air Lines Air Horn Option Air Lines Air Horn Option Air Horn Option Circuit Air Horn Option AIR HORN OPTION 3 8 VL AIR HORN OPTION ...

Page 176: ...167 Maintenance Manual Ottawa T2 4x2 0 1 9 Inter Axle Lock page Air Lines Inter Axle Option Air Lines Inter Axle Option Inter Axle Lock Option Circuit Inter Axle Lock Option INTER AXLE LOCK OPTION 3 8 VL 3 8 VL INTER AXLE LOCK OPTION 3 2 1 ...

Page 177: ...2 4x2 0 1 10 Grease Jockey Lube Pump page Air Lines Grease Jockey Lube Pump Option Air Lines Grease Jockey Lube Pump Option Grease Jockey Lube Pump Option Circuit Grease Jockey Lube Pump Option GREASE JOCKEY LUBE PUMP OPTION 3 8 VL GREASE JOCKEY LUBE PUMP OPTION P1 S R ...

Page 178: ...al Ottawa T2 4x2 0 1 11 Differential Axle Lock page Air Lines Differential Axle Lock Option Air Lines Differential Axle Lock Option Differential Axle Lock Option Circuit Differential Axle Lock Option DIFF LOCK 3 8 VL 3 8 VL DIFFERENTIAL AXLE LOCK OPTION 3 2 1 ...

Page 179: ...ir page Air Lines Additional 7 35 cu in Air Reservoir Option Air Lines Additional 7 35 cu in Air Reservoir Option Additional 7 35 cu in Air Reservoir Option Additional 7 35 cu in Air Reservoir Option 7 35 CU IN RESERVOIR OPTION 5 8 VL 1 2 VL 1 2 VL 5 8 VL 7 35 cu ft 7 35 CU IN RESERVOIR OPTION 1 2 0 150 PSI 1 2 1 2 ...

Page 180: ...0 1 Air System Circuits E Schematics 171 Maintenance Manual Ottawa T2 4x2 0 1 13 Air Dryer page Air Lines Air Dryer Option Air Lines Air Dryer Option AIR DRYER OPTION 5 8 BK 1 4 BK AIR COMP RESV UNL ...

Page 181: ...172 0 1 Air System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Air Dryer Option Air Dryer Option AIR DRYER OPTION 2 3 4 1 ...

Page 182: ...akes page Air Lines ABS Brakes Option On Highway Only Air Lines ABS Brakes Option On Highway Only ABS FRONT BRAKES ABS FRONT BRAKES ABS REAR BRAKES ABS REAR BRAKES TRACTION CONTROL OPTION 1 2 GN 1 2 GN 3 8 YW 3 8 YW 1 2 GN 1 2 GN 1 2 OE 1 2 OE SPRING SERVICE SPRING SERVICE 1 2 1 2 1 2 1 2 ...

Page 183: ...aintenance Manual Ottawa T2 4x2 ABS Brake Option Circuit ABS Brake Option TRACTION CONTROL OPTION ABS REAR BRAKES OPTION TRACTION CONTROL OPTION ABS FRONT BRAKES OPTION 42 41 1 2 11 2 12 R C H 1 2 3 R C H 1 2 3 1 2 R C H 1 2 3 R C H 1 2 3 4 PSI ...

Page 184: ...75 Maintenance Manual Ottawa T2 4x2 0 1 15 Traction Control page Air Lines Traction Control Option for ABS Brakes On Highway Only Air Lines Traction Control Option for ABS Brakes On High way Only TRACTION CONTROL OPTION 3 8 GN 3 8 GN 3 8 GN ...

Page 185: ...s E Schematics Maintenance Manual Ottawa T2 4x2 Traction Control Option for Use With ABS Brake Option Circuit Traction Control Option for Use With ABS Brake Option TRACTION CONTROL OPTION TRACTION CONTROL OPTION 42 41 1 2 3 2 1 ...

Page 186: ...enance Manual Ottawa T2 4x2 0 1 16 3rd Air Tank page Air Lines 3rd Air Tank Option Off Highway Only Air Lines 3rd Air Tank Option 3rd Air Tank Option Circuit 3rd Air Tank Option WET TANK 3RD AIR TANK OPTION 5 8 BK 3 8 VL 5 8 BK 3RD AIR TANK OPTION ...

Page 187: ... on the transmission housing All fluid passes through a filter mounted beside the reservoir 0 2 1 Cab Tilt page Hydraulic Lines Cab Tilt Hydraulic Lines Cab Tilt System Components Control Switch Hydraulic Cylinder Lanyard Safety Prop Solenoid For tilting the cab the motor is controlled by a switch on the rail A lanyard near the switch allows the operator to unlatch the safety prop prior to up or d...

Page 188: ...x2 0 2 2 Fifth Wheel Boom page Hydraulic Lines Fifth Wheel Boom Hydraulic Lines Fifth Wheel Boom Components Boom Control Valve Hydraulic Cylinders Hydraulic Relief Valve Although engine speed controls the speed of the double acting cylinders restrictors slow the downward motion ...

Page 189: ...nce Manual Ottawa T2 4x2 0 2 3 Power Steering page Hydraulic Lines Power Steering Hydraulic Lines Power Steering System Components Integral Steering Gear The power steering system shares the hydraulic fluid reservoir with the cab tilt and boom lift systems ...

Page 190: ...ydrostatic Steering page Hydraulic Lines Hydrostatic Steering Hydraulic Lines Hydrostatic Steering System Components Orbital Control Valve Power Steering Pump Reservoir Steering Cylinders The hydrostatic steering system shares the hydraulic fluid res ervoir with the cab tilt and boom lift systems ...

Page 191: ...harging page Starting and Charging Circuit Starting and Charging Circuit Components Alternator Batteries Circuit Breaker Ignition Switch Cab Accessory Fuse Panel Fuse Gauge Cab Accessory Fuse Panel Ignition Relay Ignition Switch Neutral Start Relay Start Cutout 1 Relay Start Cutout 2 Relay Start Solenoid Starter Motor with Solenoid ...

Page 192: ...wa T2 4x2 0 3 2 Cab Accessory Components page Wire Color Codes BE Blue BK Black BN Brown GN Green OE Orange PE Purple PK Pink RD Red TN Tan WE White YW Yellow Anti lock Braking System ABS For information on the anti lock braking system refer to the vendor s service manual ...

Page 193: ...WE HC1000 RD WE HC1000 RD WE HC1000 RD WE AC2000 BN HC2001 YW RD HC2001 YW RD HTR LOW GY HC1000 RD WE HC1000 FAN SW OFF C H M L HTR MED BK HTR HI OE HTR LOW GY HTR MED BK HTR HI OE HC2001 YW RD HC2001 YW RD HC2001 YW RD HC2002 YW BK HC2003 YW BK HC2003 YW BK HC2001 YW RD HC2003 YW BK HC2003 HC2002 A C LOW PRESSURE SWITCH COLD CONTROL CONNECTOR ELECTRONIC ENGINE BULKHEAD CONNECTOR HC2001 YW RD FC20...

Page 194: ... Button Horn Relay The horn operates independently of the ignition switch OTT0037 REMOVE POSITIVE STUD CAB ACC FUSE HORN CHASSIS BULKHEAD CONNECTOR NEGATIVE PASS THRU STUD HORN HORN CIRCUIT BA2002 RD HN1000 GN HN2000 GN BK HN2000 GN BK HN2000 GN BK HN2000 GN BK HN2001 GN WE GD2000 WE HORN HORN HORN 86 G U S L C F X V N D M B T P J W K R H A E 85 87 87A R7 30 10 A 1 ...

Page 195: ...CIRCUIT CAB BULKHEAD CONNECTOR GD2000 WE AC1001 BN AC1001 BN MR1001 OE MR1001 OE MR1000 RD GD2000 WE MR1001 OE GD2000 WE MR1001 OE A B A B A B C MR1000 RD GD2000 WE BUS BAR MR1000 RD GD2000 WE MR1000 RD GD2000 WE MR1000 RD GD2000 WE MR1000 RD GD2000 WE MR1000 RD GD2000 WE MR1000 RD GD2000 WE MR1000 RD GD2000 WE A B MR1000 RD GD2000 WE GD2000 WE GD2000 WE A B A B A B MIRROR CONNECTOR RIGHT SIDE MIR...

Page 196: ...TIVE PASS THRU STUD LH MIRROR CAB ACC FUSE MIRRORS MIRRORS MR1001 OE MR1000 RD MR1000 RD MR1000 RD MR1003 RD WE MR1004 RD WE MR1003 RD WE MR1003 RD WE MR1008 OE WE MR1002 BK WE MR1001 OE MR1000 RD MR1004 RD WE MR1000 RD GD2000 WE RH MIRROR NEGATIVE PASS THRU STUD HEATED MOTO MIRROR CIRCUIT HEATER CCW CW RD A B C D BK WE GN CAB BULKHEAD CONNECTOR MR1003 RD WE MR1004 RD WE MR1004 RD WE RD BK B A B C...

Page 197: ... BN AC2000 BN BA2001 RD RD2002 BN RD RD2002 BN RD RD2002 BN RD RD1003 RD GD2006 WE GD2006 WE RD2002 BN RD RD1003 RD GD2006 WE RD2002 BN RD RD1003 RD RD2002 BN RD RD2002 BN RD RD2002 BN RD RD1003 RD BA2004 RD CAB ACC RADIO BATTERY FUSE RADIO BATT 5 A 2 GD2006 WE GD2006 NEGATIVE PASS THRU STUD RD2002 BN RD GD2006 WE A B C A B A B C TERMINAL FOR CB RADIO CONNECTOR RADIO UPPER CAB CONNECTOR REMOTE POS...

Page 198: ...ition switch must be On to use the radio OTT0088 IGNITION SWITCH IGNITION SWITCH CONNECTOR RADIO CIRCUIT HOT WIRE CAB ACC IGNITION SWITCH FUSE IGN SW 10 A 1 IG1000 RD WE IG1000 RD WE AC2000 BN AC2000 BN AC2000 BN AC1001 BN AC1001 BN ACC 1 BA2001 RD BA2000 RD POSITIVE PASS THRU STUD GD2006 WE RD2002 BN RD GD2006 WE RD2002 BN RD TERMINAL FOR CB RADIO CONNECTOR B 30 R2 86 85 87 87A A POSITIVE PASS TH...

Page 199: ...use the windshield washer OTT0041 WINDSHIELD WIPER SW WIPER SWITCH CONNECTOR CHASSIS BULKHEAD CONNECTOR OPTIONAL WINDSHIELD WASHER WASHER CONNECTOR TRANSMISSION CASE GROUND CAB ACC FUSE WIPER WASHER POSITIVE PASS THRU STUD WINDSHIELD WASHER CIRCUIT WW1000 PE RD WW2003 GN WW1000 PE RD WW2003 GN WW2003 GN WW2003 GN GD1001 WE GD1001 WE WW2003 GD1001 WW2003 GN G A C B A E D F B A B U S L C F X V N D P...

Page 200: ...OTT0042 CAB ACC FUSE WIPER WASHER WIPER MOTOR CONNECTOR WIPER SWITCH CONNECTOR NEGATIVE PASS THRU STUD WIPER MOTOR ELEC WIPER POSITIVE PASS THRU STUD WINDSHIELD WIPER CIRCUIT WW1000 PE RD WW1000 PE RD WW1000 PE RD WW2001 PE BK WW2001 PE BK WW2002 PE WE WW2002 PE WE WW2000 PE WW1000 PE RD WW2001 PE BK WW2002 PE WE WW2000 PE WW2000 PE GD2001 WE BK GN RD BE BN BATT GRD PARK LO HI BA2001 RD WINDSHIELD...

Page 201: ...192 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Cab Power Board Cab Power Board Wiring ...

Page 202: ...lectrical System Circuits E Schematics 193 Maintenance Manual Ottawa T2 4x2 Cab Interior Engine Wiring Cab Interior Engine Wiring Cummins ISB 2013 Engine Cab Interior Engine Wiring Cummins QSB 6 7 T3 Engine ...

Page 203: ...194 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Cab Interior Engine Wiring Cummins QSB T4F Engine ...

Page 204: ...Optional Vehicles equipped with ABS have two service tanks and a pressure gauge for each one OTT0073 CAB BULKHEAD CONNECTOR NEGATIVE PASS THRU STUD BRAKE CONTROLS PANEL CONNECTOR GD2002 WE PL2002 C F E A H B C D G J K L M G M N W F R B E J L K T H X D V U A P S PL2002 BE RD PL2002 PL2002 ENGINE GAUGE WARNING PANEL CONNECTOR PL2002 AIR PRESS OPT AIR PRESS GD2002 A C B L G L G S1 HEADLAMP SWITCH S1 ...

Page 205: ...he set point closing the switch HOUR METER HOURS GD2000 GD2000 WE NEGATIVE PASS THRU STUD ENGINE HOURMETER CAB CONTROLS PANEL CONNECTOR 11 12 21 8 19 6 5 17 26 16 28 15 25 14 13 22 9 10 7 4 3 2 1 29 20 18 23 27 24 ELECTRONIC ENGINE BULKHEAD CONNECTOR IG2006 BN RD OIL PRESSURE SWITCH HOURMETER IG1000 GA2003 GA2003 OE WE CAB ACC CB IGNITION SWITCH BA2000 IG1001 YW CAB ACC FUSE GAUGE GAUGE RD IGN SW ...

Page 206: ...0 3 Electrical System Circuits E Schematics 197 Maintenance Manual Ottawa T2 4x2 Fuel Gauge Fuel Gauge Circuit Cummins ISB 6 7 2013 Engine ...

Page 207: ... Maintenance Manual Ottawa T2 4x2 Components Fuse Gauge Cab Accessory Fuse Panel Gauge Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch Optional Sender Fuel Level Variable Resistance The fuel level gauge displays quarter tank intervals ...

Page 208: ...0 3 Electrical System Circuits E Schematics 199 Maintenance Manual Ottawa T2 4x2 Fuel Gauge Circuit Cummins QSB Engines ...

Page 209: ...arm Buzzer Low Air Switch Low Air Switch Optional OTT0072 CAB ACC FUSE GAUGE IGNITION SWITCH LOW AIR WARNING CIRCUIT IGNITION 86 30 85 87 PR1 GAUGE 10 A 1 IG2006 BN RD IG2001 YW GD2002 WE GD2002 WE B C A AS1000 GN WE AS1000 GN WE BRAKE CONTROLS PANEL CONNECTOR LOW AIR SWITCH OPTIONAL LOW AIR SWITCH CAB BULKHEAD CONNECTOR C G M N W F R B E J L K T H X D V U A P S LOW AIR BUZZER B L NEGATIVE PASS TH...

Page 210: ...SMISSION ECU TCM 29 65 5 24 64 50 13 4 45 32 72 46 18 41 30 69 9 70 10 63 43 2 23 62 42 1 61 21 22 79 17 57 3 73 53 14 38 34 25 7 28 8 49 48 68 26 6 27 66 67 47 12 44 56 35 58 75 16 54 76 77 11 55 78 74 71 36 52 33 51 31 15 37 19 39 59 40 60 20 80 S1 HEADLAMP SWITCH PL2002 PL2002 PL2002 BE RD PL2002 BE RD TR 125 TN TR 125 TN IG2006 BN RD GD2000 WE IG2006 BN RD IG1001 YW IG2006 CAB ACC FUSE GAUGE G...

Page 211: ...accessory terminal on the ignition switch OTT0059 WITH OPTIONAL DIMMER SWITCH STANDARD S9 PANEL LTS DIMMER S1 HEADLAMP SWITCH S1 HEADLAMP SWITCH PL2002 PL2002 PL2002 BE RD GD2000 WE PL2002 BE RD IG2006 BN RD IG2006 BN RD GD2000 WE PL2002 BE RD CAB ACC FUSE GAUGE NEGATIVE PASS THRU STUD IG1001 YW CAB CONTROLS PANEL CONNECTOR ENGINE GAUGE WARNING PANEL CONNECTOR IGNITION 86 30 PR1 85 87 GAUGE 10 A 1...

Page 212: ...0 3 Electrical System Circuits E Schematics 203 Maintenance Manual Ottawa T2 4x2 Gauge Cluster Wiring Gauge Cluster Wiring Cummins ISB 2013 Engine Part A ...

Page 213: ...204 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Gauge Cluster Wiring Cummins ISB 2013 Engine Part B ...

Page 214: ...0 3 Electrical System Circuits E Schematics 205 Maintenance Manual Ottawa T2 4x2 Gauge Cluster Wiring Cummins QSB 6 7 T3 Engine Part A ...

Page 215: ...206 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Gauge Cluster Wiring Cummins QSB 6 7 T3 Engine Part B ...

Page 216: ...0 3 Electrical System Circuits E Schematics 207 Maintenance Manual Ottawa T2 4x2 Gauge Cluster Wiring Cummins QSB T4F Engine Part A ...

Page 217: ...208 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Gauge Cluster Wiring Cummins QSB T4F Engine Part B ...

Page 218: ... FAN CLUTCH RELAY AIR CONDITIONING CLUTCH PWR FAN CLUTCH OPTIONAL USER INPUT SWITCH 3 POSITION B FAN CLUTCH RELAY COIL GND AIR DRYER HEATER POWER AIR SUSPENSION DUMP VALVE FUEL HEATER OUTPUT SIGNAL START RELAY INPUT SIGNAL ECU ANTI RESTART INPUT SIGNAL KEYSWITCH CRANK POWER INPUT SIGNAL TRANSMISSION NEUTRAL AUX RELAY 2 OUTPUT POWER AUX RELAY 2 COIL PWR CAB TILT TRANSMISSION ECU BATTERY ECM1 BATTER...

Page 219: ... 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Air Dryer Optional Air Dryer Circuit Components Air Dryer Chassis Options Relay Circuit Breaker Air Dryer Cab Accessory Fuse Panel ...

Page 220: ... PUMP CIRCUIT RD BATTERY TO START SOL STARTER W SOLENOID MID FRAME CROSSMEMBER CONNECTOR GD1001 WE GD1001 WE TRANSMISSION CASE GROUND RD TILT SOL TO TILT PUMP BK GD1001 WE GD1001 WE TT2000 BK TILT SOL DN TILT MOTOR UP RD TT2001 GN TT2001 GN CHASSIS BULKHEAD CONNECTOR BA2000 RD CAB ACC FUSE TILT BUS BAR IGNITION TILT 5 G U S L C F X V N D M B T P J W K R H A E A 2 85 86 30 87 PR1 TT1000 RD BK TT100...

Page 221: ...212 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Cab Exterior Front Chassis Wiring Cab Exterior Front Chassis Wiring Cummins ISB 2013 Engine ...

Page 222: ...0 3 Electrical System Circuits E Schematics 213 Maintenance Manual Ottawa T2 4x2 Cab Exterior Front Chassis Wiring Cummins QSB 6 7 T3 Engine ...

Page 223: ...214 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Cab Exterior Front Chassis Wiring Cummins QSB T4F Engine ...

Page 224: ...0 3 Electrical System Circuits E Schematics 215 Maintenance Manual Ottawa T2 4x2 Chassis Wiring Chassis Wiring Cummins ISB 2013 Engine ...

Page 225: ...216 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Chassis Wiring Cummins QSB 6 7 T3 Engine ...

Page 226: ...0 3 Electrical System Circuits E Schematics 217 Maintenance Manual Ottawa T2 4x2 Chassis Wiring Cummins QSB T4F Engine ...

Page 227: ...atics Maintenance Manual Ottawa T2 4x2 Air System Tank Pressure Senders Air System Tank Pressure Senders Cummins ISB 2013 Engine Air System Tank Pressure Senders Cummins QSB 6 7 T3 Engine Air System Tank Pressure Senders Cummins QSB T4F Engine ...

Page 228: ...lectrical System Circuits E Schematics 219 Maintenance Manual Ottawa T2 4x2 Battery Power Distribution Battery Power Distribution Cummins ISB 2013 Engine Battery Power Distribution Cummins QSB 6 7 T3 Engine ...

Page 229: ...220 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Battery Power Distribution Cummins QSB T4F Engine ...

Page 230: ...0 3 Electrical System Circuits E Schematics 221 Maintenance Manual Ottawa T2 4x2 Cab Tilt System Control Wiring Cab Tilt System Control Wiring Cummins ISB 2013 Engine ...

Page 231: ...222 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Cab Tilt System Control Wiring Cummins QSB 6 7 T3 Engine ...

Page 232: ...0 3 Electrical System Circuits E Schematics 223 Maintenance Manual Ottawa T2 4x2 Cab Tilt System Control Wiring Cummins QSB T4F Engine ...

Page 233: ...Cab and Chassis page Backup Light and Alarm Backup Light and Alarm Circuit Components Backup Alarm Backup Lamp Circuit Breaker Reverse Cab Accessory Fuse Panel Ignition Relay Reverse Relay Transmission Case Ground The backup lamp illuminates and the alarm sounds when the transmission is shifted to reverse ...

Page 234: ...ectrical System Circuits E Schematics 225 Maintenance Manual Ottawa T2 4x2 Beacon Strobe Light Optional Beacon Strobe Light Circuit Components Accessory Relay 2 Beacon Light Switch Optional Beacon Strobe Lamp ...

Page 235: ...on vehicles that meet FMVSS and CMVSS requirements OTT0067 NEGATIVE PASS THRU STUD POSITIVE PASS THRU STUD NEGATIVE PASS THRU STUD UPPER CAB CONNECTOR CLEARANCE LIGHTS REMOTE POSITIVE STUD S1 HEADLAMP SWITCH PL2001 BE BK GD2001 WE BA2000 RD PL1000 OE WE HEADLIGHT SWITCH CONNECTOR CAB ACC FUSE PARKLIGHTS PL1000 OE WE PL1000 OE WE BUS BAR BA2002 BA2002 RD PL2000 BE PL2000 BE PL2000 BE PL2000 BE PL20...

Page 236: ...D LO BEAM BK GROUND GN HL2002 BE WE A B C HL2001 BE BK DR2000 BE DR2000 BE DR2002 RD DR2002 RD RD HI BEAM RH HEADLIGHT BK LO BEAM GN GROUND HL2002 BE WE RH HEADLIGHT CONNECTOR OPTIONS BULKHEAD CONNECTOR IG1001 YW IG1001 YW CAB ACC FUSE D R L BUS BAR DR2002 RD A 7 8 9 3 12 IGNITION 85 87 30 86 DRL 10 A 4 PR1 11 10 1 2 6 5 4 B C HL2001 BE BK GD2002 WE HL2002 BE WE HL2001 BE BK GD2002 WE DR2002 RD WE...

Page 237: ...ing Cab Accessory Fuse Panel The lamp On Off switch is on the dome light fixture Fifth Wheel Control Refer to Transmission Shifter OTT0061 GD2001 WE UPPER CAB CONNECTOR NEGATIVE PASS THRU STUD DOME LIGHT DOME LIGHT CIRCUIT CL1000 BN RD GD2001 WE CL1000 BN RD ACC 2 85 86 30 PR2 87 GD2001 WE GD2001 WE CAB ACC FUSE LIGHTING CAB LIGHTING 10 A 1 B A C D F E CL1000 BN RD AC1001 BN ...

Page 238: ...0 3 Electrical System Circuits E Schematics 229 Maintenance Manual Ottawa T2 4x2 Flood Light Flood Light Circuit Components Accessory Relay 2 Flood Light ...

Page 239: ...ACC FUSE HEADLIGHTS BA2002 RD HL2000 BE RD HL1000 OE HL2002 BE WE HL2001 BE BK HL2002 BE WE HL2002 BE WE HL2002 BE WE GD2002 WE GD2002 WE GD2002 WE HL2001 BE BK HL2001 BE BK HL2001 BE BK HL2002 BE WE GD2002 WE GD2000 WE HL2003 WE BK HL2003 WE BK TURN SIGNAL SWITCH CONNECTOR TURN SIG DIMMER SW HEADLIGHT CIRCUIT A B C D E F G H YW GN RD GY BK GY BK WE WE HL2001 BE BK LEFT HAND HEADLIGHT CONNECTOR RI...

Page 240: ...elay Trailer Auxiliary Switch Triaxle Switch Connector The trailer auxiliary switch is not used with ABS OTT0068 S17 TRAILER AUX SWITCH TS2000 BN BK TRIAXLE SWITCH CONNECTOR TRAILER AUXILIARY POWER IGNITION SWITCH JUMPER IG2000 YW TS2000 GD2004 WE TS2001 BN WE TS2001 BN WE TRAILER BREAKER TRBK 15A TS2001 BN WE REMOTE POSITIVE STUD CHASSIS BULKHEAD CONNECTOR NEGATIVE PASS THRU STUD C G M N W F R B ...

Page 241: ...002 BE RD PL2002 BE RD GD2002 WE GD2000 WE GD2000 WE GD2000 WE GD2000 WE PL2002 BE RD PL2002 BE RD DIMMER INPUT PL2002 BE RD DIMMER INPUT PL2002 BE RD DIMMER INPUT MD TRANS BULKHEAD CONNECTOR TRANSMISSION SHIFTER 5TH WHEEL CONTROL PANEL LIGHTING MD TRANS SHIFTER CONNECTOR LIGHT BAR CONNECTOR FOR HEATER CONTROL LHS LIGHT BAR CONNECTOR FOR HEATER CONTROL RHS LIGHT BAR CONNECTOR FOR FAN CONTROL GEN 4...

Page 242: ...R 30 A 4 REMOTE POSITIVE STUD BA2002 RD SL2000 BK SL1000 OE RD SL2000 BK TL2004 GN WE TL2003 YW BU2000 BK RD BU2000 BK RD PL2000 BE TL2001 TN TL2002 GN PL1000 OE WE HEADLIGHT SWITCH CONNECTOR S1 HEADLAMP SWITCH PL1000 OE WE PL2000 BE PL1000 OE WE PL2000 BE TL2001 TN TL2002 GN CAB BULKHEAD CONNECTOR CHASSIS BULKHEAD CONNECTOR CAB ACC FUSE STOPLIGHTS STOP LTS S P A U V D X H T K L J E B R F W N M G ...

Page 243: ...RD BA2002 BUS BAR REMOTE POSITIVE STUD CAB ACC FUSE PARKLIGHTS RH FRONT TURN PARK PL2000 BE PL2000 BE PL2000 BE TL2001 TN TL2001 TN TL2002 GN TL2002 GN PL2000 BE PL2000 BE TL2002 GN PL2000 BE TL2002 GN TL2002 GN LH FRONT TURN PARK SL2000 BK TL2004 GN WE TL2003 YW SL2000 BK SL2000 BK RH REAR STOP TURN TAIL LH REAR STOP TURN TAIL BACK UP LIGHT TL2004 GN WE TL2004 GN WE TL2004 GN WE GD1001 WE PL2000 ...

Page 244: ... Circuit Breakers Circuit Breaker Stop Lights Cab Accessory Fuse Panel Circuit Breaker Stop Lights Trailer Circuit Breakers Flasher Headlight Switch Ignition Relay Reverse Relay Stop Light Switch Stop Turn Tail Lamps Right and Left Turn Indicator Lamps Instrument Panel Right and Left Turn Signal and Headlight Dimmer Switch Turn Signal Parking Lamps Front Right and Left Double faced Turn Marker Lig...

Page 245: ... Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Upper Cab Harness Cummins QSB 6 7 T3 Engine Upper Cab Harness Cummins QSB T4F Engine Headlight Dimmer Switch Wiring Headlight Dimmer Switch Wiring Cummins ISB 2013 Engine ...

Page 246: ...0 3 Electrical System Circuits E Schematics 237 Maintenance Manual Ottawa T2 4x2 Headlight Dimmer Switch Wiring Cummins QSB 6 7 T3 Engine Headlight Dimmer Switch Wiring Cummins QSB T4F Engine ...

Page 247: ...trical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Auxiliary Lighting and Air Horn Auxiliary Lighting and Air Horn Cummins ISB 2013 Engine Auxiliary Lighting and Air Horn Cummins QSB 6 7 T3 Engine ...

Page 248: ...ical System Circuits E Schematics 239 Maintenance Manual Ottawa T2 4x2 Auxiliary Lighting and Air Horn Cummins QSB T4F Engine Tail Light Backup Light Wiring Tail Light Backup Light Wiring Cummins ISB 2013 Engine ...

Page 249: ...240 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Tail Light Backup Light Wiring Cummins QSB 6 7 T3 Engine Tail Light Backup Light Wiring Cummins QSB T4F Engine ...

Page 250: ...cs 241 Maintenance Manual Ottawa T2 4x2 0 3 7 Engine Controls page Throttle Pedal TPS Wiring Throttle Pedal TPS Wiring Cummins ISB 2013 Engine Throttle Pedal TPS Wiring Cummins QSB 6 7 T3 Engine Throttle Pedal TPS Wiring Cummins QSB T4F Engine ...

Page 251: ...242 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Engine Wiring Engine Wiring Cummins ISB 2013 Engine ...

Page 252: ...0 3 Electrical System Circuits E Schematics 243 Maintenance Manual Ottawa T2 4x2 Engine Wiring Cummins QSB 6 7 T3 Engine ...

Page 253: ...244 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Engine Wiring Cummins QSB T4F Engine ...

Page 254: ...0 3 Electrical System Circuits E Schematics 245 Maintenance Manual Ottawa T2 4x2 0 3 8 Exhaust page Aftertreatment Wiring Aftertreatment Wiring Cummins ISB 2013 Engine ...

Page 255: ...246 0 3 Electrical System Circuits E Schematics Maintenance Manual Ottawa T2 4x2 Aftertreatment Wiring Cummins QSB T4F Engine ...

Page 256: ...mmins QSB6 7 165 HP at 2200 rpm 123 kW at 2200 rpm 540 ft lbs at 1500 rpm 730 Nm at 1500 rpm Cummins ISB6 7 200 HP at 2300 rpm 150 kW at 2300 rpm 520 ft lbs at 1600 rpm 700 Nm at 1600 rpm Transmission standard Gearing Allison 3000RDS 6 Forward 1 Reverse Allison 3000RDS 6 Forward 1 Reverse Propeller shaft Spicer 1710 Spicer 1710 Axle front Meritor FF961 Meritor FF961 Axle s rear Meritor RS 24 160 M...

Page 257: ...s 43 545 kg 81 000 lbs 36 287 kg Wheelbase 116 inch 2 794 mm 116 inch 2 794 mm Length overall 191 inch 4 851 mm 191 inch 4 851 mm Width overall 97 inch 2 464 mm 97 inch 2 464 mm Fifth wheel boom lift capacity 50 000 lbs 27 216 kg 50 000 lbs 27 216 kg Fifth wheel FW 3500 FW 3500 Chassis weight 14 500 lbs 6 577 kg 14 500 lbs 6 577 kg Chassis Model and Configuration Ottawa T2 4x2 Ottawa T2 4x2 ...

Page 258: ...t down maximum 4 inch 100 mm cylinder 4 inch 100 mm per hour Hydraulic fluid Dexron III Pump flow standard system 10 gallons 37 5 liter per minute at 1200 rpm System capacity Tank only 20 gallons 75 7 liter System 24 gallons 90 8 liter approximate System relief pressure 2000 psi 138 bar Power Steering System Components Specification Pump flow minimum 4 gallons 15 1 liter per minute at 1200 rpm Pum...

Page 259: ...pray Chassis Boom pivot at frame Brake cam pivots Brake slack adjusters Fifth wheel pivot pins Fifth wheel top plate Fifth wheel jaws Front axle king pins Hydraulic cylinder bearings Propeller shaft splines and universal joints Lithium Grease 1 Engine Oil Coolant anti freeze SAE 15W 40 50 50 Propylene Glycol Water Also refer to engine manufacturer s specifications Hydraulic system fluid Dexron III...

Page 260: ...te mounting bolts 65 ft lbs 88 Nm Cab pivot pin retainer screws 35 ft lbs 47 Nm Cab rear door roller capscrews 75 in lbs 8 5 Nm Cab suspension Assembly mounting bolts Shock absorber mounting bolts 220 ft lbs 100 ft lbs 298 Nm 136 Nm Cab tilt cylinder mounting bolts 200 ft lbs 271 Nm Cab tilt pump mounting bolts 77 in lbs 8 7 Nm Cab tilt pump relief valve adjusting screw jam nut 80 in lbs 9 Nm Boom...

Page 261: ...252 0 4 Fastener Torque Values F Technical Data Maintenance Manual Ottawa T2 4x2 ...

Page 262: ... G Appendix 253 Maintenance Manual Ottawa T2 4x2 mm mm mm mm mm mm G Appendix page Description This section is not applicable for this vehicle ...

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