See Manual

Transcript

A. Foreword ........................................................................................................................... 1 About this manual ................................................................................................... 1 Additional Information ............................................................................................. 1 B. Safety ................................................................................................................................ 3 Hazardous Condition Signs .................................................................................... 3 Do’s and Dont’s ...................................................................................................... 4 C. Preventive Maintenance .................................................................................................. 5 Lubrication Points .............................................................................................................. 5 Lubrication Points .............................................................................................. 5 Inspections ........................................................................................................................ 6 Every Day .......................................................................................................... 6 Every 250 Hours of Operation ........................................................................... 6 Every 500 Hours of Operation ........................................................................... 6 Every 1,000 Hours of Operation ........................................................................ 6 Every 2,000 Hours of Operation ........................................................................ 6 Checklists .......................................................................................................................... 7 Daily Inspection Checklist ................................................................................. 7 Preventive Maintenance Forms ....................................................................... 10 Preventive Maintenance Technique ................................................................................ 12 General ........................................................................................................... 12 Fuel, Filters, 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 Starting ......................................................................................................... 26 Precautions ..................................................................................................... 26 Jump Starting Instructions ............................................................................... 26 Vehicle Towing ................................................................................................................ 28 Precautions ..................................................................................................... 28 Front End Towing (Front Wheels Off the Ground) .......................................... 28 Front End Towing (All Wheels On the Ground) ............................................... 29 Rear End Towing ............................................................................................ 29 Vehicle Modifications ...................................................................................................... 30 Approval .......................................................................................................... 30 Vehicle Identification ....................................................................................................... 31 Identification Plate ........................................................................................... 31 Certification Label ........................................................................................... 31 Maintenance Manual Ottawa T2 4x2 Vehicle Serial Number ..................................................................................... 32 Engine Serial Number ..................................................................................... 32 Component Location ....................................................................................................... 33 Chassis/Cab, Left Side ............................................................................................... 33 Ottawa T2, Left Side (4x2 HHD chassis shown) ........................................ 33 Chassis/Cab, Right Side ............................................................................................. 34 Ottawa T2, Right Side (4x2 HHD chassis shown) ...................................... 34 Chassis/Cab, Front/Rear ............................................................................................ 35 Ottawa T2, Front/Rear (4x2 HHD chassis shown) ..................................... 35 Chassis, Plan View ..................................................................................................... 36 Ottawa T2 Plan View (4x2 HHD chassis shown) ....................................... 36 Electrical Instruments ...................................................................................................... 37 Guide to Troubleshooting ................................................................................ 37 Basic Gauge Cluster Diagnostic Procedure .................................................... 37 Engine .................................................................................................................................. 39 Description ............................................................................................................ 39 Controls 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/Axle ...................................................................................................................... 47 Description ............................................................................................................ 47 Brakes .................................................................................................................................. 49 Controls and Instruments ................................................................................................ 49 Foot Pedal (Treadle Valve) ......................................................................................... 49 Description ................................................................................................. 49 Air Control Valves ....................................................................................................... 49 Description ................................................................................................. 49 Brake System .................................................................................................................. 50 Description ...................................................................................................... 50 Air Compressor and Governor .................................................................................... 51 Description ................................................................................................. 51 Air Reservoir ............................................................................................................... 51 Description ................................................................................................. 51 Stop Light Switch ........................................................................................................ 51 Description ................................................................................................. 51 Brakes ......................................................................................................................... 52 Description ................................................................................................. 52 Maintenance Manual Ottawa T2 4x2 Trailer Brake Air Lines ................................................................................................ 53 Description ................................................................................................. 53 Anti-lock Brake System (Optional) .............................................................................. 53 Description ................................................................................................. 53 Automatic Traction Control (Optional) ........................................................................ 54 Description ................................................................................................. 54 Manually Releasing Tractor Spring Brakes (Caging) .................................................. 54 Description ................................................................................................. 54 Diagnosis (Mechanical) ................................................................................................... 56 Brakes ............................................................................................................. 56 Steering ............................................................................................................................... 59 Steering System .............................................................................................................. 59 Description (Power Steering Components) ..................................................... 59 Description (Optional Hydrostatic Steering Components) ............................... 59 Diagnosis (Power Steering) ............................................................................................ 60 Power Steering ................................................................................................ 60 Hydraulic Pump with Priority Valve Test – Power Steering Testing ................ 60 Tools Needed .................................................................................................. 61 Diagnosis (Hydrostatic Steering) ..................................................................................... 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 .......................................... 70 Control System ................................................................................................................... 73 Introduction - General Information ........................................................................ 73 Frame, Body, Cab and Accessories .................................................................................. 75 Controls and Instruments ................................................................................................ 75 Description ...................................................................................................... 77 Low Air Warning ......................................................................................................... 81 Diagnosis ................................................................................................... 81 Hourmeter .................................................................................................................. 81 Diagnosis ................................................................................................... 81 Speedometer .............................................................................................................. 82 Diagnosis ................................................................................................... 82 Voltmeter .................................................................................................................... 83 Diagnosis ................................................................................................... 83 Seating ............................................................................................................................ 84 Description ...................................................................................................... 84 Heating, Ventilation and Air Conditioning ........................................................................ 85 Description ...................................................................................................... 85 Wiping and Cleaning of Windows ................................................................................... 86 Maintenance Manual Ottawa T2 4x2 Windshield Wipers ...................................................................................................... 86 Description ................................................................................................. 86 Diagnosis .................................................................................................... 86 Windshield Washer ..................................................................................................... 87 Description ................................................................................................. 87 Diagnosis .................................................................................................... 87 Lighting System ............................................................................................................... 88 Description ...................................................................................................... 88 Headlights ................................................................................................................... 88 Diagnosis .................................................................................................... 88 Clearance, Marker and Tail Lights .............................................................................. 89 Diagnosis .................................................................................................... 89 Brake Lights ................................................................................................................ 90 Diagnosis .................................................................................................... 90 Backup Light ............................................................................................................... 91 Diagnosis .................................................................................................... 91 Turn Signal .................................................................................................................. 92 Diagnosis .................................................................................................... 92 Beacon Light ............................................................................................................... 93 Diagnosis .................................................................................................... 93 Dome Light .................................................................................................................. 93 Diagnosis .................................................................................................... 93 Daytime Running Lights .............................................................................................. 94 Diagnosis .................................................................................................... 94 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 ................................................................... 100 Cab Frame ............................................................................................................... 100 Description ............................................................................................... 100 Door .......................................................................................................................... 101 Description ............................................................................................... 101 Repair (Rear Door Adjustment) ................................................................ 101 Roof and Door Mouldings ......................................................................................... 102 Description ............................................................................................... 102 Cab Tilting ................................................................................................................ 102 Description ............................................................................................... 102 Cab Tilt (Hydraulic) Components ............................................................. 104 Diagnosis (Cab Tilt) .................................................................................. 105 Maintenance Manual Ottawa T2 4x2 Cab Tilt Pump and Motor .......................................................................................... 106 Diagnosis (Cab Tilt Pump) ....................................................................... 106 Repair (Pump and Motor Removal) ......................................................... 106 Repair (Pump and Motor Installation) ...................................................... 107 Repair [Relief Pressure Adjustment] ........................................................ 107 Cab Tilt Cylinder ....................................................................................................... 109 Repair (Cylinder Removal) ....................................................................... 109 Repair (Cylinder Installation) .................................................................... 110 Cab Pivot Bushing .................................................................................................... 111 Repair (Pivot Bushing Removal) .............................................................. 111 Repair (Pivot Bushing Installation) ........................................................... 113 Cab Mounting and Suspension ................................................................................ 113 Description ............................................................................................... 113 Diagnosis (Cab Air Suspension) .............................................................. 114 Air Ride Suspension (Three-Point) ........................................................................... 114 Repair (Cab Suspension Assembly Removal) ......................................... 114 Repair (Cab Suspension Assembly Installation) ...................................... 115 Repair (Air Ride Level Adjustment) .......................................................... 116 Leveling Valve .......................................................................................................... 116 Repair (Valve Operation Check) .............................................................. 116 Shock Absorbers ...................................................................................................... 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 Accessories and Options .............................................................................................. 127 Accessory Relay ....................................................................................................... 127 Diagnosis ................................................................................................. 127 Heater/Air Conditioning (Optional) ............................................................................ 127 Diagnosis ................................................................................................. 127 Mirrors (Heated/Motorized) ....................................................................................... 128 Diagnosis ................................................................................................. 128 Common Hydraulics ......................................................................................................... 131 System Description ............................................................................................ 131 Tanks and Accumulators .............................................................................................. 131 Reservoir .................................................................................................................. 131 Description ............................................................................................... 131 Temperature Control, Cleaning and Hydraulic Oil ........................................................ 132 Return Filter .............................................................................................................. 132 Description ............................................................................................... 132 Common Electric .............................................................................................................. 133 Controls and Instruments .............................................................................................. 133 Description (Wiring Harness) ........................................................................ 133 Safety ............................................................................................................................ 134 Fuses, Relays and Circuit Breakers ......................................................................... 134 Description ............................................................................................... 134 Maintenance Manual Ottawa T2 4x2 Common Pneumatics ....................................................................................................... 137 Air System and Brakes ................................................................................................. 137 Description .................................................................................................... 137 Diagnosis .................................................................................................................. 137 Brakes — Air System ............................................................................... 137 Valves ............................................................................................................................ 142 Tractor Protection Valves .............................................................................. 142 Proportioning Relay (Bobtail) Valve (Optional) .............................................. 142 Quick Release Valves ................................................................................... 142 Anti-Compounding Valve (Optional) .............................................................. 142 Double (Two-Way) Check Valves ................................................................. 142 Air Dryer ........................................................................................................................ 143 Description .................................................................................................... 143 Diagnosis ....................................................................................................... 143 D. Error Codes .................................................................................................................. 145 Description .................................................................................................... 145 E. Schematics ................................................................................................................... 147 Air System Circuits ........................................................................................................ 147 Air Brakes ................................................................................................................ 147 Components ............................................................................................. 147 Air Brake System with Split Brakes ............................................................... 147 On-Highway Air System ................................................................................ 148 On-Highway Air System Circuit ..................................................................... 150 Off-Highway Air System ................................................................................ 152 Off-Highway Air System Circuit ..................................................................... 154 Cab Seating ............................................................................................................. 156 Air Lines — Driver's Seat ......................................................................... 156 Cab Suspension ....................................................................................................... 156 Air Lines — Cab Suspension ................................................................... 156 Fifth-Wheel Coupling ............................................................................................... 157 Air Lines — Fifth-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 Option Circuit ............................................................ 164 Trailer Hose Connection Coiled Air Lines Circuit ..................................... 164 Trailer Hose Connection Glad Hands Both Ends Coiled Air Lines Circuit 165 Trailer Hose Connection Straight Rubber Air Lines Circuit ....................... 165 Air Horn ..................................................................................................................... 166 Air Lines — Air Horn Option ..................................................................... 166 Air Horn Option Circuit ............................................................................. 166 Inter Axle Lock .......................................................................................................... 167 Air Lines — Inter Axle Option ................................................................... 167 Inter Axle Lock Option Circuit ................................................................... 167 Grease Jockey Lube Pump ....................................................................................... 168 Air Lines — Grease Jockey Lube Pump Option ....................................... 168 Grease Jockey Lube Pump Option Circuit ............................................... 168 Differential Axle Lock ............................................................................................... 169 Air Lines — Differential Axle Lock Option ................................................ 169 Maintenance Manual Ottawa T2 4x2 Differential Axle Lock Option Circuit ......................................................... 169 Additional 7.35 cu. in. Air Reservoir ......................................................................... 170 Air Lines — Additional 7.35 cu. in. Air Reservoir Option .......................... 170 Additional 7.35 cu. in. Air Reservoir Option ............................................. 170 Air Dryer ................................................................................................................... 171 Air Lines — Air Dryer Option .................................................................... 171 Air Dryer Option ....................................................................................... 172 ABS Brakes ............................................................................................................. 173 Air Lines — ABS Brakes Option – On-Highway Only .............................. 173 ABS Brake Option Circuit ......................................................................... 174 Traction Control ....................................................................................................... 175 Air Lines — Traction Control Option for ABS Brakes – On-Highway Only 175 Traction Control Option for Use With ABS Brake Option Circuit .............. 176 3rd Air Tank .............................................................................................................. 177 Air Lines — 3rd Air Tank Option – Off-Highway Only .............................. 177 3rd Air Tank Option Circuit ....................................................................... 177 Hydraulic System Circuits ............................................................................................. 178 Hydraulic Systems ......................................................................................... 178 Cab Tilt .................................................................................................................... 178 Hydraulic 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 Conditioning ..................................................................... 184 Horn ......................................................................................................... 185 Mirrors ...................................................................................................... 186 Radio (Optional) ....................................................................................... 188 Radio Circuit — Hot Wire ......................................................................... 189 Windshield Washer (Optional) ................................................................. 190 Windshield Wiper ..................................................................................... 191 Cab Power Board ..................................................................................... 192 Cab Interior Engine Wiring ....................................................................... 193 Cab Instrumentation ................................................................................................ 195 Air Pressure Gauge Lighting .................................................................... 195 Engine Hourmeter .................................................................................... 196 Fuel Gauge .............................................................................................. 197 Low Air Warning Alarm ............................................................................ 200 Speedometer ............................................................................................ 201 Voltmeter .................................................................................................. 202 Gauge Cluster Wiring ............................................................................... 203 Chassis Circuits ....................................................................................................... 209 Chassis Power Board ............................................................................... 209 Air Dryer (Optional) .................................................................................. 210 Cab Tilt Pump .......................................................................................... 211 Cab Exterior/Front Chassis Wiring ........................................................... 212 Chassis Wiring ......................................................................................... 215 Maintenance Manual Ottawa T2 4x2 Air System Tank Pressure Senders ......................................................... 218 Battery Power Distribution ........................................................................ 219 Cab Tilt System Control Wiring ................................................................ 221 Lighting Circuits (Cab and Chassis) ......................................................................... 224 Backup Light and Alarm ........................................................................... 224 Beacon/Strobe Light (Optional) ................................................................ 225 Clearance Lights (Optional) ...................................................................... 226 Daytime Running Lights (Optional) .......................................................... 227 Dome Light ............................................................................................... 228 Fifth-Wheel Control .................................................................................. 228 Flood Light ................................................................................................ 229 Headlights ................................................................................................ 230 Marker Lights ............................................................................................ 230 Panel Lighting ........................................................................................... 230 Strobe Light .............................................................................................. 230 Tail Lights ................................................................................................. 231 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 .............................................................................................................. 247 Standard Vehicle Data .................................................................................................. 247 Ottawa T2 Series Terminal Tractor ............................................................... 247 Hydraulic System .......................................................................................................... 249 Ottawa T2 Series 4x2 .................................................................................... 249 Fluids, Lubricants and Sealants .................................................................................... 250 Ottawa T2 Series 4x2 .................................................................................... 250 Fastener Torque Values ................................................................................................ 251 Ottawa T2 Series 4x2 .................................................................................... 251 G. Appendix ....................................................................................................................... 253 Maintenance Manual Ottawa T2 4x2 – A. Foreword 1 mm mm mm mm mm mm A. Foreword page – About this manual This service manual covers the Ottawa T2 4x2 and 6x4 terminal (yard) tractors produced by Kalmar Solutions LLC, Kalmar Terminal Tractors. You will find here descriptions of the features, location and operation of the components. Diagnostic and repair procedures are included along with schematic diagrams of the electric, pneumatic and hydraulic circuits. There is a table of specifications and a schedule for preventive maintenance. Basic information, diagnostic and repair procedures are provided for the uniquely Ottawa T2 features and components. Designed to provide the owners and operators of Ottawa T2 4x2 and 6x4 terminal tractors with the information necessary to service and maintain their vehicles properly, this manual presents the information in seven sections. 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 components, such as the steering gear, ABS controllers and other system components, that are produced by quality manufacturers and supplied to Kalmar for production of Ottawa T2 vehicles. It is our hope that this manual will help you to realize maximum utility, efficiency, reliability and durability from your Ottawa T2 tractor. For more in-depth information on individual components, service and/or maintenance manuals are available on the internet. Below is a list of websites where component manuals can be found. Additional Information • Cummins Engine - www.cummins.com • Allison Transmission - www.allisontransmisson.com • Meritor Axle - www.meritor.com • Sisu Axle - www.sisuaxles.com • Bendix Brake System - www.bendix.com • Haldex Slack Adjusters - www.hbsna.com • Holland 5th Wheels - www.safholland.com • Fontaine Armor 5th Wheels www.fontainecouplingsolutions.com • Sheppard Steering Systems - www.rhsheppard.com Maintenance Manual Ottawa T2 4x2 2 – A. Foreword • TRW Steering Components - www.trw.com • Chelsea 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 Maintenance Manual Ottawa T2 4x2 – B. Safety 3 mm mm mm mm mm mm B. Safety page – Hazardous Condition Signs The following signs accompanied by an explanation are used to advise the reader of the degree of hazard associated with the procedure being described. 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 result in damage to the product if the instruction is not followed. NOTE Information that is important without being safety related. Note is used to facilitate the work process, operation/handling or to increase understanding of the information. Maintenance Manual Ottawa T2 4x2 4 – B. Safety page – Do’s and Dont’s WARNING Always disconnect the batteries before welding on or near the vehicle. Improper welding procedures may damage the alternator or batteries. Failure to heed this warning may result in serious personal injury or property damage. • Do use care when removing the radiator filler cap. When the engine is hot, rotate the cap to the first detent, allow the pressure to dissipate and then remove it. • Do stay clear when lowering the cab. • Do set the parking brake when parking the vehicle. • Don't apply full throttle while the engine is cold. • Don't allow sparks or flames near a charging battery. • Don’t allow sparks or flames nearby when inspecting fuel, fuel tank or filler-neck strainer. • Don’t operate a vehicle in an enclosed area without adequate ventilation. • Don’t operate the vehicle with 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 vehicle using welding equipment. • Don’t operate the vehicle with air pressure below 70 PSI. • Don’t shift the transmission from neutral to drive or reverse at engine speeds above idle. Maintenance Manual Ottawa T2 4x2 0.1 Lubrication Points – C. Preventive Maintenance mm mm mm mm mm mm C. Preventive Maintenance 0.1 Lubrication Points page – Lubrication Points 1. Coolant/Antifreeze 1 3 ** 16 4 * 15 2. Engine Oil 3. Slack Adjusters Brake Cam Pivot 4. Front Axle King Pins 5. Tie Rod Ends * 14 5 * 6. Transmission Fluid 7. Diesel Fuel 12 2 7 6 9. Rear Axle Differential 8 10. Driveline Slip Yoke 8. Universal Joints 11. Hydraulic/Steering Fluid 10 11 13 12. Cab Suspension Latch 13. Diesel Exhaust Fluid 14. Front Wheel Bearings 15. Drag Link Ends 9 16. Steering Slip Joint * BOTH SIDES ** BOTH SIDES FRONT AND REAR Chassis Lubrication Diagram — Left-Hand Drive 20 19 * 17. Boom Pivot 21 18. Boom Cylinder Bearings 19. Fifth-Wheel Pivot 18 * 20. Fifth-Wheel Top Plate 21. Fifth-Wheel Jaws Side Door Hinge (not shown) Optional 17 * * BOTH SIDES Boom and Fifth-Wheel Lubrication Diagram OTT0002 Rear Door Upper Rollers (not shown) Maintenance Manual Ottawa T2 4x2 5 6 0.2 Inspections – C. Preventive Maintenance 0.2 page – Inspections Every Day Perform the inspections listed in the Daily Inspection Checklist on page 7 and page 8. At each inspection, add fluids and lubricants as indicated. Repair all leaks. Replace cracked, damaged or worn parts. page – Every 250 Hours of Operation Perform the inspections listed in column A of the chart. Refer to the Preventive Maintenance Forms on page 10 and page 11. These service procedures must be performed after every 250 hours of operation or every month, whichever 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 Preventive Maintenance Forms on page 10 and page 11. These service procedures must be performed after every 1,000 hours of operation. page – Every 2,000 Hours of Operation Perform the inspections listed in column D of the chart. Refer to the Preventive Maintenance Forms on page 10, and page 11. These service procedures must be performed after every 2,000 hours of operation. Maintenance Manual Ottawa T2 4x2 0.3 Checklists – C. Preventive Maintenance 0.3 7 Checklists page – page – Daily Inspection Checklist ❒ Fuel tank ❒ Engine oil level (engine stopped) ❒ Coolant level ❒ Windshield washer fluid level (if applicable) ❒ Fuel water separator ❒ Transmission fluid level (engine running) ❒ Hydraulic fluid level (boom full down) ❒ Diesel exhaust fluid level ❒ Front wheel hub oil level (if applicable) ❒ Engine belt 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 and washer operation ❒ Horn ❒ Radio equipment ❒ Gauges and dash lights ❒ Dome lights ❒ Turn signals ❒ Hazard lights ❒ Headlights ❒ Marker lights ❒ Backup lights ❒ Brake lights ❒ Strobe light (if applicable) ❒ Auxiliary backup lights Maintenance Manual Ottawa T2 4x2 8 0.3 Checklists – C. Preventive Maintenance ❒ Clean the cab interior. ❒ Clean the windows. ❒ Clean and adjust the mirrors. Maintenance Manual Ottawa T2 4x2 0.3 Checklists – C. Preventive Maintenance 9 DAILY INSPECTION FORM TRUCK # ________________ DRIVER NAME __________________________________________ DATE _____________ PERFORM THE FOLLOWING COMPLETE CHECK FUEL LEVEL CHECK ENGINE OIL LEVEL CHECK AIR INTAKE DUCTS COMPLETE CHECK ENGINE COOLANT LEVEL DRAIN WATER FROM AIR TANKS CHECK TRANSMISSION FLUID LEVEL COMPLETE CHECK HYDRAULIC TANK OIL LEVEL CHECK THE FOLLOWING ITEMS AND INDICATE IF “OK” OR “REPAIR NEEDED”. CIRCLE LOCATON ON DRAWINGS IF NECESSARY. DESCRIBE PROBLEMS IN REMARKS AREA AT BOTTOM OF PAGE. OK STEPS / HANDLES / PLATFORMS STARTER NEUTRAL START BACKUP ALARM HEATER / DEFROSTER MIRRORS DOORS WINDOWS WIPERS SEAT SEAT BELT REPAIR NEEDED OK REPAIR NEEDED STEERING THROTTLE BOOM OPERATION 5TH WHEEL RELEASE SERVICE BRAKES PARK BRAKE HORN(S) TRAILER AIR LINES TRAILER LIGHT CORD HEAD LIGHTS SIGNAL LIGHTS OK BACKUP LIGHTS BRAKE LIGHTS FLOOD LIGHT(S) STROBE LIGHT CAB SUSPENSION / LATCH FLUID LEAKS MUD FLAPS / FENDERS TIRES DAMAGE REMARKS: Daily Inspection Form Maintenance Manual Ottawa T2 4x2 REPAIR NEEDED 10 0.3 Checklists – C. Preventive Maintenance Preventive Maintenance Forms page – KALMAR TERMINAL TRACTOR PREVENTATIVE MAINTENANCE FORM NON-SYNTHETIC (NON – TES-295) LUBE USED IN THE TRANSMISSION TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION. √ = SATISFACTORY 0 = ADJUSTMENT NECESSARY Χ = REPAIRS NEEDED. “A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVALS, “B” INSPECTIONS AT 500 HOUR INTERVALS, “C” INSPECTIONS AT 1000 HOUR INTERVALS, AND “D” INSPECTIONS AT 2000 HOUR INTERVALS. OPERATION A B C D OPERATION A B C D CAB – INTERIOR UNDER VEHICLE CHECK OPERATION OF NEUTRAL START CHECK STEERING GEAR CHECK OPERATION OF ALL GAUGES CHECK BRAKE LININGS AND DRUMS CHECK LOW AIR BUZZER AND LIGHT CHECK SPRINGS CHECK WINDSHIELD WIPER OPERATION CHECK SHOCK ABSORBERS (IF APP.) CHECK WINDSHIELD WASHER OPERATION (IF APP.) TORQUE FRONT AXLE MOUNTING BOLTS CHECK THROTTLE OPERATION TORQUE FRONT AXLE KING PIN DRAW KEY NUT(S) CHECK HORN(S) OPERATION CHECK POWER STEERING PUMP CHECK AIR SYSTEM – MINIMUM 120 PSI, MAXIMUM 130 PSI CHECK STARTER MOUNTING AND CONNECTIONS CHECK AIR SYSTEM FOR LEAK DOWN CHECK ENGINE AND TRANSMISSION FOR LEAKS CHECK OPERATION OF BACK UP ALARM CHANGE ENGINE OIL AND FILTER CHECK HVAC SYSTEM CHANGE TRANSMISSION FILTERS BLOWER MOTOR OPERATION CHANGE TRANSMISSION FLUID TEMPERATURE CONTROL CHECK ENGINE AND TRANSMISSION MOUNTS DEFROSTER OPERATION CHECK WHEEL SEALS FOR LEAKS A/C OPERATION (IF APP.) CLEAN REAR AXLE BREATHER AUXILIARY FAN(S) (IF APP.) CHECK DIFFERENTIAL FOR LEAKS TH CHECK 5 WHEEL UNLATCH CONTROL CHECK DIFFERENTIAL OIL LEVEL CHECK OPERATION OF BOOM CHANGE DIFFERENTIAL OIL CHECK OPERATION OF WINDOWS CHECK LIFT CYLINDERS FOR LEAKS CHECK SEAT BELT SYSTEM PER 10-STEP INSPECTION TORQUE REAR AXLE MOUNTING BOLTS CHECK OPERATION OF DOOR LATCHES CHASSIS CHECK DOME LIGHT OPERATION CHECK FRONT WHEEL BEARINGS CHECK ALL GLASS AND MIRRORS CHECK FRONT AXLE OIL LEVEL (IF APP.) CHECK FIRE EXTINGUISHER CHARGE (IF APP.) REPACK FRONT WHEEL BEARINGS (IF APP.) CHECK BATTERY CABLES & HOLDDOWNS CAB DOWN – EXTERIOR 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 CHECK GLADHAND SEALS AND TRAILER AIR LINES CHECK AND TORQUE ALL WHEEL NUTS CHECK TRAILER LIGHT CORD CHECK WHEELS CHECK HEADLIGHTS / MARKER LIGHTS CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION CHECK TURN SIGNALS CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.) CHECK STROBE LIGHT (IF APP.) INSPECT PLATFORMS CHECK SPOTLIGHTS CHECK FRAME FOR CRACKS CHECK WIPER BLADES CHECK MUD FLAPS / FENDERS (IF APP.) CHECK WINDSHIELD WASHER FLUID LEVEL CHANGE HYDRAULIC SYSTEM FILTER CHECK TRANSMISSION FLUID LEVEL CHECK HYDRAULIC FLUID LEVEL CHECK ENGINE OIL LEVEL CHANGE HYDRAULIC FLUID CLEAN HYDRAULIC TANK VENT CAB UP CHECK OPERATION OF CAB TILT PUMP CHECK CAB HINGE PINS AND BUSHINGS CHECK CAB SAFETY PROP LUBRICATION CHECK CAB SUSPENSION AND LATCH CHECK / LUBRICATE REAR DOOR ROLLERS CHECK INTAKE DUCTING FOR LEAKS CHECK / LUBRICATE STEERING SLIP JOINT CHECK RADIATOR FOR LEAKS CHECK / LUBRICATE STEERING U-JOINTS CHECK RADIATOR MOUNTS CHECK / LUBRICATE ALL STEERING LUBE POINTS CHECK COOLANT LEVEL AND CONCENTRATION CHECK / LUBRICATE SLACK ADJUSTERS CHECK AND ADJUST COOLANT ADDITIVE (IF APP.) CHECK / LUBRICATE DRIVELINE U-JOINTS CHANGE ENGINE COOLANT CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS CHECK COOLANT HOSES AND CLAMPS CHECK AND LUBRICATE 5TH WHEEL TOP PLATE CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS CHECK ENGINE COOLING FAN FOR CRACKS CHECK AND LUBRICATE BOOM PIVOT BEARINGS CHECK ENGINE BELT(S) AND TENSIONER CHECK AND LUBE BOOM CYLINDER BEARING CHANGE ENGINE COOLANT FILTER (IF APP.) ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.) CHECK ENGINE AND TRANSMISSION FOR LEAKS TEST DRIVE DRAIN FUEL WATER SEPARATOR DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION CHANGE FUEL FILTER / FUEL WATER SEPARATOR CHECK AIR RESTRICTION GAUGE (IF APP.) CHANGE AIR FILTER AS NEEDED CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED CHECK EXHAUST SYSTEM CLEAN TRANSMISSION BREATHER Preventative Maintenance Form – Non-Synthetic Transmission Lubrication Maintenance Manual Ottawa T2 4x2 0.3 Checklists – C. Preventive Maintenance 11 KALMAR TERMINAL TRACTOR PREVENTATIVE MAINTENANCE FORM SYNTHETIC (TES-295) LUBE AND ALLISON HIGH-CAPACITY FILTERS USED IN THE TRANSMISSION TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION. √ = SATISFACTORY 0 = ADJUSTMENT NECESSARY Χ = REPAIRS NEEDED. “A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVALS, “B” INSPECTIONS AT 500 HOUR INTERVALS, “C” INSPECTIONS AT 1000 HOUR INTERVALS, AND “D” INSPECTIONS AT 2000 HOUR INTERVALS. OPERATION A B C D OPERATION A B C D CAB – INTERIOR UNDER VEHICLE CHECK OPERATION OF NEUTRAL START CHECK STEERING GEAR CHECK OPERATION OF ALL GAUGES CHECK BRAKE LININGS AND DRUMS CHECK LOW AIR BUZZER AND LIGHT CHECK SPRINGS CHECK WINDSHIELD WIPER OPERATION CHECK SHOCK ABSORBERS (IF APP.) CHECK WINDSHIELD WASHER OPERATION (IF APP.) TORQUE FRONT AXLE MOUNTING BOLTS CHECK THROTTLE OPERATION TORQUE FRONT AXLE KING PIN DRAW KEY NUT(S) CHECK HORN(S) OPERATION CHECK POWER STEERING PUMP CHECK AIR SYSTEM – MINIMUM 120 PSI, MAXIMUM 130 PSI CHECK STARTER MOUNTING AND CONNECTIONS CHECK AIR SYSTEM FOR LEAK DOWN CHECK ENGINE AND TRANSMISSION FOR LEAKS CHECK OPERATION OF BACK UP ALARM CHANGE ENGINE OIL AND FILTER CHECK HVAC SYSTEM CHANGE TRANSMISSION FILTERS 3000 HOURS BLOWER MOTOR OPERATION CHANGE TRANSMISSION FLUID 6000 HOURS TEMPERATURE CONTROL CHECK ENGINE AND TRANSMISSION MOUNTS DEFROSTER OPERATION CHECK WHEEL SEALS FOR LEAKS A/C OPERATION (IF APP.) CLEAN REAR AXLE BREATHER AUXILIARY FAN(S) (IF APP.) CHECK DIFFERENTIAL FOR LEAKS CHECK 5TH WHEEL UNLATCH CONTROL CHECK DIFFERENTIAL OIL LEVEL CHECK OPERATION OF BOOM CHANGE DIFFERENTIAL OIL CHECK OPERATION OF WINDOWS CHECK LIFT CYLINDERS FOR LEAKS CHECK SEAT BELT SYSTEM PER 10-STEP INSPECTION TORQUE REAR AXLE MOUNTING BOLTS CHECK OPERATION OF DOOR LATCHES CHASSIS CHECK DOME LIGHT OPERATION CHECK FRONT WHEEL BEARINGS CHECK ALL GLASS AND MIRRORS CHECK FRONT AXLE OIL LEVEL (IF APP.) CHECK FIRE EXTINGUISHER CHARGE (IF APP.) REPACK FRONT WHEEL BEARINGS (IF APP.) CHECK BATTERY CABLES & HOLDDOWNS CAB DOWN – EXTERIOR 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 CHECK GLADHAND SEALS AND TRAILER AIR LINES CHECK AND TORQUE ALL WHEEL NUTS CHECK TRAILER LIGHT CORD CHECK WHEELS CHECK HEADLIGHTS / MARKER LIGHTS CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION CHECK TURN SIGNALS CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.) CHECK STROBE LIGHT (IF APP.) INSPECT PLATFORMS CHECK SPOTLIGHTS CHECK FRAME FOR CRACKS CHECK WIPER BLADES CHECK MUD FLAPS / FENDERS (IF APP.) CHECK WINDSHIELD WASHER FLUID LEVEL CHANGE HYDRAULIC SYSTEM FILTER CHECK TRANSMISSION FLUID LEVEL CHECK HYDRAULIC FLUID LEVEL CHECK ENGINE OIL LEVEL CHANGE HYDRAULIC FLUID CLEAN HYDRAULIC TANK VENT CAB UP CHECK OPERATION OF CAB TILT PUMP CHECK CAB HINGE PINS AND BUSHINGS CHECK CAB SAFETY PROP LUBRICATION CHECK CAB SUSPENSION AND LATCH CHECK / LUBRICATE REAR DOOR ROLLERS CHECK INTAKE DUCTING FOR LEAKS CHECK / LUBRICATE STEERING SLIP JOINT CHECK RADIATOR FOR LEAKS CHECK / LUBRICATE STEERING U-JOINTS CHECK RADIATOR MOUNTS CHECK / LUBRICATE ALL STEERING LUBE POINTS CHECK COOLANT LEVEL AND CONCENTRATION CHECK / LUBRICATE SLACK ADJUSTERS CHECK AND ADJUST COOLANT ADDITIVE (IF APP.) CHECK / LUBRICATE DRIVELINE U-JOINTS CHANGE ENGINE COOLANT CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS CHECK COOLANT HOSES AND CLAMPS CHECK AND LUBRICATE 5TH WHEEL TOP PLATE CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS CHECK ENGINE COOLING FAN FOR CRACKS CHECK AND LUBRICATE BOOM PIVOT BEARINGS CHECK ENGINE BELT(S) AND TENSIONER CHECK AND LUBE BOOM CYLINDER BEARING CHANGE ENGINE COOLANT FILTER (IF APP.) ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.) CHECK ENGINE AND TRANSMISSION FOR LEAKS TEST DRIVE DRAIN FUEL WATER SEPARATOR DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION CHANGE FUEL FILTER / FUEL WATER SEPARATOR CHECK AIR RESTRICTION GAUGE (IF APP.) CHANGE AIR FILTER AS NEEDED CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED CHECK EXHAUST SYSTEM CLEAN TRANSMISSION BREATHER Preventative Maintenance Form – Synthetic Transmission Lubrication with High Capacity Filters Maintenance Manual Ottawa T2 4x2 12 0.4 Preventive Maintenance Technique – C. Preventive Maintenance 0.4 Preventive Maintenance Technique page – General The following is more detailed information for preventive maintenance. See the Lubrication Points page 5 provided in this manual. Refer to the Preventive Maintenance Forms on page 10 for additional scheduling. The hourly time limits described in this manual are absolute maximums. Harsh vehicle usage may dictate shorter intervals. Inspect frequently to discover where changes may be necessary. 0.4.1 Fuel, Filters, Fluids and Lubricants page – Maintenance The engine, transmission and axle manufacturers provide maintenance information and specify fluids and lubricants to be used in their products. Comply with the original equipment manufacturer’s specifications in order to maintain warranty coverage. Follow the periodic checklists as indicated. Fill reservoirs as necessary using specified fluids. When adding, use the same fluid as is in the reservoir. If the fluid is unknown, drain and replace it according to specification. Use only the fuel, coolant, coolant additives, diesel exhaust fluid 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 reason for lost fluid. Repair as necessary. The Kalmar Parts Catalog is customized to the vehicle. Refer to this catalog for filter part numbers. Kalmar recommends API Grade 1 grease, any high-quality lithium-based grease, or a base oil with a Timken 40 minimum rating for use in axles. Install the same lubricant as originally installed in the axles. Do not use lithium grease on front axles equipped with “WET” wheel seals. The front hubs must be inspected after every 250 hours of operation. Power steering, the boom lift and the cab tilt mechanism all use hydraulic fluid stored in a single tank mounted on the rail. A vehicle being operated in a severe application may require shorter intervals between changes. The system filter is on the hydraulic tank. Maintenance Manual Ottawa T2 4x2 0.4 Preventive Maintenance Technique – C. Preventive Maintenance 0.4.2 13 Cab Interior page – Maintenance Check Operation of Neutral Start — Move the gear selector to any position other than "N" and attempt to start the engine. The engine should not crank with the selector in any position other than "N". Check Operation of All Gauges — With the engine running verify that all gauges are functional. Check Low Air Buzzer and Light — Apply and release the brake pedal until air pressure drops below 90 psi. At that point, the low air buzzer and dash warning light should come on. Check Windshield Wiper Operation — Turn on the windshield wiper and confirm full and smooth travel of the wiper arm. Listen for any noises that might indicate a worn wiper motor. Check Windshield Washer Operation (if applicable) — Depress the washer button and confirm the flow and pattern of the 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), Maximum 130 PSI (8.96 bar) — Start the engine and run at fast idle. Maximum system pressure should be limited to a minimum of 120 P.S.I. (8.27 bar) and a maximum of 130 P.S.I. (8.96 bar). Check Air System for Leak Down — Disconnect the glad hands from any trailer. Run engine at fast idle and allow air pressure to stabilize at 120 PSI for at least one minute. Shut off engine the and observe dash gauge(s) for two minutes. The drop in pressure should not exceed 2 PSI (0.137 bar) over the two-minute period. Check Operation of Back Up Alarm — With engine running, move the gear selector to reverse and listen for back up alarm. Check HVAC System — • Blower Motor Operation With the key on, ensure that the blower motor operates at each position of the blower speed switch. • Temperature Control Confirm proper operation of the temperature control switch. Maintenance Manual Ottawa T2 4x2 14 0.4 Preventive Maintenance Technique – C. Preventive Maintenance • Defroster Operation With the engine running and the defroster control turned on, confirm air flow from the defroster vents. • Air Conditioner Operation With the engine running and the air conditioner control turned on, confirm cooled air flow from the vents. • Auxiliary Fan(s) (if applicable) With the key on, turn on the auxiliary fans and confirm operation. Check 5th Wheel Unlatch Control — With system air pressure above 100 PSI confirm that the 5th wheel jaws unlatch when the dash control is activated. Check Operation of Boom — With the engine running at fast idle activate the boom control and ensure full extension and retraction. Check Operation of Windows — Confirm that all regulated and sliding windows open and close fully. Check Seat Belt Operation — Ensure that the seatbelt latch fastens and unfastens properly. Check Rear and Side Door Latch Operation — Operate the side door latch from inside and outside the cab to ensure 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 mirrors 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 Inspect the seat belt system every 20,000 miles (32,187 km) or more often if exposed to severe environmental conditions or vocation. Check the following: Inspect belt on entire system for cuts, fraying, extreme or unusual wear. Most common areas of belt wear include the buckle/latch area, the shoulder loop area and any place where the belt makes contact with vehicle or seat. Replace the entire belt system if necessary. Inspect buckle for proper operation by inserting latch and listening for an audible click. Verify the buckle is not damaged, cracked or broken. Replace the entire belt system. Inspect buckle cable (optional component) black coating on buckle cable must not be damaged. Internal cable wires must not be exposed, frayed or broken. Replace the entire system. Maintenance Manual Ottawa T2 4x2 0.4 Preventive Maintenance Technique – C. Preventive Maintenance 15 Inspect latch for proper operation by inserting into buckle. Latch must insert smoothly and you must hear an audible click. Verify proper latching by tugging on belt. Latch must not be worn, deformed or corroded. Replace the entire belt system. Inspect shoulder loop web guide (optional component) Seat belt must move freely through shoulder loop. Shoulder loop must also pivot freely and be free of obstructions. If necessary, adjust shoulder loop hardware and/or remove obstruction. Inspect seat belt height adjuster (optional component) for damage. Mover adjuster up and down. It must move freely and lock at the different height positions. Replace the entire belt system if necessary. Inspect retractor operation. When pulled and released slowly, seat belt must spool out and retract without locking. Replace the entire belt system if necessary. Inspect mounting hardware on both sides of seat. Hardware should be tight. Hardware must not be missing, rusted, 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/or properly adjust tethers according to vehicle manufacturer’s specifications. Inspect Komfort Latch® (optional component) for function and ability to clamp on web. Replace the entire system if necessary. 0.4.3 Cab Down — Exterior page – Maintenance Check Side Door Hinge (if applicable) — Inspect the door hinge for wear and damage. Check Cab Access Steps and Handles — Inspect all steps and grab handles for proper mounting and the absence of cracks. Clean Heater/AC Filter — Remove the HVAC filter and vacuum or blow clean with low-pressure air. Check Rear Door Roller/Slide Adjustment — Inspect rear door rollers and slide for wear or damage. Check Gladhand Seals and Trailer Air Lines — Inspect seals for tears and wear. Check air lines for kinks or cracks. Maintenance Manual Ottawa T2 4x2 16 0.4 Preventive Maintenance Technique – C. Preventive Maintenance Check Trailer Light Cord (if applicable) — Inspect light cord for cuts and abrasions. As the lights of the truck are checked confirm that a trailer connected with the light cord also has lights. This can be done either with a trailer connected or with a "test box". Check Headlights/Marker Lights — Start engine, turn on light switches and confirm lights are illuminated. Check Turn Signals — With key on, activate the turn signal switch and the flasher to confirm that the turn signals are working. Check Strobe Light (if applicable) — With the key on, turn on the strobe light to confirm its operation. Check Spotlights — With the key on, turn on the spotlight(s) to confirm its operation. Check Wiper Blades — Inspect wiper blades for tears or excessive wear. Check Windshield Washer Fluid Level — Raise the hood and fill washer bottle as necessary. Check Transmission Fluid Level — With the engine running, 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 release 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 drop freely into place to support the cab when it is in the raised position. The lower cab cylinder pin and bracket should be inspected for signs of fatigue. Check Cab Suspension and Latch — Inspect the linkages of the suspension system for excessive wear and proper alignment. Inspect the air bag for leaks or signs of abrasion. Inspect the lock jaw for excessive wear and proper operation. Check Engine Intake Ducting for Leaks — Inspect all engine clean air tubes and hoses for leaks. All clamps should be checked for proper torque and all joints should be properly aligned. Check Radiator for Leaks — Inspect radiator core and tanks for signs of coolant leaks. Check Radiator Mounts — Inspect radiator mounts for wear or excessive looseness. Maintenance Manual Ottawa T2 4x2 0.4 Preventive Maintenance Technique – C. Preventive Maintenance 17 Check Coolant Level and Concentration — Check cooling system level. Coolant should be visible in radiator sight glass. It is not necessary for the coolant to be at the top of the sight glass. Test and maintain the proper antifreeze level of concentration as outlined in the appropriate engine operator's manual. Change Engine Coolant — Flush the cooling system and replace with clean coolant of the appropriate concentration. Check Coolant Hoses and Clamps — Inspect all hoses for abrasion, cracks, holes and routing. Check all clamps for proper torque. Check Fan Clutch for Operation (if applicable) — Run engine to confirm that the fan clutch engages at the proper temperature. Check Engine Cooling Fan for Cracks — Shut the engine off if running. Inspect fan blades for signs of cracking. Check Engine Belts and Tensioner — Inspect belt(s) for cracking and wear. Belt tensioner should be checked for proper operation. Check Engine and Transmission for Leaks — Perform a visual inspection of the engine and transmission looking 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 reading remains on zero, the gauge may be defective or the intake piping has a leak. The cause must be investigated and the gauge replaced and/or the piping repaired. If the initial gauge reading indicates that the filter should be changed, do so at this time. See the next item on the PM form. Change Air Filter — The air filter should be changed as needed. If the truck is equipped with a restriction gauge, replace the filter when the gauge 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 System — Visually inspect all of the exhaust system components for leaks and/or damage. Clean Transmission Breather — Confirm that the breather, located on top of the transmission, is clean and the passage is open. Do not spray directly with high pressure or cleaning solvents. Maintenance Manual Ottawa T2 4x2 18 0.4 Preventive Maintenance Technique – C. Preventive Maintenance 0.4.5 Under Vehicle page – Maintenance Check Steering Gear — Inspect steering gear for fluid leaks and excessive play. Inspect the steering linkage for wear or looseness. Check Brake Linings and Drums — Visually check linings and drums for wear and cracks. If the lining is 0.25" thick or less in any location the shoes should be replaced or relined. Check Leaf Springs — Inspect leaf springs for cracking or excessive deflection. Inspect spring pins for wear. Check Shock Absorbers (if applicable) — Inspect shock absorbers for leaks. Torque Front Axle Mounting Bolts — Re-torque front axle mounting bolts to 210 ft. lbs. (285 Nm). Torque Front Axle Kingpin Draw Key Nuts — Re-torque the steer axle kingpin draw key nut(s). Check Hydraulic Pump — Inspect the hydraulic pump for leaks. Check Starter Mounting and Connections — Confirm that starter mounting bolts are tight. Inspect electrical connections for good contact at starter terminals. Check Engine and Transmission for Leaks — Perform a visual inspection of the engine and transmission looking for any fluid leaks visible from below. 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. Replace the oil filter. Change Transmission Filters — Notice — This DOES NOT include the pan screen. The screen should only be replaced during overhaul. Change Transmission Fluid — Drain and replace transmission fluid. Use fluid meeting, at least, the minimum specifications provided in the transmission operator's manual. Check Engine and Transmission Mounts — Re-torque engine and transmission mounts. Inspect isolator material and replace if deteriorated. Check Wheel Seals for Leaks — Inspect front and rear hubs for signs of oil leaks. Replace if leaking. Clean Rear Axle Breather — Ensure that the rear axle vent turns freely. Check Differential for Leaks — Inspect rear axle housing for signs of leaks. Repair as necessary. Maintenance Manual Ottawa T2 4x2 0.4 Preventive Maintenance Technique – C. Preventive Maintenance 19 Check Differential Oil Level — Check the differential oil level per the component manufacturer's instructions. Change Differential Oil — Drain and replace differential oil. Use oil meeting, at least, the minimum specifications of the component manufacturer. Check Lift Cylinders for Leaks — Inspect cylinders for signs of leaking. Repair as necessary. Torque Rear Axle Mounting Bolts — Re-torque rear axle mounting bolts. Nut at 400 ft. lbs. (542 Nm), Bolt at 600 ft. lbs. (813 Nm). 0.4.6 Chassis page – Maintenance Check Front Wheel Bearings — Raise and support the front axle. Check for excessive play in wheel bearing. Check Front Axle Oil Level (if applicable) — Check oil level in front axle hubcaps. Fill to proper level as necessary. Repack Front Wheel Bearings (if applicable) — Remove front hubs and repack the bearings using grease meeting, at least, the minimum specifications of the component manufacturer. 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 terminals from batteries, clean connections, reattach cable terminals. Check Battery Box Cover Holddowns — Check bolts or rubber latches to ensure that the battery box cover is secured. Drain Water from Air Tanks — With air system charged, open each manual drain until all moisture is removed from system. Check and Torque All Wheel Nuts — Inspect all wheel nuts for signs of wear or damage. Re-torque all nuts to 450-500 ft. lbs. (610-678 Nm). Check Wheels — Inspect all wheels for signs of damage including oversized holes and cracks. Check Tire Air Pressure, Tread Depth and Condition — Inspect tires for damage and wear. Adjust to the proper air pressure. Check Rear Axle Planetary Fluid Level (if applicable) — Check and adjust the lubricant level in the planetary housings per the component manufacturer’s instructions. Maintenance Manual Ottawa T2 4x2 20 0.4 Preventive Maintenance Technique – C. Preventive Maintenance Inspect Platforms — Inspect the platforms for proper mounting and the absence of cracks and trip points. Check Frame for Cracks — Inspect frame rails and crossmembers for cracks and bending. Check Mud Flaps/Fenders (if applicable) — If equipped with mud flaps and/or fender, inspect these items for proper mounting and damage. Change Hydraulic System Filter — Remove and replace the hydraulic filter. Check Hydraulic Fluid Level — Start engine, raise and lower the boom two to three times to ensure that system components are filled. Lower boom to full down position, shut off engine and check fluid level on tank gauge. Fill as necessary. Change Hydraulic Fluid — Drain hydraulic tank and refill with Dexron III automatic transmission fluid. Clean Hydraulic Tank Vent — Remove any dirt collecting around vent and ensure that vent is clear. Check Cab Hinge Pins and Bushings — Inspect pins and bushings for wear or damage. 0.4.7 Lubrication page – Maintenance Check/Lubricate Rear Door Rollers — Inspect upper rollers. 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 ends and drag link ends for wear or damage. Lubricate with lithium grease. Check/Lubricate Slack Adjusters — Inspect brake slack adjusters for wear or damage. Measure the brake actuator stroke. If this measurement exceeds the component manufacturer's recommendation check brake lining and adjuster to determine which is the cause of the excessive stroke and repair as necessary. Check/Lubricate Driveline U-Joints — Inspect driveline and U-joints for wear or damage. Lubricate with lithium grease. Clean, Check Adjust and Lube 5th Wheel Jaws — Remove dirt and excessive grease from the 5th wheel jaws. Using a 5th wheel jaw gauge measure the free play. If free play exceeds 1/8" (3.175 mm) determine the cause of the excessive play and either repair or replace the jaws per the component manufacturer's recommendation. Maintenance Manual Ottawa T2 4x2 0.4 Preventive Maintenance Technique – C. Preventive Maintenance 21 Check/Lubricate 5th Wheel Top Plate — Clean and inspect the 5th wheel top plate for cracks or other damage. Apply lithium grease to the surface of the top plate. Check/Lubricate 5th Wheel Pivot Pins — Inspect 5th wheel pivot pins for wear or damage. Lubricate with lithium grease. Check/Lubricate Boom Pivot Bearings — Inspect 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. Lubricate 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 reservoir with the proper type and quantity of grease per the component manufacturer's recommendation. 0.4.8 Test Drive page – Maintenance Drive Vehicle to Check Overall Operation — Start and drive vehicle. Test the operation of all systems and components. Maintenance Manual Ottawa T2 4x2 22 0.4 Preventive Maintenance Technique – C. Preventive Maintenance Maintenance Manual Ottawa T2 4x2 0.1 The Ottawa T2 Terminal Tractor – 0. Machine Complete 23 mm mm mm mm mm mm 0. Machine Complete 0.1 The Ottawa T2 Terminal Tractor page – Description The Ottawa T2 terminal tractor by Kalmar is designed to suit the operator and the tasks. Ottawa T2 tractors are purpose-built vehicles, designed to move trailers in the most efficient manner. Controls are conveniently arranged around the operator's seat. The operator can get into the cab from the sliding rear door or optional side door. The sliding feature and latching in open and closed position means that the rear door is never in the way. Full-length grab-handles, large windows and easy access to all operator controls are some of the features of the efficiently designed cab. The trailer air lines and electrical connections are easily accessible through the rear door. Perforated decking allows the operator to move from cab to trailer comfortably and easily. A hydraulically powered boom under the fifth wheel raises a trailer high enough to allow it to be moved without raising and lowering its landing gear. These features along with in-cab fifth-wheel release and automatic relatch means that the operator is not required to climb up and down from the cab for every trailer move. The Ottawa T2 also features automatic transmissions, hydraulic cab tilt for easy maintenance access, a short turning radius and matched drive train components with durable axles that simplify maintenance even further. Ottawa T2 tractors are engineered for longevity and easy operation. Maintenance Manual Ottawa T2 4x2 24 0.2 Diesel Fuel Requirements – 0. Machine Complete 0.2 Diesel Fuel Requirements page – Precautions WARNING Do NOT smoke when handling diesel fuel. Failure to heed this warning may result in serious personal injury and property damage. Use only the fuel specified by the engine manufacturer. Improper fuel can result in corrosion, damaging deposits and premature wear. CAUTION Do NOT add anything but diesel fuel to the fuel tank. Drain the entire fuel system and fill with the correct fuel. Failure to heed this caution may result in serious property damage. Avoid using smoke suppressant additives to prevent excessive ash deposits that may result in frozen rings and guttered valves. Refer to the engine manufacturer’s service manual for fuel requirements. 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 prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Do not swallow internally. In the event the Diesel Exhaust Fluid is ingested, contact a physician immediately. CAUTION It is unlawful to tamper with or remove any component of the after-treatment system. It is also unlawful to use a catalyst solution that does not meet the specifications provided or to operate the vehicle/equipment with no catalytic solution. If the Diesel Exhaust Fluid level is found to be low, Diesel Exhaust Fluid must be added. Maintenance Manual Ottawa T2 4x2 0.2 Diesel Fuel Requirements – 0. Machine Complete 25 The following 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 Diesel Exhaust Fluid must meet the engine manufacturer's specification. See your engine operator's manual. Maintenance Manual Ottawa T2 4x2 26 0.3 Emergency Starting – 0. Machine Complete 0.3 Emergency Starting page – Precautions When jump starting one vehicle from another, both electrical systems must have the same voltage rating and polarity. CAUTION Verify that the polarity and voltage rating of the service batteries match the polarity and voltage rating of your Ottawa T2 tractor before attempting to jump start a vehicle. Due to the higher torque requirements for starting diesel engines, Ottawa T2 tractors use multiple batteries. At low temperatures, it may not be possible to start the engine in an Ottawa T2 tractor using only one battery. CAUTION Never tow a vehicle in an attempt to start the engine. This may cause serious damage to the automatic transmission. – Jump Starting Instructions 1. Position the vehicles so that the jumper cables reach comfortably but the vehicles do NOT touch. Ensure that the jumper cable insulation is NOT missing or loose. 2. Shift the automatic transmission to neutral and apply the parking brake. 3. Turn off the 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 terminal on one battery and the other end to the positive terminal 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 other end to the negative terminal of the dead battery. 6. Start and run the engine of the vehicle with the charged battery at moderate speed for several minutes, then start the engine in the vehicle that has the discharged battery. Maintenance Manual Ottawa T2 4x2 0.3 Emergency Starting – 0. Machine Complete 27 7. Remove the jumper cables by reversing the above installation sequence exactly. While removing each clamp be sure that it does not touch any other metal while connected to the other battery. WARNING Batteries produce explosive gases, contain corrosive acid and generate 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 thoroughly with water immediately and seek medical attention. Failure to heed this warning may result in serious personal injury and property damage. Maintenance Manual Ottawa T2 4x2 28 0.4 Vehicle Towing – 0. Machine Complete 0.4 Vehicle Towing page – Precautions Use proper equipment to prevent damage to vehicles during towing. Conform to applicable state and local laws for towing vehicles. Vehicles should not be towed at speeds in excess of 55 mph (89 km/h). Connect towing equipment to main structural parts of the vehicle. See Operator’s Manual for more detailed instructions. CAUTION Do NOT connect towing equipment to the bumper. Use tow hooks or tow eyes built into the frame. Use only towing equipment designed for the purpose. Follow the instructions of the wrecker manufacturer. Use safety chains. Failure to heed this caution may result in serious property damage. Secure all loose and protruding parts of the vehicles prior to towing. Do NOT stand or work under an elevated vehicle without adequate safety stands. Do NOT attempt towing operations that will jeopardize the safety of other motorists, bystanders or the towing or towed vehicles. – Front End Towing (Front Wheels Off the Ground) To relocate a disabled vehicle by front end towing with front wheels raised off the ground, follow these steps. 1. Block the rear wheels of the disabled vehicle. 2. Release the parking brake as outlined in the brake section of this manual. See Caging the brakes in the Operator’s Manual or the section 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 propeller 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. Maintenance Manual Ottawa T2 4x2 0.4 Vehicle Towing – 0. Machine Complete 29 When the vehicle has arrived at its destination, ensure it is safely positioned. 1. Block the rear wheels. 2. Install the axle shafts. 3. Remove the covers from the hub openings. 4. Align the universal joints and connect the propeller shaft. 5. Apply the parking brake before disconnecting the towing vehicle. 6. Check and fill rear axles with oil as needed. – Front End Towing (All Wheels On the Ground) The vehicle may be towed with all wheels on the ground provided 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 off the ground. – Rear End Towing When towing the vehicle with rear wheels raised, secure the steering wheel to maintain straight ahead position. Ensure that the front axle load is not more than the gross axle weight rating as indicated on the vehicle identification plate. Maintenance Manual Ottawa T2 4x2 30 0.5 Vehicle Modifications – 0. Machine Complete 0.5 Vehicle Modifications page – Approval Do not modify your Ottawa T2 tractor without approval in writing from Kalmar Solutions LLC, Kalmar Terminal Tractors. Unauthorized modifications may void the vehicle warranty. Maintenance Manual Ottawa T2 4x2 0.6 Vehicle Identification – 0. Machine Complete 0.6 31 Vehicle Identification page – Identification Plate A vehicle may be specifically identified by referring to the vehicle identification plate. The plate is located inside the cab on the top corner of the rear door opening. This plate shows the model, serial number and manufactured date for this vehicle. – Certification Label The certification label is supplied only for vehicles qualified under 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 Vehicle Identification Number (VIN), gross vehicle weight rating (GVWR), front and rear gross axle weight ratings (GAWR), wheel base, tire and rim sizes, and tire air pressure. Maintenance Manual Ottawa T2 4x2 32 – 0.6 Vehicle Identification – 0. Machine Complete Vehicle Serial Number The serial number 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 number when ordering parts or requesting field service assistance. – Engine Serial Number Cummins serial numbers are located on the top of the valve cover. Maintenance Manual Ottawa T2 4x2 0.7 Component Location – 0. Machine Complete 0.7 33 Component Location 0.7.1 Chassis/Cab, Left Side page – Ottawa T2, Left Side (4x2 HHD chassis shown) 5 3 1 4 2 8 12 11 9 7 10 6 13 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 Maintenance Manual Ottawa T2 4x2 34 0.7 Component Location – 0. Machine Complete 12. Tow Hook 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 Maintenance Manual Ottawa T2 4x2 0.7 Component Location – 0. Machine Complete 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 Maintenance Manual Ottawa T2 4x2 35 36 0.7 Component Location – 0. Machine Complete 0.7.4 Chassis, Plan View page – Ottawa T2 Plan View (4x2 HHD chassis shown) 11 13 1 5 6 7 8 15 9 10 16 3 12 2 1. Fifth-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 Maintenance Manual Ottawa T2 4x2 0.8 Electrical Instruments – 0. Machine Complete 0.8 37 Electrical Instruments page – Guide to Troubleshooting This guide is provided for diagnosis of problems in Kalmar electrical instruments. The sequence presented is intended to minimize duplication. Follow the sequence as described to prevent misdiagnosis. This guide presumes that senders and gauges are properly matched and wired and that the correct voltage is applied. WARNING Ensure that the gauge cluster and senders are matched and properly wired in circuits with correct voltage. Failure to heed this warning could result in personal injury and property damage. page – Basic Gauge Cluster Diagnostic Procedure Schematics and diagrams of the electrical circuitry appear in Section E, Schematics. The following steps describe the general path to follow when troubleshooting electrical faults that show up on the instrument panel. 1. On replacement parts, check the part numbers of the gauge and sender to ensure they are matched, 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. Momentarily apply power. The pointer should move to the far right of the scale. Remove power. If the gauge fails this test, replace the gauge and retest. 4. If the pointer jumps rapidly, overshoots or oscillates around the rest position, the sender connection contact is intermittent. Trace the sender wiring and verify that the connections are secure. If connections are tight and in good condition, replace the gauge cluster. Maintenance Manual Ottawa T2 4x2 38 0.8 Electrical Instruments – 0. Machine Complete Maintenance Manual Ottawa T2 4x2 – 1 Engine 39 mm mm mm mm mm mm 1 Engine page – Description The Ottawa T2 yard tractor is designed to utilize the benefits of a diesel engine of the type customarily 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 manufacturers. 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. Maintenance Manual Ottawa T2 4x2 40 1.1 Controls and Instruments – 1 Engine 1.1 Controls and Instruments 1.1.7 Fuel Gauge page – Diagnosis Fuel Gauge Components • Cab Accessory Circuit Breaker • Gauge Cluster • Fuel Level Sending Unit • Headlight Switch • Ignition Switch • Panel Dimmer Switch (Optional) Fuel Gauge Circuit Diagnosis Observation Zero reading Inaccurate gauge Cause Action Circuit breaker open Reset. Repair short as needed. Replace 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. Defective gauge cluster Test. Replace as needed. Maintenance Manual Ottawa T2 4x2 1.2 Fuel System – 1 Engine 1.2 41 Fuel System 1.2.1 Fuel Tank page – Description Brackets bolted to the rail hold the 50-gallon (190 liter) rectangular step fuel tank. Two-inch (51 mm) wide straps secure the tank to the two mounting brackets. Rubber strap liners protect against chafing between the straps and the tank. The manufacturer’s name plate is fastened to the side of the tank where it can easily be seen. WARNING Diesel fuel is combustible. Do NOT smoke and do NOT use an open flame while fueling. Fuel Tank and Fittings Failure to heed this warning may result in serious personal injury and property damage. 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 braided steel wire. Maintenance Manual Ottawa T2 4x2 42 1.3 Diesel Exhaust Fluid (DEF) – 1 Engine 1.3 Diesel Exhaust Fluid (DEF) 1.3.1 DEF Tank and Pump page – Description The DEF tank is locate on the left side of the tractor at the rear of the fuel tank. It is a 5-gallon size tank constructed of cross-link polyethylene (XLPE). The tank is mounted with a bracket to the frame rail. The blue fill cap signifies its use as DEF ONLY. DEF tank 1.3.6 Sensor, Low DEF Level page – Description A level sensor and level focus tube is integrated into a multifunction head unit on the DEF tank. 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 lines are electrically heated to prevent fluid freezing. Both lines are connected to the dosing pump unit with 5/16" straight fittings. The DEF suction (throttle) line (1000 mm long) connects to the multifunction head unit with a 3/8" 90-degree fitting. The DEF return (pressure) line (1750 mm long) connects to the multifunction head unit with a 5/16" 90-degree fitting. Maintenance Manual Ottawa T2 4x2 1.11 Start/Stop – 1 Engine 1.11 43 Start/Stop page – Diagnosis (Starting and Charging Diagnosis) Components • Alternator • Batteries • Ignition Switch • Starter • Starter Relay • Starter Solenoid Starting and Charging Circuit Diagnosis Observation Battery charge low/discharged Engine does not crank Cause Action 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. Battery charge low/discharged See above. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Defective relay Replace. Defective solenoid Replace. Defective starter Replace. Maintenance Manual Ottawa T2 4x2 44 1.11 Start/Stop – 1 Engine Maintenance Manual Ottawa T2 4x2 – 2 Transmission 45 mm mm mm mm mm mm 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. Maintenance Manual Ottawa T2 4x2 46 – 2 Transmission Maintenance Manual Ottawa T2 4x2 – 3 Driveline/Axle 47 mm mm mm mm mm mm 3 Driveline/Axle page – Description An Ottawa T2 tractor will be equipped with one of several manufacturer’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 features. 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. Maintenance Manual Ottawa T2 4x2 48 – 3 Driveline/Axle Maintenance Manual Ottawa T2 4x2 4.1 Controls and Instruments – 4 Brakes 49 mm mm mm mm mm mm 4 Brakes 4.1 Controls and Instruments 4.1.1 Foot Pedal (Treadle Valve) page – Description This foot-actuated valve is actually two valves that operate in quick sequence. It is connected in the front and rear brake circuitry so that the rear brakes begin to act before the front brakes when the operator steps on the pedal. When air pressure is correct in both circuits, the second stage is driven via air pressure by the first stage. If air is lost to the first stage, the second stage is driven mechanically by the first stage. 4.1.9 Air Control Valves page – Description 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 vehicle operation with trailer in tow requires that both knobs be depressed. All braking control then transfers to the foot pedal. Operating in bobtail mode requires that the red knob be pulled out (stop trailer air supply) and the yellow knob be depressed (release tractor parking brakes). Instrument Panel 4 — Trailer Air Supply and Tractor Parking Control Knobs Maintenance Manual Ottawa T2 4x2 50 4.3 Brake System – 4 Brakes 4.3 Brake System page – Description Major components of the air brake system include the following items. • Air Compressor and Governor • Air Control Valves • Air Dryer (Optional) • Air Reservoirs (Air Storage) • Brake Chambers and Parking Brakes • Double (Two-Way) Check Valves • Foot Pedal (Treadle Valve) • Foundation (Wheel) Brakes • Proportioning (Bobtail) Valve (Optional) • Quick Release 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) foundation 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 spring-actuated, but compressed air is required to release them. A buzzer and an indicator light warn of low pressure in the system when pressure falls below 70 psi. The air pressure gauge reflects the actual system pressure. Maintenance Manual Ottawa T2 4x2 4.3 Brake System – 4 Brakes 4.3.1 51 Air Compressor and Governor page – Description Pressure is supplied by a reciprocating piston-type compressor mounted on the engine. The compressor shares engine lubrication and coolant systems. Running continuously, the compressor requires a governor to maintain the necessary system pressure. The governor is mounted on the compressor. Operating in conjunction with an unloading valve, the governor directs air into the reservoirs or out the exhaust port. Air Compressor Governor 4.3.4 Air Reservoir page – Description The air reservoirs maintain a sufficient quantity of air under pressure to sustain several applications of the brakes. Standard vehicles with a split brake system (DOT/EPA approved vehicles) have three air reservoirs. In the three-reservoir system, one serves as the primary, sometimes called the wet tank. It supplies air to the other two reservoirs 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 to operate in the event the other should fail. Each tank has its own drain valve to release water and oil that may have accumulated in the tank during operation. System pressure is monitored by a low pressure sensor that communicates with an indicator light mounted in the instrument panel and a buzzer mounted on an electrical relay panel on the cross member below the steering column. The indicator and buzzer are activated while the system pressure is below 70 psi. 4.3.9 Stop Light Switch page – Description This is an air-actuated switch that causes the stop lights to illuminate when system air pressure increases to 5 psi after depressing the foot pedal. Maintenance Manual Ottawa T2 4x2 52 4.3 Brake System – 4 Brakes 4.3.10 Brakes page – Description Brake Chambers and Parking Brakes — In the front are two single chamber units at the wheel ends. These operate the foundation brakes described below. In the rear are two dual chamber units at the wheel ends. These operate both the foundation brakes and the parking brakes. When there are dual rear axles, brake chambers are typically mounted on the forward axle, but are sometimes supplied on both axles. The brake chamber is designed to move the shoes against the drums using air pressure. Air pressure is released into the chamber by the foot pedal. Push rods change the air pressure into mechanical action to rotate the brake cam shafts. The push rods in the brake chambers provide a 2.25-2.50-inch (5764 mm) range of stroke length. The second chamber in the dual chamber unit uses the air pressure to keep a powerful spring compressed. This spring, attached to the push rod, provides the parking brake action. When system air pressure falls below 43 PSI, the springs activate the push rods and apply the foundation brakes. When system 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. BRAKE CHAMBER PUSH ROD S-CAM BRAKE SHOES BRAKE DRUM OTT0012 SLACK ADJUSTER Slack Adjusters — Slack adjusters change the distance the brake shoes have to travel to contact the drum. During each application of the brakes, automatic adjusters detect the rotation of the brake cam shaft. They retain the setting at the point where the lining contacts the drum. This setting changes as the drum and linings wear. Foundation (Wheel) Brakes — The foundation brakes consist of brake drums on the wheels and shoes lined with friction material attached to the axles. Actuated via cams rotated by push rods in the brake chambers, the shoes are pressed against the drums. Air pressure controlled by the foot pedal supplies the force necessary to stop the wheels from rotating. Slack Adjuster Diagram Maintenance Manual Ottawa T2 4x2 4.3 Brake System – 4 Brakes 4.3.11 53 Trailer Brake Air Lines page – Description Coiled service (blue) and supply (red) lines provide trailer braking controls. Both air lines must be connected in order to release the trailer parking brakes. Trailer Electrical Connector and Brake Hoses 4.3.14 Anti-lock Brake System (Optional) page – Description Some vehicles will be equipped with an anti-lock brake system (ABS). This system prevents the wheels from completely stopping rotation (locking up) when the brakes are applied. The benefit of this is to overcome the tendency of a vehicle to lose steering control during emergency braking. Toothed rings and sensors at the wheel ends work together to reflect individual wheel speeds. The sensors send the data to the EC-60 electronic control 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. Braking action then continues evenly until the foot pedal is released. There is an indicator light on the instrument panel to warn when the system malfunctions. This system can also check the trailer for a proper operating system. A malfunction in the trailer system actuates a separate light on the instrument panel. Diagnosis and fault code clearing are available through the EC-60 electronic control unit if so equipped. There is a diagnostic connection behind the grille opening in the front bumper. The connection can be used by a laptop with appropriate software or a handheld Bendix RDU diagnostic tool. Maintenance Manual Ottawa T2 4x2 54 4.3 Brake System – 4 Brakes 4.3.15 Automatic Traction Control (Optional) page – Description Some vehicles that are equipped with ABS may also be equipped with full-time automatic traction control (ATC). The ATC indicator lamp blinks when ATC is working. ATC uses the ABS wheel sensors. It compares front wheel speed to rear wheel speed and left rear wheel speed to right rear wheel speed. When a set ratio is exceeded, ATC applies the rear brakes to the appropriate wheel end. ATC operates only at speeds less than 25-30 miles per hour (40-48 kilometers per hour). At higher speeds, vehicle reaction to a sudden application of the brakes on 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 release 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 released manually (caged). To release the spring brakes, the actual spring in the brake canisters must be mechanically compressed. A release stud, or spring caging tool, must be used to manually compress the brake chamber. DANGER Never manually release (cage) the spring brakes before the wheels are properly blocked. If the wheels are not properly blocked before releasing the spring brakes, the vehicle may move unexpectedly. This could result in serious injury or death. Maintenance Manual Ottawa T2 4x2 4.3 Brake System – 4 Brakes 55 The following steps can be used to release the standard brake chambers used on most Kalmar tractors. If your vehicle is equipped with other optional brake chambers, refer to that manufacturer’s operation or service manual. 1. Shut the engine off and remove the key. 2. BLOCK ALL wheels front and rear to prevent the vehicle from rolling forward and backward. 3. Determine whether the chamber has an internal or external caging tool (see figures). Proceed to step 4 with an external-mounted tool. See step 8 for internal types. 4. Remove the access plug 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. OTT0144 7. Try to pull the caging tool out; it should not pull out. If it does, repeat steps 5 and 6. Internal 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 the threaded portion of the release tool is out. It should extend approximately 3 inches (76.2 mm) out of the nut. OTT0145 3 inches (76.2 mm) — Type 2430 and 3030 Chambers External Caging Tool 4 inches (101.6 mm) — Type 3036 and 3636 Chambers CAUTION Never use an impact wrench to tighten the nut onto the release bolt. Never exceed the above lengths and never exceed 50 ft. lbs. (67.79 Nm) of torque on the release nut or the chamber may be damaged. Maintenance Manual Ottawa T2 4x2 56 4.9 Diagnosis (Mechanical) – 4 Brakes 4.9 Diagnosis (Mechanical) page – Brakes Components • Brake Drums • Brake Shoes Brakes — Mechanical Diagnosis Observation Pulls to one side Insufficient braking power Slow application Cause Action Brakes out of adjustment Adjust slack adjusters. Poor front end alignment Inspect and repair as needed. Unequal tire pressure or tread Inspect. Repair or replace as needed. Uneven vehicle loading Inspect. Redistribute load as needed. Loose front wheel bearings Inspect. Repair or replace as needed. 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 needed. Air line(s) restricted Inspect. Repair or replace as needed. Poor adjustment or poor lubrication Inspect. Adjust or lubricate as needed. Air line(s) restricted Inspect. Repair or replace as needed. Treadle valve leaking Inspect. Repair or replace as needed. Brake chamber leaking Inspect. Repair or replace as needed. Spring brake chamber leaking Inspect. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 4.9 Diagnosis (Mechanical) – 4 Brakes Observation Slow release Service brakes do not release Brakes grab Uneven braking Cause 57 Action Treadle valve return slowed by dirt and grime Clean and lubricate as needed. Poor adjustment or poor lubrication Inspect. Adjust or lubricate as needed. Air line(s) restricted Inspect. Repair or replace as needed. Valve exhaust ports (e.g., treadle, quick release, relay) plugged Inspect. Repair or replace as needed. Broken or weak shoe or chamber spring Inspect. Repair or replace as needed. Treadle valve return slowed by dirt and grime Clean and lubricate as needed. Air line(s) restricted Inspect. Repair or replace as needed. Valve exhaust ports (e.g., treadle, quick release, relay) plugged Inspect. Repair or replace as needed. 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 needed. Defective valves Inspect. Repair or replace as needed. Actuating linkages (e.g., slack adjusters, push rods) bind Inspect. Repair or replace as needed. Poor adjustment or poor lubrication Inspect. Adjust or lubricate as needed. Grease or oil on linings Determine source of grease or oil. Repair as needed. Clean drums and replace shoes. Broken diaphragm or return spring Inspect. Repair or replace as needed. Drum out of round Inspect. Repair or replace as needed. Brake chamber diaphragm leaking Inspect. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 58 4.9 Diagnosis (Mechanical) – 4 Brakes Observation Cause No pressure buildup Action Refer to Brake Air System Diagnosis 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 Maintenance Manual Ottawa T2 4x2 5.2 Steering System – 5 Steering mm mm mm mm mm mm 59 5 Steering 5.2 Steering System page – Description (Power Steering Components) The standard power steering system uses an integral power steering gear and the transmission-mounted hydraulic pump. The system operates on fluid drawn from the common reservoir shared with the boom and cab tilt systems. Integral Power Steering Gear — When the steering wheel is turned, force is transmitted from the steering wheel to the steering gear input shaft. A torsion bar pinned at one end to the input shaft and at the other end to the worm shaft, turns with the input shaft and exerts a rotational force on the worm shaft. In response to this rotational force, the worm shaft, acting through the recirculating ball mechanism, moves the rack piston axially through the gear-housing cylinder bore. The rack piston’s axial movement is resisted by its engagement to the sector shaft, which is connected by linkage to the steered wheels. Because of this resistance, the input shaft actuates the control valve and twists the torsion bar. Pressurized fluid directed by the control valve, assists 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 hydraulic pump (either engine mounted or mounted via a PTO on the transmission), steering cylinders, a reservoir and fluid lines. The orbital control valve has a steering wheel attached; the steering cylinders are attached to the front axle and connected to the steered wheels. The orbital control valve is made up of two sections: the control valve section and the metering section. The control valve section directs fluid to and from the metering section and the steering cylinders, and regulates the pressure to the steering cylinders. The control valve section is made up of a mechanically actuated spool valve and pressure chambers to provide circuit isolation. The metering section controls the amount of fluid to the steering cylinders while maintaining the relationship between the steering wheel and the steered wheels. This section can also act as a manual pump providing manual steering in the event of an inoperable hydraulic pump. The metering section consists of a rotor that orbits within a fixed stator to force oil through the section, and a commutator to channel the fluid to the valve section. Maintenance Manual Ottawa T2 4x2 60 5.3 Diagnosis (Power Steering) – 5 Steering 5.3 Diagnosis (Power Steering) page – Power Steering Components • Power Steering Gear • Power Steering Pump • Reservoir The following guide covers symptoms that may be remedied by adjustments outside of the steering gear. For symptoms indicating problems within the steering gear, consult the manufacturer's service manuals. Power Steering Diagnosis Observation Hard steering Cause Action Overloaded axle Review GAWR specifications. Reload as needed. Underinflated tires Inflate correctly. Front end misaligned Align front end. Worn linkages Replace as needed. Damaged king pins or tie rods Repair or replace as needed. Steering column binding Repair as needed. Weak fluid flow rate Review manufacturer's manual or replace pump. Wheel cuts restricted Axle stop setting Reset. Steering-to-frame interference Drag link adjustment Reset. Pitman arm adjustment Reset. Air in system Bleed system. Low fluid level Add fluid as needed. Inconsistent steering pressure – Hydraulic Pump with Priority Valve Test – Power Steering Testing Issue – Weak or No Steering Assist (The pump has a priority valve that controls the fluid flow going to the steering gear box.) 1. Check fluid flow from 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 operate correctly. Maintenance Manual Ottawa T2 4x2 5.3 Diagnosis (Power Steering) – 5 Steering 61 c. Close the flow valve on the steering analyzer and record the pressure _________ psi. The pressure needs to be 2100 to 2200 psi at pump relief. d. If pump pressure is less than 2100 psi, the pressure relief on the pump needs to be adjusted. (Contact a Kalmar Field Service Representative for more information on setting the pump pressure relief.) e. When turning the steering to the left, there should be 1700 to 1900 psi before poppet relief. When turning to the right, there should be 1600 to 1800 psi before poppet relief. f. If the pump is not producing 4-1/2 to 5 GPM of flow and 2100 to 2200 psi and the steering is not operating correctly, the steering gear relief spring plungers may be set incorrectly in the steering gear box. (See Kalmar service bulletin # SB09TI0017.) g. If the pump is not producing 4-1/2 to 5 GPM of flow at idle, the priority valve may be sticking due to contamination. To clean the priority valve, follow the 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 body lightly against a block of wood. This should cause the priority spool to slide out of the spool bore. d. Clean the spool bore and spool with clean solvent and dry with shop air or wipe dry with clean, lint-free shop towel. e. Replace the priority flow orifice in the spring bore of the priority valve spool. f. Replace the priority flow spring in the valve spool and with solid end of valve spool entering first, slide the valve spool with orifice and spring into the valve spool bore. g. Install the plug and tighten. h. Test pump. If there is no change in pump performance, replace the pump. Note: Applies to systems using a single pump for steering and 5th wheel boom hydraulics. – Tools Needed • Steering analyzer • 3000 psi pressure gauge • 1/2" drive ratchet • 1/2” drive 1-1/16" deep well socket • 1/2” drive extension 3" Maintenance Manual Ottawa T2 4x2 62 5.3 Diagnosis (Power Steering) – 5 Steering • 1/2” end wrench • Allen wrench 5/16” Maintenance Manual Ottawa T2 4x2 5.4 Diagnosis (Hydrostatic Steering) – 5 Steering 5.4 63 Diagnosis (Hydrostatic Steering) page – Hydrostatic Steering Hydrostatic steering is optional. Components • Orbital Control Valve • Power Steering Pump • Steering Cylinders • Reservoir The following guide covers symptoms that may be remedied by adjustments outside the orbital control valve. For symptoms indicating problems within the orbital control valve, consult the manufacturer's service manuals. Hydrostatic Steering Diagnosis Observation Hard steering Cause Action Overloaded axle Review GAWR specifications. Reload as needed. Underinflated tires Inflate correctly. Front end misaligned Align front end. Worn linkages Replace as needed. Damaged king pins or cylinder connections Repair or replace as needed. Steering column binding Repair as needed. Weak fluid flow rate Review the manufacturer's manual and/or replace pump. Leaking fluid hoses Repair or replace as needed. Wheel cuts restricted Axle stop setting incorrect Reset. Inconsistent steering pressure Air in system Bleed system. Low fluid level Add fluid as needed. Leaking fluid hoses Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 64 5.4 Diagnosis (Hydrostatic Steering) – 5 Steering Maintenance Manual Ottawa T2 4x2 – 6 Suspension 65 mm mm mm mm mm mm 6 Suspension page – Description (Vehicle Suspension) RUBBER BLOCK The front suspension consists of parabolic leaf springs. There are 3 steel leaves on each side. Rubber blocks mounted on each axle reduce the shock of bottoming out. Leaf Spring Suspension The front spring anchors and tow hooks are parts of special components welded to the front ends of the rails. Another weldment provides attachment for the rear spring hanger on each side. Front Spring Anchor and Tow Hook Spring slippers retain the rear leaf springs at the rear mounting brackets. The standard vehicle is equipped with a rear axle (or axles) attached directly to the frame rails without any suspension system. Axle housings are rigidly attached to the frame, captured by means of weldments mounted inside and outside of each rail. Rear Spring Slipper Maintenance Manual Ottawa T2 4x2 66 6.2 Front Springs – 6 Suspension 6.2 Front Springs page – Repair (Springs Removal) 1. Park the vehicle on level ground and chock the rear wheels. 2. Raise the front of the vehicle high enough to relieve all tension on the front springs while allowing the front wheels to remain in contact with the ground. Place jack stands under the frame to support the front of the vehicle in the raised position. 3. With the vehicle raised, chock the front wheels to prevent the axle from moving as the springs are removed in the following steps. 4. Remove the nut and washer from the bolt at the front spring eye and the nut and washer from the bolt at the rear of the spring. 5. Using a suitable pry bar, remove the bolt securing the front spring to the frame brackets. 6. Support the spring and 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 position on the front axle and install the mounting bolts, washers and nuts to secure the assembly to the axle. Tighten the bolts and nuts to specification. 2. Align the spring eye with the front frame bracket and install the bolt, washer and nut. Tighten the nut to specification. CAUTION Use care to avoid damage to the spring pins as they are being installed. 3. Install the bolt, washer and nut to secure the rear of the spring to the frame bracket. Tighten the nut to specification. 4. Repeat steps 1 through 3 to install the spring assembly at the opposite side. 5. Remove the jack stands and lower the vehicle to the ground. NOTE After 50 hours of operation — Check and retighten the bolts, if necessary. Maintenance Manual Ottawa T2 4x2 7.2 Lift and Lower – 7 Load Handling 67 mm mm mm mm mm mm 7 Load Handling 7.2 Lift and Lower page – Description (Boom Components) 1. Boom Pivot 5 2. Boom 4 * 3. Boom Lift Cylinder Pivots 3 * 4. Fifth-Wheel Pivot 2 * BOTH SIDES Elevated Boom with Fifth Wheel OTT0002a 1 * 5. Fifth-Wheel Plate The standard hydraulically operated boom is the basis for the fifth-wheel lifting system. The forward end of the boom assembly is attached to the frame at a pivot point behind the cab. Mounted at the rear of the boom is the fifth wheel which is raised and lowered through the action of two hydraulic cylinders installed between the boom and frame weldments just forward of the rear axle. Power to operate the cylinders is supplied by the hydraulic pump mounted on 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 liter) 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 ports are precision machined and threaded to accept the “T” and “P” pressure (inlet) passages. The valve is open-centered and closed port. Incorporated in the valve assembly are load check valves and a relief cartridge with a maximum relief pressure of 2000 psi (138 bar) for the 5-inch (127 mm) diameter cylinders. The valve is actuated remotely from the cab by the boom lift control lever. The boom lift control lever is attached to a control cable that pulls and pushes the control valve spool to the desired positions. Maintenance Manual Ottawa T2 4x2 68 7.2 Lift and Lower – 7 Load Handling 7.2.1 Boom Lift Cylinders page – Description The standard configuration utilizes two 4-inch (100 mm) diameter 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. Maintenance Manual Ottawa T2 4x2 7.11 Diagnosis (Boom) – 7 Load Handling 7.11 69 Diagnosis (Boom) page – Diagnosis Components • Boom Lift Cylinders • Control Valve • Filter • Hydraulic Pump • Hydraulic Relief Valve • Reservoir • Wet Line Kit Connection Maximum Pressure — Hydraulic Relief Valve Vehicle Maximum Pressure All Ottawa T2 4x2 and 6x4 tractors with 4-inch cylinders 2000 psi (138 bar) WARNING Do NOT feel for leaks. Hydraulic fluid under high pressure may have knife-like characteristics. Failure to heed this warning could result in severe personal injury. Boom Diagnosis Observation Cylinders leak down Cause Damaged seals or cylinder wall Action 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 slowly Pump inlet restricted Remove restriction. Worn pump Replace. Internal leakage in control valve Replace. Optional: Install seal kits. Internal leakage in cylinders Replace cylinder. Optional: Install seal kits. External leakage from hoses Maintenance Manual Ottawa T2 4x2 Replace leaking hose. 70 7.11 Diagnosis (Boom) – 7 Load Handling Observation Stalls under load Inoperative Jerky, erratic movement Cause Action Valve actuating cable/lever not centered Adjust. Unbind. Lubricate as needed. Low fluid level Add fluid as needed. Low relief valve setting Adjust or replace. Extraordinary internal leakage Test circuits to isolate point of leakage. External leakage from hoses Replace leaking hose. Extraordinary pump wear Replace. Seized or damaged lever or control cable Repair as needed. Extreme internal leakage Test circuits to isolate point of leakage. External leakage from hoses Replace leaking hose. Air in system Inspect fittings and seals. Replace as needed. – Hydraulic Pump with Priority Valve Tests – Boom Issue – Boom Slow to Lift 1. Check control valve pressure setting. a. Install 3000 psi pressure gauge at the test port in the cylinder hose bulkhead fitting located at the back of the boom platform just in front of the fifth wheel plate. b. Deadhead cylinders at maximum length. c. Record pressure reading at maximum engine RPM ________ psi. 2. If pressure reading is not equal to 2000 psi, adjust the relief pressure at the control valve. a. Remove the acorn nut located in front of the control valve below the control valve lever. b. Adjust the pressure using a 5/16 allen wrench. Turn adjusting screw 1/4 turn and recheck pressure. To increase the pressure, turn the adjusting screw clockwise. To decrease the pressure, turn the adjusting screw counterclockwise. 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 31/2 to 5 GPM at engine idle and 23-25 GPM at maximum engine RPMS. Maintenance Manual Ottawa T2 4x2 7.11 Diagnosis (Boom) – 7 Load Handling – 71 Issue – Boom Not Lifting 1. Check that the fifth wheel control valve cable is operating freely. 2. Check 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. Maintenance Manual Ottawa T2 4x2 72 7.11 Diagnosis (Boom) – 7 Load Handling Maintenance Manual Ottawa T2 4x2 – 8 Control System mm mm mm mm mm mm 8 Control System page – Introduction - General Information Not available. Maintenance Manual Ottawa T2 4x2 73 74 – 8 Control System Maintenance Manual Ottawa T2 4x2 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories 75 mm mm mm mm mm mm 9 Frame, Body, Cab and Accessories 9.1 Controls and Instruments page – 1 2 3 15 4 5 6 31 7 8 9 10 11 16 17 18 19 20 14 21 29 23 12 13 14 24 28 22 26 30 32 33 25 27 Maintenance Manual Ottawa T2 4x2 76 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories POS Name Standard DOT/EPA Tractor Off-Highway Tractor 1 Air Diffuser S S 2 Radio A A 3 Main Gauge Panel S S 4 Headlight Switch S S 5 Dimmer Switch S A 6 Air Diffuser S S 7 Rear Wiper Switch A A 8 Front Wiper Switch S S 9 Ignition Switch S S 10 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 Option Switches U U 28 Air Restriction Indicator A A 29 Power Studs A A 30 Start Regen Switch S S 31 Idle Increase/Decrease Switch S S 32 Diagnostic Switch S S 33 On-Board Diagnostic Plug Port S S S=Standard A=Assigned options U=Unassigned options Maintenance Manual Ottawa T2 4x2 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories 77 Description Gauges, controls and indicators appear in four panels in front and to the side of the driver as shown. The left dash panel and main gauge panel are mounted in front of the steering wheel. The center and right dash panels are mounted between the left dash panel and the bulk head assembly. The Main Gauge Panel and Center Dash 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 optional air conditioning system. Left Dash Panel • 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 — Provides the following controls and interface connections. IDLE INCREASE/ DECREASE SWITCH START DIAGNOSTIC REGEN SWITCH SWITCH Lower Left Dash Panel • Start Regen Switch • Idle Increase/Decrease Switch • Diagnostic Switch • On-Board Diagnostic Plug Port OBD PLUG PORT Maintenance Manual Ottawa T2 4x2 78 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories 1 2 3 Main Gauge Panel — Displays the following gauges and indicator lights. • Gauges 1. DEF Gauge, DOT Tractors Only Volt Meter, Off-Highway Only 2. Speedometer 3. Fuel Gauge 4. Rear Brake Air Pressure Gauge 5. Odometer and Hour Meter 6. Front Brake Air Pressure Gauge 6 Main Gauge Panel 5 4 • LEFT CENTER RIGHT 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 Indicators – 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 Belt – Right Turn Signal – High Exhaust System Temperature. DOT/EPA Tractors only. – DPF (Diesel Particulate Filter) Regen needed. DOT/EPA Tractors only. – Service Maintenance Manual Ottawa T2 4x2 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories 79 Center Dash Panel — Displays the following gauges, controls and indicators. • Controls – Fan Speed Control – Mode Selector – Temperature Control – Air Recirculation Switch – Air Conditioner Switch (Optional) – Front Floodlights – Rear Floodlight – Dome Light – Air Horn Center Dash Panel – 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 Restriction Indicator Maintenance Manual Ottawa T2 4x2 80 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories Driver Controlled Differential Lock If equipped, the Driver Controlled Differential Lock control rocker 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. Driver Controlled Differential Lock Maintenance Manual Ottawa T2 4x2 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories 9.1.36 81 Low Air Warning page – Diagnosis The vehicle will be equipped with one of two air braking systems. Vehicles that travel on the roads are made to comply with the regulations in Federal Motor Vehicle Safety Standard (FMVSS) 121. Vehicles that do not travel on the roads have an equally reliable braking system. An anti-lock braking system option may also be found on the vehicle. Components • Gauge Cluster • Headlight Switch • Low Air Buzzer • Low Air Pressure Switch (Indicator) • Panel Dimmer Switch (Optional) Low Air Warning Circuit Diagnosis Observation Inoperative light and buzzer Inoperative buzzer, light OK Inoperative light, buzzer OK Cause Action Circuit breaker open Reset. Replace as needed. Short circuit Test. Repair as needed. Switch grounded Test. Repair as needed. Defective air switch Test. Repair as needed Defective assembly Replace. Open circuit Test. Repair as needed. Defective buzzer Replace. Open circuit Test. Repair as needed. 9.1.38 Hourmeter page – Diagnosis Components • Cab Accessory Fuse • Gauge Cluster • Ignition Switch Hourmeter Circuit Diagnosis Observation Inoperative Cause Circuit breaker open Maintenance Manual Ottawa T2 4x2 Action Reset. Repair short as needed. Replace circuit breaker as needed. 82 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories Observation Intermittent Runs unevenly, or fast or slow Cause Action Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Mislocated wiring Inspect routing. Relocate wires or isolate terminals as needed. Defective wiring Inspect wires for kinks and breaks. Repair or replace as needed. Mislocated wiring Inspect routing. Relocate wires or isolate terminals as needed. Defective gauge cluster Replace. 9.1.39 Speedometer page – Diagnosis The speedometer may include an optional connection to the pulse generator. Components • Cab Accessory Circuit Breaker • Gauge Cluster • Headlight Switch • Ignition Switch • Panel Dimmer Switch (Optional) Electronic Speedometer Circuit Diagnosis Observation Panel lamp does not light Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Inaccurate Defective wiring Inspect connections and wires. Test circuits. No reading Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Mislocated wiring Inspect routing. Relocate wires or isolate terminals as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 9.1 Controls and Instruments – 9 Frame, Body, Cab and Accessories 9.1.41 83 Voltmeter page – Diagnosis Components • Cab Accessory Circuit Breaker • Circuit Breaker • Headlight Switch • Ignition Switch • Panel Dimmer Switch (Optional) • Gauge Cluster Voltmeter Circuit Diagnosis Observation Panel lamp does not light Inaccurate Inoperative Cause Action Defective dimmer switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Defective gauge cluster Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective gauge cluster Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 84 9.3 Seating – 9 Frame, Body, Cab and Accessories 9.3 Seating page – Description The tractor is fitted with a seat suspended on an air spring. The firmness of the ride is adjusted by changing the air pressure. 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 chugging. This locking lever is mounted on the inside of the seat. Driver's Seat — Side View Maintenance Manual Ottawa T2 4x2 9.4 Heating, Ventilation and Air Conditioning – 9 Frame, Body, Cab and Accessories 9.4 85 Heating, Ventilation and Air Conditioning page – Description A heater 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. Maintenance Manual Ottawa T2 4x2 86 9.5 Wiping and Cleaning of Windows – 9 Frame, Body, Cab and Accessories 9.5 Wiping and Cleaning of Windows 9.5.1 Windshield Wipers page – Description The windshield wiper is electrically driven. A rotary switch on the instrument panel also controls its operating speed. The Off parked position is at the counterclockwise limit. Maximum speed is at the clockwise limit. page – Diagnosis Components • Circuit Breaker 8A • Ignition Switch • Wiper Motor • Wiper Relay • Wiper Switch Windshield Wipers Circuit Diagnosis Observation Inoperative Operate slowly Operate at one speed Do not park Cause Action No power Turn on ignition switch. Linkage binding Repair or replace as needed. Defective switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Linkage binding Repair or replace as needed. Low battery charge Recharge battery or replace as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Defective motor Replace. Defective switch Replace. Defective motor Replace. Linkage binding Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 9.5 Wiping and Cleaning of Windows – 9 Frame, Body, Cab and Accessories Observation Cause Action Defective switch Replace. Defective motor Replace. 9.5.4 87 Windshield Washer page – Description A windshield washer system is an available option. page – Diagnosis The windshield washer is optional equipment. Components • Accessory Relay • Ignition Switch • Windshield Washer Motor • Windshield Washer Switch Windshield Washer Circuit Diagnosis Observation Inoperative Cause Action 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. Replace circuit breaker as needed. Defective relay Replace. Defective motor Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 88 9.6 Lighting System – 9 Frame, Body, Cab and Accessories 9.6 Lighting System page – Description Kalmar provides a dome light, instrument panel lighting, headlights, marker lights and a trailer electrical connector with circuit breakers. A work area floodlight and a beacon are mounted on an upper rear corner of the cab. 9.6.1 Headlights page – Diagnosis Components • Dimmer Switch • Headlights • Headlight Relay • Headlight Switch • Headlight Switch Circuit Breaker • High-Beam Indicator Light Headlight Circuit Diagnosis Observation LH or RH headlight inoperative (high or low beam) Both headlights inoperative Inoperative headlight dimmer Cause Action Defective lamp Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective headlight switch Replace. Defective relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Defective dimmer switch Replace. Defective relay Replace. Maintenance Manual Ottawa T2 4x2 9.6 Lighting System – 9 Frame, Body, Cab and Accessories 9.6.3 89 Clearance, Marker and Tail Lights page – Diagnosis Clearance and marker lights are standard only on vehicles assembled to meet FMVSS and CMVSS requirements. Trailer marker and trailer tail light circuits are also controlled by the headlight switch via a trailer lights relay. A separate circuit breaker protects each trailer circuit. Components • Clearance Lights • Headlight Switch • Marker Lights (Trailer) (If Applicable) • Marker Lights (Vehicle) • Parking Light Circuit Breaker 10A • Tail Lights (Trailer) (If Applicable) • Tail Lights (Vehicle) • Trailer Circuit Breaker 15A • Trailer Lights Relay Cab Clearance and Marker Light Circuit Diagnosis Observation Cause Individual light inoperative All lights inoperative Action Defective lamp Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Defective light switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Trailer Clearance, Marker and Tail Light Circuit Diagnosis Observation Individual light inoperative All lights inoperative Cause Action Defective lamp Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective headlight switch Replace. Maintenance Manual Ottawa T2 4x2 90 9.6 Lighting System – 9 Frame, Body, Cab and Accessories Observation Cause Action Defective relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. 9.6.4 Brake Lights page – Diagnosis Components • Brake Light Switch • Flasher Circuit Breaker 30A • Stop/Tilt Circuit Breaker 20A • Trailer Circuit Breakers 15A • Turn Signal Flasher • Turn Signal Switch • Turn/Stop Light Lamps Brake Lights Circuit Diagnosis Observation Inoperative light Inoperative brake lights Cause Action Defective lamp Replace. Defective turn signal switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Defective lamp Replace. Defective brake light switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 9.6 Lighting System – 9 Frame, Body, Cab and Accessories 9.6.5 91 Backup Light page – Diagnosis This circuit may contain an optional circuit breaker between the accessories relay and the flood light switch/backup flood relay. Components • Accessory Relay • Backup Alarm • Backup Light (rear of frame) • Backup Relay • Cab Flood Light Switch • Circuit Breaker 15A • Ignition Switch Backup Light Circuit Diagnosis Observation Inoperative backup light Cause Action Defective lamp Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective backup relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Flood Light Circuit Diagnosis Observation Inoperative Cause Action Defective lamp Replace. Defective light switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 92 9.6 Lighting System – 9 Frame, Body, Cab and Accessories 9.6.6 Turn Signal page – Diagnosis Components • Brake Light Switch • Flasher Circuit Breaker 30A • Stop/Tilt Circuit Breaker 20A • Trailer Circuit Breakers 15A • Turn Signal Flasher • Turn Signal Switch • Turn/Stop Light Lamps Turn Signal Circuit Diagnosis Observation Inoperative light Inoperative turn signal Cause Action Defective lamp Replace. Defective turn signal switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Defective turn signal flasher Replace. Defective turn signal switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 9.6 Lighting System – 9 Frame, Body, Cab and Accessories 9.6.8 93 Beacon Light page – Diagnosis This circuit may contain an optional circuit breaker between the accessories relay and the beacon light switch. Components • Accessory Relay • Beacon Light • Beacon Light Switch • Ignition Switch Beacon Light Circuit Diagnosis Observation Inoperative Cause Action Defective beacon lamp Replace. Defective switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. 9.6.11 Dome Light page – Diagnosis Components • Cab Accessory Circuit Breaker • Dome Light Dome Light Circuit Diagnosis Observation Inoperative Cause Action Defective lamp Replace. Defective dome light switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 94 9.6 Lighting System – 9 Frame, Body, Cab and Accessories 9.6.12 Daytime Running Lights page – Diagnosis Daytime running lights are optional equipment. Components • Daytime Running Light Module • Headlights • Ignition Switch • Module Fuse 10A Daytime Running Lights Circuit Diagnosis Observation Inoperative Cause Action 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. 9.6.14 Trailer Auxiliary Power page – Diagnosis Components • Accessory Relay • Ignition Switch • Trailer Auxiliary Switch • Trailer Circuit Breaker 15A • Trailer Wiring Disconnect Trailer Auxiliary Circuit Diagnosis Observation No power at connector Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 9.6 Lighting System – 9 Frame, Body, Cab and Accessories 9.6.15 95 Transmission Shifter/Fifth-Wheel Control and Panel Lighting page – Diagnosis Components • Electroluminescent Lamps • Incandescent Lamps • Headlight Switch • Parking Light Circuit Breaker 10A • Panel Dimmer Switch Electroluminescence Electroluminescent (EL) lamps consist of two wafer-thin panels, one transparent and one opaque, that produce light when energized electrically. The panels are separated by an extremely narrow space. If a lamp is pinched so that the two panels come in contact, a short is created. EL lamps require an inverter to change direct current to high cycle alternating current and increase the voltage. A shorted EL lamp will cause the inverter to shut down. To isolate the defective lamp, disconnect one lead to each lamp and reconnect one at a time. A good lamp lights when connected. Transmission Shifter/Fifth-Wheel Control and Panel Lighting Circuit Diagnosis Observation Inoperative light Cause Action Defective lamp Replace. Defective dimmer switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring (or inverter) Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 96 9.7 Signal System – 9 Frame, Body, Cab and Accessories 9.7 Signal System 9.7.1 Horn page – Diagnosis Components • Horn • Horn Button (Switch) • Horn Circuit Breaker 15A • Horn Relay Horn Circuit Diagnosis Observation Inoperative horn Diminished sound Cause Action Circuit breaker open Reset. Repair short as needed. Replace 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. Defective horn Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. 9.7.2 Emergency Flasher page – Diagnosis Components • Brake Light Switch • Flasher Circuit Breaker 30A • Stop/Tilt Circuit Breaker 20A • Trailer Circuit Breakers 15A • Turn Signal Flasher • Turn Signal Switch • Turn/Stop Light Lamps Emergency Flasher Circuit Diagnosis Observation Inoperative light Cause Defective lamp Maintenance Manual Ottawa T2 4x2 Action Replace. 9.7 Signal System – 9 Frame, Body, Cab and Accessories Observation Cause 97 Action Defective turn signal switch Replace. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. 9.7.5 Backup Alarm – page Diagnosis This circuit may contain an optional circuit breaker between the accessories relay and the flood light switch/backup flood relay. Components • Accessory Relay • Backup Alarm • Backup Light (rear of frame) • Backup Relay • Cab Flood Light Switch • Circuit Breaker 15A • Ignition Switch • Reverse Switch Backup Alarm Circuit Diagnosis Observation Inoperative alarm Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective alarm Replace. Defective backup relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 98 9.8 Maintenance and Communication – 9 Frame, Body, Cab and Accessories 9.8 Maintenance and Communication 9.8.1 Radio page – Description A radio is an available option. page – Diagnosis Components • Accessory Relay • Radio • Radio Circuit Breaker 15A • Speakers Radio Circuit Diagnosis Observation Inoperative radio Poor performance Cause Action Circuit breaker open Reset. Repair short as needed. Replace 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. Defective antenna Repair or replace. Defective speakers Repair or replace. Defective radio Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 9.9 Glass/Window/Mirrors – 9 Frame, Body, Cab and Accessories 9.9 99 Glass/Window/Mirrors page – Description Windows and Ventilation — The 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 unobstructed view in that direction. 9.9.5 Rear-View Mirror page – Description Mirrors — Heated and heated/motorized outside rear view mirrors are optional equipment. Maintenance Manual Ottawa T2 4x2 100 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 9.10 Construction and Suspension of Cab/Deck 9.10.1 Cab Frame page – Description The cab four walls are constructed of 14-gauge steel for strength. The walls are attached to the deck at four points by grade 5 bolts tightened to 120 ft lb (163 Nm). The cab frame and structure 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 fully-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 walkway are covered by matting with an abrasive surface for safer footing. Ottawa 4x2 — Rear View with Tilted Cab The instrument panel frame and the engine bulkhead inside the cab help make the assembly rigid. Foam insulation lines the engine side of the firewall. Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 9.10.2 101 Door page – Description The rear door slides and latches in open or closed position and gives quick access to the walkway and frame decking. The orientation of the door in its opening is adjustable. Refer to the repair procedures section for more information. page – Repair (Rear Door Adjustment) Use the following procedures to maintain smooth operation of the rear door. 1. With the door closed, adjust the upper rollers (A) to obtain a parallel, 3/8 inch (9.5 mm) gap between the right side of the door and the right side of the cab (1). A 2 2 1 Adjust, as required, by installing shims between either roller assembly and the top of the door to rotate the door in position. shim 53568426 = 1/16 inch (1.6 mm) shim 53568427 = 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). C 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 door (3). D When adjusting the guide assembly, adjust the guide block (B) using the guide block retaining bolts, so it allows free, easy movement along the lower guide without an excess of play in both the open and closed positions. 3 1 C 3 B 4. On doors with rubber bumpers (C), loosen the locknut and adjust so they are retracted as far as possible. With the door closed, adjust the striker loop to the center of the latch opening (D). 5. Adjust the rubber bumpers (C) to compress the rubber 1/16 inch (1.6 mm) when the door is latched and tighten the locking nut. 6. Repeat steps 4 and 5 with the door in the closed position. Maintenance Manual Ottawa T2 4x2 102 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 9.10.3 Roof and Door Mouldings page – Description The roof of the standard cab rises at an angle from the windshield permitting a rear door opening approximately 68 inches (1.73 m) high. 9.10.4 Cab Tilting page – Description The cab can be tilted to 45 degrees by means of the hydraulic system. The cab can be tilted to 90 degrees, if needed, by providing a suitable hoist to carry the weight and disconnecting the lift cylinder. 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 which to unlock the cab safety prop during the raising or lowering operation. Cab Tilt Cylinder and Safety Prop The cab attaches and pivots in front on two pins. The pins are fastened to the front ends of the rails. Left Front Cab Tilt Pivot Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 103 The cab tilt system electric pump motor is mounted on the hydraulic tank. It serves only the cab’s tilting system on the tractor. Electric Pump Motor — Cab Tilt System 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. A B Cab Tilt Control Switch and Lanyard A — Cab Tilt Control Switch B — Safety Prop Release Cable After the cab reaches the full down position, the latching mechanism makes a loud sound. The latching bar alignment can be adjusted. Refer to the repair procedures section for more information. Cab Suspension Latching Bar Maintenance Manual Ottawa T2 4x2 104 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories page – Cab Tilt (Hydraulic) Components The cab tilt system is an electro/hydraulic system that utilizes the tractor battery to power an electric motor that drives the hydraulic pump. The inlet port of the pump draws in hydraulic oil from the common reservoir. This fixed displacement pump forces the oil through its outlet port, through the valve pressure passage, out the work port, and to the base end of the tilt cylinder. Because of the load, pressure rises until the piston moves the rod, thereby raising the cab. If the switch is held in the Up position after the cylinder has fully extended, pressure will rise to the relief setting of 3200 psi (221 bar). The relief valve will open and pressure will not increase above the set point. Cab Tilt Cylinder and Safety Prop When tilting the cab back down, the solenoid-operated directional control valve (with two positions) is energized. The valve shifts position and allows a return path for oil from the tilt cylinder. 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. The function of the return restriction is to slow the rate of oil exhausting from the tilt cylinder. The effect of this restriction is to provide a slow, controlled return to the Down position for the cab. Electric Pump Motor — Cab Tilt Cab Latch — One hydraulic cylinder and one mechanical locking mechanism are utilized to safely secure the cab in the Down position. The locking fingers are spring-loaded to the Lock position and are unlatched by the cylinder during the tilt up operation. The latching cylinder simply tees into the work line that connects to the base end of the tilt cylinder. The latch cylinder and the tilt cylinder receive hydraulic oil under pressure at the same time. Since the latch cylinders require less pressure to operate, they will unlatch prior to the lifting of the cab. After they are unlatched and pressure rises, the tilt cylinder will extend, raising the cab. Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 105 Cab Tilt Safety Prop — An additional mechanical safety device is used to ensure that the cab cannot be inadvertently lowered. The cab safety prop is similar to a hood prop in function; but instead of holding the hood (or cab in this case), it acts as a solid 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. A B Cab Tilt Control Switch and Lanyard A — Cab Tilt Control Switch B — Safety Prop Release Cable page – Diagnosis (Cab Tilt) Components • Stop/Tilt Circuit Breaker 20A • Tilt Pump Control Switch • Tilt Pump Motor • Tilt Solenoid DANGER Do NOT work under the raised cab before ensuring that the cab safety prop is locked in position. Failure to heed this danger could result in severe personal injury or death. Cab Tilt Diagnosis Observation Cause Action Inoperative pump Electrical See Electrical section. Motor runs — cab does not tilt Low fluid Add fluid as needed. Line leakage Locate and repair. Maintenance Manual Ottawa T2 4x2 106 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 9.10.6 Cab Tilt Pump and Motor page – Diagnosis (Cab Tilt Pump) Components • Stop/Tilt Circuit Breaker 20A • Tilt Pump Control Switch • Tilt Pump Motor • Tilt Pump Solenoid Cab Tilt Pump Circuit Diagnosis Observation Inoperative motor Raised cab does not return Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective tilt pump control switch Replace. Defective tilt pump solenoid Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective tilt pump control switch Replace. Defective tilt pump valve Replace. Motor operates — cab does not rise Refer to Hydraulic section. page – Repair (Pump and Motor Removal) WARNING The hydraulic fluid in the system is under pressure. Care should be taken whenever the system is opened. Loosen fittings slightly and allow pressure to bleed off before removing hoses. Safety glasses must be worn when working on the hydraulic system. Failure to heed this warning may result in serious personal injury or property damage. The cab tilt pump and motor are located on the hydraulic tank. Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 107 1. Disconnect the negative cable from the battery. 2. Locate and disconnect the two wires (1) at the solenoid under the pump motor. 3. Locate and disconnect the battery cable (2) at the pump motor. 1 4. Clean the area around the hydraulic hose fittings on the pump with compressed air to reduce the possibility of contamination. 3 5. Position a catch can under the valve to prevent spills. 6. Disconnect and cap the hydraulic line (3) attached to the pump. 7. Remove the two mounting bolts, flatwashers and locknuts and then remove the pump and motor assembly. 2 – Repair (Pump and Motor Installation) 1. Place the cab tilt pump and motor assembly in position on the hydraulic tank. Install the two mounting bolts, flatwashers and locknuts; tighten securely. 2. Uncap 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 fittings for leaks. 9. Check the fluid level in the hydraulic tank; adjust as necessary. – Repair [Relief Pressure Adjustment] 1. Raise the cab to the full-tilt position. Check to ensure that the safety latch has engaged. A 2. Slightly loosen the fitting at the cab tilt cylinder to relieve system pressure. 3. Install a “T” fitting in the supply line from the pump to the cab latch and connect a hydraulic pressure gauge to the fitting. OTT0143 4. Locate the adjusting screw (A) on the pressure relief valve body. The valve can be found between the inlet port on the pump and the motor. 5. While holding the adjusting screw with an Allen wrench, loosen the jam nut. Maintenance Manual Ottawa T2 4x2 108 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 6. With the cab raised all the way up, hold the tilt control switch in the “UP” position. Note the reading on the hydraulic 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 fittings for leaks. 11. Lower the cab. Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 9.10.7 109 Cab Tilt Cylinder page – Repair (Cylinder Removal) WARNING 1. The hydraulic fluid in the system is under pressure. Care should be taken whenever the system is opened. Loosen fittings slightly and allow pressure to bleed off before removing hoses. 2. Safety glasses must be worn when working on the hydraulic system. 3. Use a safety strut to hold the cab in the raised position when the cylinder is removed. 1. Raise the cab using the cab tilt system. 2 NOTE If unable to raise the cab using the cab tilt system due to component failure, use the following steps to raise the cab. a. Release the cab latch by supplying hydraulic pressure to the latch mechanism. This can be done by engaging the cab tilt pump or, if the pump is not functioning, by attaching a small hand or electric pump to the hydraulic line for the latch. 1 b. Secure an overhead hoist to the rear of the cab and raise the cab to its full-tilt position. 2. Place a safety bar between the bottom of the deck and the frame in a manner that prohibits the safety bar from slipping. 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. 6. Remove the hydraulic line from the cylinder. 7. Plug or cap the hose end to prevent contamination; secure the line above the frame rail to prevent loss of hydraulic fluid. Maintenance Manual Ottawa T2 4x2 110 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 8. Remove the cab tilt cylinder from the vehicle as follows: 2000 year model and newer trucks — Remove the cotter key (1) from the support pin securing the lower end of the cylinder to the lower cylinder mounting bracket. While supporting the cylinder, remove the locknut and bolt (2) securing the upper end of the cylinder to the deck. 1999 year model and older trucks — Remove the cylinder support bolt from the lower end of the cylinder and remove the cylinder from the vehicle. – Repair (Cylinder Installation) 1. Prior to reassembly, inspect all fasteners, including support pins, bolts, nuts, etc., for damage and/or wear. Replace all parts that are damaged or show wear. 2. Support the cab tilt cylinder in place on the vehicle while installing 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 adjustable collar around the cylinder and through the mounting bracket and cylinder eye. 1999 year model and older trucks — Install the bolt and locknut through the bracket and cylinder mounting eye and tighten to 200 ft. lbs (271 Nm). 4. Unplug the hydraulic hose end and connect it to the cylinder port. 5. Connect the electrical cables to the relay on the bottom of the cylinder. 6. Using the cab tilt switch, raise the cab and remove the safety bar. 7. Again, 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 fittings for leaks. 9. Check the fluid level in the hydraulic tank; adjust as necessary. PIVOT PIN RETAINER SPACER BRACKET CAB PIVOT PIN CAB PIVOT BUSHING Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 9.10.8 111 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. Maintenance Manual Ottawa T2 4x2 112 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 1. Raise the cab to the full-tilt position and make sure the safety arm is in place. SPACER BRACKET CAMP 2. Remove the SNAPTRAC® bolts from the left front corner of the frame cross member and from the bottom of the cabchannel. Allow the SNAPTRAC® to hang loose. 3. Remove the p-clamp that secures the frame and engine harnesses at the left front corner of the front cross member. SPACER BRACKET 4. Remove the heater hose p-clamp at the front right top of the frame cross member. 5. Remove the spacer bracket clamp from the spacer bracket. 6. Remove the spacer bracket at the front left cab pivot pin. 7. Remove the cab pivot retainers from the pivot pins at the left and right sides of the cab. 8. Remove the front fascia and side skirts. 9. Place 4x4x6-inch blocks on the top of the frame rails to support the cab, then lower the cab onto the blocks. This will help stabilize the cab while removing the cab bushings. CAB PIVOT PIN 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 removed. PIVOT PIN RETAINER 10. Stabilize the right rear of the cab deck by chaining it down. CAB PIVOT BUSHING 11. Using a drift, drive the front cab pivot pins out. 12. Using the cab tilt switch, operate the switch in the “UP” position until the cab deck has cleared the cab tilt bushings in the frame. 13. Support the front of the cab deck by placing additional blocks between the deck and frame. 14. Using a drift, drive the old bushings out of the left and right cab pivot blocks. SPACER BRACKET CAB PIVOT PIN PIVOT PIN RETAINER CAB PIVOT BUSHING – Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 113 Repair (Pivot Bushing Installation) 1. Install new bushings into the cab pivot blocks. NOTE The bushings are a light press-fit. 2. Remove the additional blocks placed in position to support the cab in the raised position after the pivot pins were removed. 3. Using the cab tilt switch, lower the cab deck down to the desired height on the original blocks placed in position to support the cab. Install the cab tilt pins. 4. Install the cab pivot retainer at each pivot pin. 5. Install the spacer bracket at the front left cab pivot pin. 6. Install the spacer bracket clamp. 7. Install the front fascia and side skirts. 8. Install the p-clamp that secures the frame and engine harnesses at the left front corner of the front 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 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 suspension system on one rail at a rear corner. The system consists of a latching catch bracket, two shock absorbers, an air cushion and an adjustable height control valve. Air is supplied via the vehicle air system. Correctly adjusted, the system controls the ride height and relieves stress on the cab pivots. A cab leveling valve works automatically when a load is applied (e.g., when someone steps into the cab or pulls down strongly on a cab entry handle). The flow of system air for adjustment is audible. The sound can be used to determine the serviceability of the valve. Adjustment should be complete in two to 10 seconds. Cab Air Suspension and Latching System page – Maintenance Manual Ottawa T2 4x2 114 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories Diagnosis (Cab Air Suspension) Components • Cab Leveling Valve • Cab Shock Absorbers Cab Leveling Valve and Shock Absorber Diagnosis Observation Cause Action Cab leveling too fast or too slow Clogged leveling valve Inspect. Replace as needed. Uncontrolled cab bounce No air in airbag Turn on air ride air valve. Shock absorbers worn Inspect. Replace as needed. Worn out cab pivot bushings Replace cab pivot bushings. 9.10.11 Air Ride Suspension (Three-Point) page – Repair (Cab Suspension Assembly Removal) 1. Park the vehicle on firm level ground. 1 2. Raise and support the cab. 3. After the cab is raised and supported, briefly press the cab “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. 2 DSC2445 6. Remove the four mounting bolts (3, 4) securing the suspension assembly to the frame rail (driver's side). Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 115 Repair (Cab Suspension Assembly Installation) – 1. From the inner side of the frame rail, insert bolts into the two lower suspension mounting holes. These bolts will support the suspension assembly as it is placed in position in the next step. 2. Align the air suspension assembly with the two lower mounting bolts (4) and place it in position against the frame rail. 3. Install the bolts, washers and locknuts (3) in the two upper mounting holes to secure the suspension assembly to the frame. 4. Install the washers and locknuts on the lower mounting bolts (5). Tighten all four mounting bolts and nuts (3, 4) to 220 ft. lbs (298 Nm). 4 KMR1001a 3 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. Adjust the latch bar plate until it is centered in the latch and hand tighten the outer mounting nuts. DSC2441a 5 10. Raise and support the cab. Then, tighten all four of the latch bar plate mounting nuts to 65 ft. lbs (88 Nm). 11. Make sure all lines are routed away from the rubber bumper contact area on the deck. Reroute and secure the lines if necessary. 12. Check the hydraulic lines for leaks. NOTE After 100 hours of operation — Recheck fasteners for tightness. – Maintenance Manual Ottawa T2 4x2 116 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories Repair (Air Ride Level Adjustment) 1. Park the vehicle on firm level ground. 2. Start and run the engine until the air system has a minimum of 100 psi of air pressure. 3. Shut the engine down. 4. Turn on (open) the air supply to the cab suspension by turning the “T-handle” valve on the bottom of the deck counterclockwise. 5. Remove the plastic clip (2) in the center of the plastic linkage rod connected to the control arm on the suspension assembly. 1 2 6. Use tape to mark the linkage rod's current position (3). 3 7. Adjust the linkage rod length as required to set proper ride height. Disengage the serrated lower end (4) of the rod from the serrated portion of its upper sleeve (1): DSC2443 4 To raise ride level — Decrease the rod (4) length by placing 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 proper ride height. 9.10.12 Leveling Valve page – Repair (Valve Operation Check) Check for proper operation of the leveling valve as follows: 1. While holding the cab entry handle in the “DOWN” position, count the time in seconds it takes for the air spring to raise the ride height. 2. If the noted time is: Within 2–10 seconds — Valve is OK. Under 2 seconds — Valve is damaged or filter is clogged. Over 10 seconds — Valve is damaged or filter is clogged. DSC2433 3. Replace the valve if the valve is damaged or the filter is clogged. Maintenance Manual Ottawa T2 4x2 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories 9.10.13 117 Shock Absorbers page – Repair (Shock Removal) Replacement of the shock absorber is necessary if the cab ride becomes 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 securing 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 absorber at the opposite side of the assembly. DSC2441b 1 – Maintenance Manual Ottawa T2 4x2 118 9.10 Construction and Suspension of Cab/Deck – 9 Frame, Body, Cab and Accessories Repair (Shock Installation) 1. Place the shock absorber in position between the mounting brackets at the side of the suspension assembly. 2. Install the 7/16-inch bolts and nuts to secure the shock absorber in the top and bottom mounting brackets. 3. Tighten the bolts and nuts to specification. 4. Repeat the procedure to install the second shock absorber at the opposite side of the assembly. 5. Unlock the cab tilt cylinder and lower the cab. 9.10.14 Cab Latch Bar Plate page – Repair (Latch Bar Plate Adjustment) The position of the cab latch bar plate is important. When properly 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. DSC2454 2 2. With the plate loosened, lower the cab slowly ensuring the latch bar properly seats in the hold down latch (3) at the top of the suspension assembly. 3. Make adjustments (side-to-side, fore and aft) to center the bar in the latch. 3 4. Tighten the two nuts (1) which are accessible at the outer end (long end) of the cab latch bar plate. 5. Raise the cab and tighten all four (1, 2) cab latch bar plate mounting nuts to specification. DSC2447 1 6. Lower the cab and recheck the position of the bar in the latch. Readjust if necessary. Maintenance Manual Ottawa T2 4x2 9.12 Chassis – 9 Frame, Body, Cab and Accessories 9.12 119 Chassis page – Description 8 10 9 7 5 3 1 6 4 2 Frame Construction 1. Front 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 Maintenance Manual Ottawa T2 4x2 120 9.12 Chassis – 9 Frame, Body, Cab and Accessories The frame rails (3) are reinforced C channels. Front and rear crossmember weldments (1) (10) are bolted to the frame rail ends forming a box structure. A rear tie bar angle bracket (9) is bolted inside the rails beneath the rear crossmember. Skid ramp weldments (8) are bolted at the outside of the rails, with skid ramp/rear crossmember mounting brackets (7) bolted underneath, inside the rails. Front spring hanger and bumper mount weldments (2) are bolted to the underside of the rails at the front end. Inverted L-shaped reinforcements (5) are bolted to the outside of the C channels, stretching from the rear of the cab to the rear rail ends. A weldment structure (6) extends downward from each rail reinforcement ahead of the rear axle to provide anchor points for the lower ends of the boom cylinders and mounting for the rear axle. Boom pivots (4) are bolted inside the rails just forward of the rail reinforcements, 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 heavy service requires that the rails be reinforced after reshaping and alignment. If the failure is the result of too many or improperly located holes in one or both rails, the frame should be replaced unless safe practice will permit adding reinforcement. Always follow the guidelines for adding reinforcement to the rails and for drilling holes in the rails. WARNING Welding produces so much heat that there is a risk of changing the physical properties of the steel in the frame rails. If the vehicle may be economically restored to service by means of welding, contact Kalmar sevice department, or ensure that best welding practices are rigorously followed so as to avoid changing the properties of the steel. Failure to heed this warning may result in severe property damage. Maintenance Manual Ottawa T2 4x2 9.12 Chassis – 9 Frame, Body, Cab and Accessories 121 WARNING Do NOT cut the rails or holes in the rails using a welding torch. Do NOT drill holes in top or bottom rail flanges. Failure to heed this warning may result in severe property damage. Frame Diagnosis Observation Cracked rails Sagging rails Cause Action Loose bolts Install larger bolts. Refer to instructions for repairing cracked rails elsewhere in this manual. Reinforce rail. Overloading Refer to instructions for repairing cracked rails elsewhere in this manual. Reinforce rail. 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 the rails, or replace the frame as needed. Notches anywhere in rails Vehicle fire Vehicle collision Equipment added beyond vehicle capacity Buckled rails Fifth wheel raised to maximum while maneuvering a loaded trailer Maintenance Manual Ottawa T2 4x2 Straighten, reinforce and align the rails, or replace the frame as needed. 122 9.12 Chassis – 9 Frame, Body, Cab and Accessories Observation Cause Action Equipment added beyond vehicle capacity Load shift (e.g., surging liquid) in a loaded trailer Vehicle fire Vehicle collision Rails weakened by added holes, notches, extraordinary welding or cutting Misaligned rails Misaligned axle or weak 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. Misaligned axle Align the axle. Broken Huck bolts Replace broken Huck bolts with 5/8, grade 8 bolts. page – Maintenance Manual Ottawa T2 4x2 9.12 Chassis – 9 Frame, Body, Cab and Accessories 123 Repair (Frame Damage Analysis) This section is not intended to cover the causes of all possible frame problems; however, it should be of valuable assistance in preparing complete, concise reports. The purpose of this information is to emphasize the fact that frame damage doesn’t just happen, there is always a cause or reason. An example of this would be a vehicle involved in a collision. The reason for damage in this case is apparent; however, other damages can be encountered where the reasons are not so apparent. Three types of frame damage can be classified as follows: 1. Collision 2. Excessive bending moment 3. Localized stress concentration Damage caused by collision should be repaired using proper methods and reinforcement. Excessive bending moment damage is caused by overloading, improper weight distribution or misapplication of the vehicle. Excessive bending moment damage 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) CAUTION When welding on a Kalmar truck: 1. Always disconnect the wiring at the battery terminals and ECUs. 2. The ground for the welder should always be attached as close as possible to the work area. 3. Failure to adhere to these cautions can result in permanent damage to the electrical system. In general, when making reinforcements of any type, observe the following practices. 1. Contact the Kalmar Engineering Department for design approval. 2. Taper reinforcement plates to avoid abrupt changes in section modulus. Angles at the edge of a reinforcement plate should be less than 45 degrees. 3. When reinforcement plates are shaped by use of a cutting torch, all cracks, nicks and burrs must be removed from the edges by grinding. Burrs must also be removed from the edges of holes. Maintenance Manual Ottawa T2 4x2 124 9.12 Chassis – 9 Frame, Body, Cab and Accessories 4. Make reinforcements long enough so that they can be tapered and still extend beyond the critical area. page – Repair (Making Reinforcements, Attachment) Reinforcements must be attached with grade 8 bolts, locknuts and hardened washers on both ends of the bolt. This provides a good torque surface to maintain tight bolts. Avoid attaching reinforcements by welding. (In some cases, welding may be acceptable. Such cases include the plug weld used on strap or web reinforcements.) Bolt holes that are enlarged or irregularly worn may be reamed to accept the next larger bolt diameter. For critical areas, body-fit bolts require reaming the hole to a nonstandard size to effect an interference fit for the bolt. Whenever possible, use existing frame holes rather than drill new ones. In general, when attaching reinforcements to the frame, use bolts and observe the following: 1. Use existing holes, if possible. 2. Do not drill holes in the frame flange. 3. Holes should be made as close to the neutral axis (halfway between the flanges) as possible. 4. Bolt holes should be no larger than those already existing 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 will normally start from the edge of a flange. It will progress across the flange and through the web section of a rail. Ultimately, it will continue through the other flange. This type of crack may result from high concentrations of stress in small areas of the frame, excessive bending moment and torsion loading. Sunburst cracks will radiate out from a hole in the web section of a rail or cross member. They are caused by high loads being applied at a mounting bracket or cross member, which is not securely or properly attached to the rail. If cracks occur to both the rail and reinforcement of a steel frame, they must be repaired separately. The flanges must react independently to prevent localized stress concentrations. Use a copper spacer between the flanges of cracked base rail flanges and reinforcement flanges. Cross member mounting flange cracks may be repaired in the same manner as side rail cracks. However, the weld bead should be built up to provide a Maintenance Manual Ottawa T2 4x2 9.12 Chassis – 9 Frame, Body, Cab and Accessories 125 good smooth radius. If extensive damage is incurred to a cross member, the cross member should be replaced. It may be necessary to align the frame and level the rails before repairing the frame. The following procedure should be used to repair cracks in a rail, reinforcement or cross member. 1. Remove any equipment that will interfere with 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 depend 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 the proper electrode and proper welding techniques. 6. Grind the weld smooth on both the inside and outside of the rail or cross member. Be extremely careful to eliminate weld buildup or notches on the edge of the flange. Maintenance Manual Ottawa T2 4x2 126 9.13 Bodywork – 9 Frame, Body, Cab and Accessories 9.13 Bodywork 9.13.3 Footstep page – Description A two-step ladder is attached to the cab deck by the back 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 entry 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 perforated decking extends toward the fifth wheel on top of the boom. Cab Access Ladders and Decking Maintenance Manual Ottawa T2 4x2 9.16 Accessories and Options – 9 Frame, Body, Cab and Accessories 9.16 127 Accessories and Options 9.16.1 Accessory Relay page – Diagnosis Components • Accessory Circuit Breakers • Accessory Relay • Ignition Switch Accessory Relay Circuit Diagnosis Observation Cause Action One accessory inoperative Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. All accessories inoperative Defective relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. 9.16.2 Heater/Air Conditioning (Optional) page – Diagnosis Components • AC On/Off Switch • Blower Motor • Cold Control • Heater/AC Relay • Heater Resistor Block • Heater Switch • Ignition Switch Heater/Air Conditioning Circuit Diagnosis Observation Inoperative blower Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective resistor Replace. Defective heater switch Replace. Defective heater/AC relay Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 128 9.16 Accessories and Options – 9 Frame, Body, Cab and Accessories Observation Blower operates at one or two speeds only Cause Action Defective blower motor Replace. Defective resistor Replace. Defective heater switch Replace. 9.16.3 Mirrors (Heated/Motorized) page – Diagnosis Heated and motorized (remotely controlled) mirrors are optional equipment. Components • Mirrors • Mirror Heat Switch • Motorized Mirror Switch (Left-Hand) • Motorized Mirror Switch (Right-Hand) Heated Mirror Circuit Diagnosis Observation Inoperative heater Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective heater switch Replace. Defective mirror Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Heated Motorized Mirror Circuit Diagnosis Observation Inoperative heater Inoperative motor Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective heater switch Replace. Defective mirror Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective motor Replace. Maintenance Manual Ottawa T2 4x2 9.16 Accessories and Options – 9 Frame, Body, Cab and Accessories Observation Inoperative motor Cause Defective wiring Maintenance Manual Ottawa T2 4x2 129 Action Inspect connections and wires. Test circuits. Repair or replace as needed. 130 9.16 Accessories and Options – 9 Frame, Body, Cab and Accessories Maintenance Manual Ottawa T2 4x2 10.3 Tanks and Accumulators – 10 Common Hydraulics 131 mm mm mm mm mm mm 10 Common Hydraulics page – System Description WARNING The hydraulic fluid in the system is under pressure. Care should be taken whenever the system is opened. Loosen fittings slightly and allow pressure to bleed off before removing hoses. Safety glasses must be worn when working on the hydraulic system. Failure to heed this warning may result in serious personal injury or property damage. The hydraulic system of the current production Ottawa tractors is composed of three subsystems. They are the boom (hoist), cab tilt and power steering. The common link among these three subsystems is the shared reservoir, return filter and hydraulic fluid. With the exception of these items, all subsystems operate independently. The three subsystems have their own control valves and output actuators (cylinders). The power steering is an open-centered circuit; that is, hydraulic 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 20-gallon capacity. It is fitted with a level sight gauge and a breather. Maintenance Manual Ottawa T2 4x2 132 10.6 Temperature Control, Cleaning and Hydraulic Oil – 10 Common Hydraulics 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 continuously filtering fluid that is used in all three subsystems: boom, cab tilt and power steering. Maintenance Manual Ottawa T2 4x2 11.1 Controls and Instruments – 11 Common Electric 133 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. Maintenance Manual Ottawa T2 4x2 134 11.2 Safety – 11 Common Electric 11.2 Safety 11.2.2 Fuses, Relays and Circuit Breakers page – 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 power board is located in the chassis over the transmission on the left side. See following figures for fuse, breaker and relay locations. Maintenance Manual Ottawa T2 4x2 11.2 Safety – 11 Common Electric J1 DASH_10 IGN 135 MAIN_BATT POWER_PT_IGN PWR_PT_BAT2 ACCY PWR_PT_BAT GAUGES_10 HIGHBEAM BATTERY_UNFUSED DRL SWITCH_15 DRL_10 LUBE_IGN WIPE/WASH_15 PNL/TAIL HVAC_30 IGNITION_UNFUSED STD TRLR_LIGHTS_30 PARK_LIGHTS_10 J3 EXT_LIGHTS_25 ACCY2 RADIO/ACCY_15 DRL1 MIRRORS_15 CAB_LIGHT_10 FOGLIGHTS_10 PARK_LPS_10 FLASHER DIAG_10 HORN HEADLIGHTS_15 HORN_10 STOPLAMPS_20 J2 LUBE_BAT FLASHER_30 GND RADIO_BATT_15 MAIN_GND Cab Power Board Maintenance Manual Ottawa T2 4x2 136 11.2 Safety – 11 Common Electric Chassis Power Board Maintenance Manual Ottawa T2 4x2 12.1 Air System and Brakes – 12 Common Pneumatics 137 mm mm mm mm mm mm 12 Common Pneumatics 12.1 Air System and Brakes page – Description The main function of the vehicle air system is to provide compressed air to operate the brakes. Compressed air also operates the cab suspension, driver’s seat suspension and posture features, fifth-wheel unlatching, trailer brakes and optional interaxle lockout. DANGER Only trained air brake technician must be allowed to service the air brakes. Failure to heed this danger could result in severe personal injury or death. 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 Valve • Pressure Relief Valve • Quick Release Valve • Rear Brake Chambers Maintenance Manual Ottawa T2 4x2 138 12.1 Air System and Brakes – 12 Common Pneumatics • Reservoirs (DOT/EPA: primary, front and rear) • Stoplight Switch • Tractor Protection Valve Brakes — Air System Diagnosis Observation Frequent air dryer purging (cycling) Cause Action Excessive system leakage Inspect system connections and valves. Repair or replace as needed. 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 unloader as needed. Maintenance Manual Ottawa T2 4x2 12.1 Air System and Brakes – 12 Common Pneumatics Observation Water in reservoirs Dryer safety valve discharging No pressure buildup (continuous exhaust at dryer purge valve) Fails to purge Cause 139 Action Desiccant saturated Replace desiccant cartridge. Refer to Medium Duty Truck Unit Repair Manual. External charge air did not pass through air dryer Ensure charge air enters filter valve at compressor. Air dryer not purging Inspect purge valve. Refer to Medium Duty Truck Unit Repair Manual. Purge time too short Refer to Frequent Purging (Cycling) above. Desiccant cartridge plugged or saturated Replace desiccant cartridge. Refer to Medium Duty Truck Unit Repair Manual. Defective internal check valve Test. Replace as needed. Defective hose, tubing or fittings between dryer and main supply reservoir Inspect hose, tubing and fittings for holes, kinks and other restrictions. Repair or replace as needed. 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. Repair or replace as needed. Inlet and outlet air connections reversed Reconnect lines correctly. Defective check valve between dryer and first reservoir Test. Repair or replace as needed. Kinked or blocked discharge line Straighten, clean, repair or replace as needed. Excessive air system leakage Inspect system connections and valves. Repair or replace as needed. Broken, kinked, plugged or disconnected purge control line Test line — compressor unloaded. Defective purge valve Inspect. Repair or replace air dryer as needed. Refer to Medium Duty Truck Unit Repair Manual. Maintenance Manual Ottawa T2 4x2 140 12.1 Air System and Brakes – 12 Common Pneumatics Observation Desiccant expelled through purge valve Low air pressure warning Pressure drops quickly: engine stopped, brakes applied Pressure drops: engine stopped, brakes applied Cause Action Air dryer vibration Inspect. Repair or replace as needed. Defective desiccant cartridge Inspect. Repair or replace as needed. Defective compressor piston rings Inspect supply air. If oil is present, repair or replace compressor as needed. Refer to Medium Duty Truck Unit Repair Manual. Defective electrical circuitry Inspect. Repair or replace as needed. Half of dual system failed Inspect gauges. Repair or replace failed components 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. Treadle valve leak Inspect. Repair or replace as needed. Brake chamber leak Inspect. Repair or replace as needed. Lines or fittings leak Inspect. Repair or replace as needed. Treadle valve leak Inspect. Repair or replace as needed. Lines or fittings leak Inspect. Repair or replace as needed. Spring chamber leak Inspect. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 12.1 Air System and Brakes – 12 Common Pneumatics Observation Pressure does not reach normal Pressure builds too slowly Pressure too high No brakes Cause 141 Action Reservoir drain cocks open Inspect and close as needed. Excessive system leakage Inspect system connections and valves. Repair or replace as needed. Poor governor adjustment Inspect. Adjust, repair or replace as needed. Defective air pressure gauge Inspect. Repair or replace as needed. Defective air compressor Inspect. Repair or replace as needed. 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. Defective air pressure gauge Inspect. Repair or replace as needed. Poor governor adjustment Inspect. Adjust, repair or replace as needed. Air line(s) restricted Inspect. Repair or replace as needed. Air line(s) restricted or broken Inspect. Repair or replace as needed. Defective treadle valve Inspect. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 142 12.4 Valves – 12 Common Pneumatics 12.4 Valves page – Tractor Protection Valves Located in the circuitry between the tractor and the trailer, a special valve responds to the trailer air supply knob, or to a broken trailer air line, by cutting off the air supply to the trailer system. page – Proportioning Relay (Bobtail) Valve (Optional) Available as an option, this valve is designed to detect if a trailer is connected to the brake air system. When a trailer is not present, the valve causes the front brakes to do a larger percentage of the work than when a trailer is present. Connected downstream of the primary reservoir, system air enters its supply port. If no trailer is present, pistons in the valve are repositioned so that, when the pedal is applied, a larger percentage of air goes to the front brakes causing them to assume a greater part of the work of stopping the tractor. If a trailer is present 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 of the foot pedal. The purpose of this valve is to dump the air out of the spring chambers much more quickly than would be possible if the air had to travel back through the supply lines. page – Anti-Compounding Valve (Optional) Also available is an anti-compounding valve that prevents the service brakes from adding to (compounding) the effort exerted by the parking brakes. It protects against brake cracking and damage to the linings. page – Double (Two-Way) Check Valves These are used to sense pressure from front and rear, or supply and service, and allow the dominant pressure to actuate the trailer brakes, the stop light switch and release the parking brakes. A two-way quick release valve combines the two functions in a single housing. Maintenance Manual Ottawa T2 4x2 12.5 Air Dryer – 12 Common Pneumatics 12.5 143 Air Dryer page – Description An air dryer for the brake system is available as optional equipment. In the circuit between the compressor and the reservoir, it removes water vapor from the air. It also removes any oil vapor that may blow by the compressor. page – Diagnosis Components • Ignition Circuit Breaker 30A • Ignition Switch Air Dryer Circuit Diagnosis Observation Inoperative heater Cause Action Circuit breaker open Reset. Repair short as needed. Replace circuit breaker as needed. Defective ignition switch Replace. Defective wiring Inspect connections and wires. Test circuits. Repair or replace as needed. Maintenance Manual Ottawa T2 4x2 144 12.5 Air Dryer – 12 Common Pneumatics Maintenance Manual Ottawa T2 4x2 – D. Error Codes mm mm mm mm mm mm 145 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. Maintenance Manual Ottawa T2 4x2 146 – D. Error Codes Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics 147 mm mm mm mm mm mm E. Schematics 0.1 0.1.1 page – Air System Circuits Air Brakes Components • ABS Electronic Control Unit • ABS Modulator Valve • Air Compressor • Air Dryer (Optional) • Air Pressure Governor • Air Reservoirs (Storage Tanks) • Brake Chambers • Check Valves • Foot Pedal (Treadle) Valve • Interaxle Lockout (6x4 only, ABS) • Pressure Relief Valves • Proportioning Relay Valve • Quick Release Valves • Slack Adjusters • Stoplight Switch • Tractor Parking Brake Control Valve • Tractor Protection Valves • Trailer Air Supply Control Valve • Two-Way Check and Quick Release Valves Vehicles intended for road use conform to Federal Motor Vehicle 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 roads. Vehicles intended for road use also conform to applicable Canadian Motor Vehicle Safety Standards (CMVSS). page – Air Brake System with Split Brakes The Ottawa ABS has three air reservoirs (storage tanks); primary, front and rear. The primary acts as the supply tank to both front and rear service tanks. The instrument panel displays a pressure gauge for each service tank. – Maintenance Manual Ottawa T2 4x2 148 0.1 Air System Circuits – E. Schematics On-Highway Air System CAB TRAILER TRACTOR/TRAILER PARK BRAKE PARK VALVE OPTION TRACTOR (RED) PARK (YELLOW) PP-1 3/8" YW DEL SUP SUP DEL 5TH WHEEL UNLATCH DEL PP-7 CON DEL EXH QUICK TRAILER AIR R14 VALVE OPTION INSIDE CAB 5TH WHEEL INTERLOCK OPTION SUP EXH 3/8" BK 3/8" BL 3/8" BL 3/8" BL 3/8" RD 3/8" RD 3/8" BK 3/8" BK 3/8" VL 3/8" YW 1/2" GN TP-3DC FOOT VALVE 1 2 1/2" GN 3/8" RD DC-4 3/8" RD 1/2" OE 1/2" OE 3/8" OE 3/8" GN TRAILER HAND BRAKE OPTION 1/2" OE QR-1 5/8" OE 1/2" GN 1/2" OE 1/2" OE E-7 DEL 3/8" VL 3/8" OE 3/8" GN 3/8" YW 3/8" BK 3/8" VL SUP DEL REAR BRAKES FRONT BRAKES 3/8" GN 3/8" RD DEL SUP DEL EXH 3/8" OE 5/8" OE 5/8" GN 5/8" OE 3/8" GN 3/8" YW 3/8" BK 3/8" VL 3/8" RD 3/8" VL 5/8" OE 5/8" GN 5/8" OE 3/8" GN 5/8" OE 5/8" OE AIR HORN OPTION GREASE JOCKEY LUBE PUMP OPTION On-Highway Air System – Part A Maintenance Manual Ottawa T2 4x2 3/8" BK 0.1 Air System Circuits – E. Schematics 149 – SPRING SERVICE 5TH WHEEL UNLATCH CYLINDER 7.35 CU. IN. RESERVOIR OPTION 1/4" BL 3/8" BK SUP 5/8" GN 1/2" GN DEL SER CON REAR BRAKES RESERVOIR DEL 1/2" GN BP-R1 3/8" GN 5/8" GN WET TANK 5/8" OE 3/8" YW PR-4 AIR DRYER OPTION QR-1C FRONT BRAKES RESERVOIR 5/8" BK 1/4" BK 3/8" VL 3/8" YW UNL AIR COMP. RESV 5/8" OE 5/8" GN 3/8" VL 3/8" VL INTER AXLE LOCK OPTION 1/4" VL 3/8" GN 3/8" RD 3/8" YW CAB AIR SUSPENSION DIFF LOCK OPTION SERVICE SPRING 5/8" OE 5/8" GN 3/8" GN 3/8" YW 3/8" RD On-Highway Air System – Part B Maintenance Manual Ottawa T2 4x2 150 0.1 Air System Circuits – E. Schematics On-Highway Air System Circuit – TRACTOR/TRAILER PARK BRAKE VALVE OPTION 4 1 5TH WHEEL INTERLOCK OPTION 2 1 1 2 3 3 3 2 12 2 1 11 21 11 22 12 ABS FRONT BRAKES OPTION GREASE JOCKEY LUBE PUMP OPTION AIR HORN OPTION 4 PSI 0 2 AIR DRYER OPTION 2 1 On-Highway Air System Circuit – Part A Maintenance Manual Ottawa T2 4x2 1 2 2 0.1 Air System Circuits – E. Schematics 151 4 PSI TRAILER HOSE CONNECTION 21 22 4 PSI 23 24 1-4 11 12 QUICK TRAILER AIR - R14 VALVE OPTION TRACTION CONTROL OPTION TRAILER HAND BRAKE OPTION 41 12 42 11 1 2 7.35 CU. IN. RESERVOIR OPTION 0 - 150 PSI 1 2 0 - 150 PSI 1 2 DIFF LOCK OPTION On-Highway Air System Circuit – Part B – Maintenance Manual Ottawa T2 4x2 ABS REAR BRAKES OPTION 2 152 0.1 Air System Circuits – E. Schematics Off-Highway Air System CAB TRAILER PARK (RED) TRACTOR/TRAILER PARK BRAKE VALVE OPTION TRACTOR PARK (YELLOW) PP-1 PP-7 3/8" YW SUP CON DEL DEL EXH SUP 5TH WHEEL UNLATCH DEL QUICK TRAILER AIR R14 VALVE OPTION INSIDE CAB 5TH WHEEL INTERLOCK OPTION SUP DEL EXH 3/8" BK 3/8" BL 3/8" BL 3/8" BL 3/8" RD 3/8" RD TP-3DC FOOT VALVE 1 2 1/2" GN 3/8" BK 3/8" VL 3/8" BK 3/8" RD 3/8" YW 1/2" GN DC-4 1/2" OE 1/2" OE 3/8" OE 3/8" GN TRAILER HAND BRAKE OPTION 1/2" OE QR-1 5/8" OE 1/2" GN 1/2" OE E-7 1/2" OE DEL 3/8" VL 3/8" OE 3/8" GN 3/8" YW 3/8" BK 3/8" VL SUP DEL REAR BRAKES FRONT BRAKES DEL 3/8" GN DEL SUP EXH 3/8" OE 5/8" OE 5/8" GN 5/8" OE 5/8" GN 3/8" YW 3/8" BK 3/8" VL 3/8" VL 5/8" OE 5/8" GN 5/8" OE 5/8" GN 5/8" OE 5/8" OE AIR HORN OPTION GREASE JOCKEY LUBE PUMP OPTION Off-Highway Air System – Part A Maintenance Manual Ottawa T2 4x2 3/8" BK 0.1 Air System Circuits – E. Schematics 153 – SPRING SERVICE 5TH WHEEL UNLATCH CYLINDER 7.35 CU. IN. RESERVOIR OPTION 1/4" BL 3/8" BK 1/2" GN QR-1 SERVICE BRAKES REAR BRAKES RESERVOIR 1/2" GN 3RD AIR TANK OPTION 5/8" GN 5/8" OE 3/8" YW QR-1 SPRING BRAKES AIR DRYER OPTION FRONT BRAKES RESERVOIR 3/8" YW 3/8" VL 5/8" BK 1/4" BK UNL AIR COMP. 3/8" VL RESV 3/8" VL 3/8" VL INTER AXLE LOCK OPTION 5/8" OE 5/8" GN 1/4" VL 5/8" GN 3/8" YW CAB AIR SUSPENSION DIFF LOCK OPTION SERVICE SPRING 5/8" OE 5/8" GN 5/8" GN 3/8" YW Off-Highway Air System – Part B Maintenance Manual Ottawa T2 4x2 154 0.1 Air System Circuits – E. Schematics Off-Highway Air System Circuit – TRACTOR/TRAILER PARK BRAKE VALVE OPTION 4 1 5TH WHEEL INTERLOCK OPTION 2 1 1 2 3 3 3 2 12 2 1 11 21 11 22 12 GREASE JOCKEY LUBE PUMP OPTION AIR HORN OPTION 4 PSI 3RD AIR TANK OPTION 0 2 AIR DRYER OPTION 2 1 Off-Highway Air System Circuit – Part A Maintenance Manual Ottawa T2 4x2 2 0.1 Air System Circuits – E. Schematics 155 4 PSI TRAILER HOSE CONNECTION 21 22 4 PSI 23 24 1-4 11 12 QUICK TRAILER AIR - R14 VALVE OPTION TRAILER HAND BRAKE OPTION 1 2 7.35 CU. IN. RESERVOIR OPTION 0 - 150 PSI 1 2 0 - 150 PSI 1 2 DIFF LOCK OPTION Off-Highway Air System Circuit – Part B Maintenance Manual Ottawa T2 4x2 2 1 156 0.1 Air System Circuits – E. Schematics 0.1.2 page – Cab Seating Air Lines — Driver's Seat Components • Air Control Valve • Air Reservoir • Air Spring The adjustable driver's seat cushion rides on an air bag. A locking mechanism allows the driver to stop fore and aft chugging if desired. Seating comfort controls are 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 page – Cab Suspension 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 rubber bumper prevents the cab from striking the rails. Refer to the main air system schematics in 0.1.1 Air Brakes for cab suspension air lines. Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics 0.1.4 157 Fifth-Wheel Coupling Air Lines — Fifth-Wheel Latch page – 5TH WHEEL UNLATCH AIR LINES FIFTH WHEEL 3/8 BK 3/8 YW 5TH WHEEL AND BOOM 5TH WHEEL UNLATCH 3/8 YW TO BRAKE TANK MANIFOLD, 8 PORT TO TRACTOR PARK (YELLOW) PLUGS TO TRACTOR PARK (RED) 3/8 YW BRAKE TREADLE NE 3/8 BK SI DE TO BRAKE SYSTEM PLUGS DELIVERY SUPPLY R FA SID E TO SERVICE RESERVOIR OTT0049 AR PLUG Air Lines — Fifth-Wheel Latch Components • Air Control Valve • Air Cylinder • Air Reservoir Pressing the control valve button 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. Maintenance Manual Ottawa T2 4x2 158 0.1 Air System Circuits – E. Schematics 5TH WHEEL UNLATCH DEL SUP 3/8" VL DEL 3/8" VL SUP TR-3 3/8" BK 3/8" RD 3/8" BL 3/8" RD Air Lines — Fifth-Wheel Unlatch Maintenance Manual Ottawa T2 4x2 CON 0.1 Air System Circuits – E. Schematics – 159 5th Wheel Interlock Option Circuit 5TH WHEEL INTERLOCK OPTION 1 3 2 4 3 1 5th Wheel Interlock Option Maintenance Manual Ottawa T2 4x2 2 160 0.1 Air System Circuits – E. Schematics 0.1.5 page – Tractor/Trailer Park Brake Air Lines — Tractor/Trailer Park Brake Option TRAILER PARK (RED) TRACTOR PARK (YELLOW) MV-3 DEL EXH SUP SUP DEL 3/8" BL 3/8" RD 3/8" OE 3/8" GN 3/8" YW Air Lines — Tractor/Trailer Park Brake Option Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics – 161 Tractor/Trailer Park Brake Valve Option Circuit TRACTOR/TRAILER PARK BRAKE VALVE OPTION 11 22 12 3 21 Tractor/Trailer Park Brake Valve Option Maintenance Manual Ottawa T2 4x2 162 0.1 Air System Circuits – E. Schematics 0.1.6 page – Quick Trailer Air/R14 Valve Air Lines — Quick Trailer Air/R14 Valve Option QUICK TRAILER AIR R14 VALVE OPTION 5/8" RD 3/8" RD DC-4 3/8" RD TP-3DC FOOT VALVE 1 2 5/8" OE 5/8" GN 5/8" OE 5/8" GN 5/8" OE 5/8" GN Air Lines — Quick Trailer Air/R14 Valve Option Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics 163 Quick Trailer Air/R14 Valve Option Circuit – 21 22 23 24 41 12 2 42 1-4 11 12 2 1 11 QUICK TRAILER AIR - R14 VALVE OPTION FROM SUPPLY SIDE OF TREADLE Quick Trailer Air/R14 Valve Option 0.1.7 Trailer Hand Brake Air Lines — Trailer Hand Brake Option page – TP-3DC FOOT VALVE 1 2 1/2" OE DC-4 1/2" OE 3/8" OE 3/8" VL 3/8" BL 3/8" VL EXH 1/2" OE TC-2 SUP DEL 3/8" OE TRAILER HAND BRAKE OPTION Air Lines — Trailer Hand Brake Option Maintenance Manual Ottawa T2 4x2 164 – 0.1 Air System Circuits – E. Schematics Trailer Hand Brake Option Circuit 3 1 12 2 11 TRAILER HAND BRAKE OPTION Trailer Hand Brake Option – Trailer Hose Connection Coiled Air Lines Circuit TRAILER HOSE CONNECTION Trailer Hose Connection Coiled Air Lines Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics – 165 Trailer Hose Connection Glad Hands Both Ends Coiled Air Lines Circuit TRAILER HOSE CONNECTION GLAD HAND CONNECTORS Trailer Hose Connection Glad Hands Both Ends Coiled Air Lines – Trailer Hose Connection Straight Rubber Air Lines Circuit TRAILER HOSE CONNECTION STRAIGHT RUBBER HOSE Trailer Hose Connection Straight Rubber Air Lines Maintenance Manual Ottawa T2 4x2 166 0.1 Air System Circuits – E. Schematics 0.1.8 page – Air Horn Air Lines — Air Horn Option 3/8" VL AIR HORN OPTION Air Lines — Air Horn Option – Air Horn Option Circuit AIR HORN OPTION Air Horn Option Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics 0.1.9 page – 167 Inter Axle Lock Air Lines — Inter Axle Option 3/8" VL INTER AXLE LOCK OPTION 3/8" VL Air Lines — Inter Axle Option – Inter Axle Lock Option Circuit 3 1 Inter Axle Lock Option Maintenance Manual Ottawa T2 4x2 2 INTER AXLE LOCK OPTION 168 0.1 Air System Circuits – E. Schematics 0.1.10 page – Grease Jockey Lube Pump Air Lines — Grease Jockey Lube Pump Option GREASE JOCKEY LUBE PUMP OPTION 3/8" VL Air Lines — Grease Jockey Lube Pump Option – Grease Jockey Lube Pump Option Circuit GREASE JOCKEY LUBE PUMP OPTION P1 Grease Jockey Lube Pump Option Maintenance Manual Ottawa T2 4x2 R S 0.1 Air System Circuits – E. Schematics 0.1.11 page – 169 Differential Axle Lock Air Lines — Differential Axle Lock Option 3/8" VL DIFF LOCK 3/8" VL Air Lines — Differential Axle Lock Option – Differential Axle Lock Option Circuit 3 1 Differential Axle Lock Option Maintenance Manual Ottawa T2 4x2 2 DIFFERENTIAL AXLE LOCK OPTION 170 0.1 Air System Circuits – E. Schematics 0.1.12 page – Additional 7.35 cu. in. Air Reservoir Air Lines — Additional 7.35 cu. in. Air Reservoir Option 5/8" VL 1/2" VL 7.35 CU. IN. RESERVOIR OPTION 1/2" VL 5/8" VL Air Lines — Additional 7.35 cu. in. Air Reservoir Option – Additional 7.35 cu. in. Air Reservoir Option 7.35 CU. IN. RESERVOIR OPTION 2 1 1 0 - 150 PSI 2 2 1 7.35 cu.ft. Additional 7.35 cu. in. Air Reservoir Option Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics 0.1.13 page – 171 Air Dryer Air Lines — Air Dryer Option AIR DRYER OPTION 5/8" BK UNL AIR COMP. 1/4" BK RESV Air Lines — Air Dryer Option Maintenance Manual Ottawa T2 4x2 172 – 0.1 Air System Circuits – E. Schematics Air Dryer Option 2 1 4 3 Air Dryer Option Maintenance Manual Ottawa T2 4x2 AIR DRYER OPTION 0.1 Air System Circuits – E. Schematics 0.1.14 ABS Brakes Air Lines — ABS Brakes Option – On-Highway Only SPRING SERVICE 1/2" OE 2 1 1 2 1/2" GN ABS FRONT BRAKES ABS REAR BRAKES TRACTION CONTROL OPTION 1/2" GN 1/2" GN 3/8" YW 3/8" YW 2 1 ABS REAR BRAKES 1 ABS FRONT BRAKES 2 page – 173 1/2" GN 1/2" OE SERVICE SPRING Air Lines — ABS Brakes Option – On-Highway Only Maintenance Manual Ottawa T2 4x2 174 0.1 Air System Circuits – E. Schematics ABS Brake Option Circuit – R + 3 C - 2 H + 1 3 R + C H + 2 1 TRACTION CONTROL OPTION 41 12 2 42 2 11 1 1 2 ABS FRONT BRAKES OPTION ABS REAR BRAKES OPTION H + 1 4 PSI 2 C - H + R + C 3 1 R + ABS Brake Option Maintenance Manual Ottawa T2 4x2 2 3 0.1 Air System Circuits – E. Schematics 0.1.15 page – 175 Traction Control Air Lines — Traction Control Option for ABS Brakes – On-Highway Only TRACTION CONTROL OPTION 3/8" GN 3/8" GN 3/8" GN Air Lines — Traction Control Option for ABS Brakes – On-Highway Only Maintenance Manual Ottawa T2 4x2 176 – 0.1 Air System Circuits – E. Schematics Traction Control Option for Use With ABS Brake Option Circuit TRACTION CONTROL OPTION 3 1 2 41 42 1 2 Traction Control Option for Use With ABS Brake Option Maintenance Manual Ottawa T2 4x2 0.1 Air System Circuits – E. Schematics 0.1.16 page – 177 3rd Air Tank Air Lines — 3rd Air Tank Option – Off-Highway Only 3RD AIR TANK OPTION WET TANK 5/8" BK 3/8" VL Air Lines — 3rd Air Tank Option – 3rd Air Tank Option Circuit 3RD AIR TANK OPTION 3rd Air Tank Option Maintenance Manual Ottawa T2 4x2 5/8" BK 178 0.2 Hydraulic System Circuits – E. Schematics 0.2 Hydraulic System Circuits Hydraulic Systems page – One electric motor with integral pump and one hydraulic fluid reservoir are shared by the fifth-wheel boom, cab tilt and power steering systems. Each system operates independently. The motor is mounted on the transmission housing. All fluid passes through a filter mounted beside the reservoir. 0.2.1 Cab Tilt Hydraulic Lines — Cab Tilt page – CAB TILT HYDRAULIC SYSTEM HYDRAULIC CAB TILT CYLINDER HYDRAULIC PUMP CAB UNLOCK ADAPTOR OTT0048 HYDRAULIC RESERVOIR TANK 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 down movement. Maintenance Manual Ottawa T2 4x2 0.2 Hydraulic System Circuits – E. Schematics 0.2.2 page – 179 Fifth-Wheel Boom 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. Maintenance Manual Ottawa T2 4x2 180 0.2 Hydraulic System Circuits – E. Schematics 0.2.3 page – Power Steering 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. Maintenance Manual Ottawa T2 4x2 0.2 Hydraulic System Circuits – E. Schematics 0.2.4 page – 181 Optional Hydrostatic Steering 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 reservoir with the cab tilt and boom lift systems. Maintenance Manual Ottawa T2 4x2 182 0.3 Electrical System Circuits – E. Schematics 0.3 Electrical System Circuits 0.3.1 page – Starting and Charging 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 Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 0.3.2 page – 183 Cab Accessory Components 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. Maintenance Manual Ottawa T2 4x2 184 0.3 Electrical System Circuits – E. Schematics Heater and Air Conditioning – HEATER/AIR CONDITIONING CIRCUIT HC1000 RD/WE HC2001 YW/RD FC2000 BK A/C SWITCH HC2001 YW/RD HC2002 YW/BK HC2001 YW/RD HC2001 YW/RD HC2003 YW/BK COLD CONTROL A B HEATER & A/C FAN MOTOR HC1000 RD/WE B A CAB ACC FUSE HVAC 30 A NEGATIVE PASS-THRU STUD A/C HIGH PRESSURE SWITCH IGNITION SWITCH CONNECTOR OPTIONAL A/C COMPRESSOR 3 ACC #1 AC1000 BN A/C LOW PRESSURE SWITCH I A C D B HVAC S BK 85 87 87A AC2000 BN GD2001 WE NEGATIVE PASS-THRU STUD A B 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 86 30 BA2001 RD R2 HC2003 YW/BK OPTIONAL A/C HIGH PRESSURE POSITIVE PASS-THRU STUD Heating and Air Conditioning Circuits Components • Accessory Relay #1 • Air Conditioner Switch • Cab Fan (Optional) • Cold Control (AC Optional) • Fan Switch • Fuse — HVAC (Cab Accessory Fuse Panel) • HVAC Fan Motor • Ignition Switch Air conditioning is optional equipment. Maintenance Manual Ottawa T2 4x2 OTT0036 HC1000 RD/WE HTR-LOW GY HTR-MED BK HTR-HI OE HC1000 RD/WE HC2001 YW/RD A/C LOW PRESSURE SWITCH & COLD CONTROL CONNECTOR A/C LOW PRESSURE SWITCH & COLD CONTROL CONNECTOR HC2001 YW/RD HC2002 HC2003 CAB CONTROL PANEL CONNECTOR HC2001 YW/RD HC2003 YW/BK HC2001 YW/RD A B E L H D J K F G M A B C GD2001 WE HC1000 RD/WE HC1000 RD/WE HC2001 FC2000 B A C D F E GD2001 WE HC1000 RD/WE HC1000 RD/WE AIR CONDITIONER SWITCH CONNECTOR ELECTRONIC ENGINE BULKHEAD CONNECTOR HTR-LOW GY HTR-MED BK HTR-HI OE HC1000 RD/WE OPTIONAL CAB FAN HC1000 FAN SW L OFF M H C 0.3 Electrical System Circuits – E. Schematics 185 Horn – HORN CIRCUIT HORN HN2000 GN/BK HN2000 GN/BK CAB ACC FUSE HORN HORN 10 A HORN 86 30 R7 CHASSIS BULKHEAD CONNECTOR HN1000 GN HN2000 GN/BK HN2001 GN/WE HORN GD2000 WE NEGATIVE PASS-THRU STUD OTT0037 85 87 87A 1 HN2000 GN/BK BA2002 RD G U S L C F X V N D M B T P J W K R H A E REMOVE POSITIVE STUD Horn Circuit Components • Circuit Breaker — Horn (Cab Accessory Fuse Panel) • Horn • Horn Button • Horn Relay The horn operates independently of the ignition switch. – Maintenance Manual Ottawa T2 4x2 186 0.3 Electrical System Circuits – E. Schematics Mirrors Heated (Optional) MIRROR CONNECTOR LEFT SIDE A B CAB BULKHEAD CONNECTOR C G M N W F R B E J L K T H X D V U A P S MR1000 RD GD2000 WE MIRROR CONNECTOR LEFT SIDE MR1000 RD A GD2000 WE B MIRROR HEAT CONVEX RIGHT SIDE MR1000 RD GD2000 WE MR1001 OE GD2000 WE MR1000 RD GD2000 WE BUS BAR CONVEX MIRROR CONNECTOR LEFT AC1001 BN A B MR1000 RD GD2000 WE CAB ACC FUSE MIRRORS MIRRORS MR1000 RD GD2000 WE MR1000 RD GD2000 WE MR1000 RD GD2000 WE A B NEGATIVE PASS-THRU STUD GD2000 WE MIRROR DASH HARNESS CONNECTOR MR1001 OE GD2000 WE MR1000 RD 15 A 4 A B MIRROR CONNECTOR RIGHT SIDE A B C MR1001 OE GD2000 WE MR1000 RD MIRROR HEAT CONVEX RIGHT SIDE MR1000 RD GD2000 WE A B CONVEX MIRROR CONNECTOR RIGHT GD2000 WE MR1001 OE MIRROR HEAT RIGHT SIDE MIRROR CONNECTOR RIGHT SIDE MIRROR HEAT SWITCH 4 5 1 AC1001 BN 85 87 ACC #2 86 30 PR2 POSITIVE PASS-THRU STUD OTT0078 MIRROR HEAT RIGHT SIDE HEATED MIRROR CIRCUIT Heated Mirror Circuit Components • Circuit Breaker — Optional Accessory • Heater Switch • Left-Hand Mirror Heater • Right-Hand Mirror Heater An indicator lamp illuminates when the mirror heater is active. The ignition switch must be On to use the mirror heater. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 187 Heated and Motorized (Optional) 85 ACC #2 86 87 30 NEGATIVE PASS-THRU STUD GD2000 WE LH MIRROR MIRROR CONNECTOR LEFT HAND CAB ACC FUSE MIRRORS MIRRORS A B MR1000 RD GD2000 WE MR1001 OE MR1000 RD MR1003 RD/WE MR1004 RD/WE MOTO MIRROR DASH HARNESS CONNECTOR A B C 15 A 4 MR1003 RD/WE MR1004 RD/WE BUS BAR RD BK GD2000 WE MR1000 RD HEATER MR1004 RD/WE D E F AC1001 BN PR2 C G M N W F R B E J L K T X H D V U A P S CAB BULKHEAD CONNECTOR NEGATIVE PASS-THRU STUD GD2000 WE RH MIRROR CCW MR1000 RD MR1003 RD/WE MR1004 RD/WE A B C D RD BK WE GN CW HEATER MIRROR CONNECTOR RIGHT HAND MIRROR REMOTE SWITCH RIGHT HAND MR1000 RD HEATED MOTO-MIRROR CIRCUIT 6 5 2 MR1008 OE/WE MIRROR HEAT SWITCH MR1002 BK/WE GD2000 WE MR1003 RD/WE MR1001 OE OTT0077 3 Heated and Motorized Mirror Circuit Components • Circuit Breaker — Optional Accessory • Heater Switch • Left-Hand Mirror Heater • Left-Hand Mirror Motor • Left-Hand Motor Switch • Right-Hand Mirror Heater • Right-Hand Mirror Motor • Right-Hand Motor Switch An indicator lamp illuminates when the mirror heater is active. The ignition switch must be On to use the mirror heater and motor. Maintenance Manual Ottawa T2 4x2 188 0.3 Electrical System Circuits – E. Schematics Radio (Optional) – IGNITION SWITCH RADIO CIRCUIT B 10 A BA2001 RD 3 TERMINAL FOR CB RADIO CONNECTOR A B C GD2006 WE RD2002 BN/RD RD1003 RD B D A POSITIVE PASS-THRU STUD RADIO UNDER DASH CONNECTOR RADIO UPPER CAB CONNECTOR GD2006 WE RD2002 BN/RD RD1003 RD A B C REMOTE POSITIVE STUD GD2006 WE RD2002 BN/RD RD1003 RD RADIO UNDER DASH A B NEGATIVE PASS-THRU STUD GD2006 RD2002 BN/RD RD1003 RD BA2004 RD CAB ACC RADIO BATTERY FUSE RADIO BATT 5 A Radio Circuit Maintenance Manual Ottawa T2 4x2 2 OTT0040 30 RD2002 BN/RD AC2000 BN RD2002 BN/RD TERMINAL FOR RADIO CONNECTOR RADIO OVERHEAD 86 R2 GD2006 WE 5 A 87 87A 1 GD2006 WE RD2002 BN/RD CAB ACC RADIO FUSE RADIO ACCY IGNITION SWITCH CONNECTOR RD2002 BN/RD ACC #1 85 I BUS BAR AC1001 BN BUS BAR AC1001 BN IG1000 RD/WE C CAB ACC IGNITION SWITCH FUSE IGN SW BA2000 RD RD2002 BN/RD POSITIVE PASS-THRU STUD S IG1000 RD/WE AC2000 BN A 0.3 Electrical System Circuits – E. Schematics 189 Radio Circuit — Hot Wire – IGNITION SWITCH B RADIO CIRCUIT HOT WIRE 1 ACC #1 87A 86 AC2000 BN 30 BA2001 RD R2 BUS BAR AC1001 BN RD2002 BN/RD GD2006 WE B A B D CAB ACC RADIO FUSE RADIO ACCY 10 A TERMINAL FOR CB RADIO CONNECTOR POSITIVE PASS-THRU STUD 3 RD2002 BN/RD GD2006 WE RADIO UPPER CAB CONNECTOR NEGATIVE PASS-THRU STUD Radio Circuit — Hot Wire Components • Accessory Relay #1 • Circuit Breaker — Radio Battery (Cab Accessory Fuse Panel) • Fuse — Ignition Switch (Cab Accessory Fuse Panel) • Fuse — Radio (Cab Accessory Fuse Panel) • Ignition Switch The ignition switch must be On to use the radio. Maintenance Manual Ottawa T2 4x2 OTT0088 AC1001 BN 85 87 I AC2000 BN 10 A IG1000 RD/WE A BA2000 RD C POSITIVE PASS-THRU STUD CAB ACC IGNITION SWITCH FUSE IGN SW IGNITION SWITCH CONNECTOR S IG1000 RD/WE AC2000 BN A 190 0.3 Electrical System Circuits – E. Schematics Windshield Washer (Optional) – WINDSHIELD WIPER SW WINDSHIELD WASHER CIRCUIT L OPTIONAL WINDSHIELD WASHER H W B CAB ACC FUSE WIPER/WASHER WIPER/WASH 15 A WW2003 GN 4 ACC #1 85 87 87A 86 30 R2 BA2001 RD POSITIVE PASS-THRU STUD A B WW2003 GN GD1001 WE G U S L C F X V N D M B T P J W K R H A E WW2003 GN WASHER CONNECTOR GD1001 WE TRANSMISSION CASE GROUND OTT0041 BUS BAR AC1000 BN C B WW1000 PE/RD A E WW2003 GN D F WIPER SWITCH CONNECTOR CHASSIS BULKHEAD CONNECTOR WW2003 A GD1001 B WW1000 PE/RD WW2003 GN P Windshield Washer Circuit Components • Accessory Relay #1 • Circuit Breaker — Wiper/Washer (Cab Accessory Fuse Panel) • Windshield Washer Motor • Windshield Wiper Switch The ignition switch must be On to use the windshield washer. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 191 Windshield Wiper – WINDSHIELD WIPER CIRCUIT WINDSHIELD WIPER SW H W L B P ACC #1 GRD WIPER MOTOR CONNECTOR F GD2001 WE WW2000 PE WW1000 PE/RD WW2002 PE/WE WW2001 PE/BK E D C B A HI AC1000 BN WW2002 PE/WE F CAB ACC FUSE WIPER/WASHER WIPER/WASH 15 A 4 Windshield Wiper Circuit Components • Accessory Relay #1 • Circuit Breaker — Wiper/Washer (Cab Accessory Fuse Panel) • Windshield Wiper Motor • Windshield Wiper Switch The ignition switch must be On to use the windshield wiper. Maintenance Manual Ottawa T2 4x2 OTT0042 LO BN BE BK RD GN WW1000 PE/RD PARK BUS BAR ELEC. WIPER AC1000 BN BATT WW2002 PE/WE WIPER MOTOR E NEGATIVE PASS-THRU STUD D WIPER SWITCH CONNECTOR A R2 WW2001 PE/BK WW2000 PE WW1000 PE/RD POSITIVE PASS-THRU STUD BA2001 RD 30 B 87A WW2001 PE/BK WW2000 PE WW1000 PE/RD 87 C 86 85 192 – 0.3 Electrical System Circuits – E. Schematics Cab Power Board Cab Power Board Wiring Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Cab Interior Engine Wiring Cab Interior Engine Wiring (Cummins ISB 2013 Engine) – Cab Interior Engine Wiring (Cummins QSB 6.7 T3 Engine) Maintenance Manual Ottawa T2 4x2 193 194 0.3 Electrical System Circuits – E. Schematics – Cab Interior Engine Wiring (Cummins QSB T4F Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 0.3.3 195 Cab Instrumentation Air Pressure Gauge Lighting page – STANDARD AIR GAUGE LIGHTING CIRCUIT S9 PANEL LTS DIMMER S1 HEADLAMP SWITCH AIR PRESS PL2002 PL2002 S1 HEADLAMP SWITCH L F E A H B C D G J K L M ENGINE GAUGE & WARNING PANEL CONNECTOR C G PL2002 BE/RD M N W F R B E J L K T H X D V U A P S PL2002 B C A OPT AIR PRESS G L G PL2002 GD2002 BRAKE CONTROLS PANEL CONNECTOR GD2002 WE NEGATIVE PASS–THRU STUD CAB BULKHEAD CONNECTOR OTT0073 WITH OPTIONAL DIMMER SWITCH Air Pressure Gauge Lighting Circuit Components • Gauge • Gauge (Second Service Tank) • Gauge Lamp • Gauge Lamp (Second Service Tank) • Headlight Switch • Panel Dimmer Switch (Optional) Vehicles equipped with ABS have two service tanks and a pressure gauge for each one. Maintenance Manual Ottawa T2 4x2 196 0.3 Electrical System Circuits – E. Schematics Engine Hourmeter – ENGINE HOURMETER HOUR METER GD2000 HOURS 3 1 NEGATIVE PASS–THRU STUD WE 2 S BA2000 10 A 1 IGNITION 85 86 87 PR1 30 IG1001 A C B G M J F K 11 12 CAB CONTROLS PANEL CONNECTOR 21 8 19 6 5 17 26 16 28 15 GA2003 OE/WE 25 14 13 22 9 10 7 4 3 2 1 29 20 CAB ACC 18 FUSE GAUGE 23 GAUGE 27 24 10 A 1 ELECTRONIC ENGINE BULKHEAD CONNECTOR IG2006 BN/RD OIL PRESSURE SWITCH (HOURMETER) OTT0071 POSITIVE PASS–THRU STUD CAB ACC CB IGNITION SWITCH IGN SW RD D L H IG1000 RD/WE IG1000 RD/WE GA2003 OE/WE E GD2000 GA2003 IG1000 YW Engine Hourmeter Circuit Components • Circuit Breaker — Ignition Switch (Cab Accessory Fuse Panel) • Fuse — Gauge (Cab Accessory Fuse Panel) • Hourmeter • Ignition Relay • Oil Pressure (Hourmeter) Switch The hourmeter operates when engine oil pressure reaches the set point closing the switch. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Fuel Gauge Fuel Gauge Circuit (Cummins ISB 6.7 2013 Engine) Maintenance Manual Ottawa T2 4x2 197 198 0.3 Electrical System Circuits – E. Schematics 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. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics Fuel Gauge Circuit (Cummins QSB Engines) Maintenance Manual Ottawa T2 4x2 199 200 0.3 Electrical System Circuits – E. Schematics Low Air Warning Alarm – LOW AIR WARNING CIRCUIT CAB ACC FUSE GAUGE GAUGE IG2006 BN/RD IG2001 YW 10 A 1 IGNITION SWITCH IGNITION 85 87 86 PR1 30 NEGATIVE PASS–THRU STUD GD2002 WE B LOW AIR BUZZER AS1000 GN/WE C G M N W F R B E J L K T H X D V U A P S GD2002 WE AS1000 GN/WE B C A BRAKE CONTROLS PANEL CONNECTOR LOW AIR SWITCH OPTIONAL LOW AIR SWITCH CAB BULKHEAD CONNECTOR Low Air Warning Alarm Circuit Components • Fuse — Gauge (Cab Accessory Fuse Panel) • Ignition Relay • Low Air Alarm Buzzer • Low Air Switch • Low Air Switch (Optional) Maintenance Manual Ottawa T2 4x2 OTT0072 L 0.3 Electrical System Circuits – E. Schematics 201 Speedometer – WITH OPTIONAL DIMMER SWITCH S9 PANEL LTS DIMMER S1 HEADLAMP SWITCH SPEEDOMETER CIRCUIT S1 HEADLAMP SWITCH GA1 SPEEDOMETER MD TRANS V HARNESS CAB CONNECTOR B C D G J K L M TR-125 TN TR-125 TN F L MH E J G C D K A B 85 87 ENGINE GAUGE AND WARNING PANEL CONNECTOR IGNITION 86 30 PR1 CAB ACC FUSE GAUGE GAUGE 10 A TR-125 TN – VEHICLE SPEED-SPEEDO NEGATIVE PASS-THRU STUD GD2000 WE IG2006 BN/RD IG2006 PL2002 BE/RD TR-125 TN PL2002 F E DSO S IG2006 BN/RD GD2000 WE G IG2006 BN/RD A GD2000 WE H I PL2002 BE/RD PL2002 L 1 IG1001 YW OTT0056 GEN-4 3000 TRANSMISSION 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 67 66 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 PL2002 GEN-4 ECU CONNECTOR STANDARD Speedometer Circuit Components • Fuse — Gauge (Cab Accessory Fuse Panel) • Gauge (Speedometer) • Gauge Lamp • Headlight Switch • Ignition Relay • Panel Dimmer Switch (Optional) Some tractor speedometers may also display the total distance traveled. The speedometer is affected by DIP switch settings, tire size, gear ratios and the source of pulse generation. Maintenance Manual Ottawa T2 4x2 202 0.3 Electrical System Circuits – E. Schematics Voltmeter – WITH OPTIONAL DIMMER SWITCH VOLTMETER CIRCUIT STANDARD S9 PANEL LTS DIMMER S1 HEADLAMP SWITCH S1 HEADLAMP SWITCH GA5 VOLT L G GD2000 WE IG2006 BN/RD PL2002 30 PR1 CAB ACC FUSE GAUGE IG1001 GAUGE YW 10 A 1 C A B F J K PL2002 BE/RD G GD2000 WE M 86 IG2006 BN/RD D CAB CONTROLS PANEL CONNECTOR IGNITION 85 87 F L H PL2002 BE/RD NEGATIVE PASS–THRU STUD PL2002 BE/RD OTT0059 K L M D G J C H B ENGINE GAUGE & WARNING PANEL CONNECTOR F E A PL2002 I Voltmeter Circuit Components • Fuse — Gauge (Cab Accessory Fuse Panel) • Gauge Lamp • Headlight Switch • Ignition Relay • Panel Dimmer Switch (Optional) • Voltmeter The voltmeter detects the voltage at the accessory terminal on the ignition switch. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Gauge Cluster Wiring Gauge Cluster Wiring (Cummins ISB 2013 Engine) – Part A Maintenance Manual Ottawa T2 4x2 203 204 0.3 Electrical System Circuits – E. Schematics Gauge Cluster Wiring (Cummins ISB 2013 Engine) – Part B Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Gauge Cluster Wiring (Cummins QSB 6.7 T3 Engine) – Part A Maintenance Manual Ottawa T2 4x2 205 206 0.3 Electrical System Circuits – E. Schematics Gauge Cluster Wiring (Cummins QSB 6.7 T3 Engine) – Part B Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Gauge Cluster Wiring (Cummins QSB T4F Engine) – Part A Maintenance Manual Ottawa T2 4x2 207 208 0.3 Electrical System Circuits – E. Schematics Gauge Cluster Wiring (Cummins QSB T4F Engine) – Part B Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 0.3.4 Chassis Circuits Chassis Power Board page – J1 INPUT IGNITION SIGNAL INPUT REVERSE SIGNAL OUTPUT REVERSE SIGNAL BACKUP ALARM CHASSIS BACKUP LIGHTS ECM IGN DEF SENDER IGN ABS MODULE IGN TRANSMISSION ECU IGN INPUT ACCESSORY SIGNAL AUX POWER FROM AUX RELAY 5TH WHEEL INDICATION POWER OPTIONAL USER INPUT, SWITCH 1 POSITION B / AUX RELAY COIL GND OPTIONAL USER INPUT, SWITCH 4 POSITION B / FAN CLUTCH RELAY COIL PWR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 FAN CLUTCH 15 16 OPTIONAL USER INPUT, SWITCH 3 POSITION B / FAN CLUTCH RELAY COIL GND 17 AIR DRYER HEATER POWER 18 AIR SUSPENSION DUMP VALVE 19 FUEL HEATER 20 OUTPUT SIGNAL START RELAY 21 INPUT SIGNAL ECU ANTI RESTART 22 FAN CLUTCH RELAY AIR CONDITIONING CLUTCH PWR J2 INPUT SIGNAL KEYSWITCH CRANK POWER 1 INPUT SIGNAL TRANSMISSION NEUTRAL 2 AUX RELAY 2 OUTPUT POWER 3 AUX RELAY 2 OUTPUT POWER 4 AUX RELAY 2 COIL PWR 5 CAB TILT 6 TRANSMISSION ECU BATTERY 7 ECM1 BATTERY 8 ECM1 BATTERY 9 AFTERTREATMENT EXHAUST POWER 10 ECM2 BATTERY 11 OUTPUT KEYSWITCH BATTERY POST 12 ABS MODULE BATTERY 13 ABS MODULE BATTERY 14 SPARE BATTERY 15 DEF LINE HEATER COMMAND 16 LINE HEATER 1 17 LINE HEATER 2 18 LINE HEATER 3 19 DEF PUMP HEATER COMMAND 20 DEF PUMP HEATER SUPPLY 21 Chassis Power Board Wiring Maintenance Manual Ottawa T2 4x2 209 210 – 0.3 Electrical System Circuits – E. Schematics Air Dryer (Optional) Air Dryer Circuit Components • Air Dryer • Chassis Options Relay • Circuit Breaker — Air Dryer (Cab Accessory Fuse Panel) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 211 Cab Tilt Pump – TILT PUMP CIRCUIT BATTERIES RD (BATTERY-TO-STARTER) RD BK RD (BATTERY-TO-START SOL.) RD STARTER W/SOLENOID RD (TILT SOL.-TO-TILT PUMP) WE TT2001 TRANSMISSION CASE GROUND GD1001 WE GD1001 WE GN GD1001 MID-FRAME CROSSMEMBER CONNECTOR 30 BA2000 RD B TT2001 GN C TT2000 BK A TT1000 RD/BK BK TT2000 RD TILT MOTOR -UP- WE TILT SOL. -DN- 86 TILT SWITCH HARNESS CONNECTOR TILT PUMP CONTROL SWITCH CAB ACC FUSE TILT TILT 5 A OTT0035 PR1 BUS BAR 85 87 IGNITION TT2001 GN TT1000 RD/BK TT2000 BK TT1000 RD/BK CHASSIS BULKHEAD CONNECTOR GN GD1001 G U S L C F X V N D M B T P J W K R H A TT1000 E RD/BK TT2001 TT1000 RD/BK 2 Cab Tilt Pump Circuit Components • Batteries • Fuse — Tilt (Cab Accessory Fuse Panel) • Ignition Relay • Starter with Solenoid • Tilt Pump Control Switch • Tilt Pump Motor (Up) • Tilt Solenoid (Down) • Tilt Solenoid to Pump Maintenance Manual Ottawa T2 4x2 212 – 0.3 Electrical System Circuits – E. Schematics Cab Exterior/Front Chassis Wiring Cab Exterior/Front Chassis Wiring (Cummins ISB 2013 Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Cab Exterior/Front Chassis Wiring (Cummins QSB 6.7 T3 Engine) Maintenance Manual Ottawa T2 4x2 213 214 0.3 Electrical System Circuits – E. Schematics – Cab Exterior/Front Chassis Wiring (Cummins QSB T4F Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Chassis Wiring Chassis Wiring (Cummins ISB 2013 Engine) Maintenance Manual Ottawa T2 4x2 215 216 0.3 Electrical System Circuits – E. Schematics – Chassis Wiring (Cummins QSB 6.7 T3 Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Chassis Wiring (Cummins QSB T4F Engine) – Maintenance Manual Ottawa T2 4x2 217 218 0.3 Electrical System Circuits – E. Schematics 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) – Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics Battery Power Distribution Battery Power Distribution (Cummins ISB 2013 Engine) – Battery Power Distribution (Cummins QSB 6.7 T3 Engine) Maintenance Manual Ottawa T2 4x2 219 220 0.3 Electrical System Circuits – E. Schematics – Battery Power Distribution (Cummins QSB T4F Engine) – Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 221 Cab Tilt System Control Wiring Cab Tilt System Control Wiring (Cummins ISB 2013 Engine) Maintenance Manual Ottawa T2 4x2 222 0.3 Electrical System Circuits – E. Schematics – Cab Tilt System Control Wiring (Cummins QSB 6.7 T3 Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 223 – Cab Tilt System Control Wiring (Cummins QSB T4F Engine) Maintenance Manual Ottawa T2 4x2 224 0.3 Electrical System Circuits – E. Schematics 0.3.5 page – Lighting Circuits (Cab and Chassis) 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. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Beacon/Strobe Light (Optional) Beacon/Strobe Light Circuit Components • Accessory Relay #2 • Beacon Light Switch (Optional) • Beacon/Strobe Lamp Maintenance Manual Ottawa T2 4x2 225 226 0.3 Electrical System Circuits – E. Schematics • Flood Light Switch • Fuse — Exterior Lighting (Cab Accessory Fuse Panel) The flood light switch is mounted on the instrument panel. Clearance Lights (Optional) REMOTE POSITIVE STUD TRAILER CONNECTOR NEGATIVE PASS-THRU STUD PL2001 BE/BK GD2001 WE TRAILER 85 LIGHTS 86 87 30 87A R1 BUS BAR PL1000 OE/WE BA2002 PL2000 BE PARK LTS 3 HEADLIGHT SWITCH CONNECTOR PL1000 OE/WE BA2000 RD POSITIVE PASS-THRU STUD OTT0067 1 2 3 4 5 6 7 CLEARANCE LIGHT CIRCUIT PL2000 BE D C A B NEGATIVE PASS-THRU STUD CAB ACC FUSE PARKLIGHTS 10 A PL1000 OE/WE CAB BULKHEAD CONNECTOR PL2000 BE 10 A BA2002 RD S1 HEADLAMP SWITCH UPPER CAB CONNECTOR GD2001 WE BK B A C D F E BN 10 A MARKER ID PL2000 BE TAIL/CLRNC BN – TAIL/RR CLRNC/LIC PL2001 BE/BK PL2000 BE TRAILER BREAKERS GD2001 WE CLEARANCE LIGHTS BK – SIDE MRKR/ID PL2001 BE/BK C G M N W F R B E J L K T H X D V U A P S PL2000 BE – Clearance Lights Circuit Components • Cab Clearance Lamps • Circuit Breaker — Marker/ID Lights (Trailer Breakers) • Circuit Breaker — Parking Lights (Cab Accessory Fuse Panel) • Circuit Breaker — Tail/Clearance Lights (Trailer Breakers) • Headlight Switch • Trailer Lights Relay Double-faced Turn/Marker Lights are standard equipment on vehicles that meet FMVSS and CMVSS requirements. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 227 Daytime Running Lights (Optional) – LH HEADLIGHT LH HEADLIGHT CONNECTOR HL2002 – BE/WE HL2001 – BE/BK GD2002 – WE RD – HI BEAM BK – LO BEAM GN – GROUND RH HEADLIGHT CONNECTOR DR2002 – RD HL2002 – BE/WE HL2001 – BE/BK GD2002 – WE DR2002 – RD DR2000 – BE DR2002 – RD DAYTIME RUNNING LIGHTS CIRCUIT A B C F E D C B A 7 8 9 3 12 11 10 1 2 6 5 4 OPTIONS BULKHEAD CONNECTOR DR2002 – RD IG1001 YW IGNITION 85 87 86 30 PR1 IG1001 YW CAB ACC FUSE D.R.L. DRL 10 A 4 DAYTIME RUNNING LIGHTS MODULE (WE) POWER TO HEADLIGHT (RD) BATTERY (BK) GROUND (GN) LOW BEAM (GN) HI BEAM (BE) IGNITION DAYTIME RUNNING LIGHTS CONNECTOR Daytime Running Lights Circuit Components • Daytime Running Lights Module • Fuse — Daytime Running Lights (Cab Accessory Fuse Panel) • Head Lamps • Ignition Relay Maintenance Manual Ottawa T2 4x2 OTT0060 HL2002 – BE/WE HL2001 – BE/BK DR2000 – BE BUS BAR HI BEAM – RD A LO BEAM – BK B GROUND – GN C RH HEADLIGHT 228 0.3 Electrical System Circuits – E. Schematics Dome Light – DOME LIGHT CIRCUIT GD2001 WE CL1000 BN/RD ACC #2 85 86 87 30 DOME LIGHT GD2001 WE CL1000 BN/RD PR2 E F D A C GD2001 WE 1 NEGATIVE PASS-THRU STUD OTT0061 10 A GD2001 WE CAB ACC FUSE LIGHTING CAB LIGHTING CL1000 BN/RD AC1001 BN B UPPER CAB CONNECTOR Dome Light Circuit Components • Accessory Relay #2 • Dome Lamp with Switch • Fuse — Cab Lighting (Cab Accessory Fuse Panel) The lamp On/Off switch is on the dome light fixture. – Fifth-Wheel Control Refer to Transmission Shifter. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Flood Light Flood Light Circuit Components • Accessory Relay #2 • Flood Light Maintenance Manual Ottawa T2 4x2 229 230 0.3 Electrical System Circuits – E. Schematics • Flood Light Switch • Fuse — Exterior Lighting (Cab Accessory Fuse Panel) Headlights – TURN SIGNAL SWITCH CONNECTOR HEADLIGHT CIRCUIT YW GN RD GY BK GY/BK WE WE TURN SIG & DIMMER SW HI BEAM-RD A LO BEAM-BK B GROUND-GN C C G M N W F R B E J L K T H X D V U A P S R4 HL2000 BE/RD HL2001 BE/BK HL2002 BE/WE HEAD LTS 2 HL2001 BE/BK HL2002 BE/WE GD2002 WE HL2001 BE/BK HL2002 BE/WE GD2002 WE CAB BULKHEAD CONNECTOR HL2001 BE/BK HL2002 BE/WE A B C RD-HI BEAM BK-LO BEAM GN-GROUND GD2002 WE GD2002 WE HI-LOW 85 HEAD LTS 86 87 30 87A RIGHT HAND HEADLIGHT CONNECTOR HL2001 BE/BK HL2002 BE/WE CAB ACC FUSE HEADLIGHTS LEFT HAND HEADLIGHT CONNECTOR B HL2000 BE/RD C HL1000 OE A D BUS BAR BA2002 RD RH HEADLIGHT LH HEADLIGHT NEGATIVE PASS-THRU STUD Headlight Circuit Components • Circuit Breaker — Head Lights (Cab Accessory Fuse Panel) • Headlamps • Headlight Relay (High/Low) • Headlight Switch • Turn Signal and Dimmer Switch – Marker Lights Refer to Clearance, Marker and Tail Lights. – Panel Lighting Refer to Transmission Shifter. – Strobe Light Refer to Beacon/Strobe Light. Maintenance Manual Ottawa T2 4x2 OTT0062 HL2000 BE/RD HL1000 OE HL2003 WE/BK HEADLIGHT SWITCH CONNECTOR 15 A HL2003 WE/BK GD2000 WE NEGATIVE PASS-THRU STUD S1 HEADLAMP SWITCH REMOVE POSITIVE STUD A B C D E F G H 0.3 Electrical System Circuits – E. Schematics 231 Tail Lights – Refer to Turn Signal, Tail, Brake Lights and Emergency Flasher. Trailer Auxiliary Power – TRAILER AUX SWITCH POWER RELAY B19 30 B A 87A AB2000 RD TS2000 IG2000 REMOTE POSITIVE STUD IG2000 YW AC2000 BN TRIAXLE SWITCH CONNECTOR IGNITION SWITCH JUMPER-ABS HARNESS IGNITION SWITCH JUMPER NEGATIVE PASS THRU STUD GD2004 WE TS2001 BN/WE B A TS2000 BN/BK IG2000 YW A B S17 TRAILER AUX SWITCH 85 87 C G M N W F R B E J L K T H X D V U A P S CHASSIS BULKHEAD CONNECTOR TRAILER BREAKER TS2001 BN/WE TRBK 15A Trailer Auxiliary Power Circuit Components • Circuit Breaker — TRBK (Trailer Breaker) • Ignition Switch Jumper • Ignition Switch Jumper (ABS Harness) • Relay — B19 (Trailer Auxiliary Switch Power Relay) • Trailer Auxiliary Switch • Triaxle Switch Connector The trailer auxiliary switch is not used with ABS. Maintenance Manual Ottawa T2 4x2 OTT0068 86 TS2001 BN/WE TRAILER AUXILIARY POWER 232 0.3 Electrical System Circuits – E. Schematics Transmission Shifter, Fifth-Wheel Control and Panel Lighting – WITH OPTIONAL DIMMER SWITCH STANDARD TRANSMISSION SHIFTER/5TH WHEEL CONTROL & PANEL LIGHTING S9 PANEL LTS DIMMER MD TRANS BULKHEAD CONNECTOR GEN-4 3000 LEVER SHIFTER MD TRANS SHIFTER CONNECTOR LIGHT BAR CONNECTOR FOR HEATER CONTROL LHS LIGHT BAR CONNECTOR FOR HEATER CONTROL RHS GD2000 PL2002 GD2000 WE LIGHT BAR E L H D J K F PL2002 BE/RD G M GD2000 WE A B C PL2002 BE/RD LIGHT BAR CONNECTOR FOR OPTION SWITCHES CAB CONTROL PANEL CONNECTOR NEGATIVE PASS-THRU STUD GD2000 WE PL2002 BE/RD PL2002 BE/RD LIGHT BAR CONNECTOR FOR FAN CONTROL PL2002 BE/RD GD2000 WE PL2002 BE/RD PL2002 BE/RD PL2002 BE/RD – DIMMER INPUT PL2002 BE/RD C G M N W F R B E J L K T H X D V U A P S CAB BULKHEAD CONNECTOR 5TH WHEEL CONTROL CONNECTOR PL2002 BE/RD GD2002 WE NEGATIVE PASS-THRU STUD 5TH WHEEL CONTROL OTT0063 ENGINE GAUGE & WARNING PANEL CONNECTOR 9 10 5 13 12 11 3 1 8 15 14 16 7 2 4 6 LIGHT BAR PL2002 BE/RD – DIMMER INPUT PL2002 MD TRANS V HARNESS CAB CONNECTOR (IN CAB AT ‘B’ PILLAR) F E A H B C D G J K L M PL2002 BE/RD M L F H B A K C E D J G PL2002 PL2002 BE/RD – DIMMER INPUT 12 35 11 22 21 5 31 14 4 3 33 34 13 1 2 32 24 15 25 30 40 18 8 37 17 36 26 10 16 27 20 23 28 39 38 19 7 29 6 9 LIGHT BAR S1 HEADLAMP SWITCH LIGHT BAR S1 HEADLAMP SWITCH Transmission Shifter, Fifth-Wheel Control and Panel Lighting Circuit Components • Headlight Switch • Lamps (2 — Fifth-Wheel Control) • Light Bar — Heater Control LHS • Light Bar — Heater Control RHS • Light Bar — Fan Control • Light Bar — Option Switches • Panel Dimmer Switch (Optional) The electroluminescent lamp illuminates when the ignition switch is in the Run position. It operates independently of the headlight switch. Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 233 Turn Signal, Tail, Brake Lights and Emergency Flasher – NEGATIVE PASS-THRU STUD PL1000 OE/WE CHASSIS BULKHEAD CONNECTOR TL2001 TN FLASHER TURN SIGNAL SWITCH CONNECTOR TL2000 TN/WE TL2001 TN TL2002 GN TL2003 YW TL2004 GN/WE SL2000 BK A B C D E F G H GD2000 WE TL2000 TN/WE L TL2002 GN B YW GN RD GY BK GY/BK WE WE PL1000 OE/WE TL1000 OE/BK 30 A 4 TURN SIG & DIMMER SW D C A B PL2000 BE 20 A 1 FLASHER PL2000 BE TL2001 TN TL2001 TN GD2000 WE GD2000 WE TL2002 GN CAB ACC FUSE STOPLIGHTS BA2002 RD STOP LTS HEADLIGHT SWITCH CONNECTOR F E A H B C D G J K L M ENGINE GAUGE & WARNING PANEL CONNECTOR BUS BAR REMOTE POSITIVE STUD GD2000 WE LH TURN E L H D J K F G M A B C CAB CONTROL PANEL CONNECTOR GD2000 WE TL2002 GN RH TURN PL1000 OE/WE S1 HEADLAMP SWITCH TL2002 GN TL2001 TN PL2000 BE BU2000 BK/RD TL2003 YW TL2004 GN/WE SL2000 BK NEGATIVE PASS-THRU STUD X U S L G F C T M V J D K N P A B E H R W BU2000 BK/RD CAB BULKHEAD CONNECTOR TL2002 GN TL2001 TN SL1000 OE/RD SL2000 BK TURN SIGNAL, TAIL, BRAKE LIGHTS & EMERGENCY FLASHER REMOTE POSITIVE STUD CAB ACC FUSE STOPLIGHTS BA2002 RD STOP LTS 20 A 1 Turn Signal, Tail, Brake Lights and Emergency Flasher Circuit — Part A Maintenance Manual Ottawa T2 4x2 C G M N W F R B E J L K T H X D V U A P S 234 0.3 Electrical System Circuits – E. Schematics TL2004 GN/WE PL2000 BE GD1001 WE RH FRONT TURN/PARK GD1001 WE GD1001 WE SL2000 BK BU2000 BK/RD TL2004 GN/WE CAB ACC FUSE PARKLIGHTS PARK LTS GD1001 WE PL2000 BE TL2002 GN TL2001 TN PL2000 BE TL2001 TN TL2002 GN TL2001 TN BU2000 BK/RD BACK-UP LIGHT GD1001 WE SL2000 BK STOPLIGHT CONNECTOR D C E B A GD1001 WE TL2003 YW PL2000 BE TAIL LIGHTS CONNECTOR LH REAR STOP/TURN/TAIL SL2000 BK BU2000 BK/RD TL2004 GN/WE TL2003 YW LH FRONT TURN/PARK PL2000 BE TL2002 GN PL2000 BE PL1000 OE/WE (NOT USED WHEN STOP/TURN/TAIL LIGHT IS COMBINED) BU2000 BK/RD TL2004 GN/WE GD1001 WE TL2003 YW PL2000 BE TL2003 YW 10 A 3 TL2004 GN/WE PL2000 BE GD1001 WE BA2002 BUS BAR TRANSMISSION CASE GROUND GD1001 WE TL2002 GN PL2000 BE GD1001 WE PL2000 BE TL2002 GN REMOTE POSITIVE STUD BA2002 RD RH REAR STOP/TURN/TAIL PL2000 BE BU2000 BK/RD TL2003 YW TL2004 GN/WE SL2000 BK REVERSE R5 86 30 CAB ACC FUSE REVERSE BU1000 BK REVERSE 7.5 A 2 TL2002 GN TL2001 TN IG1001 YW 85 87 87A CIRCUIT BREAKERS RH TURN 10 A LH TURN IGNITION PR1 86 30 GN YW 10 A TL2002 GN TL2001 TN CAB ACC FUSE STOPLIGHTS SL1000 OE/RD SL2000 BK SL2000 BK STOP LTS 15 A RD YW – LH TURN RD – STOP GN – RH TURN SL2000 BK 1 2 3 4 5 6 7 SL1000 OE/RD STOP LIGHT SWITCH TRAILER CONNECTOR Turn Signal, Tail, Brake Lights and Emergency Flasher Circuit — Part B Maintenance Manual Ottawa T2 4x2 OTT0064 85 87 87A 0.3 Electrical System Circuits – E. Schematics 235 Components • Backup Lamp • Circuit Breaker — Flasher (Cab Accessory Fuse Panel) • Circuit Breaker — Left Turn (Trailer Circuit Breakers) • Circuit Breaker — Parking Lights (Cab Accessory Fuse Panel) • Circuit Breaker — Reverse (Cab Accessory Fuse Panel) • Circuit Breaker — Right Turn (Trailer 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 Lights are standard equipment on vehicles manufactured to FMVSS and CMVSS specifications. – Upper Cab Harness Upper Cab Harness (Cummins ISB 2013 Engine) Maintenance Manual Ottawa T2 4x2 236 0.3 Electrical System Circuits – E. Schematics – 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) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Headlight/Dimmer Switch Wiring (Cummins QSB 6.7 T3 Engine) – Headlight/Dimmer Switch Wiring (Cummins QSB T4F Engine) Maintenance Manual Ottawa T2 4x2 237 238 – 0.3 Electrical System Circuits – E. Schematics 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) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Auxiliary Lighting and Air Horn (Cummins QSB T4F Engine) – Tail Light/Backup Light Wiring Tail Light/Backup Light Wiring (Cummins ISB 2013 Engine) Maintenance Manual Ottawa T2 4x2 239 240 0.3 Electrical System Circuits – E. Schematics – Tail Light/Backup Light Wiring (Cummins QSB 6.7 T3 Engine) – Tail Light/Backup Light Wiring (Cummins QSB T4F Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 0.3.7 page – 241 Engine Controls 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) – Maintenance Manual Ottawa T2 4x2 242 0.3 Electrical System Circuits – E. Schematics Engine Wiring Engine Wiring (Cummins ISB 2013 Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics – Engine Wiring (Cummins QSB 6.7 T3 Engine) Maintenance Manual Ottawa T2 4x2 243 244 0.3 Electrical System Circuits – E. Schematics – Engine Wiring (Cummins QSB T4F Engine) Maintenance Manual Ottawa T2 4x2 0.3 Electrical System Circuits – E. Schematics 0.3.8 page – Exhaust Aftertreatment Wiring Aftertreatment Wiring (Cummins ISB 2013 Engine) Maintenance Manual Ottawa T2 4x2 245 246 0.3 Electrical System Circuits – E. Schematics – Aftertreatment Wiring (Cummins QSB T4F Engine) Maintenance Manual Ottawa T2 4x2 0.1 Standard Vehicle Data – F. Technical Data 247 mm mm mm mm mm mm F. Technical Data 0.1 Standard Vehicle Data page – Ottawa T2 Series Terminal Tractor Standard features, dimensions and performance specifications are presented below for three typical chassis configurations. Optional equipment items are available including ABS braking systems and GCW ratings up to 125,000 pounds (56,700 kg) depending on the engine, transmission and axle combinations. Chassis Model and Configuration Ottawa T2 4x2 Ottawa T2 4x2 Off-Highway DOT/EPA Certified Engine (standard) Cummins QSB6.7 Cummins ISB6.7 Peak power 165 HP at 2200 rpm 200 HP at 2300 rpm (123 kW at 2200 rpm) (150 kW at 2300 rpm) 540 ft. lbs. at 1500 rpm 520 ft. lbs. at 1600 rpm (730 Nm at 1500 rpm) (700 Nm at 1600 rpm) Allison 3000RDS Allison 3000RDS Gearing 6 Forward, 1 Reverse 6 Forward, 1 Reverse Propeller shaft Spicer 1710 Spicer 1710 Meritor FF961 Meritor FF961 Meritor RS-24-160 Meritor RS-24-160 Air Air with ABS S-cam, 16.5x5 inch S-cam, 16.5x5 inch (419x127 mm) (419x127 mm) S-cam, 16.5x7 inch S-cam, 16.5x7 inch (419x178 mm) (419x178 mm) Slack adjusters Automatic Automatic Air compressor WABCO, 15.2 cfm WABCO, 15.2 cfm Application (certification) Torque Transmission (standard) Axle, front Axle(s), rear Brake system Wheel ends: Front – type, size Rear – type, size (0.43 m Air reservoirs Tires 3/minute) (0.43 m3/minute) 5,688 cu.inch (2 tanks) 5,688 cu.inch (3 tanks) (93.2 liter) (93.2 liter) 11R 22.5, 14PR 11R 22.5, 14PR Maintenance Manual Ottawa T2 4x2 248 0.1 Standard Vehicle Data – F. Technical Data Chassis Model and Configuration Ottawa T2 4x2 Ottawa T2 4x2 12,000 lbs. (5,443 kg) 12,000 lbs. (5,443 kg) 30,000 lbs. (13,608 kg) 30,000 lbs. (13,608 kg) 81,000 lbs. (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) 50,000 lbs. (27,216 kg) 50,000 lbs. (27,216 kg) FW 3500 FW 3500 14,500 lbs. (6,577 kg) 14,500 lbs. (6,577 kg) GAWR Front Rear GCWR Fifth-wheel boom lift capacity Fifth wheel Chassis weight Maintenance Manual Ottawa T2 4x2 0.2 Hydraulic System – F. Technical Data 0.2 page – 249 Hydraulic System Ottawa T2 Series 4x2 The hydraulic system includes three sub-systems. • Fifth-wheel boom • Power steering • Cab tilt All three draw and use fluid from a common 16-gallon reservoir. Specifications for the individual sub-systems follow. Boom System Components Boom drift down (maximum, 4-inch (100 mm) cylinder) Hydraulic fluid Pump flow (standard system) Specification 4-inch (100 mm) per hour Dexron® III 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 Power Steering System Components Pump flow (minimum) Pump relief setting Cab Tilt System Components Pump flow (minimum) Pump relief setting Maintenance Manual Ottawa T2 4x2 2000 psi (138 bar) Specification 4 gallons (15.1 liter) per minute at 1200 rpm 2100 psi (145 bar) Specification 0.3 gallons (1.1 liter) per minute at 1200 rpm 3200 psi (159 bar) 250 0.3 Fluids, Lubricants and Sealants – F. Technical Data 0.3 Fluids, Lubricants and Sealants page – Ottawa T2 Series 4x2 Following are the specified fluids, lubricants and sealants by component. These are to be used in accordance with the recommended maintenance schedule. Component Sealant or Lubricant Axle, rear EP 85-140 (Also, refer to axle manufacturer’s specifications.) Cab: Cab pivot bearings Lubriplate® or equivalent (semi-fluid grease having extreme pressure properties and containing zinc oxide) Cab tilt release mechanism Door striker bolts Seat adjuster slides Cab: Door hinges Silicone spray Rear door rollers Chassis: Boom pivot (at frame) Brake cam pivots Brake slack adjusters Fifth-wheel pivot pins Lithium Grease #1 Fifth-wheel top plate Fifth-wheel jaws Front axle king pins Hydraulic cylinder bearings Propeller shaft splines and universal joints Engine: Oil SAE 15W-40 Coolant, anti-freeze 50/50 Propylene-Glycol/Water (Also, refer to engine manufacturer’s specifications.) Hydraulic system fluid Dexron® III Steering fluid (power steering) Dexron® III (from hydraulic system) Steering linkage (slip joint, knuckles, tie rod and drag link ends) Transmission fluid/lubricant (automatic) Lithium grease (warm weather) NLGI 0 lubricant (cold weather) Transynd TES-295 Approved (Also, refer to transmission manufacturer’s specifications.) Wheel bearings, front axle: Grease lubricated NLGI 1 or 2 Oil lubricated EPA 85-140 (Also, refer to axle manufacturer’s specifications.) Maintenance Manual Ottawa T2 4x2 0.4 Fastener Torque Values – F. Technical Data 0.4 251 Fastener Torque Values page – Ottawa T2 Series 4x2 Following are the specified torque values required for scheduled maintenance operations and typical repair and/or adjustment procedures covered in this manual. Component Specified Torque Value Axle mounting: Front axle clamp plate bolts 210 ft. lbs. 285 Nm Bolt head 600 ft. lbs. 813 Nm Nut 400 ft. lbs. 542 Nm 380 ft. lbs. 515 Nm Cab latch mounting bolts 65 ft. lbs. 88 Nm Cab latch bar plate 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 Assembly mounting bolts 220 ft. lbs. 298 Nm Shock absorber mounting bolts 100 ft. lbs. 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 Upper mount bolts 55 ft. lbs. 75 Nm Lower mount bolts 55 ft. lbs. 75 Nm Lower mount cross-bar locknuts 600 ft. lbs. 813 Nm Boom pivot cross-bar bolts 380 ft. lbs. 515 Nm Boom pump mounting bolts 55 ft. lbs. 75 Nm Boom pump relief valve adjusting screw jam nut 15 ft. lbs. 20 Nm Steering gear mounting bolts 350 ft. lbs. 475 Nm 450-500 ft. lbs. 610-678 Nm Rear axle clamp plate bolts: Rear axle torque link bolts Cab suspension: Boom cylinder mounting: Wheel lug nuts Maintenance Manual Ottawa T2 4x2 252 0.4 Fastener Torque Values – F. Technical Data Maintenance Manual Ottawa T2 4x2 – G. Appendix mm mm mm mm mm mm G. Appendix page – Description This section is not applicable for this vehicle. Maintenance Manual Ottawa T2 4x2 253