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4x2 & 6x4 Maintenance Manual

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1. X DY e oc 11 Fifth Wheel Boom Hydraulic Fluid Tank Hydraulic Fluid Filter Air Tank Service Air Brakes Battery Box BOC Steps Boom Pivot Fuel Filter Cab Lift Cylinder Radiator Charge Air Cooler Cab Pivots Optional Air Dryer 12 13 14 15 16 17 Engine Oil Dipstick Air Cleaner Transmission Fluid Dipstick Air Tank Supply Air Brakes Fuel Tank Fifth Wheel 39 4 4 Chassis Plan View 4 Component Location OTT0008 Maintenance manual Ottawa 4x2 6x4 40 Notes 5 1 Safety 5 Diagnostic Procedures 41 5 Diagnostic Procedures 5 1 Safety Summary Safety always comes first There are comprehensive reminders in the early pages of this manual of the precautions that are re quired while working around any vehicle Information will be found there about towing these yard tractors Welding is also covered as is safe battery handling 5 2 Electrical Guide to Troubleshooting This guide is provided
2. le Engine Oil Pressure Gauge Circuit Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 145 Components Fuse Gauge Cab Accessory Fuse Panel Gauge Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch Optional Sender Oil Pressure Variable Resistance The engine oil pressure gauge reads in pounds per square inch PSI Maintenance manual Ottawa 4x2 6x4 146 9 3 Electrical System Circuits 9 Schematics Fuel Gauge FUEL LEVEL GAUGE CIRCUIT 55 GA2000 CHASSIS BULKHEAD CONNECTOR LU PL2002 GD2000 WE 102006 BN RD LEVEL SENDER phys WITH OPTIONAL ul rine DIMMER SWITCH STANDARD 2 D 77 591 PANEL LTS SISIS ENGINE GAUGE amp WARNING DIMMER PANEL CONNECTOR VY VYYVVYY u u rimjo o o 2 P S gt 8 FUEL LEVEL s SENDER CONNECTOR ilu Sly als HEADLANP E gt gt 7 7 ji RDBK JP T 0 N 5 TRANSMISSION m 2 NEGATIVE E gt CI PPASSTHRU L PL2002 BE RD 162006 BN RD IGNITION MT Tu PRI CABACC FUSE GAUGE IG1001 YW GAUGE 10 1 Fuel Gauge Circuit Components Fuse
3. 54 Donnie Hight 5 5 ee uS 55 Hleadlights ere rte ene bte aet belit Len debet 55 Trailer Auxiliary 56 Transmission Shifter Fifth Wheel Control and Panel Lighting 57 Turn Signal Brake Lights and Emergency Flasher 58 Accessori s and Options ende rette m e aet ee tee 59 ACCOSSOLy RELAY 7 i ERR saan aqa DURAN E paksa RE E DER 59 Alt DION me th Rte tent das 59 Gab e ax eum ae ctm 60 Heater Air Conditioning Optional 61 lene LEE 62 Mirrors Heated Motorized uu 63 Radio Optional nt te ete a hu pereas 64 Windshield Washer i tet ce eee recte tee eb ee deese 65 Windshield 66 Hydraulic iet e rete 67 BOOM 67 Cap 68 Power Steerirg seio tesi e ERR ERREUR 69 Mechanical icc Sanath nier etie Te reed 70 Brakes ient eO Ie etu aid e OR ee 70 t Su 73 Brakes Air System a 73 Gab Air SUSPENSION Cere tet ote rti ro ER Re P Edu 76 ILLOTE U Ke E RARE EA T TEA 77 E E 77 Sche
4. ee 71 METRE mam TRANSMISSION OIL af ef TEMPERATURE GAUGE ommend CIRCUIT p ri ull HEADLAMP HEADLAMP SWITCH SWITCH FUSE IGNITION OPTIONS SWITCH BULKHEAD e pROSITIVE Bazoo NSW CONNECTOR 3 8 STUD 10A 1 101000 RD WE L222 Larm TRANS TEMP TRANSMISSION a GAUGE CONNECTOR GA2006 _ 59842006 8 IGNITION We 602000 We GD2000 WE VY 12 VV VY a OPTIONS PANEL 8 CONNECTOR WA JUMPER 3 i teen MT zB CONNECTOR STUD amp ss 002000 WE GD2000 WE 8 55 PL2002 AC2000 BN opnons l TO MAIN CONNECTOR 3 JUMPER EI 2 Transmission Oil Temperature Gauge Circuit Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 151 Components Circuit Breaker Ignition Switch Cab Accessory Fuse Panel Gauge Lamp Headlight Switch Ignition Switch Panel Dimmer Switch Optional Sender Transmission Oil Temperature Transmission Oil Temperature Gauge The transmission oil temperature gauge reads in degrees Fahrenheit F Maintenance manual Ottawa 4x2
5. 262 GA2003 PASS THRU IGNITION z 22 STUD SWITCH 28 1 5 28 Hi 8 4 5 RD BATTERY TO STARTER EI 8 SIE IGNITION 4 2114 E SWITCH GEN 4 3000 2 gren CONNECTOR TRANSMISSION jm gt I ECU B cABACC 8 A 102000 YW 49 B FUSE IGNITION H 48 2 SWITCH 8 601001 d I gt CHASSIS BULKHEAD 6 10 A 1 o02o0o20wux zozmr calzzucrau z IRRAAARAAARARARAAARARA CONNECTOR TRANSMISSION Ha Pa gt Se 572000 PK 12 gA 2 H Ke C 9 512002 95 216 KE Hid HE 25 274 Bz 852 15 337 HIE 919 HI 5l ct E ol ee eee P 3 Starting and Charging Circuit Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 131 Components Alternator Batteries Circuit Breaker Ignition Switch Cab Accessory Fuse Panel Fuse Gauge Cab Accessory Fuse Panel Ignition Relay Ignition Switch Neutral Start Relay Oil Pressure Hourmeter Switch Start Cutout 1 Relay Start Cutout 2 Relay Start Solenoid Starter Motor with Solenoid 9 3 2 Cab Accessory
6. s CLEAN REAR AXLE BREATHER CHECK DIFFERENTIAL FOR LEAKS imi CHECK DIFFERENTIALOILLEVEL 7 _ CHECK LIFT CYLINDERS FOR LEAKS CHECK OTTO RIDE RUBBER ISOLATOR IF APP TORQUE REAR AXLE MOUNTING BOLTS et i eS CHECK FRONT WHEEL BEARINGS CHECK FRONT AXLE OIL LEVEL IF APP CHECK BATTERY CABLES amp HOLDDOWNS CHECK BATTERIES FOR CRACKS OR ACID DAMAGE _ CLEAN BATTERY CABLE CONNECTIONS m d s ueni CHECK BATTERY BOX COVER HOLDDOWNS DRAIN WATER FROM AIR TANKS AND TORQUE ALL WHEEL NUTS CHECK WEES u aa es Em E CHECK TIRE AIR PRESSURE TREAD DEPTH amp CONDITION CHECK REAR AXLE PLANETARY FLUID LEVEL IF APP INSPECT PLATFORMS CHECK FRAME FOR CRACKS CHECK MUD FLAPS FENDERS IF APP CHANGE HYDRAULIC SYSTEM FILTER J CHECK HYDRAULIC FLUID LEVEL CHANGE HYDRAULIC FLUID 1 CLEAN HYDRAULIC TANK CHECK CAB HINGE PINS AND BUSHINGS CHECK LUBRICATE REAR DOOR ROLLERS CHECK LUBRICATE HOOD HINGE m CHECK LUBRICATE STEERING SLIP JOINT ss CHECK LUBRICATESTEERINGUJOINTS CHECK LUBRICATE ALL STEERING LUBEPOINTS CHECK LUBRICATE SLACK ADJUSTERS CHECK LUBRICATE LEAF SPRING PINS AND BU
7. 00 140 Ammeter Optional I n 141 Engine Coolant Temperature Gauge 142 Engine Hourmeter 24 224442 nennen nennen entren nnn nnns 143 Engine Oil Pressure 2 2224 11010 144 uel 146 Low Air Warning eiii crt aee tc tere eee epe ttd 147 Speedometer Optional 148 Tachometer Optional 149 Transmission Oil Temperature Gauge sss 150 MoOltmeter a eroe Let etri mte una 152 Ghassis CIFCUlls oim coc nan erat 153 Air Dryer Optional ean Cede de naso 153 etos rd uscite te 154 Lighting Circuits Cab and Chassis sse 155 Backup Light and Alarm essen 155 Beacon Strobe Light eer ete re nee ri n rend ed 156 Clearance Lights ur qu u uuu aa Uu aan m nnne ntn nnne 157 Daytime Running Lights Optional 158 Bera 159 Fifth Wheel Control u 160 Flood as S u etes 160 Heacllights 161 Table of Contents Marker Eight tege wel belt pee ees 161 Panel Lighting sete ub aie eerte beg 161 Strobe lIght u ning ei dades 161 Tall LAG MIS iei eth E
8. E Ax R AR 37 Ottawa Series Right Side 4x2 chassis shown 37 Ghassis Gab Front Rear ttd rex et eee EO ED Eee D de aad 38 Ottawa Series Front Rear 4x2 chassis shown 38 Chassis Plan VIeW eset E EE 39 Ottawa Series Plan View 4x2 chassis shown 39 Table of Contents Diagnostic Procedures 41 Sale ac DEA 41 tereti it 41 Electrical bu kaq ones x des uere dia 41 Guide to Troubleshooting u mu enne 41 Basic Gauge Diagnostic Procedure sss 41 iem 43 Starting and Charging 43 Cab Instruments uicti to e ete e pae o etd eere 44 Low Air Warring ctt c tuii e tu enit 44 td reete elei bees 45 Coolant Oil and Fuel Gauges 46 Hourmetet kum kup eet t ge 47 Speedomelter nem aen alte ae eius 48 BEledoncl 49 EE 50 cd 51 Backup Light and Alarm Flood 51 Beacon Eight ukanaka kau ttt Et E ee pr EE teet 52 Clearance Marker Tail Lights 2 53 Daytime Running
9. 7 2 Cab Deck 7 Repair Procedures 101 KMR1001a Cab Suspension Assembly Installation 1 10 11 12 Ai 1 From the inner side ofthe 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 Align the air suspension assembly with the two lower mounting bolts 4 and place it in position against the frame rail Install the bolts washers and locknuts 3 in the two upper mounting holes to secure the suspension assembly to the frame Install the washers and locknuts on the lower mounting bolts 5 Tighten all four mounting bolts and nuts 3 4 to 220 ft Ibs Reconnect the hydraulic lines to the latch at the top of the assembly Reconnect the air line to the suspension leveling valve Secure all hydraulic lines away from moving parts Loosen the cab latch bar plate on the bottom of the cab deck 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 Raise and support the cab Then tighten all four of the latch bar plate mounting nuts to 65 ft Ibs Make sure all lines are routed away from the rubber bumper contact area on the deck Reroute and secure the lines if necessary Check the hydraulic lines for leaks NOTE After 100 hours of
10. OTT0002 BOTH SIDES Boom and Fifth Wheel Lubrication Diagram Maintenance manual Ottawa 4x2 6x4 82 6 1 Checklists 6 Scheduled Maintenance Daily Inspection Checklist At each inspection add fluids and lubricants as indicated Re pair all leaks Replace cracked damaged or worn parts g Fuel tank O Engine oil level engine stopped Coolant level O Windshield washer fluid level if applicable Fuel water separator g Transmission fluid level engine running O Hydraulic fluid level boom full down O Front wheel hub oil level if applicable O Engine belt condition and tension J Steering system J Hoses and wiring 1 Exhaust system Drain air tanks 1 Trailer lines glad hand seals and trailer cord Catwalk boom deck and grab handles Lift cylinders Cab doors and latches J Cab hold down latch J Fifth Wheel secondary lock jaws and cylinder operation Boom control lever operation Tire condition 1 Oil pressure alarm and gauge operation J Transmission shift lever operation O Backup alarm operation Windshield wiper and washer operation J Horn Radio equipment 0 Gauges and dash lights Dome lights Turn signals J Hazard lights Headlights Marker lights O Backup lights Brake lights Strobe light if applicable 1 Auxiliary backup lights Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance 83 Clea
11. A CAUTION Use care to avoid damage to the spring pins as they are being installed e Install the hangers pins 2 washers and nuts to secure the rear of the spring to the frame bracket Tighten the nuts to specification Repeat steps 1 through 3 to install the spring assembly at the opposite side 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 4x2 6x4 100 7 2 Cab Deck 7 Repair Procedures T 2 Cab Deck 7 2 1 Air Ride Suspension Three Point Cab Suspension Assembly Removal C 1 Parkthe vehicle on firm level ground 7 2 Raise and support the cab 3 Afterthe cab is raised and supported briefly press the cab til switch to the DOWN position This will evacuate extra fluid from the cylinder 4 Turn off the air supply to the cab suspension by turning the small T handle valve 1 clockwise It is located next to the latch bar plate on the bottom of the deck 5 Disconnect and cap the hydraulic lines 1 connected to the latch at the top of the suspension assembly 6 Disconnect the air line 2 from the leveling valve on the suspension assembly 7 Remove the four mounting bolts 3 4 securing the suspen sion assembly to the frame rail driver s side Maintenance manual Ottawa 4x2 6x4
12. E Turn Signal Tail Brake Lights and Emergency Flasher Circuit Part B Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics Components Backup Lamp Circuit Breaker Flasher Cab Accessory Fuse Panel Circuit Breaker Parking Lights Cab Accessory Fuse Panel Circuit Breaker Reverse Cab Accessory Fuse Panel Circuit Breaker Stop Lights Cab Accessory Fuse Panel Circuit Breaker Left Turn Trailer Circuit Breakers Circuit Breaker Right Turn Trailer Circuit Breakers 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 Signal and Headlight Dimmer Switch Turn Indicator Lamps Instrument Panel Right and Left Turn Signal Parking Lamps Front Right and Left Double faced Turn Marker Lights are standard equipment on vehicles manufactured to FMVSS and CMVSS specifications Maintenance manual Ottawa 4x2 6x4
13. 3 Description and Operation 17 e e o Instrument Panel 1 3 1 4 Seating 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 in side of the seat 3 1 5 Instrument Panel Gauges Controls and Indicators Gauges controls and indicators appear in five panels in front and to the side of the driver as shown below Panels 1 and 2 mount in front of the steering wheel Panel 3 is mounted in the transition between the cab instrument panel and the top of the bulkhead assembly Panels 4 and 5 are mounted on top of the bulkhead assembly Panels 1 and 2 are backlit when the headlights are on The dim mer switch is optional Panel 1 displays the following gauges controls and indicator lights along with an air diffuser for the heating and optional air conditioning system Gauges and Controls Fuel Oil Pressure Water Temperature Tachometer Optional Speedometer Optional Headli
14. gt 45 2 NC MN gt a gt 5 gt L J opu 63 gt 43 ENGINE GAUGE AND 2 WARNING PANEL DSO CONNECTOR 42 1 S z a gt NEGATIVE 2 79 PL2002 BE RD rc M 50 STUD gt MD TRANS V gt n HARNESS CAB IGNITION CABACC 8 MES CONNECTOR a FUSEGAUGE amp le 0 GAUGE gEN43000 2 TRANSMISSION ECU TCM 10 A 1 TR 125 TN VEHICLE SPEED SPEEDO 151001 YW 10770056 Speedometer Circuit Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 149 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 Tachometer Optional lt TA2000 PE 2000 2000 PL2002 BE RD gt lt 555 5555 T 522275222 7
15. 3 1 Cab Deck 3 Description and Operation 15 3 1 3 Cab Tilting The cab can be tilted to 45 by means of the hydraulic system The cab can be tilted to 90 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 OTT0030 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 4x2 6x4 16 3 1 Cab Deck 3 Description and Operation The hydraulic system electric pump motor is mounted on the transmission housing It serves all hydraulic circuits on the tractor 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 DSC2520 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 4x2 6x4 3 1 Cab Deck
16. 5 Diagnostic Procedures Observation Cause Action Pressure does not reach normal Reservoir drain cocks open Excessive system leakage Poor governor adjustment Defective air pressure gauge Defective air compressor Inspect and close as needed Inspect system connections Repair or replace as needed Inspect Adjust repair or replace as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Pressure builds too slowly Engine idle too slow Excessive system leakage Defective air compressor Inspect Repair or replace as needed Inspect system connections Repair or replace as needed Inspect Repair or replace as needed Pressure too high Defective air pressure gauge Poor governor adjustment Air line s restricted Inspect Repair or replace as needed Inspect Adjust repair or replace as needed Inspect Repair or replace as needed No brakes Air line s restricted or broken Defective treadle valve Inspect Repair or replace as needed Inspect Repair or replace as needed Cab Air Suspension Components CabLeveling 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 Shock absorbers worn Inspect Replac
17. 9 3 Electrical System Circuits 9 Schematics 155 BU2000 BK RD 9 3 5 Lighting Circuits Cab and Chassis Backup Light and Alarm CHASSIS BULKHEAD CONNECTOR 87A po ee 5 BACKUP LIGHT AND ALARM ALARM CIRCUIT x m e 2 ta N BACKUP ALARM E CONNECTOR 2 m S BACKUP 5 o 08 BU2000 BK RD a BU2000 BK RD DA BU2000 BK RD TRANSMISSION CASE GROUND IGNITION p ni CAB ACC CIRCUIT BREAKER REVERSE IG1001 YW PEVERSE x m s 5 86 a 30 BU1000 BK wo 8 S 5 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 4x2 6x4 156 EL2001 YW WE GD2001 WE E NEGATIVE PASS THRU STUD ACC 2 85 y 87 86 30 9 3 Electrical System Circuits 9 Schematics mnoo gt AC1001 BN lt Beacon Strobe Light UPPER CAB CONNECTOR EL2001 YW WE lt gt BEACON GD2001 WE 91 STROBE LIGHT OPTION FLOOD BEACON LIGHT SWITCH SWITCH Jill x a 6 5 2 e CN T FLOOD amp BEACON LIGHT CONNECTOR RE xz W
18. The Ottawa ABS has three air reservoirs storage tanks pri mary front and rear The primary acts as the supply tank to both front and rear service tanks The instrument panel dis plays a pressure gauge for each service tank Maintenance manual Ottawa 4x2 6x4 3 8 BK TRACTOR YELLOW TRAILER PARK CAB AIR OPTIONS D 1s1 OPTIONAL DRYER 288 FIREWALL 1 4 5 8 GN 5 8 3 8 OE 3 8 BL 3 8 RD WET TANK I Paar TRACTOR PROTECTION VALVE TYPICAL AIR SYSTEM WITH ABS m STOPLIGHT SWITCH I me BRAKES me 5 8 BK D 1 2 BK AL L 5 8 Nn ee BRAKES RESEVOIR me yd H r C DEL ek FI B meu Koy 9227 u a OTT0043 122 9 1 Air System Circuits 9 Schematics Air Brake System without ABS The air brake system without ABS has two air storage tanks supply and service There is one pressure gauge on the instru ment panel Maintenance manual Ottawa 4x2 6x4 1 3 8 BL DERE BL O20 3 8 BL FIREWALL 1 4 BK CAB AIR OPTIONS 1 2 BL L BRAKE TANK TRAILER PARK RED 3 8 BK 5 8 BK TRACTOR PARK YELLOW 3 8 OE un 1 2 BL 3 8 RD 3 8 BK TRACTOR PROTECTION VALVE RED EMERGENCY DG BLUE SERVICE L ek dep H STOPLIGHT
19. 2001 YWRD __ _ _ 2001 YWRD ACLOWPRESSURE ul i 0 SWITCH amp COLD 1 25 CONTROL CONNECTOR S zl COLD Sle elz CONTROL als Ss Sui oS as i il HC1000 RD WE HC2001 YW RD HEATER amp Kal AIC LOW NEGATIVE PRESSURE p PASS THRU EL STUD t 8 NEGATIVE 0202 c la PASS THRU STUD HIGH USE UAE IGNITION SWITCH PRESSURE zu CONNECTOR SWITCH x HC2003 YW BK z COMPRESSOR OPTIONAL HIGH 3 PRESSURE o ACC 1 lt AC1000 BN POSITIVE EA m BA20 RD PASS THRU 3 STUD E Fuse HVAC Cab Accessory Fuse Panel Ignition Switch Air conditioning is optional equipment Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 133 Horn ILICE CX DI 71 HORN CIRCUIT x x 2 CAB ACC E FUSE HORN 8 POSITIVE E 842002 RD CHASSIS BULKHEAD STUD CONNECTOR NE e e HN1000 GN 5 HN2000 GN BK HN2001 GN WE GD2000 WE PASA THR STUD x n 5 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 4x2 6x4 134 9 3 Electrical System Circui
20. 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 4x2 6x4 TT0054 L 9 3 Electrical System Circuits 9 Schematics 147 Low Air Warning Alarm p SS Components LOW AIR WARNING CIRCUIT Fuse Gauge Cab Accessory Fuse Panel IGNITION SWITCH CAB ACC FUSE GAUGE Ignition Relay 85 1G2006 BN RD 162001 YW Low Air Alarm Buzzer Low Air Switch Low Air Switch Optional 10 A 1 NEGATIVE PASS THRU STUD GD2002 WE BUZZER G 1902002 WE lt gt dg AS1000 GN WE N ona ri atop a E LOWAIR OPTIONAL SWITCH LOW AIR is SWITCH kk x lt D v u alg BULKHEAD 5 s CONNECTOR S EE EE ENE E ENEE EA Low Air Warning Alarm Circuit Maintenance manual Ottawa 4x2 6x4 148 9 3 Electrical System Circuits 9 Schematics Speedometer Optional 1 DIMMER SWITCH STANDARD Ts FT PANELLTS SPEEDOMETER TEM CIRCUIT LS gd do ou 4 HEADLAMP HEADLAMP SWITCH SWITCH r Mis 4 22 4 gt gt 24 2 XP
21. MAINTENANCE MANUAL OTTAWA 4x2 amp 6x4 Table of Contents Foreword Introduction Ottawa Terminal Tractor presi V dined Safety SUMMA te Ie eet iier e bete iic t e aedes Hazardous Conditions n Diesel Fuel Requirements errar einn ie ertt onere teer Precautiolis u ERE PER RED Emergency Starting 5 itera et nee nim nri eet ees P recautiors s oit re ren ttt ve abite Jump Starting e v uer epe Vance pee EE PPrecautions a cde el edt edge ee s Front End Towing Front Wheels Off the Ground Front End Towing All Wheels On the Ground 10 Bear End Towing y L cte ite i 10 Vehicle ModifiGations u 10 Vehicle Identification 11 L cation DescriptlOr rettet ttv et ret e Po in ino tee P Ee Uv i E 11 Identification PLAC eens iio erre retire Re Re she 11 Certification n mime etes 11 Serial NIIA ee a iiem Ue 11 Engine Serial Nutmb6r cre ter ei t pec cid EP qas 11 Description and Operation 13 Gab Deck inis ete etate t kha aa tcs dt 13 CORSIF Clon 13 Cab Mounting and Suspension
22. Y SATISFACTORY OPERATION CTA BI CID CHECK OPERATION OFNEUTRALSTART RR J CHECK LOW AIR BUZZER AND LIGHT CHECK WINDSHIELD WIPER OPERATION CHECK WINDSHIELD WASHER OPERATION IF APP CHECK THROTTLE OPERATION v CHECK HORN S OPERATION CHECK AIR SYSTEM MINIMUM 120 PSI MAXIMUM I30PSI CHECK AIR SYSTEM FOR LEAK DOWN E ES ESE CHECK OPERATIONOFBACKUPALARM CHECK HVAC SYSTEM BLOWER MOTOR OPERATION 1 TEMPERATURECONTROL DEFROSTEROPERATION A C OPERATION IF APP AUXILIARY FAN S IF APP CHECK 5 WHEEL UNLATCH CONTROL es Bl CHECK OPERATION OF BOOM m CHECK OPERATION OF WINDOWS Ba CHECK SEAT BELT OPERATION im CHECK REAR AND SIDE DOOR LATCH OPERATION JR EBE CHECK DOME LIGHT OPERATION CHECK ALL GLASS AND MIRRORS CHECK FIRE EXTINGUISHER CHARGE IF APP CAB DOWN EXTERIOR CHECKSIDEDOORHINGE j CHECK CAB ACCESS STEPS ANDHANDLES CLEANHEATER ACFILTER 41 CHECK REAR DOOR ROLLER SLIDE ADJUSTMENT CHECK GLADHAND SEALS AND TRAILER AIRLINES CHECK TRAILER LIGHT CORD IF APP NN CHECK TURN SIGNALS CHECK STROBE LIGHT IF APP I CHECK SPOTLIGHTS CHECK WIPER BLADES CHECK WINDSHIE
23. enne enne nre nenne 126 Air Lines Fifth Wheel Latch 000 eren 126 Hydraulic System Circuits nennen 127 HydrauliC Systems eee eee 127 Tilia xa LIE 127 Hydraulic Lines Cab Tilt eese 127 Firth Wheel BOOM uu k Qu PLA yak ai 128 Hydraulic Lines Fifth Wheel Boom see 128 PoWer Steering aset atu oS beet tese sues 129 Hydraulic Lines Power Steering a 129 Electrical System Circuits eese enn nnn nnns 130 Starting and Charging 130 Starting and Charging 130 Cab Accessory Components 4 2 110100000001 131 Wire Color Codes 131 Anti lock Braking System ABS 132 Heater and Air 132 FIOM eet e tune bc tas be aeg FA 133 134 Radio eiie tete 136 Windshield Washer Optional sse 138 Windshield Wiper etre e c te ete ete rt eret rne etie 139 Cab Instrumentation 140 Air Pressure Gauge Lighting
24. 0 uw c oxr dxrcmummmizzoo A Yw A HEADLIGHT N TURN SIG amp R CIRCUIT one Si Kk HL2003 WE BK WE H GD2000 WE NEGATIVE dhassTHRU 51 STUD HEADLAMP SWITCH HL2003 WE BK LH HEADLIGHT RH HEADLIGHT gt x 88 62 LEFT HAND RIGHT HAND 3 Sa HEADLIGHT HEADLIGHT HEADLIGHT CONNECTOR CONNECTOR SWITCH CONNECTOR fJ HIBEAM RD HL2001_BE BK HL2001 BE BK g RD HIBEAM 10 BEAM BK 2002 HL2002 BK LO BEAM 602002 WE f REMOVE 2002 RD IN GHOUND GN chy a 002002 WE B POSITIVE 32 STUD mi oS sis 85 HEAD 179 86 CAB BULKHEAD E 87 zF Ep m SIS HL2000 BE RD 5 SR HL2001 lt 2001 BE BK NEGATIVE lt HEADLIGHTS HL2002 BE WE HL2002 dH PASS THRU o HEAD LTS lt STUD a lt 15 A 2 OTT0062 L 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 BeacorvStrobe Light Tail Lights Refer to Turn Signal Tail Brake Lights and Emergency Flasher Maintenance manual Ottawa 4x2 6x4 162 9 3 Electric
25. 1 2 KMR1004a V KMR1004b Parkthe vehicle on level ground and chock the rear wheels 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 With the vehicle raised chock the front wheels to prevent the axle from moving as the springs are removed in the fol lowing steps Remove the nut and washer from the pin 1 at the front spring eye and the nuts and washers from the shackle pins 2 at the rear of the spring Using a suitable pry bar remove the pins 1 2 securing the front spring to the frame brackets Support the spring and remove the nuts washers and bolts 3 securing the bump stop spring assembly and spacer to the front axle Remove the bump stop spring assembly and spacer Repeat steps 4 through 7 to remove the spring assembly at the opposite side Maintenance manual Ottawa 4x2 6x4 7 1 Chassis 7 Repair Procedures 99 KMR1004c Springs and Pins Installation 1 Place the spacer spring assembly and bump stop in posi tion on the front axle and install the mounting bolts 3 washers and nuts to secure the assembly to the axle Tight en the bolts and nuts to specification Align the spring eye with the front frame bracket and install the pin 1 washer and nut Tighten the nut to specification
26. 6x4 152 WITH OPTIONAL DIMMER SWITCH PANEL LTS MER DIM 4 51 HEADLAMP SWITCH PL2002 9 3 Electrical System Circuits 9 Schematics STANDARD HEADLANP SWITCH E os J IGNITION Voltmeter VOLTMETER CIRCUIT Y Y Y mo CAB ACC FUSE GAUGE eum ww pu ee STUD ENGINE GAUGE amp WARNING PANEL CONNECTOR PL2002 BE RD zl z 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 4x2 6x4 AC1002 BN RD 9 3 Electrical System Circuits 9 Schematics 9 3 4 Chassis Circuits Air Dryer Optional AIR DRYER CIRCUIT AIR DRYER CONNECTOR CHASSIS BULKHEAD GD1001 WE CONNECTOR NG 2 0 O u x CHASSIS OPTIONS 86 30 BA2000 RD POSITIVE PASS THRU STUD AC1002 BN RD CAB ACC FUSE AIR DRYER AIR DRYER BUS BAR Air Dryer Circuit Components Air
27. CONNECTOR gt 125 gu 3 i i a88 2 3 a a S 175 S 8 ooo lt 26 o G 16 gt o qd 28 15 GA2002 GN BK gt GAz002 GNBK TJ TEMPERATURE x 225 u 2 PL2002 BE RD gt 32 IGNITION 2 uue 1 87 41 aepo 292 PRI CAB ACC 20 FUSE GAUGE 18 9 I za 10A 1 STUD gt ELECTRONIC ENGINE 0052 BULKHEAD CONNECTOR Engine Coolant Temperature Gauge Circuit Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics Components Coolant Temperature Gauge Fuse Gauge Cab Accessory Fuse Panel Gauge Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch Optional Sender Water Temperature Variable Resistance The engine coolant temperature gauge reads in degrees Fahrenheit F Engine Hourmeter POSITIVE PASS THRU 4 D STUD CAB ACC CB IGNITION SWITCH ENGINE HOURMETER NEGATIVE PASS THRU STUD ELECTRONIC ENGINE _ BULKHEAD CONNECTOR CAB CONTROLS PANEL CONNECTOR 21 gt VY YYYYYYY BIS 162006 BN RD OIL o 8 PRESSURE SWITCH 8 HOURMETER 8 amp 2 ol GA2003 OE WE 161000 RD WE BA2000 RD IGN SW IGNITION 1G1001 YW CAB ACC
28. The power steering system shares the hydraulic fluid reservoir with the cab tilt and boom lift systems Maintenance manual Ottawa 4x2 6x4 130 9 3 Electrical System Circuits 9 Schematics 9 3 Electrical System Circuits 9 3 1 Starting and Charging Starting and Charging Circuit IIIS RCS U I ere M PEU cU MSIE aT c ELECTRONIC ENGINE j BULKHEAD CONNECTOR POSITIVE STARTING AND one EX STUD io 2000 RD CHARGING ae 5 rg B 26 E C CU IT 8 FUSE GAUGE 19 2 HOURMETER s GAUGE 162006 BNRD 15 gt 102006 BN RD B 1571 GA2003 OEWE 251962003 OEWI GA2003 1312 RD ALTERNATOR TO STARTER 2 gt 5 10 GEN 4 ECU CONNECTOR 122 25 I HE GD1001 He E 58 i 8 5 2 STARTER 4 265 WISOLENOID amp 32 2 S 2 EE n TR 14 TN NEUTRAL START MD TRANS Vb gl l 55 gt gt CONNECTOR ale 8 MID FRAME 2 SELON ERE BATTERIES FEMHE STUD E EE 58 602001 WE 842000 RD b BARA 5 2 23 NEGATIVE
29. to the pump 3 Connect the two wires to the solenoid under the pump motor Connect the battery cable to the pump motor Check the fluid level in the hydraulic tank Connect the negative cables from the batteries po oy de 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 Maintenance manual Ottawa 4x2 6x4 108 7 2 Cab Deck 7 Repair Procedures 9 Check the fluid level in the hydraulic tank adjust as necessary Relief Pressure Adjustment 2001 and Newer Trucks 1 Raise the cab to the full tilt position Check to ensure that the safety latch has engaged Slightly loosen the fitting at the cab tilt cylinder to relieve system pressure Install a T fitting in the supply line from the pump to the cab latch and connect a hydraulic pressure gauge to the fitting Locate the adjusting screw on the pressure relief valve body The valve can be found between the inlet port on the pump and the motor While holding the adjusting screw with an Allen wrench loosen the jam nut With the cab raised all the way up hold the tilt control Switch in the UP position Note the reading on the hydrau lic pressure gauge Turn the adjusting screw in or out as required to reach the specified relief pressure Using an Allen wrench hold the adjusting screw in place and tighten the jam nut securely Disconnect the hy
30. 28 Trailer Elect 3 2 Chassis 3 Description and Operation rical Connector and Brake Hoses Trailer Brake Air Lines 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 Stop Light Switch This is an air actuated switch that caus es the stop lights to illuminate when system air pressure in creases to 5 PSI after depressing the foot pedal Anti lock Brake System Optional Some vehicles will be equipped with an anti lock brake system ABS This system prevents the wheels from completely stop ping 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
31. 3 1 6 Electrical Equipment 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 Lighting Kalmar provides a dome light instrument panel lighting headlights marker lights and a trailer electrical con nector with circuit breakers A work area floodlight and a bea con are mounted on an upper rear corner of the cab An optional strobe light may be substituted for the beacon Fuses Relays and Circuit Breakers The fuse panel is mounted underneath the instrument panel on the right side e The relay panel is mounted under instrument panel 1 The fuse Trailer Electrical Connector and Brake Hoses panel cover includes diagrams of the panels 3 1 7 Heating Air Conditioning 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 3 1 8 Accessories and Options Mirrors Heated and heated motorized outside rear view mir rors are optional equipment Radio A radio is an available option Windshield Wiper Also optional equipment the wiper is electrically driven ro
32. Cab Accessory Circuit Breaker e Coolant Temperature Gauge e Coolant Temperature Sending Unit Headlight Switch Ignition Switch Panel Dimmer Switch Optional Oil Pressure Gauge Components Cab Accessory Circuit Breaker Headlight Switch Ignition Switch e Oil Pressure Gauge Oil Pressure Sending Unit Panel Dimmer Switch Optional Fuel Gauge Components Cab Accessory Circuit Breaker FuelLevel Gauge Fuel Level Sending Unit Headlight Switch Ignition Switch Panel Dimmer Switch Optional Refer to Basic Gauge Diagnostic Procedure page 41 Coolant Temperature Oil Pressure or Fuel Gauge Circuit Diagnosis Observation Cause Action Zero reading Circuit breaker open Open circuit loose connection Defective gauge Defective alternator Reset Repair short as needed Re place circuit breaker as needed Test Repair as needed Test Replace as needed Test Replace as needed Inaccurate gauge Defective gauge Test Replace as needed Does not return to zero with ignition off Defective gauge Test Replace as needed Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 47 Hourmeter Components Cab Accessory Fuse Hourmeter Gauge Ignition Switch Oil Pressure Switch Refer to Basic Gauge Diagnostic Procedure page 41 Hourmeter Circuit Diagnosis Observation Cause Action
33. Desiccant cartridge plugged or saturated Defective internal check valve Defective hose tubing or fittings between dryer and main supply reservoir Replace desiccant cartridge Refer to Medium Duty Truck Unit Repair Manual Test Replace as needed Inspect hose tubing and fittings for holes kinks and other restrictions Repair or replace as needed No pressure buildup continuous exhaust at dryer purge valve Purge valve leaking Defective governor Purge control line connected to reservoir or governor exhaust port Defective electrical circuitry Inlet and outlet air connections reversed Defective check valve between dryer and first reservoir Kinked or blocked discharge line Excessive air system leakage Inspect Repair or replace air dryer as needed Refer to Medium Duty Truck Unit Repair Manual Test Adjust or replace as needed Connect to governor unloader port Test Repair or replace as needed Reconnect lines correctly Test Repair or replace as needed Straighten clean repair or replace as needed Inspect system connections Repair or replace as needed Fails to purge Broken kinked plugged or disconnected purge control line Defective purge valve Test line compressor unloaded Inspect Repair or replace air dryer as needed Refer to Medium Duty Truck Unit Repair Manual Maintenance manual Ottawa 4x2 6x4 5 5 Pneumatic 5 Diagnostic Pro
34. Dryer Chassis Options Relay 153 TRANSMISSION GROUND OTT0034 Circuit Breaker Air Dryer Cab Accessory Fuse Panel Maintenance manual Ottawa 4x2 6x4 154 9 3 Electrical System Circuits 9 Schematics Cab Tilt Pump TILT PUMP CIRCUIT BATTERIES RD BATTERY TO STARTER RD d R BK RD BATTERY TO START SOL RD Q STARTER W SOLENOID RD TILT SOL TO TILT PUMP MID FRAME CROSSMEMBER RRR CONNECTOR GD1001 WE TT2001 GN TRANSMISSION CASE GROUND 112001 GN 112001 GN S Tm TT1000 RD BK 000 BK TILT SWITCH x u T HARNESS CONNECTOR aj Jo s z m c 5 5 8 R 8 8 2 EJ E O2o20wx zazm o a zxrmr ju c m I RAAAAAAAAAAAAAAAAAAATA 8 E E 9 CHASSIS BULKHEAD lt CONNECTOR PUMP Ge 5 2 CONTROL SWITCH Fig IGNITION S 295 85 86 2000 RD 23 CAB ACC FUSE TILT BUS BAR s 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 4x2 6x4 OTT0035 gt
35. FUSE GAUGE GAUGE Engine Hourmeter Circuit Maintenance manual Ottawa 4x2 6x4 143 TT0071 2 144 9 3 Electrical System Circuits 9 Schematics 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 Engine Oil Pressure Gauge MEME M LC A c cc SC CR MM ME LN ee DNO 71 ENGINE OIL WITH OPTIONAL PRESSURE GAUGE DIMMER PL2002 BE RD 0 SWITCH STANDARD gt lt Owen awe 1 EE 1 AN eel E e a 58 HEADLAMP HEADLAMP OR NOR VV CONNECTOR SWITCH SWITCH o Sos lt s 115 1215 Tr el k n gt ar 2 8 8 4 m gt gt a 8 8 2001 13 GA2001 OE BK a a 2215 72 oL p ee TE IVa 3 902000 WE PASS THRU 29 2 i PL2002 BE RD STUD 20 182 IGNITION 23 gt vtr zp N ELECTRONIC ENGINE FUSE GAUGE BULKHEAD CONNECTOR IG1001 YW ae 10A 1 OTT0053
36. Inoperative Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Mislocated wiring Inspect routing Relocate wires or isolate terminals as needed Intermittent Defective wiring Inspect wires for kinks and breaks Repair or replace as needed Mislocated wiring Inspect routing Relocate wires or isolate terminals as needed Runs unevenly or fast or slow Defective gauge Replace Maintenance manual Ottawa 4x2 6x4 48 5 2 Electrical 5 Diagnostic Procedures Speedometer The speedometer may include an optional connection to the pulse generator Components Cab Accessory Circuit Breaker Electronic Speedometer Headlight Switch Ignition Switch Panel Dimmer Switch Optional Pulse Generator Optional Refer to Basic Gauge Diagnostic Procedure page 41 Electronic Speedometer Circuit Diagnosis Observation Cause Action Panel lamp does not light Circuit breaker open Loose lamp Burned out lamp Defective wiring Reset Repair short as needed Re place circuit breaker as needed Inspect lamp Tighten or replace as needed Inspect Replace lamp match sys tem voltage Inspect connections and wires Test circuits Repair or replace as needed Inaccurate Wrong DIP switch settings Correct settings Refer to th
37. LHS Light Bar Heater Control RHS Light Bar Fan Control Light Bar Option Switches Panel Dimmer Switch Optional Maintenance manual Ottawa 4x2 6x4 164 9 3 Electrical System Circuits 9 Schematics The electroluminescent lamp illuminates when the ignition Switch is in the Run position It operates independently of the headlight switch Turn Signal Tail Brake Lights and Emergency Flasher HEADLAMP SWITCH RI LH TURN TURN Q Q a S Z ENGINEGAUGE 2 E e S amp WARNING S HEADLIGHT 2 CAB CONTROL S PANEL S SWITCH PANEL CONNECTOR 8 CONNECTOR CONNECTOR IvvvvvYvvYvv sz WM Yyyy N ozxmo uou xr ajo lt q ul z s B ME AB A s 8 5 3 FUSESTOPLIGHTS 5 amp 3 S S8 REMOTE a al POSITIVE F 2 F a STUD PL1000 OE WE 5 C S PASS THRU o STUD CHASSIS 5 BULKHEAD a CONNECTOR FLASHER TL1000 OE BK FLASHER S gt Lo G Sl S a gt L P 112002 M TL200 N V gt 1 PL2000 BE p TURN SIGNAL um BU2000 BK RD SWITCH CONNECTOR 8 NP N P A TL2000 TN WE 2 112001 TN 1 2002 E gt c DIMMER SW E TL2004 NWE _ 1 112004 GNWE R 12000 1 512000 BK W PASS THRU GD2000
38. Pump Motor Cab Tilt 3 2 Chassis 3 Description and Operation 31 OTTO0030 Cab Tilt Components The cab tilt system is an electro hydraulic system that utilizes the tractor battery to power an electric motor that drives the hy draulic pump The inlet port of the pump draws in hydraulic oil from the common reservoir This fixed displacement pump forc es the oil through its outlet port through the valve pressure passage out the work port and to the base end of the tilt cylin der 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 The relief valve will open and pressure will not increase above the set point When tilting the cab back down the solenoid operated direc tional control valve with two positions is energized The valve shifts position and allows a return path for oil from the tilt cylin der A one way check valve blocks oil returning from the relief valve and pump inlet and directs it through a return filter and 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 func tion of the return restriction is to slow the rate of oil e
39. Repair or replace as needed Defective switch Replace Defective motor Replace Maintenance manual Ottawa 4x2 6x4 5 3 Hydraulic 5 3 5 Diagnostic Procedures Hydraulic Boom Components Control Valve Filter Boom Lift Cylinders Hydraulic Pump Hydraulic Relief Valve Reservoir Wet Line Kit Connection Maximum Pressure Hydraulic Relief Valve Vehicle Maximum Pressure All Ottawa 4x2 and 6x4 tractors with 5 inch cylinders 2000 PSI A 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 Cause Action Oylinders leak down Damaged seals or cylinder wall Worn control valve Replace cylinder Replace Drops slightly momentarily before lifting Load check seat or control valve spring malfunction Clean or replace as needed Lifts slowly Pump inlet restricted Worn pump Internal leakage in control valve Internal leakage in cylinders Valve actuating cable lever not centered Remove restriction Replace Replace Replace Adjust Unbind Lubricate as needed Maintenance manual Ottawa 4x2 6x4 68 5 3 Hydraulic 5 Diagnostic Procedures Observation Cause Action Stalls under load Low fluid level Low relief valve setting Ext
40. as needed Intermittent Mislocated wiring Inspect routing Relocate wires or isolate terminals as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Inaccurate Incorrect switch position Refer to DATCON technical manual for correct configuration Maintenance manual Ottawa 4x2 6x4 50 5 2 Electrical 5 Diagnostic Procedures Voltmeter Components Cab Accessory Circuit Breaker Circuit Breaker Headlight Switch Ignition Switch Panel Dimmer Switch Optional Voltmeter Refer to Basic Gauge Diagnostic Procedure page 41 Voltmeter Circuit Diagnosis Observation Cause Action Panel lamp does not light Loose lamp Burned out lamp Defective dimmer switch Circuit breaker open Defective wiring Inspect lamp Tighten or replace as needed Replace lamp match system voltage Replace Reset Repair short as needed Re place circuit breaker as needed Inspect connections and wires Test circuits Repair or replace as needed Inaccurate Defective gauge Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Inoperative Circuit breaker open Reset Repair short as needed Re Defective gauge Defective wiring place circuit breaker as needed Replace Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual
41. at tached as close as possible to the work area 3 Failure to adhere to these cautions can result in permanent damage to the electrical system Maintenance manual Ottawa 4x2 6x4 7 1 Chassis 7 Repair Procedures 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 sec tion 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 4 Make reinforcements long enough so that they can be ta pered and still extend beyond the critical area 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 ac ceptable 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 When ever possible use existing frame holes rather
42. axle load is not more than the gross axle weight rating as indicated on the vehicle identification plate 1 6 Vehicle Modifications Do not modify your Ottawa tractor without approval in writing from Kalmar Industries Corporation Unauthorized modifica tions may void the vehicle warranty Maintenance manual Ottawa 4x2 6x4 2 1 Location Description 2 Vehicle Identification 11 2 Vehicle Identification 2 1 Location Description Identification Plate A vehicle may be specifically identified by referring to the vehicle identification plate The plate is located inside the cab MODEL SERIAL NO DATE on the top of the driver s door frame at the rear This plate shows the model serial number and manufactured date for this Kalmar Industries Corp 415 E Dundee Street vehicle Ottawa Kansas USA 66067 0770010 Certification Label The certification label is supplied only for vehicles qualified un der EPA DOT regulations It is located inside the cab on the VEHICLE TYPE DATE MFG A post behind the driver s door The certification label shows the ZZZ ZZ M vehicle type and date of manufacture Also shown are the Ve gt gt zT hicle Identification Number VIN gross vehicle weight rating GVWR gt gt A GVWR front and rear gross axle weight ratings GAWR PA Kalmar Industries USA L L C f TIRES wheel base ti
43. 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 Dosetthe parking brake when parking the vehicle Don t apply full throttle while the engine is cold Don allow sparks or flames near a charging battery Don t allow sparks or flames nearby when inspecting fuel fuel tank or filler neck strainer Dontoperate a vehicle in an enclosed area without ade quate 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 Dont 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 4x2 6x4 1 3 Diesel Fuel Requirements 1 Introduction 1 3 Diesel Fuel Requirements Precautions A WARNING Do NOT smoke when handling diesel fuel Failure to heed this warning may result in serious personal inju ry and property damage Use only the fuel
44. due to component failure use the following steps to raise the cab a Release the cab latch by supplying hydraulic pres sure 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 hyaraulic line for the latch 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 slip ping 3 Using the cab tilt switch or overhead hoist if necessary lower the cab until it rests on the safety bar and all pressure is removed from the cylinder 4 Clean the area around the hose fitting on the pump with compressed air to reduce the possibility of contamination Position a catch can under the fitting to prevent spills 6 Remove the hydraulic line from the cylinder 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 4x2 6x4 106 7 2 Cab Deck 7 Repair Procedures 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 sup porting the cylinder remove the locknut and bolt 2 secur ing the upper end of the cylin
45. fluid as is in the reservoir If the fluid is unknown drain and re place it according to specification Use only the fuel coolant coolant additives 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 Determine the reason for lost fluid Re pair 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 lith ium based grease or a base oil with a Timken 40 minimum rat ing 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 ve hicle being operated in a severe application may require short er intervals between changes The system filter is on the hydraulic tank Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance 87 Cab Interior Neutral Start Move the gear selector to any position oth er than N and attempt to start the engine The engine should not crank with the selector in any position other than N All Gauges With the e
46. for diagnosis of problems in Ottawa Truck DATCON electrical instruments The sequence present ed 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 A WARNING Ensure that the gauges 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 Basic Gauge Diagnostic Procedure Schematics and diagrams of the electrical circuitry appear in Section 9 Schematics The following steps describe the general path to follow when troubleshooting electrical faults that show up on instrument panel gauges 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 and sender Wiring should be intact and tightly connected Tighten and replace wiring as required 3 If the gauge still does not work ensure that the steel hous ing of the sender is properly seated Provide a three wire jumper to bypass the system wiring Connect ignition or accessory voltage to the I terminal on the back of the gauge Connect the system ground wire to the G terminal and the sender signal lead to the S terminal Maintenance manual Ottawa 4x2 6x4 42
47. for signs of damage Replace as necessary Battery Cable Connections Remove the cable terminals from batteries clean connections reattach cable terminals Battery Box Cover Holddowns Check the bolts or rubber latches to ensure that the battery box cover is secured Air Tanks With the air system charged open each manual drain until all moisture is removed from the system All Wheel Nuts Inspect all wheel nuts for signs of wear or damage Wheels Inspect all wheels for signs of damage including oversized holes and cracks Tires Inspect tires for damage and wear Adjust to the air pressure specified for the tire Rear Axle Planetary Housing If Applicable Check and adjust the lubricant level in the planetary housings per the component manufacturer s instructions Platforms Inspect the platforms for proper mounting and the absence of cracks and trip points Frame Inspect the frame rails and cross members for cracks and bending Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance 93 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 external hydraulic filter Hydraulic Fluid Level Start the engine raise and lower the boom twice to ensure that the system components are filled Lower the boom to full down position shut off
48. lubricant cold weather Transmission fluid lubricant automatic Transynd TES 295 Approved Also refer to transmis sion manufacturer s specifications Wheel bearings front axle Grease lubricated NLGI 1 or 2 Cil lubricated EPA 85 140 Also refer to axle manufacturer s specifications Maintenance manual Ottawa 4x2 6x4 118 8 4 Fastener Torque Values 8 Specifications 8 4 Fastener Torque Values Ottawa Series 4x2 and 6x4 Following are the specified torque values required for sched uled maintenance operations and typical repair and or adjust ment procedures covered in this manual Component Specified Torque Value Axle mounting Front axle clamp plate bolts 210 ft Ibs Rear axle clamp plate bolts Bolt head 600 ft Ibs Nut 400 ft Ibs Rear axle torque link bolts 380 ft Ibs Cab latch mounting bolts 65 ft Ibs Cab latch bar plate mounting bolts 65 ft Ibs Cab pivot pin retainer screws 35 ft Ibs Cab rear door roller capscrews 75 in lbs Cab suspension Assembly mounting bolts 220 ft Ibs Shock absorber mounting bolts 100 ft 16 Cab tilt cylinder mounting bolts 200 ft Ibs Cab tilt pump mounting bolts 35 ft Ibs Cab tilt pump relief valve adjusting screw jam nut 80 in Ibs Boom cylinder mounting Upper mount bolts 55 ft Ibs Lower mount bolts 55 ft Ibs Lower mount cross bar locknuts 600 ft Ibs Boom pivot cross bar locknuts 60
49. mine the cause and repair or replace the jaws per the com ponent manufacturer s recommendation Fifth Wheel Top Plate Clean and inspectthe fifth wheel top plate for cracks or other damage Apply grease to the surface of the top plate Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance Fifth Wheel Pivot Pins Inspect fifth wheel pivot pins for wear or damage Lubricate Boom Pivot Bearings Inspect boom pivot bearings for wear or damage Lubricate Boom Cylinder Bearings Inspect boom cylinder bear ings for wear or damage Lubricate Hydraulic Pump Drive If Applicable Applies only to trucks built prior to March 2007 Remove the hydraulic pump from the PTO Inspect the splined coupling shaft for wear On units equipped with a zerk fitting removal of the PTO is not necessary Lubricate Otto Ride Pivot Points If Applicable Inspect all Otto Ride pivot points for wear or damage On Otto Ride systems equipped with a single point lube system inspect lube lines to ensure delivery of lubricant to all points Depending on the type of lube system lubricate the single point or each pivot point Autolube Reservoir If the vehicle is equipped with an automatic lubrication system inspect all lubrication points for sufficient grease Fill the system reservoir with the prop er type and quantity of grease per the component manufac turer s recommendation Test Drive Overall Opera
50. of the disabled vehicle 2 Release the parking brake as outlined in the brake section of this manual 3 Disconnect the propeller shaft at the axle Secure the propeller shaft to the frame or cross member Remove the axle shafts if there is damage or suspected damage to the axle s 6 Coverthe hub openings to prevent loss of lubricant or entry of dirt or foreign objects Maintenance manual Ottawa 4x2 6x4 1 6 Vehicle Modifications 1 Introduction When the vehicle has arrived at its destination ensure it is safely positioned 1 Block the rear wheels Install the axle shafts Remove the covers from the hub openings Align the universal joints and connect the propeller shaft Soc oae DO 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 provid ed the steering system is operating normally Remember that the steering will not have power assist and the vehicle will not have brakes A tow bar must be used between the towing and the disabled vehicle To relocate a disabled vehicle by towing with all wheels on the ground follow the procedure described above for towing with front wheels 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
51. our hope that this manual will help you to realize maximum utility efficiency reliability and durability from your Ottawa tractor Maintenance manual Ottawa 4x2 6x4 Notes Maintenance manual Ottawa 4x2 6x4 1 1 The Ottawa Terminal Tractor 1 Introduction 3 1 Introduction 1 1 The Ottawa Terminal Tractor Description The Ottawa terminal tractor by Kalmar is designed to suit the operator and the tasks Ottawa tractors are purpose built vehi cles 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 side or through the sliding rear 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 de signed cab The trailer air lines and electrical connections are easily acces sible through the rear door Perforated decking allows the op erator to move from cab to trailer comfortably and easily A hydraulically powered boom under the fifth wheel raises a trail er high enough to allow it to be moved without raising and low ering its landing gear These features along with in cab fifth wheel release and automatic relatch means that the oper ator is not required to climb up and down from the cab for every trailer move The Ottawa also features auto
52. s guide Change Engine Coolant Flush the cooling system and replace with clean coolant of the appropriate concentration Coolant Hoses and Clamps Inspect all hoses for abra sion cracks holes and routing Check all clamps for proper torque Fan Clutch for Operation If Applicable Run the en gine to confirm that the fan clutch engages at the proper temperature Engine Cooling Fan for Cracks Shut the engine off if running Inspect fan blades for signs of cracking Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance Engine Belts and Tensioner Inspect belt s for crack ing and wear The belt tensioner should be checked for proper operation Change Engine Coolant Filter If Applicable Replace the engine coolant filter A filter containing the proper SCA should be used to maintain the specified concentration level Engine and Transmission for Leaks Perform a visual inspection of the engine and transmission looking for 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 Air Restriction Gauge If Applicable Record the read ing on the gauge reset start the engine run to high idle and shut off the engine If the reading remains zero the gauge may b
53. s name plate is fastened to the side of the tank where it can easily be seen Fuel Level Sending Unit 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 Fuel Hoses Fuel hoses are constructed of rubber and braid ed steel wire Fuel Tank and Fittings Maintenance manual Ottawa 4x2 6x4 34 Notes Maintenance manual Ottawa 4x2 6x4 4 1 Chassis Cab Left Side 4 Component Location 35 4 Component Location 4 1 Chassis Cab Left Side Ottawa Series Left Side 4x2 chassis shown OTTO0005 Maintenance manual Ottawa 4x2 6x4 36 4 1 Chassis Cab Left Side 4 Component Location Qo Sb Qro Ur Be OO D o 14 Cab Air Ride Air Spring Height Control Valve Assembly Side Entry Ladder Cab Tilt Switch Boom Lift Cylinder Upper Mount Fifth Wheel Pivot Boom Lift Cylinder Lower Mount Cab Tilt Lanyard Hydraulic Fluid Tank Hydraulic Fluid Filter 11 12 13 Cab Air Ride Shock Absorber 15 16 Battery Box BOC Steps Cab Tilt Pump Fuel Filter Cab Tilt Cylinder Safety Bar Tow Hook Maintenance manual Ottawa 4x2 6x4 4 2 Chassis Cab Right Side 4 Component Location 37 4 2 Chassis Cab Right Sid
54. 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 apart Holes in a reinforcement plate should be at least two times the material thickness from the edge of the plate Maintenance manual Ottawa 4x2 6x4 7 1 Chassis 7 Repair Procedures 97 7 1 3 Repairing Cracks in Steel Rails or Cross Members Types 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 mu
55. 0 110 146 Length overall ins 181 181 244 Width overall ins 97 97 97 Maintenance manual Ottawa 4x2 6x4 114 8 1 Standard Vehicle Data 8 Specifications Chassis Model and Configuration Ottawa 4x2 Ottawa 4x2 Ottawa 6x4 Turning radius ft 17 17 19 85 Fifth wheel boom lift capacity Ibs 60 000 60 000 60 000 Fifth wheel FW 3500 FW 3500 FW 3500 Chassis weight Ibs 14 500 14 500 18 000 Maintenance manual Ottawa 4x2 6x4 8 2 Hydraulic System 8 Specifications 115 8 2 Hydraulic System Ottawa Series 4x2 and 6x4 The hydraulic system includes three sub systems Fifth wheel boom Power steering Cabtilt All three draw and use fluid from a common 16 gallon reservoir Specifications for the individual sub systems follow Boom System Components Specification Boom drift down maximum 5 inch 3 inches per hour cylinder Hydraulic fluid Dexron III Pump flow standard system 10 gpm at 1200 rpm System capacity Tank only 16 gallons System 21 gallons approximate System relief pressure 2000 psi Power Steering System Components Specification Pump flow minimum 4 gpm at 1200 rpm Pump relief setting 2100 psi Cab Tilt System Components Specification Pump flow minimum 0 3 gpm at 1200 rpm Pump relief setting 3200 psi Maintenance manual Ottawa 4x2 6x4 116 8 3 Fluids Lubricants an
56. 0 ft Ibs Boom pump mounting bolts 55 ft Ibs Boom pump relief valve adjusting screw jam nut 15 ft 16 Spring pin bolts fixed shackle front axle 150 ft 16 Steering gear mounting bolts 350 ft Ibs Wheel lug nuts 450 500 ft Ibs Maintenance manual Ottawa 4x2 6x4 9 1 Air System Circuits 9 Schematics 119 9 Schematics 9 1 Air System Circuits 9 1 1 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 Vehi cle Safety Standard FMVSS 121 This standard specifies test requirements for air brake systems Semi trailer tractors must be equipped with an anti lock brake system ABS and meet stopping distance requirements under normal and emergency conditions ABS is optional on tractors that do not use the roads Vehicles intended for road use also conform to applicable Canadian Motor Vehicle Safety Standards CMVSS Maintenance manual Ottawa 4x2 6x4 120 9 1 Air System Circuits 9 Schematics Air Brake System with ABS
57. 1 WITH OPTIONAL ENGINE TACHOMETER DIMMER CIRCUIT SWITCH STANDARD can m TACHOMETER PANEL LTS PL2002 BE RD Q DIMMER DEM 9 G PL2002 BE RD el GA1000 BN RD a si 602000 WE S HEADLAMP HEADLAMP SIR SWITCH SWITCH elo ENGINE GAUGE amp Xy r GUESS OUI a IGNITION s e GAB ACE ESI lt TACHOMETER SIGNAL 161001 vw SAUGE NEGATIVE CONNECTOR c gt PASS THRU lt 1 g 10K 1 STUD 5 J g TACHOMETER SIGNAL CAB EXTERIOR 1 BULKHEAD CONNECTOR OTT0057 L Tachometer Circuit Maintenance manual Ottawa 4x2 6x4 150 9 3 Electrical System Circuits 9 Schematics Components Alternator Fuse Gauge Cab Accessory Fuse Panel Ignition Relay Gauge Tachometer Gauge Lamp Tachometer Gauge Lamp Water Temperature Gauge Water Temperature Headlight Switch Panel Dimmer Switch Optional The tachometer displays crankshaft revolutions per minute RPM Transmission Oil Temperature Gauge
58. 2 6x4 9 3 Electrical System Circuits 9 Schematics IGNITION SWITCH RADIO CIRCUIT HOT WIRE A ji 9 t OA OS l AE e EE IGNITION SWITCH 5 lt IGNITION SWITCH FUSE POSITIVE IGN SW afolo m PASSTHRU C BA2000 RD 161000 RD WE TUD 10A 1 z a o ACC 1 lt 85 86 AC2000 BN 1001 BN 87 POSITIVE 57 30 2001 RD H PASS THRU AC1001 BN Re STUD x CAB ACC o _ RADIO FUSE gt RADIO ACCY RD2002 10A 3 RD2002 BN RD TERMINAL FOR CB NEGATIVE RADIO CONNECTOR 002006 WE 002006 WE PASS THRU RADIO UPPER STUD CAB CONNECTOR 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 4x2 6x4 137 138 9 3 Electrical System Circuits 9 Schematics WINDSHIELD WIPER SW WASHER CIRCUIT WWh1000 PE RD WIPER SWITCH CONNECTOR AC1000 BN CAB ACC FUSE WIPER WASHER WIPER WASH BA2001 RD POSITIVE STUD WW2003 GN Windshield Washer Optional OPTIONAL WINDSHIELD WASHER CHASSIS BULKHEAD r CONNECTOR WASHER CON
59. 24 00000 eene nennen nenne 14 Cab Titing y ya m 15 Suo EE 17 Instrument Panel Gauges Controls and Indicators 2 2 17 Electrical Egui mari t sS ee 19 Heating Air Conditioning eene nennen nennen 19 Accessories and Options uuu tete ne heri Ie pede ae 19 u umu 20 BA n M 20 lt cod eec Lu ees Sens 22 Vehicle Suspension Including Otto Ride 2 22 Air System and Brakes n 24 deeem eco te ert p i 24 Anti lock Brake System Optional 28 Automatic Traction Control Optional sse 29 Hydra lic Systermi at a una aym u asya bee T 29 System OV rVISW i niece tret t dept bec a EE UE eati ec Bened 29 Boom Components esee nennen nennen sinn 30 Cab Tilt SD A h a aB nnne nns 31 Power Steering Components sse 32 Fuel System ee sene er ret tr 33 Component Location 35 Ghassis Gab eee tede ite ied dual tb a bt vena 35 Ottawa Series Left Side 4x2 chassis shown 35 Right Side
60. 3 1 1 Construction Cab The cab four walls roof and deck are constructed of 12 gauge galvanneald steel for strength and rust protection The walls are attached to the deck at four points by grade 5 bolts tightened to 120 ft Ib The deck provides the floor inside the cab and the walkway out side the cab The floor and walkway are covered by matting with an abrasive surface for safer footing The instrument panel frame and the engine bulkhead inside the cab help make the assembly rigid Insulation panels line the roof and the engine side of the bulkhead Roof The roof of the standard cab rises at an angle from the windshield permitting a rear door opening approximately 68 inches high Doors The rectangular driver s door is attached to the cab by a full length piano type hinge 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 Windows and Ventilation The window in the driver s door moves up and down via a regulator handle on the door A fixed side window ahead of the driver s door permits a full view on that side A small ventilator door below this window provides fresh air inside at the driver s feet A three section window on the opposite wall allows an unobstructed view in that direction The front and rear sections of this window slid
61. 5 2 Electrical 5 Diagnostic Procedures A Without power the gauge pointer may indicate any val ue Often it will indicate the previous signal from the sender B Turn on the ignition without starting the engine The pointer should indicate zero or full PSI If the pointer indicates outside the endpoints go to step 3Bc below If the pointer falls within the endpoints go to step 3Bd below a If the pointer is stuck noticeably outside dial scale endpoints lightly tap the lens If tapping results in the pointer moving to an acceptable position look for an open in the sender circuit or replace the gauge Go to step 3Bc below If the pointer rests significantly toward the far left of the scale remove power to the gauge Remove the sender wire from S terminal on the back of the gauge Momentarily apply power to the gauge If the pointer does not travel to the far right of the scale replace the gauge If the pointer rests significantly toward the far right of the scale remove power to the gauge Remove the sender wire from S terminal on the back of the gauge Testthe resistance of the sender and its wir ing using an ohmmeter The reading should be be tween 0 250 ohms If the resistance is more than 250 ohms check the sender wiring to sender hous ing or flange grounding Also look for an open in the sender wiring circuit If the electrical wiring is correct and properly grounded remove the sender and test the sender r
62. 67 LOT Clearance Lights Circuit Components Circuit Breaker Parking Lights Cab Accessory Fuse Panel Circuit Breaker Marker ID Lights Trailer Breakers Circuit Breaker Tail Clearance Lights Trailer Breakers Cab Clearance Lamps Headlight Switch Trailer Lights Relay Double Face Turn Marker Lights are standard equipment on vehicles that meet FMVSS and CMVSS requirements Maintenance manual Ottawa 4x2 6x4 158 9 3 Electrical System Circuits 9 Schematics Daytime Running Lights Optional LH HEADLIGHT RH HEADLIGHT HIBEAM RD Am HL2002 BE WE HL2002 BEWE A RD HI BEAM BK LO BEAM lc GN GROUND LH HEADLIGHT RH HEADLIGHT OPTIONS CONNECTOR CONNECTOR BULKHEAD CONNECTOR DR2002 RD DR2002 RD IGNITION 161001 YW CAB ACC FUSE D R L BUS BAR 161001 YW DR2002 RD HL2002 BE WE HL2001 BE BK 082002 RD 082000 BE DAYTIME RUNNING LIGHTS MODULE POWER TO FR HEADLIGHT DAYTIME RUNNING LIGHTS CIRCUIT DAYTIME RUNNING LIGHTS CONNECTOR 0060 lo Daytime Running Lights Circuit Components Daytime Running Lights Module Fuse Daytime Running Lights Cab Accessory Fuse Panel Head Lamps Ignition Relay Maintenance manual Ottawa 4x2 6x4
63. A ojm lt x a gt m 5 8 e ur ACC FUSE EXTERIOR LIGHTING EXT LIGHTING 25 1 Beacon Strobe Light Circuit Maintenance manual Ottawa 4x2 6x4 BEACON LIGHT CIRCUIT Me OTT0066 PL2001 BE BK Q uP Pc coxr aAazxrcmolpmzzzoo CONNECTOR CLEARANCE LIGHT CIRCUIT 9 3 Electrical System Circuits 9 Schematics TRAILER BREAKERS TAIL CLRNC 10A MARKER ID PL2001 BE BK 157 Components Accessory Relay 2 Beacon Strobe Lamp Fuse Exterior Lighting Cab Accessory Fuse Panel Beacon Light Switch Optional Flood Light Switch The flood light switch is mounted on the instrument panel Clearance Lights lt BK SIDE MRKR ID TRAILER CONNECTOR NEGATIVE PASS THRU A PL1000 OE WE PL2000 BE PL1000 OE WE PL2000 BE TRAILER LIGHTS 86 Ke Ri GD2001 WE 85 POSITIVE 3 PASS THRU STUD STUD BA2000 RD REMOTE 1 BA2002 RD CLEARANCE POSITIVE DD LIGHTS STUD ET 8 S a m ul J 2 s s ME a UPPER HEADLAMP e o CAB SWITCH 8 2 FUSE PARKLIGHTS B PARK LTS m o dl sh 5 m 2d N HEADLIGHT S S a SWITCH S CONNECTOR o NEGATIVE m 5 PASS THRU 2 STUD S 8 E T00
64. AC1001 BN 9 3 Electrical System Circuits 9 Schematics Dome Light DOME LIGHT CIRCUIT GD2001 WE CL1000 BN RD p DOME LIGHT eo CL1000 BN RD UPPER CAB CONNECTOR CAB ACC FUSE LIGHTING CL1000 BN RD GD2001 WE CAB LIGHTING NEGATIVE 0 PASS THRU STUD GD2001 WE 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 Maintenance manual Ottawa 4x2 6x4 159 0061 160 9 3 Electrical System Circuits 9 Schematics Fifth Wheel Control Refer to Transmission Shifter Flood Light joies s m nm s ss s samina Components FLOOD LT FLOOD LIGHT SWITCH Accessory Relay 2 CIRCUIT Flood Light Flood Light Switch Fuse Exterior Lighting Cab Accessory Fuse Panel EL2000 BE BK FLOOD amp BEACON LIGHT CONNECTOR EL2000 BE BK EL2000 BE BK GD2001 WE NEGATIVE PASS THRU STUD UPPER CAB CONNECTOR EL2000 BE BK lt EL1000 BN BK EL2000 BN BK CAB ACC FUSE EXTERIOR LIGHTING EXT LIGHTING EL1000 BN BK AC1001 BN nem Flood Light Circuit Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 161 Headlights TURN SIGNAL 71 SWITCH CONNECTOR
65. CESSARY X REPAIRS NEEDED INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVALS B INSPECTIONS AT 500 HOUR INTERVALS INSPECTIONS AT 1000 HOUR INTERVALS AND D INSPECTIONS AT 2000 HOUR INTERVALS SHADED BOXES INDICATE THAT THE OPERATION SHOULD NOT BE DONE AT THAT INTERVAL L 1 OPERATION T ATBICID UNDER VEHICLE CHECK OPERATIONOFNEUTRALSTART McHECKsTEERINGGENR C C 1 L 1 CHECK OPERATION OF ALL GAUGES CHECK LOW AIR BUZZER AND LIGHT _ _ CHECK WINDSHIELD WIPER OPERATION CHECK WINDSHIELD WASHER OPERATION APP CHECK THROTTLE OPERATION __ T CHECKHORNG OPERATION CHECK AIR SYSTEM MINIMUM 120 PSI MAXIMUM I30PSI CHECK AIR SYSTEM FOR LEAKDOWN CHECK OPERATION OF BACK UP ALARM BLOWERMOTOROPERATION TEMPERATURE CONTROL DEFROSTER OPERATION LAIC OPERATION IF APP _ AUXILIARY FANS QF APP _ CHECK 5 WHEELUNLATCHCONTROL CHECKOPERATIONOFBOOM CHANGEDIFFERENTIALOIL CHECK OPERATION OF WINDOWS CHECKSEATBELTOPERATION a CHECK REAR AND SIDE DOOR LATCH OPERATION TORQUE REAR AXLE MOUNTING BOLTS CHECK DOME LIGHT OPERATION CHECK ALL GLASS _ CHECK FIRE EXTINGUISHER CHARGE UF APP CHECK SIDEDOORHINGE CHECK CAB ACCESS STEPS AND HANDLES CLEANHEATER ACFILT
66. Components Wire Color Codes BE Blue BK Black BN Brown GN Green OE Orange PE Purple PK Pink RD Red Tan White YW Yellow Maintenance manual Ottawa 4x2 6x4 132 9 3 Electrical System Circuits 9 Schematics Anti lock Braking System ABS For information on the anti lock braking system refer to the vendor s service manual Heater and Air Conditioning Heating and Air Conditioning Circuits Components Accessory Relay 1 Air Conditioner Switch Cab Fan Optional Cold Control AC Optional HVAC Fan Motor Fan Switch HEATER AIR CONDITIONING 1 CIRCUIT OFF ELECTRONIC ENGINE BULKHEAD CONNECTOR 5 bag 12 gt 2 5 m 8 M 58 1000 RD WE 5 EL MA I 35 OPTIONAL AIR CONDITIONER ME CAB FAN SWITCH CONNECTOR 162 HC2001_YW RD gt HC2001 _ 2000 3 ala T ER 8 gs a sls elie LOW PRESSURE 98 o amp 5 SWITCH amp COLD CABCONTROL SB s CONTROL CONNECTOR PANEL CONNECTOR Y ES
67. Diagnostic Procedure page 41 Low Air Warning Circuit Diagnosis Observation Cause Action Inoperative light and buzzer Circuit breaker open Short circuit Switch grounded Defective air switch Defective assembly Reset Replace as needed Test Repair as needed Test Repair as needed Test Repair as needed Replace Inoperative buzzer light OK Open circuit Defective buzzer Test Repair as needed Replace Inoperative light buzzer OK Open circuit Bulb burned out Test Repair as needed Replace Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures Ammeter Components Ammeter Headlight Switch 45 Panel Dimmer Switch Optional Shunt Refer to Basic Gauge Diagnostic Procedure page 41 Ammeter Circuit Diagnosis Observation Cause Action Zero reading Circuit breaker open Open circuit loose connection Defective gauge Defective alternator Reset Repair short as needed Re place circuit breaker as needed Test Repair as needed Test Replace as needed Test Replace as needed Inaccurate gauge Defective gauge Test Replace as needed Does not return to zero with ignition off Defective gauge Test Replace as needed Maintenance manual Ottawa 4x2 6x4 46 5 2 Electrical 5 Diagnostic Procedures Coolant Oil and Fuel Gauges Coolant Gauge Components
68. ER SSS CHECK REAR DOOR ROLLER SLIDE ADJUSTMENT CHECK GLADHAND SEALS AND TRAILER AIR LINES CHECK TRAILER LIGHT CORD IF APP CHECK HEADLIGHTS MARKER LIGHTS CHECKTURNSIONALS C CHECK STROBE LIGHT AF APP CHECK SPOTLIGHTS C CHECK WIPER BLADES T CHECK WINDSHIELD WASHER FLUID LEVEL CHECK OPERATION OFCABTILTPUMP CHECK CABSAFETYPROP SSCS CHECK CAB SUSPENSION ANDLATCH CHECK ENGINE INTAKE DUCTING FORLEAKS CHECK RADIATORFORLEAKS CHECK RADIATOR MOUNTS CHECK COOLANT LEVEL AND CONCENTRATION CHECK AND ADJUST COOLANT ADDITIVE IF APP CHANGE ENGINE COOLANT jM CHECK COOLANT HOSES ANDCLAMPS CHECK FAN CLUTCH FOR OPERATION IFAPP CHECK ENGINE COOLING FAN FOR CRACKS CHECKENGINEBELT S AND TENSIONER CHANGE ENGINE COOLANT FILTER IF APP i CHECK ENGINE AND TRANSMISSION FOR LEAKS DRAIN FUEL WATER SEPARATOR T CHECK AIR RESTRICTION GAUGE IFAPP _ i bh 2222222 TORQUE CAB TO DECK MOUNTING BOLTS E ANE NI pee eee si Preventive Maintenance Form Non Synthetic Transmission Lubrication Maintenance manual Ottawa 4x2 6x4 OTT0003 6 1 Checklists 6 Scheduled Maintenance KALMAR TERMINAL TRACTOR PREVENTATIVE MAINTENANCE FORM 2007 OR NEWER ENGINES SYNTHETIC TES 295 LUBE AND ALLISON HIGH CAPACITY FILTERS USED IN THE TRANSMISSION
69. HYDRAULIC RESERVOIR TANK OTT0048 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 4x2 6x4 128 9 2 Hydraulic System Circuits 9 Schematics 9 2 2 Fifth Wheel Boom Hydraulic Lines Fifth Wheel Boom 5TH WHEEL M AIR LINES FIFTH DEL WHEEL m 3 8 BK 5TH WHEEL AND BOOM gt e q 9TH WHEEL L L_UNLATCH_ TO BRAKE TANK MANIFOLD 8 PORT 38 YW TO TRACTOR Ln PARK YELLOW ni gt PLUGS TO TRACTOR PARK RED gt CHH 3 8 YW BRAKE PLUG TREADLE Ip 3 8 BK TO BRAKE SYSTEM TO SERVICE RESERVOIR OTT0049 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 4x2 6x4 9 2 Hydraulic System Circuits 9 Schematics 129 9 2 3 Power Steering Hydraulic Lines Power Steering POWER STEERING HYDRAULIC SYSTEM HYDRAULIC PUMP STEERING GEAR HYDRAULIC TANK OTT0050 Hydraulic Lines Power Steering System Components Integral Steering Gear
70. LD WASHER FLUID LEVEL CAB UP CHECK OPERATION OF CAB TILTPUMP CHECK CAB SAFETY PROP CHECK RADIATORFORLEAKS o T CHECK RADIATOR MOUNTS CHECK COOLANT LEVEL AND CONCENTRATION Ee CHECK COOLANT HOSES AND CLAMPS _ CHECK FAN CLUTCH FOR OPERATION Ez CHECK ENGINE COOLING FANFORCRACKS CHECK ENGINE BELT S AND TENSIONER CHANGE ENGINE COOLANT FILTER F APP MJ CHECK ENGINE AND TRANSMISSION FOR LEAKS DRAIN FUEL WATER SEPARATOR CHANGE FUEL WATER SEPARATOR CHECK AIR RESTRICTION GAUGE IF APP CHECK EXHAUST SYSTEM _ T CHECK TRANSMISSION FLUID LEVEL __ CLEAN TRANSMISSION BREATHER Wai Wall ee ad EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION 0 ADJUSTMENT NECESSARY A INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVALS B INSPECTIONS 500 HOUR INTERVALS INSPECTIONS 1000 HOUR INTERVALS AND D INSPECTIONS AT 2000 HOUR INTERVALS SHADED BOXES INDICATE THAT THE OPERATION SHOULD NOT BE DONE AT THAT INTERVAL X REPAIRS NEEDED UNDER VEHICLE CHECK STEERING GEAR 1 1 CHECK BRAKE LININGS ANDDRUMS CHECK LEAF SPRINGS
71. 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 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 135 Heated and Motorized Optional CAB BULKHEAD _ CONNECTOR 86 lt 30 NIS z SD2000 lt NEGATIVE STUD R 902000 WE LJ PASS THRU 5 B STUD E LH MIRROR MIRROR J RH MIRROR CONNECTOR L LEFT HAND 555 pi MR1000 RD MR1000 RD T MR1000 RD BK 2 GD2000 WE MR1003 RD WE MR1003 RD WE ra MR1004 RD WE H MR1004 RD WE D eo gt e 55 CONNECTOR FUSE ele A S RIGHT HAND MIRRORS el sis ele MR1001 OE QS xz 5 amp CONNECTOR REMOTE SWITCH RIGHT HAND GD2000 WE MR1001 OE P 3 MIRROR HEAT MR1000 RD CIRCUIT El gt 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 M
72. NECTOR GD1001 B 7 GD1001 WE WW2003 Az WW2003 GN WW2003 GN GD1001 WE TRANSMISSION CASE GROUND m rmx zcuuzoz x moroco T0041 ES 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 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 139 Windshield Wiper WINDSHIELD WINDSHIELD WIPER CIRCUIT WIPER SW ACC 1 85 86 2 BA2001 RD PASS THRU f E a 5 a og e WIPER SWITCH CONNECTOR UN NEGATIVE o PASS THRU WIPER MOTOR STUD BATT e GRD WIPER MOTOR aj amp z ui f CONNECTOR 52 F N N S PARK BN E lt GD2001 WE ui BE D WW2000 PE LLI BK C WWh1000 PE RD RD B WW2002 PE WE 4 LO GN A WW2001 PE BK 2 AC1000 BN c CAB ACC FUSE lt WIPER WASHER WIPER WASH 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 Ot
73. Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 5 2 3 Lighting 51 Backup Light and Alarm Flood Light 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 e Backup Flood Relay Backup Light rear of frame e Cab Flood Light Switch Circuit Breaker 15A Flood Light Ignition Switch Reverse Switch Backup Light and Alarm Circuit Diagnosis Observation Cause Action Inoperative alarm Circuit breaker open Defective alarm Defective backup flood relay Defective wiring Reset Repair short as needed Re place circuit breaker as needed Replace Replace Inspect connections and wires Test circuits Repair or replace as needed Inoperative backup light Defective lamp Circuit breaker open Defective backup flood relay Defective wiring Replace Reset Repair short as needed Re place circuit breaker as needed Replace Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 52 5 2 Electrical 5 Diagnostic Procedures Flood Light Circuit Diagnosis Observation Cause Action Inoperative Defective lamp Defective light switch Circuit breaker open Defective relay Defective wiring Replace Replace Reset Repair s
74. Ottawa 4x2 6x4 7 2 Cab Deck 7 Repair Procedures 111 9 16 y DSC2483 DSC2480 7 2 8 Rear Door Rear Door Adjustment Use the following procedures to maintain smooth operation of the rear door 1 Measure the gap between the closed door and the upper corner of the door frame If the measurement is not 9 16 inch 0 563 inch loosen the capscrews 1 that hold the rollers Move the door in the appropriate direction to reach 9 16 inch then tighten the capscrews to specification Measure the gap between the closed door and the lower corners of the door frame If the measurement is not 9 16 inch 0 563 inch adjust the lower guide and or rollers as follows a Checkthe rollers with the door in both the open and closed positions and determine where the rollers are closest to the guide b Attheclosest position adjustthe rollers so thatthey are snug against the lower guide Adjust the outer rollers first and then the center rollers c the rollers are adjusted to the lower guide close the door and adjust the lower roller mounting plate to a gap of 9 16 inch Maintenance manual Ottawa 4x2 6x4 112 Notes Maintenance manual Ottawa 4x2 6x4 8 1 Standard Vehicle Data 8 Specifications 113 8 Specifications 8 1 Standard Vehicle Data Ottawa Series Terminal Tractor Standard features dimensions and performance specifications are presented below for three typical cha
75. SHINGS CHECK LUBRICATE DRIVELINE U JOINTS CLEAN CHECK ADJUST AND LUBE S WHEELJAWS CHECK AND LUBRICATE 5 WHEEL TOP PLATE CHECK AND LUBRICATE 57 WHEEL PIVOT PINS CHECK AND LUBRICATE BOOM PIVOT BEARINGS L OTO IESBDRIVE UJU UU U qe Tr quee DRIVE VEHICLE TO CHECK OVERALL OPERATION Riana ee aa 222 Preventive Maintenance Form Synthetic Transmission Lubrication with High Capacity Filters Maintenance manual Ottawa 4x2 6x4 OTTO004 85 6 1 Checklists 6 Scheduled Maintenance Preventive Maintenance Technique The following is more detailed information for preventive main tenance See the Lubrication Points page 81 provided in this manual Refer to the Preventive Maintenance Forms page 84 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 Fuel Filters Fluids and Lubricants 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
76. SWITCH TAILLIGHTS TYPICAL AIR SYSTEM WITHOUT ABS OTT0044 124 9 1 Air System Circuits 9 Schematics 9 1 2 Cab Seating Air Lines Driver s Seat AIR LINES DRIVER S SEAT BRAKE TREADLE AIR SEAT SYSTEM CAB FLOOR 2 RESERVOIR 7 TO MANIFOLD m 8 PORT T NEAR SIDE Air Lines Driver s Seat Components Air Control Valve Air Spring Air Reservoir OTT0045 The adjustable driver s seat cushion rides on an air bag A lock ing 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 Maintenance manual Ottawa 4x2 6x4 9 1 Air System Circuits 9 Schematics 125 9 1 3 Cab Suspension Air Lines Cab Suspension BRAKE AIR LINES CAB TREADLE SUSPENSION TO BRAKE SYSTEM AIR RIDE SUSPENSION HEIGHT CONTROL SUSPENSIO USPENSION TO DR ENS VALUE q AIRRIDE TO SERVICE RESERVOIR TO MANIFOLD r3 8 NEEDLE VALUE NEAR SIDE ae 5 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 ra
77. WE dh NEGATIVE STUD BU2000_BK RD CAB BULKHEAD CONNECTOR TL2002 GN 001 TN 511000 OE RD 12000 BK TURN SIGNAL TAIL BRAKE FUSE STOPLIGHTS REMOTE BA2002 RD STOP LTS LIGHTS amp EMERGENCY FLASHER P ma Q u ccoxra4zxrc c imoz msz zezk A A Turn Signal Tail Brake Lights and Emergency Flasher Circuit Part A Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 165 RH REAR STOP TURN TAIL RH FRONT GD1001 WE TURN PARK 97 NOT USED WHEN TRANSMISSION STOP TURN T BU2000 BK RD BACK UP CASE LIGHT I COMBINED C LIGHT GROUND 512000 BK GD1001 WE STOPLIGHT CONNECTOR 5506 E RD Dr 601001 WE L E ES mud PUT TEES 1 2003 YW BIZ 52 Bag BBE STOP TURNTAIL GD1001 WE BUS BAR CAB ACC FUSE PARKLIGHTS PARK LTS TAIL LIGHTS CONNECTOR LH FRONT lt 601001 WE g TL2002 GN 00 PL2000 BE U2000 BK TL2003 YW 1 2004 12000 BK CAB ACC FUSE REVERSE 85 IGNITION 5 BU1000 BK REVERSE 161001 YW Et 75A 2 PR BREAKERS TL2002 GN RHTURN GN CAB ACC FUSE STOPLIGHTS SL2000 BK STOP LTS 6 7 NN V TRAILER CONNECTOR
78. _ CONNECTOR 7 8 5 s gt e s 8 8 gt S L n j S O 1 2 2 GA2004 GY Am GA2004 GY e GA2004 542005 2005 GYIRD 5 2005 GY RD e 4 AMMETER DASH CONNECTOR NEGATE PL2002 BE RD PL2002 BE RD GD2000 WE PASE THRU EI L 602000 WE 1 GD2000 WE BI LIGHT BAR d connecter LIGHT BAR NNECTOR JUMPER CONNECTOR AMMETER FOR OPTION CHASSIS SWITCHED CONNECTOR GA2005 GY RD GA2005 GY RD GA2004 GY GA2004 GY 22 RD w RD 0 SHUNT STARTER WISOLENOID l BATTERIES RD BATTERY TO STARTER TRANSMISSION CASE GROUND Ammeter Gauge Circuit Maintenance manual Ottawa 4x2 6x4 142 9 3 Electrical System Circuits 9 Schematics Components Alternator Ammeter Ammeter Lamp Ammeter Shunt Batteries Headlight Switch Light Bar Panel Dimmer Switch Optional Starter with Solenoid Engine Coolant Temperature Gauge WITH OPTIONAL DIMMER SWITCH STANDARD DIMMER PL2002 BE RD NI 102006 BN RD GD2000 WE GA2002 GN BK S1 1 HEADLAMP HEADLAMP ol X SWITCH SWITCH s e M yl sel S ENGINE GAUGE amp 9 lt WARNING PANEL RE 5757
79. aintenance manual Ottawa 4x2 6x4 136 9 3 Electrical System Circuits 9 Schematics Radio Optional dm NP ewe9 LL Enc IGNITION SWITCH RADIO CIRCUIT OVERHEAD UNDER DASH S IGNITION POSITIVE CONNECTO CAB ACC PASS THRU RD IGNITION STUD SWITCH FUSE IGNSW 1000 AC1001 BN BA m RD2002 BN RD o 85 86 AC2000 BN lt o CAB ACC 3 2001 RD POSITIVE m RADIO FUSE 87A 3 PASS THRU RADIO i Kos a RADIO ACCY STUD UNDER DASH RD2002 BN RD L 5A 3 TERMINAL FOR CB RADIO CONNECTOR RADIO UNDER 8 DASH CONNECTOR S a a 2 gt I gt z m TERMINAL amp RADIO UPPER gis FORRADIO 8 S SIS NEGATIVE connector 8 8 CONNECTOR Ba 602006 PASS THRU GD2006 WE 602006 WE _ 602006 WE H OVERHEAD B RD2002 BN RD 4 RD2002 BN RD s 7 RD2002 BNRD RD2002 BN RD c 2L RD1003 RD RD1003 RD c RD1003 RD RD1003 RD OY L POSITIVE BA2004 RD GB AGE m STUD lt RADIO u BATTERY FUSE 2 RADIO BATT 3 o el m NT Radio Circuit Overhead Under Dash Maintenance manual Ottawa 4x
80. al System Circuits 9 Schematics Trailer Auxiliary Power TRAILER AUX TRAILER AUXILIARY SWITCH POWER POWER RELAY NEGATIVE PASS THRU STUD GD2004 WE 152001 BN WE CHASSIS BULKHEAD CONNECTOR TRAILER TS2000 BN BK B AUX 162000 YW A SWITCH REMOTE POSITIVE STUD AB2000 RD TS2000 162000 _162000 YW TRIAXLE AC2000 BN SWITCH CONNECTOR A B B 2 2 J lt lt lt TS2001 BN WE IGNITION Nuewmo SWITCH SWITCH JUMPER JUMPER ABS HARNESS TRAILER BREAKER TRBK TS2001 BN WE 15A Qou c jo xrazmxrcmumoxmmzzzoo A A 10770068 4 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 4x2 6x4 WITH OPTIONAL DIMMER SWITCH s PANEL LTS DIMMER D 51 HEADLAMP SWITCH PL2002 BE RD STANDARD 51 HEADLAMP SWITCH PL2002 BE RD DIMMER INPUT Z u zr m lt O u Q gt O AAAAAAAAAAAARI ENGINE GAUGE amp WARNING PANEL CONNECTOR Rz wurmoeoaooor2z PL2002 BE RD PL2002 BE RD 9 3 Electrical System Circuits 9 Schematics 163 Transmission Shifter Fifth Wheel Cont
81. are removed Stabilize the right rear of the cab deck by chaining it down 10 Using a drift drive the front cab pivot pins 4 out 11 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 12 Support the front of the cab deck by placing additional blocks between the deck and frame 13 Using a drift drive the old bushings out of the left and right cab pivot blocks Maintenance manual Ottawa 4x2 6x4 110 7 2 Cab Deck 7 Repair Procedures 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 de sired height on the original blocks placed in position to sup port the cab Install the cab tilt pins Install the cab pivot retainer 2 at each pivot pin Install the spacer bracket 1 at the front left cab pivot pin Install both front headlight buckets Install the p clamp that secures the frame and engine har nesses at the left front corner of the front cross member 8 Install the SNAPTRAC bolts at the front left corner of the frame cross member and from the bottom of the cab channel a 9 Lower the and check for hose routing issues Maintenance manual
82. cedures 75 Observation Cause Action Desiccant expelled through purge valve Air dryer vibration Defective desiccant cartridge Defective compressor piston rings Defective electrical circuitry Inspect Repair or replace as needed Inspect Repair or replace as needed Inspect supply air If oil is present repair or replace compressor as needed Refer to Medium Duty Truck Unit Repair Manual Inspect Repair or replace as needed Low air pressure warning Half of dual system failed System failed Defective governor Defective compressor Excessive air system leakage Inspect gauges Repair or replace failed components as needed Inspect for leaks Repair or replace failed components as needed Test Adjust or replace as needed Inspect Repair or replace as needed Inspectsystem connections Repair or replace as needed Pressure drops quickly engine stopped brakes applied Treadle valve leak Brake chamber leak Lines or fittings leak Inspect Repair or replace as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Pressure drops engine stopped brakes applied Treadle valve leak Lines or fittings leak Spring chamber leak Inspect Repair or replace as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 76 5 5 Pneumatic
83. cross mem ber at the rear end of the cab to a point under the ramp at the rear ends of the rails The cross member is bolted to triangular braces welded to the forward ends of these plates The triangu lar braces are also welded to the upper flanges of the rails Inverted L shaped reinforcements are welded to the outside of the C channel stretching from the cross member to the rear ax le Other short inverted L shaped pieces are welded to the tops of the flanges near the fifth wheel Short upright L shaped re inforcements support the lower flanges of the rails at strategic points There is one cross member located near the rear of the cab In front the rails are held square by the weldment that anchors the cab pivot pins and in the rear by the weldments that form the ramp A weldment structure extends downward from each rail ahead of the rear axle to provide anchor points for the lower ends of the boom cylinders The front end of the boom rides in pivot points through the rails Additional reinforcements are welded to the rails in locations designed to provide extra support for the frame under high tor sional or shock loads Maintenance manual Ottawa 4x2 6x4 22 3 2 Chassis 3 Description and Operation RUBBER BLOCK SS f OTT0027 ottoozs W Front Spring Anchor and Tow Hook 3 2 2 Powertrain Engines The Ottawa yard tractor is designed to utilize the benefits of a six cylinder diesel engine of the type custo
84. ctrical 5 Diagnostic Procedures Horn Components Horn Horn Button Switch Horn Circuit Breaker 15A Horn Relay Horn Circuit Diagnosis Observation Cause Action Inoperative horn Circuit breaker open Defective wiring Reset Repair short as needed Re place circuit breaker as needed Inspect connections and wires Test circuits Repair or replace as needed Defective horn button switch Replace Defective horn relay Replace Defective horn Replace Diminished sound Defective horn Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 63 Mirrors Heated Motorized Heated and Motorized remotely controlled mirrors are option al equipment Components Mirrors Mirror Heat Switch Motorized Mirror Switch Left Hand Motorized Mirror Switch Right Hand Heated Mirror Circuit Diagnosis Observation Cause Action Inoperative heater Circuit breaker open Defective heater switch Defective mirror Defective wiring Reset Repair short as needed Re place circuit breaker as needed Replace Replace Inspect connections and wires Test circuits Repair or replace as needed Hea ted Motorized Mirror Circuit Diagno s s Observation Cause Action Inoperative heater Cir
85. cuit breaker open Defective heater switch Defective mirror Defective wiring Reset Repair short as needed Re place circuit breaker as needed Replace Replace Inspect connections and wires Test circuits Repair or replace as needed Inoperative motor Circuit breaker open Defective motor Defective wiring Reset Repair short as needed Re place circuit breaker as needed Replace Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 64 5 2 Electrical 5 Diagnostic Procedures Radio Optional Components e Accessory Relay Radio Radio Circuit Breaker 15A Speakers Radio Circuit Diagnosis Observation Cause Action Inoperative radio Circuit breaker open Defective relay Defective speakers Defective radio Defective wiring Reset Repair short as needed Re place circuit breaker as needed Replace Repair or replace Replace Inspect connections and wires Test circuits Repair or replace as needed Poor performance Defective antenna Defective speakers Defective radio Defective wiring Repair or replace Repair or replace Replace Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 65 Windshield Washer The windshield washer is optional equi
86. d Sealants 8 Specifications 8 3 Fluids Lubricants and Sealants Ottawa Series 4x2 and 6x4 Following are the specified fluids lubricants and sealants by component These are to be used in accordance with the rec ommended maintenance schedule Component Sealant or Lubricant Axle rear EP 85 140 Also refer to axle manufacturer s specifications Cab Cab pivot bearings Cab tilt release mechanism Door striker bolts Seat adjuster slides Lubriplate or equivalent semi fluid grease having extreme pressure properties and containing zinc oxide Cab Door hinges Rear door rollers Silicone spray Chassis Boom pivot at frame Brake cam pivots Brake slack adjusters Fifth wheel pivot pins Fifth wheel top plate Fifth wheel jaws Front axle king pins Hydraulic cylinder bearings Otto Ride pivots Propeller shaft splines and universal joints Speedometer adapter Spring shackle pins Lithium Grease 1 Engine Cil Coolant anti freeze SAE 15W 40 50 50 Ethylene Glycol Water Also refer to engine manufacturer s specifications Hydraulic system fluid Dexron III Steering fluid power steering Dexron III from hydraulic system Maintenance manual Ottawa 4x2 6x4 8 3 Fluids Lubricants and Sealants 8 Specifications 117 Component Sealant or Lubricant Steering linkage slip joint knuckles tie rod and drag Lithium grease warm weather link ends NLGI 0
87. d tires Front end misaligned Worn linkages Damaged king pins or tie rods Steering column binding Weak fluid flow rate Review GAWR specifications Reload as needed Inflate correctly Align front end Replace as needed Repair or replace as needed Repair as needed 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 Inconsistent steering pressure Air in system Low fluid level Bleed system Add fluid as needed Maintenance manual Ottawa 4x2 6x4 70 5 4 Mechanical 5 Diagnostic Procedures 5 4 Mechanical Brakes Components Brake Drums Brake Shoes Brakes Mechanical Diagnosis Observation Cause Action Pulls to one side Poor front end alignment Unequal tire pressure or tread Uneven vehicle loading Loose front wheel bearings Inspect and repair as needed Inspect Repair or replace as needed Inspect Redistribute load as needed Inspect Repair or replace as needed Insufficient braking power Low air system pressure Poor adjustment poor lubrication or worn brake linings Defective components e g slack adjusters push rods cams Air line s restricted Inspect for leaks Repair or replace as necessary Inspect Adjust lubricate and repair as needed Inspect Repair or replace a
88. der to the deck 1999 year model and older trucks Remove the cylin der support bolt from the lower end of the cylinder and re move the cylinder from the vehicle 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 Support the cab tilt cylinder in place on the vehicle while in stalling the locknuts and bolts to attach the rear end of the cylinder to the mounting bracket on the frame rail Tighten the locknuts and bolts to 200 ft Ibs Attach the front end of the cylinder to the mounting bracket on the frame as follows 2000 year model and newer trucks Install an adjust able collar around the cylinder and through the mounting bracket and cylinder eye 1999 year model and older trucks Install the bolt and locknut through the bracket and cylinder mounting eye and tighten to 200 ft Ibs Unplug the hydraulic hose end and connect it to the cylin der port Connect the electrical cables to the relay on the bottom of the cylinder Using the cab tilt switch raise the cab and remove the safety bar Again using the cab tilt switch raise and lower the cab to bleed all air from the system the system is self bleeding Check all hoses and fittings for leaks Check the fluid level in the hydraulic tank adjust as necessary Maintenance manual Ottawa 4x2 6x4 7 2 Cab Deck 7 R
89. draulic 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 7 2 7 Cab Pivot Bushing Pivot Bushing Removal A WARNING Make sure all safety devices are in place while the cab is in the raised position Maintenance manual Ottawa 4x2 6x4 7 2 Cab Deck 7 Repair Procedures 109 KMR1002a Raise the cab to the full tilt position and make sure the safe ty arm is in place Remove the SNAPTRACO bolts from the left front corner of the frame cross member and from the bottom of the cab channel Allow the SNAPTRAC to hang loose Remove the p clamp that secures the frame and engine harnesses at the left front corner of the front cross member Remove the heater hose p clamp at the front right top of the frame cross member Remove the spacer bracket 1 at the front left cab pivot pin Remove the cab pivot retainers 2 from the pivot pins at the left and right sides of the cab Remove both front headlight buckets Place 4x4x6 inch blocks on the top of the frame rails to sup port the cab then lower the cab onto the blocks This will help stabilize the cab while removing the cab bushings 4 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
90. duled Maintenance 81 Checkliste ee reet rU EPA HG teile imi Ree 81 etes ea 81 Daily Inspection Checklist trt tete erect En eres 82 Every 250 Hours of Operation n 83 Every 500 Hours of Operation eee 83 Every 1 000 Hours of Operation a 83 Every 2 000 Hours of Operation a 83 Table of Contents Preventive Maintenance 84 Preventive Maintenance Technique enn 86 Interior E deer e tend tete Rena 87 Cab Down Exterior nennen nnns nnne ens 88 Gab Up vientos oen tabe dad d catu ates ads 89 Under Vehicle y eem aiia neu bete ERR sya 91 d 92 TET 93 TeStiDrives aces cet eai ee a a P 94 Repair Procedures 95 GEL ME 95 Frame Damo ga u 95 eei Dea tu RR 95 Making Reinforcement A nnn nennen 95 General Information 2122 tat ete er i e entend 95 Attachment x nere ap tir HDI IUE D QN SRM ix 96 Re
91. e Ottawa Series Right Side 4x2 chassis shown 0006 Fifth Wheel Pivot Boom Lift Cylinder Upper Mount Vertical Muffler and Exhaust Pipe Engine Access Panel Tow Hook Hydraulic System Pump Fuel Tank Boom Lift Cylinder Lower Mount o m gt N Maintenance manual Ottawa 4x2 6x4 38 4 3 Chassis Cab Front Rear 4 Component Location 4 3 Chassis Cab Front Rear Ottawa Series Front Rear 4x2 chassis shown Q Front Panel Removable Rear Door Glad Hands Air Brake Trailer Electrical Connector 7 pin Air Brake Chambers Rear Axle Fifth Wheel Front Leaf Springs N Oar GD D Maintenance manual Ottawa 4x2 6x4 OTT0007 4 4 Ottawa Series Plan View 4x2 chassis shown Chassis Plan View
92. e as needed Maintenance manual Ottawa 4x2 6x4 5 6 Structural 5 Diagnostic Procedures 77 5 6 Structural Chassis Components Frame Fuel Tanks Otto Ride NOTE Frame rails are not serviceable For repair or replacement call Parts and Service Ottawa Truck 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 re stored to service by means of welding call Parts and Service Ottawa Truck 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 A WARNING Do NOT cut the rails or holes in the rails using a weld ing torch Do NOT drill holes in top or bottom rail flanges Failure to he
93. e defective or the intake piping has a leak Dis cover the cause and repair or replace parts as necessary If the initial gauge reading indicates that the filter should be changed do so at this time Change Air Filter The air filter should be changed as necessary If the truck is equipped with a restriction gauge replace the filter when the gauge indicates Change Air Dryer Desiccant If Applicable The des iccant should be changed as necessary Change as soon as water is evident when the system air tanks are drained Exhaust System Visually inspect all of the exhaust sys tem components for leaks and or damage 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 Clean Transmission Breather Confirm that the breath er located on top of the transmission is clean and the pas sage is open Do not spray directly with high pressure or cleaning solvents Tighten Cab to Deck Mounting Bolts Tighten the cab to deck fasteners Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance 91 Under Vehicle Steering Gear Inspect the steering gear for fluid leaks and excessive play Inspect the steering linkage for wear or looseness Brake Linings and Drums Visually check linings and drums for wear and cracks If the lining is 0 25 inch thick or less in any location the sho
94. e horizontally as needed for ventilation Maintenance manual Ottawa 4x2 6x4 14 3 1 Cab Deck 3 Description and Operation Access A two step ladder is attached to the cab deck by the side door In addition three steps made from 10 gauge perfo rated steel are mounted on the battery box for access to the frame decking and the rear door Grab handles designed to ac commodate 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 perforat ed decking extends toward the fifth wheel on top of the boom 3 1 2 Cab Mounting and Suspension 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 sus pension system on one rail at a rear corner The system con sists 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 con trols 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 acab 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 Maintenance manual Ottawa 4x2 6x4
95. e man ual for specifications Change of tire size gear ratio or Calculate pulses per mile kilome pulse source ter Recalibrate speedometer as described in the DATCON manual Defective wiring or sender Inspect connections and wires Test circuits Inspect sender Re pair or replace as needed No reading Circuit breaker open Reset Repair short as needed Re Mislocated wiring Wrong DIP switch settings Defective wiring Pulse generator gears damaged Pulse generator inoperative place circuit breaker as needed Inspect routing Relocate wires or isolate terminals as needed Correct settings Refer to the man ual for specifications Inspect connections and wires Test circuits Repair or replace as needed Replace gears Replace generator Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 49 Tachometer The tachometer is optional equipment Components Alternator Cab Accessory Circuit Breaker Headlight Switch Ignition Switch Panel Dimmer Switch Optional Tachometer Refer to Basic Gauge Diagnostic Procedure page 41 Tachometer Circuit Diagnosis Observation Cause Action Inoperative Circuit breaker open Reset Repair short as needed Re place 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
96. ed this warning may result in se vere property damage Maintenance manual Ottawa 4x2 6x4 78 5 6 Structural 5 Diagnostic Procedures Frame Diagnosis Observation Cause Action while maneuvering a loaded trailer 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 Cracked rails 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 Sagging rails Overloading Straighten reinforce and align the rails or replace the frame as needed Uneven loading Holes in rail flange Too many rail web holes Rail web holes too close together Four or more rail web holes aligned vertically Welds on flange No filler blocks Rail web holes cut with torch Notches anywhere in rails Vehicle fire Vehicle collision Equipment added beyond vehicle capacity Buckled rails Fifth wheel raised to maximum Straighten reinforce and align the rails or replace the frame as needed Maintenance manual Ottawa 4x2 6x4 5 6 Structural 5 Diagnostic Procedures 79 Observation Cause Action Misaligned rails Misaligned axle or weak spring These condit
97. em sender If the gauge does not operate correctly troubleshoot sender circuit as in step 3Bd 5 2 1 Engine Starting and Charging Components Alternator Batteries Ignition Switch Starter Starter Relay Starter Solenoid Starting and Charging Circuit Diagnosis Observation Cause Action Battery charge low discharged Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Defective battery Replace as needed Defective alternator Repair or replace as needed Engine does not crank Battery charge low discharged See above Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Defective relay Replace Defective solenoid Replace Defective starter Replace Maintenance manual Ottawa 4x2 6x4 44 5 2 Electrical 5 Diagnostic Procedures 5 2 2 Cab Instruments Low Air Warning The vehicle will be equipped with one of two air braking sys tems 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 Air Pressure Gauge Headlight Switch Low Air Buzzer Low Air Pressure Switch Indicator Low Air Warning Light Panel Dimmer Switch Optional Refer to Basic Gauge
98. epair Procedures 107 7 2 6 Cab Tilt Pump and Motor 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 hy draulic system The cab tilt pump and motor are located on a bracket below the left main frame rail just rear of the engine with the cab tilt cylinder 1 Disconnect the negative cable from the battery 2 Locate and disconnect the two wires 1 at the solenoid un der the pump motor 3 Locate and disconnect the battery cable 2 at the pump motor 4 Clean the area around the hydraulic hose fittings on the pump with compressed air to reduce the possibility of contamination Position a catch can under the valve to prevent spills Disconnect and cap the two hydraulic lines 3 attached to the pump 7 Remove the two mounting bolts flatwashers and locknuts remove the adjustable collar 4 from around the center of the pump and then remove the pump and motor assembly Pump and Motor Installation 1 Place the cab tilt pump and motor assembly in position on the frame rail mounting bracket Install the two mounting bolts flatwashers and locknuts tighten securely Install the adjustable collar around the center of the pump 2 Uncap the hose ends and connect the two hydraulic lines
99. es should be replaced or relined Leaf Springs Inspect leaf springs for cracking or exces sive deflection Inspect spring pins and shackles for wear Shock Absorbers If Applicable Inspect shock ab Sorbers for leaks Tighten Front Axle Mounting Bolts Tighten front axle mounting bolts Tighten King Pin Draw Key Nuts Tighten steer axle king pin draw key nuts Hydraulic Pump Inspect the hydraulic pump for leaks Starter Mounting and Connections Confirm that start er mounting bolts are tight Inspect electrical connections for good contact at starter terminals Engine and Transmission for Leaks Perform a visual inspection of the engine and transmission looking for fluid leaks visible from below Change Engine Oil and Filter Drain and replace the engine oil Use oil that meets or exceeds the minimum specifications in the engine operator s manual Replace the oil filter Change Transmission Filters Follow transmission manufacturer s procedures NOTE This does NOT include the pan screen The screen should only be replaced during overhaul Change Transmission Fluid Drain and replace the transmission fluid Use fluid that meets or exceeds the min imum specifications provided in the transmission operator s manual Engine and Transmission Mounts Tighten the engine and transmission mounts Inspect isolator material and re place if deteriorated Wheel Seals for Leaks Inspect
100. esistance independent of the installation If it is not within specifications replace the sender If the pointer is within the dial scale endpoints dis connect the sender wire from the sender Keep the sender installed in its proper location Allow the sender wire to hang freely CAUTION The sender lead must be disconnected for this test Failure to heed this caution will result in severe dam age to the sender Momentarily apply power to the gauge The pointer should move off scale to the extreme left Remove power from the gauge Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 43 e 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 Go to step 3A above 4 Ifthe pointer jumps rapidly overshoots or oscillates around the rest position the sender connection contact is intermit tent Trace the sender wiring and verify that the gauge and sender connections are secure If connections are tight and in good condition replace the gauge 5 Ifthe pointer stops hesitates or shows any evidence of sticking replace the gauge If the pointer moves extremely slowly replace the gauge Remove power and attach sender wire to S terminal on back of the gauge Check operation with syst
101. ght Switch Panel Dimmer Switch Optional Maintenance manual Ottawa 4x2 6x4 18 3 1 Cab Deck 3 Description and Operation Indicator Lights Wait to Start Service Soon Check Engine Stop Engine Left Turn Panel 2 displays the following gauges controls and indicator lights Gauges and Controls Hourmeter Voltmeter HVAC Temperature Control HVAC Directional Controls Fan Speed Switch HVAC On Off Switch Optional Instrument Panel 2 Flood Light Switch lgnition Key Switch Windshield Wiper Switch Optional Windshield Washer Switch Optional Indicator Lights High Beam Right Turn Low Brake Air Pressure lit below 70 PSI Panel 3 may be blank but it is available for additional gauges controls and indicators as needed Panels 4 and 5 display the following gauges and controls Air Gauge Second Air Gauge with split air system Tractor Park Control Trailer Air Supply Control Transmission Shifter Fifth Wheel and Boom Control Fifth Wheel Latch Control Instrument Panels 4 and 5 Electroluminescent EL displays for the transmission shifter and the fifth wheel control glow when the ignition switch is in the On position Each of the panels has room to add additional gauges and in dicator lights as needed Maintenance manual Ottawa 4x2 6x4 3 1 Cab Deck 3 Description and Operation 19
102. hort as needed Re place circuit breaker as needed Replace Inspect connections and wires Test circuits Repair or replace as needed Beacon Light This circuit may contain an optional circuit breaker between the accessories relay and the beacon light switch Components Accessory Relay Beacon Light e Beacon Light Switch Ignition Switch Beacon Light Circuit Diagnosis Observation Cause Action Inoperative Defective beacon lamp Defective switch Circuit breaker open Defective wiring Replace Replace Reset Repair short as needed Re place circuit breaker as needed Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 53 Clearance Marker and Tail Lights Clearance and marker lights are standard only on vehicles as sembled 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 Diagnosi
103. ils Maintenance manual Ottawa 4x2 6x4 126 9 1 Air System Circuits 9 Schematics 9 1 4 Fifth Wheel Coupling Air Lines Fifth Wheel Latch 5TH WHEEL r AIR LINES FIFTH DEL WHEEL m 3 8 BK 5TH WHEEL AND BOOM gt e WHEEL q WHEEL L I uNLATCH 22 m TO BRAKE TANK MANIFOLD 8 PORT 3 8 YW TO TRACTOR PARK YELLOW H T gt PLUGS TO TRACTOR PARK P 3 8 YW BRAKE i PLUG TREADLE 3 8 BK TO BRAKE SYSTEM TO SERVICE RESERVOIR OTT0049 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 4x2 6x4 9 2 Hydraulic System Circuits 9 Schematics 127 HYDRAULIC CAB TILT CYLINDER CAB UNLOCK ADAPTOR I 9 2 Hydraulic System Circuits Hydraulic Systems 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 9 2 1 Cab Tilt Hydraulic Lines Cab Tilt CAB TILT HYDRAULIC SYSTEM HYDRAULIC PUMP
104. ime running light Replace module Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 55 Dome Light Components Cab Accessory Circuit Breaker DomeLight Dome Light Circuit Diagnosis Observation Cause Action Inoperative Defective lamp Replace Defective dome light switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Headlights Components Dimmer Switch Headlights Headlight Relay Headlight Switch Headlight Switch Circuit Breaker High Beam Indicator Light Headlight Circuit Diagnosis Observation Cause Action LH or RH headlight inoperative Defective lamp Replace high or low beam Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Both headlights inoperative Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective headlight switch Replace Defective relay Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Inoperative headlight dimmer Defective dimmer switch Replace Defective relay Replace Maintenance manual Ottawa 4x2 6x4 56 5 2 Electrical 5 Diagnostic Procedures Trailer Auxiliary Power Components e Accessory Relay lgni
105. in ders installed between the boom and frame weldments just for ward of the rear axle Power to operate the cylinders is supplied by the hydraulic pump mounted on the transmission OF P Boom Lift Cylinders The standard configuration utilizes two 5 inch diameter lift cylinders with a capacity of 60 000 pounds and a lifting height of 17 inches The cylinders are dou ble 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 Hydraulic Pump On a standard chassis the hydraulic pump is a fixed positive displacement gear type The pump is rated at 10 gallons per minute at high idle approximately 1200 RPM A relief valve in the lift control valve limits operating pressure Control Valve The valve housing is a one piece mono block casting The A and 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 for the 5 inch 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 4x2 6x4 Electric
106. inge for wear and damage Cab Access Steps and Handles Inspect all steps and grab handles for proper mounting and the absence of cracks Heater AC Filter Remove the HVAC filter and vacuum or blow clean with low pressure air Rear Door Roller Slide Adjustment Inspect the roller and slide adjustment for wear and damage Glad Hand Seals and Trailer Air Lines Inspect seals for tears and wear Check air lines for kinks or cracks 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 Headlights Marker Lights Start the engine turn on light switches and confirm lights are burning Turn Signals With the key on activate the turn signal switch and the flasher to confirm that the turn signals are working Strobe Light If Applicable With the key on turn on the strobe light to confirm its operation Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance 89 Spotlights With the key on turn on the spotlight s to confirm its operation Wiper Blades Inspect wiper blades for tears or exces Sive wear Windshield Washer Fluid Level If Applicable Fill the washer bottle as necessary Cab Up Cab Tilt Pump Pull the cab release cable and activate the cab til
107. ions may give the appearance of misaligned rails Vehicle collision Towing load attached to one rail Operating over rough terrain Inspect Repair as needed Straighten reinforce and align the rails or replace the frame as needed Improper tracking Improper front end alignment Misaligned rails Misaligned axle Align the front end Straighten reinforce and align the rails or replace the frame as needed Align the axle Maintenance manual Ottawa 4x2 6x4 80 Notes Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance 81 6 Scheduled Maintenance 6 1 Checklists Lubrication Points Coolant Antifreeze Engine Oil Slack Adjusters Brake Cam Pivot Front Axle King Pins Tie Rod Ends Transmission Fluid Diesel Fuel 9o n oom Universal Joints 9 Rear Axle Differential 10 Driveline Slip Yoke 11 Hydraulic Steering Fluid 12 Cab Suspension Latch 13 Spring Shackle Pins 14 Front Wheel Bearings 15 Drag Link Ends 16 Steering Slip Joint BOTH SIDES BOTH SIDES FRONT AND REAR Chassis Lubrication Diagram Left Hand Drive OTT0001 17 Boom Pivot 18 Boom Oylinder Bearings 19 Fifth Wheel Pivot 20 Fifth Wheel Top Plate 21 Fifth Wheel Jaws Side Door Hinge not shown Rear Door Upper Rollers not shown
108. k 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 Reservoirs DOT EPA primary front and rear Off High way supply and service Stoplight Switch Tractor Protection Valve Brakes Air System Diagnosis Observation Cause Action Frequent air dryer purging cycling Excessive system leakage Defective internal check valve Defective governor Purge valve leaks Compressor unloader leaks Inspectsystem connections Repair or replace as needed Test Replace as needed Test Adjust or replace as needed Test Replace as needed Slight leakage permitted Uncover inlet cavity and inspect piston Repair or replace unloader as needed Maintenance manual Ottawa 4x2 6x4 74 5 5 Pneumatic 5 Diagnostic Procedures Observation Cause Action Water in reservoirs Desiccant saturated External charge air did not pass through air dryer Air dryer not purging Purge time too short Replace desiccant cartridge Refer to Medium Duty Truck Unit Repair Manual Ensure charge air enters filter valve at compressor Inspect purge valve Refer to Medium Duty Truck Unit Repair Manual Refer to Frequent Purging Cycling above Dryer safety valve discharging
109. lace Defective dimmer switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring or inverter Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 58 5 2 Electrical 5 Diagnostic Procedures Turn Signal Brake Lights and Emergency Flasher Components Brake Light Switch Flasher Circuit Breaker 30A Stop Tilt Circuit Breaker 20A Trailer Circuit Breakers 15A Turn Signal Switch Turn Signal Flasher Turn Stop Light Lamps Turn Signal Brake Lights and Emergency Flasher Circuit Diagnosis Observation Cause Action Inoperative light Defective lamp Defective turn signal switch Circuit breaker open Defective wiring Replace Replace Reset Repair short as needed Re place circuit breaker as needed Inspect connections and wires Test circuits Repair or replace as needed Inoperative turn signal Defective turn signal flasher Defective turn signal switch Circuit breaker open Defective wiring Replace Replace Reset Repair short as needed Re place circuit breaker as needed Inspect connections and wires Test circuits Repair or replace as needed Inoperative brake lights Defective lamp Defective brake light switch Circuit breaker open Defective wiring Replace Replace Reset Repair short as needed Re place circ
110. les do NOT touch Ensure that the jumper cable insulation is NOT missing or loose 2 Shiftthe 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 ter minal on one battery and the other end to the positive ter minal on the other battery NEVER connect positive to negative 5 Clamp one end ofthe second cable to the negative terminal ofthe charged battery and the other end to the negative ter minal of the dead battery 6 Start and run the engine of the vehicle with the charged bat tery at moderate speed for several minutes then start the engine in the vehicle that has the discharged battery Maintenance manual Ottawa 4x2 6x4 1 4 Emergency Starting 1 Introduction 7 Remove the jumper cables by reversing the above installa tion sequence exactly While removing each clamp be sure that it does not touch any other metal while connected to the other battery A 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 ba
111. lves Air Reservoirs Air Storage Air Dryer Optional Tractor Protection Valves e Proportioning Bobtail Valve Optional Quick Release Valves Double Two Way Check Valves Brake Chambers and Parking Brakes Slack Adjusters Foundation Wheel Brakes Trailer Brake Air Lines Stop Light Switch Within the system are two separate air distribution circuits These operate the rear primary and front secondary founda tion brakes Air flow within the two circuits is controlled through a series of valves which supply or release air to the chambers in response to the driver s command The parking brakes are spring actuated but compressed air is required to release them A buzzer and an indicator light warn of low pressure in the sys tem when pressure falls below 70 PSI The air pressure gauge reflects the actual system pressure Maintenance manual Ottawa 4x2 6x4 3 2 Chassis 3 Description and Operation 25 Air Compressor Governor Instrument Panel 4 Trailer Air Supply and Tractor Parking Control Knobs Air Compressor and Governor 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 ai
112. marily found in fire engines dump trucks and refuse haulers Engine options are provided for OFF HIGHWAY and DOT EPA certi fied applications with a choice of power ratings available from several engine manufacturers Transmission The standard transmission is an automatic Allison RDS series Axles An Ottawa 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 Service and Maintenance Information 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 3 2 3 Vehicle Suspension Including Otto Ride The front suspension consists of shackled leaf springs There are 10 steel leaves on the driver s side and nine on the other side Rubber blocks mounted on each axle reduce the shock of bottoming out The front spring anchors and tow hooks are parts of special components welded to the front ends of the rails Another weld ment provides attachment for the rear spring hanger on each side Maintenance manual Ottawa 4x2 6x4 Rear Spring Hanger Rear Axle Attachment 3 2 Chassis 3 Description and Operation 23 OTT0029 Eyes at the rear of the front springs connect to the rear spring anchor via shackles and pin
113. matic 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 tractors are engineered for longevity and easy operation Maintenance manual Ottawa 4x2 6x4 1 2 Safety Summary 1 Introduction 1 2 Safety Summary Hazardous Conditions The following signs accompanied by an explanation are used to advise the reader of the degree of hazard associated with the procedure being described A DANGER A situation that may result in serious personal injury possibly death if the instruction is not followed A 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 Do s and Don ts A 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 Maintenance manual Ottawa 4x2 6x4 1 2 Safety Summary 1 Introduction 5 Douse care when removing the radiator filler
114. ment 2001 and Newer Trucks 108 Gab Pivot BUSRING idee t eh Det da ce edi nee e 108 Pivot Bushing Removal 108 Pivot Bushing Installation 110 Roar DOOL LET 111 es rte netiis 111 Specifications 113 Standard Vehicle Data rette thi eer e e E a aat aeaa aaa 113 Ottawa Series Terminal Tractor 113 Hydraulic SVSterri doeet ret re ete teer UR RT Pide 115 Ottawa Series 4x2 and 6X4 a 115 Fluids Lubricants And Sealants uuu nini eet eet xti rada avr ge ra ea TRA 116 Ottawa Series 4x2 and 6X4 enne 116 Fastener Torque Values rug e ede ettet eg rede Dee t 118 Ottawa Series 4x2 and 6X4 nennen 118 Schematics 119 Table of Contents Air System Circuits e pde e eh Pete EO PR de P Cui ete bens 119 Al Brakes 119 COMPOMENMIS i usata edet bn eee eed ede neas 119 Air Brake System with ABS 1 na 120 Air Brake System without ABS 122 Seating apayan ce n De ea mt Ete 124 Air Lines Driver s SO al eit eet pte ene edant a 124 Cab SusperisiOD oii edere akha AR E ox assia 125 Air Lines Cab Suspension esses 125 Fifth Wheel Coupling
115. n filter and hy draulic 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 hydrau lic oil flows continuously through the center of the control valve even while the steering wheel is not moving Power steering and the boom systems use the same hydraulic pump The pump is equipped with a priority valve that directs the first four gallons per minute of flow to the steering circuit Reservoir Fluid and Filter The standard hydraulic reser voir has a 16 gallon capacity It is fitted with a level sight gauge and a breather The return filter is located near the tank in the boom circuit return line where it is continuously filtering fluid that is used in all three subsystems boom cab tilt and power steering Maintenance manual Ottawa 4x2 6x4 30 3 2 Chassis 3 Description and Operation OTT0002a BOTH SIDES Elevated Boom with Fifth Wheel Boom Components Boom Pivot Boom Boom Lift Cylinder Pivots Fifth Wheel Pivot Fifth Wheel Plate The standard hydraulically operated boom is the basis for the fifth wheel lifting system The forward end of the boom assem bly 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 cyl
116. n the cab interior J Clean the windows J Clean and adjust the mirrors Every 250 Hours of Operation Perform the inspections listed in column A of the chart Refer to the Preventive Maintenance Forms page 84 These service procedures must be performed after every 250 hours of operation or every month whichever occurs first Every 500 Hours of Operation Perform the inspections listed in column B of the chart Refer to the Preventive Maintenance Forms page 84 These service procedures must be performed after every 500 hours of operation or every three months whichever occurs first Every 1 000 Hours of Operation Perform the inspections listed in column C of the chart Refer to the Preventive Maintenance Forms page 84 These service procedures must be performed after every 1 000 hours of operation Every 2 000 Hours of Operation Perform the inspections listed in column D of the chart Refer to the Preventive Maintenance Forms page 84 These service procedures must be performed after every 2 000 hours of operation Maintenance manual Ottawa 4x2 6x4 84 6 1 Checklists 6 Scheduled Maintenance Preventive Maintenance Forms KALMAR TERMINAL TRACTOR PREVENTATIVE MAINTENANCE FORM 2007 OR NEWER ENGINES NON SYNTHETIC TES 295 LUBE USED IN THE TRANSMISSION EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION Y SATISFACTORY 0 ADJUSTMENT NE
117. ng 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 steer ing 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 re sponse 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 movementis 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 direct ed 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 Maintenance manual Ottawa 4x2 6x4 3 2 Chassis 3 Description and Operation 33 3 2 6 Fuel System Fuel Tank Brackets bolted to the rail hold the 24 inch diam eter 50 gallon fuel tank Two inch wide straps secure the tank to the two mounting brackets Rubber strap liners protect against chafing between the straps and the tank The manufac turer
118. ngine running verify that all gaug es are functional 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 Windshield Wiper Operation Turn on the windshield wiper and confirm full and smooth travel of the wiper arm Listen for noises that might indicate a worn wiper motor Windshield Washer Operation If Applicable De press the washer button and confirm the flow and pattern of the washer fluid Throttle Operation Depress and release the foot throt tle and check for binding and ease of operation Horn s Operation Sound electric and air horns if ap plicable to confirm proper operation Air System Start the engine and run at fast idle Maxi mum system pressure should be between 120 PSI and 130 PSI Air System Leak Down Disconnect the glad hands from the trailer Run the engine at fast idle and allow air pressure to stabilize at 120 PSI for at least one minute Shut off the engine and observe the dash gauge s for two minutes The drop in pressure should not exceed 2 PSI over the two minute period Backup Alarm With the engine running move the gear selector to reverse and listen for the backup alarm HVAC System Blower Motor Operation With the key on ensure that the blower motor oper ates at each position of the blower speed switch Temperature Control Confirm p
119. 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 3 Replace the valve if the valve is damaged or the filter is clogged Maintenance manual Ottawa 4x2 6x4 7 2 Cab Deck 7 Repair Procedures 103 7 2 3 Shock Absorbers Shock Removal Replacement of the shock absorber is necessary if the cab ride becomes too bouncy under normal operating conditions 1 2 Raise the cab and lock it in the full tilt position Remove the nuts 1 from the 7 16 inch mounting bolts se curing the shock absorber in the top and bottom mounting brackets at one side of the suspension assembly Remove the bolts and remove the shock absorber from the assembly Repeat the procedure to remove the second shock absorb er at the opposite side of the assembly Shock Installation 1 Place the shock absorber in position between the mounting brackets at the side of the suspension assembly Install the 7 16 inch bolts and nuts to secure the shock ab sorber in the top and bottom mounting brackets Tighten the bolts and nuts to specification Repeat the procedure to install the second shock absorber at the opposite side of the assembly Unlock the cab tilt cylinder and lower the cab Maintenance manual Ottawa 4x2 6x4 104 7 2 Cab Deck 7 Repair Procedures 7 2 4 Cab Latch Bar Plate Latch Bar Plate Adjustmen
120. of grease or oil Repair as needed Clean drums and replace shoes Inspect Repair or replace as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Uneven braking Poor adjustment or poor lubrication Grease or oil on linings Broken diaphragm or return spring Drum out of round Brake chamber diaphragm leaking Inspect Adjust or lubricate as needed Determine source of grease or oil Repair as needed Clean drums and replace shoes Inspect Repair or replace as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 72 5 4 Mechanical 5 Diagnostic Procedures Observation Cause Action No pressure buildup 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 Refer to Brake Air System Diagnosis table Maintenance manual Ottawa 4x2 6x4 5 5 Pneumatic 5 Diagnostic Procedures 5 5 73 Pneumatic Brakes Air System A DOT EPA system includes three reservoirs primary front and rear Off highway vehicles have only two reservoirs supply and service Components Air Compressor Air Control Valve Air Dryer Optional Antilock Modulator Valve Optional Automatic Slac
121. operation fasteners for tightness r Ride Level Adjustment Park the vehicle on firm level ground Maintenance manual Ottawa 4x2 6x4 102 7 2 Cab Deck 7 Repair Procedures 2 Startandrunthe engine until the air system has a minimum of 100 psi of air pressure 3 Shutthe engine down Turn on open the air supply to the cab suspension by turn ing the valve on the bottom of the deck counter clockwise 5 Remove the plastic clip 2 in the center of the plastic linkage rod connected to the control arm on the suspension assembly 6 Use tape to mark the linkage rod s current position 3 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 To raise ride level Decrease the rod 4 length by plac ing the rod deeper into the upper sleeve 1 To lower ride level ncrease the rod length by reducing the insertion of the rod in the sleeve NOTE One inch 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 7 2 2 Leveling Valve 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
122. pairing Cracks in Steel Rails or Cross Members 97 Types ot Cracks rok tuer oretenus eds eter ce 97 Front Springs and Pilis t eet beet i t bec ibo Pe i 98 Springs and Pins Removal U 98 Springs and Pins Installation sese 99 Gab D6ck tL CC De 100 Air Ride Suspension 100 Cab Suspension Assembly Removal 100 Cab Suspension Assembly Installation 101 Air Ride Level Adjustment 101 Leveling eet Evo ete De ete de eb atahay ean 102 Valve Operation Check I 102 Shock Absorbers tes nerd teint beet d dies 103 Shock Removal aa Yawa ia ayu enne nnns 103 Shock InstallatiOn uuu rtp e rre erect tne hit ptus 103 Bar Plate ro eer T CER E AER te a api 104 Latch Bar Plate Adjustment 2 104 Gab Tilt Cylinder S opener 105 Cylinder Removal erdt hero tait ibas 105 Cylinder Installation ra 106 Gab Tilt Pump andiMotot sss ss cere at Eee dan ok aia odd 107 Pump and Motor Removal essen 107 Pump and Motor Installation 2 107 Relief Pressure Adjust
123. panel to warn when the system malfunctions This system can also check the trailer for a proper operating system A malfunction in the trailer sys tem 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 diagnos tic connection behind the grille opening in the front bumper The connection can be used by a laptop with appropriate soft ware or a handheld Bendix RDU diagnostic tool Maintenance manual Ottawa 4x2 6x4 3 2 Chassis 3 Description and Operation 29 Automatic Traction Control Optional 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 operates only at speeds less than 25 30 miles per hour At higher speeds vehicle reaction to a sudden application of the brakes on one side may cause loss of driver control 3 2 5 Hydraulic System System Overview 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 retur
124. pment Components e Accessory Relay Ignition Switch Windshield Washer Motor Windshield Washer Switch Windshield Washer Circuit Diagnosis Observation Cause Action Inoperative No fluid Add fluid as needed Hose or nozzle plugged Clean as needed Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective relay Replace Defective motor Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 66 5 2 Electrical 5 Diagnostic Procedures Windshield Wipers Windshield wipers are optional equipment Components Circuit Breaker 8A Ignition Switch Wiper Motor Wiper Relay Wiper Switch Windshield Wipers Circuit Diagnosis Observation Cause Action Inoperative Linkage binding Repair or replace as needed Defective switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective relay Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Operate slowly Linkage binding Repair or 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 Operate at one speed Defective switch Replace Defective motor Replace Do not park Linkage binding
125. r into the reservoirs or out the exhaust port Foot Pedal Treadle Valve This foot actuated valve is ac tually two valves that operate in quick sequence Itis 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 Air Control Valves 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 Air Reservoirs The air reservoirs maintain a sufficient quan tity of air under pressure to sustain several applications of the brakes On vehicles equipped with the anti lock brake system there are three reservoirs Other vehicles have only two In the three reservoir system one serves as the primary some times called the wet tank It supplies air to the other two reser voirs independently A pressure relief valve in the primary tank protects the system from excessive p
126. raordinary internal leakage Extraordinary pump wear Add fluid as needed Adjust or replace Test circuits to isolate point of leakage Replace Inoperative Seized or damaged lever or control cable Extreme internal leakage Repair as needed Test circuits to isolate point of leakage Jerky erratic movement Air in system Inspect fittings and seals Replace as needed Cab Tilt Components Stop Tilt Circuit Breaker 20A Tilt Pump Control Switch Tilt Pump Motor Tilt Solenoid DANGER jury or death 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 in 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 4x2 6x4 5 3 Hydraulic 5 Diagnostic Procedures 69 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 Cause Action Hard steering Overloaded axle Underinflate
127. re lease 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 Maintenance manual Ottawa 4x2 6x4 3 2 Chassis 3 Description and Operation 27 BRAKE CHAMBER PUSH ROD SLACK ADJUSTER Slack Adjuster Diagram 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 re lease valve combines the two functions in a single housing 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 the brake chambers provide 2 25 2 50 inch range of stroke length The second chamber in the dual chamber unit uses the air pre
128. re and rim sizes and tire air pressure GAWR RIMS FRONT AT _ PSI COLD DUAL n ZZZ Z LLZ LLII TIRES V GAWR S REAR AT PSI COLD DUAL z 2 on THIS VEHICLE CONFORMS TO ALL APPLICABLE H FEDERAL MOTOR VEHICLE SAFETY STANDARDS EFFECT ON THE DATE OF MANUFACTURE SHOWN Kalmar g 222 EAST DUNDEE STREET OTTAWA KANSAS USA OTT0009 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 above Always refer to this number when ordering parts or requesting field service assistance OTTO0011 Engine Serial Number Cummins serial numbers are located on the left hand side tim ing gear cover Caterpillar serial numbers are located on the rear of the engine on the left hand side Maintenance manual Ottawa 4x2 6x4 12 Notes Maintenance manual Ottawa 4x2 6x4 3 1 Cab Deck 3 Description and Operation 13 Ottawa 4x2 Rear View with Tilted Cab OTT0014 3 Description and Operation The Ottawa 4x2 and 6x4 models are utilitarian vehicles with features designed specifically for application as yard tractors Information describing the major components and systems of these vehicles is presented in this section under the headings of Cab Deck and Chassis When appropriate the function and operation of the parts and systems is included 3 1 Cab Deck
129. ressure 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 Maintenance manual Ottawa 4x2 6x4 26 3 2 Chassis 3 Description and Operation SUPPLY TANK T FRONT _ SERVICE TANK LJ OTT0013 Air Storage Tanks Two Reservoir System In the two reservoir system compressed air goes to the supply tank where it passes through to the service tank and from there to the rest of the system A pressure relief valve in the supply tank protects the system from excessive pressure 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 Air Dryer 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 re moves any oil vapor that may blow by the compressor Tractor Protection Valves Located in
130. rol and Panel Lighting TRANSMISSION SHIFTER 5TH WHEEL CONTROL amp PANEL LIGHTING MD TRANS Lf BULKHEAD CONNECTOR PL2002 BE RD DIMMER INPUT PL2002 BE RD DIMMER INPUT GEN 4 3000 SHIFTER lt lt lt 116 lt lt lt lt lt lt lt MD TRANS 25 SHIFTER CONNECTOR PEP LIGHT BAR LIGHT BAR LIGHT BAR YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY YYYYYY LIGHT BAR LIGHT BAR LIGHT BAR 16 CONNECTOR CONNECTOR CONNECTOR FOR HEATER Y HEATER Y FOR FAN 2 CONTROL MD TRANS V HARNESS 20 CONTROLLHS CONTROL RHS 23 3 2000 1 IN CAB AT PILLAR 3 2 4 602000 WE 177700 39 PL2002 BE RD l GD2000 WE p 7 KL LIGHT BAR 29 PL2002 BERD 6 LIGHT BAR CONNECTOR 9 FOR OPTION SWITCHES Re Z Z ZZ Y Y v lada CAB CONTROL of lu PANEL CONNECTOR ul m al 8 8 E como we of SEGA STUD CAB BULKHEAD CONNECTOR 5TH WHEEL cK CONTROL CONNECTOR PL2002 BE RD PL2002 BE RD y PL2002 BE RD__s PL2002 BE RD Niel AS L lt 602002 WE lt R 5TH WHEEL NEGATIVE B PASS THRU CONTROL STUD HX L ni lt D lt lt dE gt ele 8 s lt Le Transmission Shifter Fifth Wheel Control and Panel Lighting Circuit Components Headlight Switch Lamps 2 Fifth Wheel Control Light Bar Heater Control
131. roper operation of the temperature con trol switch 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 con trol turned on confirm cooled air flow from the vents Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance Auxiliary Fan s If Applicable With the key on turn on the auxiliary fans and con firm operation Fifth Wheel Unlatch Control With system air pressure above 100 PSI confirm that the fifth wheel jaws unlatch when the dash control is activated Boom With the engine running at fast idle activate the boom control and verify full extension and retraction Windows Confirm that all regulated and sliding windows open and close fully Seat Belt Operation Verify that the seat belt latch fas tens and unfastens properly Rear and Side Door Latch Operation Operate the side door latch from inside and outside the cab to ensure proper operation Dome Light Operation With the key on turn on the cab dome light and confirm operation All Glass and Mirrors Inspect all glass and mirrors for cracks and breaks Fire Extinguisher Charge If Applicable If the vehicle is equipped with a fire extinguisher confirm that it is prop erly charged Cab Down Exterior Side Door Hinges Inspect the door h
132. rt eire Paste ret 161 Trailer Auxiliary Power 162 Transmission Shifter Fifth Wheel Control and Panel Lighting 163 Turn Signal Tail Brake Lights and Emergency Flasher 164 vi Notes Maintenance manual Ottawa 4x2 6x4 Foreword 1 Foreword This service manual covers the Ottawa 4x2 and 6x4 terminal yard tractors produced by Kalmar Industries Corporation You will find here descriptions of the features location and opera tion of the components Diagnostic and repair procedures are included along with schematic diagrams of the electric pneu matic and hydraulic circuits There is a table of specifications and a schedule for preventive maintenance Basic information diagnostic and repair procedures are provid edfor the uniquely Ottawa features and components Designed to provide the owners and operators of Ottawa 4x2 and 6x4 ter minal tractors with the information necessary to service and maintain their vehicles properly this manual presents the infor mation in eight 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 com ponents such as the steering gear ABS controllers and other system components that are produced by quality manufactur ers and supplied to Kalmar for production of Ottawa vehicles It is
133. s Observation Cause Action Individual light inoperative Defective lamp Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed All lights inoperative Defective light switch Replace Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 54 5 2 Electrical 5 Diagnostic Procedures Trailer Clearance Marker and Tail Light Circuit Diagnosis Observation Cause Action Individual light inoperative Defective lamp Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed All lights inoperative Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective headlight switch Replace Defective relay Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Daytime Running Lights Daytime running lights are optional equipment Components Daytime Running Light Module Headlights Ignition Switch Module Fuse 10A Daytime Running Lights Circuit Diagnosis Observation Cause Action Inoperative Defective lamp Replace Defective fuse Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Defective dayt
134. s Bushings on each pin help to re duce friction The standard vehicle is equipped with a rear axle or axles at tached directly to the frame rails without any suspension sys tem Axle housings are rigidly attached to the frame captured by means of weldments mounted inside and outside of each rail Otto Ride Optionally a system can be installed to soften the ride at the rear axle This suspension frees the axle housing from rigid attachment to the frame rails The boom lift cylinders are attached to the forward side of the axle housing instead of the rails To resist axle housing rollover and limit misalignment a special frame is attached between the rails above and behind the axle housing A hollow cylindrical rubber cushion mounted on this special frame limits the axle housing rollover Sideways motion is limit ed by a torque rod attached to the special frame and the right side rail Maintenance manual Ottawa 4x2 6x4 3 2 Chassis 3 Description and Operation 3 2 4 Air System and Brakes The main function of the vehicle air system is to provide com pressed air to operate the brakes Compressed air also oper ates the cab suspension driver s seat suspension and posture features fifth wheel unlatching trailer brakes and optional in teraxle lockout Brake System Major components of the air brake system include the following items Air Compressor and Governor Foot Pedal Treadle Valve Air Control Va
135. s needed Inspect Repair or replace as needed Slow application Poor adjustment or poor lubrication Air line s restricted Treadle valve leaking Brake chamber leaking Spring brake chamber leaking Inspect Adjust or lubricate as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 5 4 Mechanical 5 Diagnostic Procedures 71 Observation Cause Action Slow release Treadle valve return slowed by dirt and grime Poor adjustment or poor lubrication Air line s restricted Valve exhaust ports 0 treadle quick release relay plugged Clean and lubricate as needed Inspect Adjust or lubricate as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Service brakes do not release Broken or weak shoe or chamber spring Treadle valve return slowed by dirt and grime Air line s restricted Valve exhaust ports e g treadle quick release relay plugged Inspect Repair or replace as needed Clean and lubricate as needed Inspect Repair or replace as needed Inspect Repair or replace as needed Brakes grab Grease or oil on linings Drum out of round Defective valves Actuating linkages e g slack ad justers push rods bind Determine source
136. specified by the engine manufacturer Improp er fuel can result in corrosion damaging deposits and prema ture wear CAUTION Do NOT add anything but diesel fuel to the fuel tank Drain the entire fuel system and fill with the correct fu el Failure to heed this caution may result in serious property damage 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 Maintenance manual Ottawa 4x2 6x4 1 4 Emergency Starting 1 Introduction 7 14 Emergency Starting 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 ser vice batteries match the polarity and voltage rating of your Ottawa tractor before attempting to jump start a vehicle Due to the higher torque requirements for starting diesel en gines Ottawa tractors use multiple batteries At low tempera tures it may not be possible to start the engine in an Ottawa tractor using only one battery A 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 com fortably but the vehic
137. ssis configurations Optional equipment items are available including ABS braking systems and GCW ratings up to 125 000 pounds depending on the engine transmission and axle combinations Chassis Model and Configuration Ottawa 4x2 Ottawa 4x2 Ottawa 6x4 Application certification Off Highway DOT EPA DOT EPA Certified Certified Engine standard Cummins QSB6 7 Cummins ISB07 Cummins ISBO7 Peak power HP 9 rpm 160 at 2200 200 at 2300 200 at 2300 Torque ft los rpm 540 at 1500 520 at 1600 520 at 1600 Transmission standard Allison 3000RDS Allison 3000RDS Allison 3000RDS Gearing 3 Forward 1 4 Forward 1 4 Forward 1 Reverse Reverse Reverse Propeller shaft Spicer 1710 Spicer 1710 Spicer 1710 Axle front Meritor FF961 Meritor FF961 Meritor FF961 Axle s rear Meritor Meritor Meritor RS 23 186 RS 24 160 RT 40 145 Brake system Wheel ends type size ins Air Air with ABS Air with ABS Front type size ins S cam 16 5x5 S cam 16 5x5 S cam 16 5x5 Rear type size ins S cam 16 5x7 S cam 16 5x7 S cam 16 5x7 Slack adjusters Manual Automatic Automatic Air compressor Air reservoirs cu ins Wabco 15 2 cfm 3 582 2 tanks Wabco 15 2 cfm 5 688 3 tanks Wabco 15 2 cfm 5 688 3 tanks Tires 11 22 5 14PR 11R 22 5 14PR 11R 22 5 14PR GAWR Ibs Front 12 000 12 000 12 000 Rear 23 000 24 000 40 000 GCWR lbs 96 000 80 000 80 000 Wheelbase ins 11
138. ssure 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 acti vate the push rods and apply the foundation brakes When sys tem air pressure rises above the set point it overcomes the spring pressure and releases the brakes For service the springs can be released manually if the engine cannot be started or if air pressure cannot be restored to the system Slack Adjusters Slack adjusters change the distance the brake shoes have to travel to contact the drum During each ap plication 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 Manual adjusters include a worm gear and an adjusting screw that provide the means to reset the clearance between the shoe and the drum Manual adjustments have to be made when the vehicle is stationary and the adjusting screws are ac cessible Foundation Wheel Brakes The foundation brakes consist of brake drums on the wheels and shoes lined with friction ma terial 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 Maintenance manual Ottawa 4x2 6x4
139. st 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 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 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 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 Grindthe 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 4x2 6x4 98 7 1 Chassis 7 Repair Procedures 7 1 4 Front Springs and Pins Springs and Pins Removal
140. t The position of the cab latch bar plate is important When prop erly positioned it relieves stress on the cab deck assembly To properly position the cab latch bar plate use this procedure 1 Raise the cab and loosen all four nuts 1 2 securing the cab latch bar plate to the bottom of the cab deck 2 With the plate loosened lower the cab slowly ensuring the latch bar properly seats in the hold down latch 3 atthe top of the suspension assembly 3 Make adjustments side to side fore and aft to center the bar in the latch 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 6 Lower the cab and recheck the position of the bar in the latch Readjust if necessary Maintenance manual Ottawa 4x2 6x4 7 2 Cab Deck 7 Repair Procedures 105 7 2 5 Cab Tilt Cylinder Cylinder Removal A 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 Usea safety strut to hold the cab in the raised position when the cylinder is removed 1 Raise the cab using the cab tilt system NOTE If unable to raise the cab using the cab tilt system
141. t switch The cab should rise Cab Safety Prop Inspect the cab safety prop that en closes the cab lift cylinder It should drop freely into place to support the cab when it is in the raised position The low er cab cylinder pin and bracket should be inspected for signs of fatigue Cab Suspension and Latch Inspect the linkages of the suspension system for excessive wear and proper align ment Inspect the air bag for leaks or signs of abrasion In spect the lock jaw for excessive wear and proper operation 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 Radiator for Leaks Inspect the radiator core and tanks for signs of coolant leaks Radiator Mounts Inspect the radiator mounts for wear or excessive looseness Coolant Level and Concentration Check the cooling system level Coolant should be visible in the 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 lev el of concentration as outlined in the appropriate engine op erator s manual Coolant Additive If Applicable Using the appropriate test method for the diesel coolant additive DCA or supple mental coolant additive SCA being used e g Nalcool maintain the recommended level of concentration as out lined in the applicable engine operator
142. tary 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 Windshield Washer A windshield washer system is also an available option Maintenance manual Ottawa 4x2 6x4 20 3 2 Chassis 3 Description and Operation 3 2 3 2 1 Chassis Frame Frame Construction 0770070 O Q Main Rail 2 Inverted L Channel Rail Reinforcement 2 Triangular Brace 2 Inverted L Channel Welded Riser 2 Inverted L Channel Welded Support 2 Inverted L Channel Median Cross Member Fifth Wheel Boom Pivot Bushing 2 L Channel Support 2 9 L Channel Support 2 10 Inverted L Channel Welded Reinforcement 2 11 Rail Reinforcing Plate 2 12 13 14 15 16 17 18 19 20 21 Weldment Cross Member and Ramps Axle Mounting Bracket 4 Boom Lift Cylinder Mounting Weldment 2 Boom Lift Cylinder Pivot Bushing Front Spring Rear Mounting Bracket 2 Rear Motor Mount 2 Front Motor Mount 2 Front Spring Front Mounting Bracket with Tow Hook 2 Front Cross Member Cab Pivot Pin Bushing 2 Maintenance manual Ottawa 4x2 6x4 3 2 Chassis 3 Description and Operation 21 The frame rails are reinforced C channels Flat plates are weld ed to the upper and lower flanges of each rail near the outer edges forming boxes These plates reach from the
143. tawa 4x2 6x4 140 9 3 Electrical System Circuits 9 Schematics 9 3 3 Cab Instrumentation Air Pressure Gauge Lighting p tem 4 Components WITH OPTIONAL DIMMER SWITCH STANDARD AIR GAUGE Gauge E pier LIGHTING CIRCUIT E NI Gauge Second Service Tank 3 4 Gauge Lamp EMI LEE Gauge Lamp Second Service Tank Headlight Switch Panel Dimmer Switch Optional Vehicles equipped with ABS have two service tanks and a 1 4 lig AR Pressure gauge for each one 23 2 eed 2 EK i 2002 2224 ges B lt PANEL CONNECTOR METER STUD fene if CONNECTOR Dig 45 el l 8 BULKHEAD S lt CONNECTOR El D E e e t em rap e t 9 Air Pressure Gauge Lighting Circuit Maintenance manual Ottawa 4x2 6x4 9 3 Electrical System Circuits 9 Schematics 141 Ammeter Optional WITH OPTIONAL SWITCH STANDARD AMMETER CIRCUIT s l PANEL LTS DIMMER 1 1 HEADLAMP HEADLAMP SWITCH SWITCH ale OPTIONS BULKHEAD
144. the engine and check the fluid level on the tank gauge Fill as necessary Change Hydraulic Fluid Drain the hydraulic tank and refill with the specified hydraulic fluid Hydraulic Tank Vent Remove dirt collecting around the vent and ensure that the vent is clear Cab Hinge Pins and Bushings Inspect pins and bush ings for wear or damage Lubrication Rear Door Rollers Inspect upper rollers Replace if binding or damaged Lubricate Hood Hinge Inspect the hood hinge for wear and dam age Lubricate Steering Slip Joint Inspect the slip joint for wear or damage Lubricate Steering U Joints Inspect the u joints for wear or dam age Lubricate Steering Lube Points Inspect king pins tie rod ends and drag link ends for wear or damage Lubricate Slack Adjusters Inspect the brake slack adjusters for wear or damage Measure the brake actuator stroke If this measurement exceeds the component manufacturer s specification check the brake lining and adjuster to determine the cause of the excessive stroke and repair as necessary Leaf Spring Pins and Bushings Inspect spring pins hangers and pin bushings for wear or damage Lubricate Driveline U Joints Inspect driveline and u joints for wear or damage Lubricate Fifth Wheel Jaws Remove dirt and excessive grease from the fifth wheel jaws Using a fifth wheel jaw gauge measure the free play If free play exceeds 1 8 inch deter
145. 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 Proportioning Relay Bobtail Valve Optional Available as an option this valve is designed to detect if a trailer is con nected 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 en ters 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 as sume 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 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 Quick Release Valves Each brake chamber connects to its own quick release valve nearby This valve responds to the
146. the front and rear hubs for signs of oil leaks Replace if leaking Rear Axle Breather Ensure that the rear axle vent turns freely Differential Inspect the rear axle housing for signs of leaks Repair as necessary Maintenance manual Ottawa 4x2 6x4 6 1 Checklists 6 Scheduled Maintenance Differential Oil Level Check the differential oil level per the component manufacturer s instructions Change Differential Oil Drain and replace differential oil Use oil that meets or exceeds the minimum specifications of the component manufacturer Lift Cylinders Inspect cylinders for leaks Repair as necessary Otto Ride Rubber Isolator If Applicable Inspect the isolator for signs of cracking or loss of elasticity Replace as necessary Rear Axle Mounting Bolts Tighten rear axle mounting bolts Chassis Front Wheel Bearings Raise and support the front axle Check for excessive play in wheel bearing Front Axle Oil Level If Applicable Check the oil level in the front axle hubcaps Fill to proper level as necessary Front Wheel Bearings If Applicable Remove front hubs and repack the bearings using grease that meets or exceeds the minimum specifications of the component manufacturer Battery Cables and Holddowns Inspect the battery for signs of abrasion or breaking Repair and reroute as necessary Ensure that the batteries are properly secured Batteries Inspect the batteries
147. tion Start and drive the vehicle Test the operation of all systems and components Maintenance manual Ottawa 4x2 6x4 7 1 Chassis 7 Repair Procedures 95 7 Repair Procedures 7 1 Chassis 7 1 1 Frame Damage 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 in formation 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 dam age is caused by overloading improper weight distribution or misapplication of the vehicle Excessive bending moment dam age will occur at different areas on various types of vehicles The effects of excessive bending moment will vary by type of vehicle 7 1 2 Making Reinforcements General Information A CAUTION When welding on a Kalmar truck 1 Always disconnect the wiring at the battery termi nals and ECUs 2 The ground for the welder should always be
148. tion Switch Trailer Auxiliary Switch Trailer Circuit Breaker 15A Trailer Wiring Disconnect Trailer Auxiliary Circuit Diagnosis Observation Cause Action No power at connector Circuit breaker open Defective wiring Reset Repair short as needed Re place circuit breaker as needed Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 57 Transmission Shifter Fifth Wheel Control and Panel Lighting Components Electroluminescent Lamps Incandescent Lamps Headlight Switch Inverter 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 Cause Action Inoperative light Defective lamp Rep
149. ts 9 Schematics HEATED MIRROR CAB BULKHEAD Le CIRCUIT org lt MIRROR HEAT MIRROR M MIRROR MIRROR HEAT RIGHT SIDE CONNECTOR N CONNECTOR RIGHT SIDE LEFT SIDE we RIGHT SIDE Ar 1000 RD R 5 MR1000 RD A Ej 602000 B GD2000 WE 8171 e gt D CS MIRROR E MIRROR LEFT SIDE L RIGHT SIDE K MR1000 RD Af MR1000 RD MR1000 RD lt MRI000 RD Aj MR100 RD MIRROR HEAT 902000 WE B GD2000 WE GD2000 WE H GD2000 WE 002000 WE MIRROR HEAT _convex x CONVEX RIGHT SIDE D RIGHT SIDE Y U NEGATIVE Ars MR1000 RD AI GD2000 WE PASS THRU MR1000 RD Ag Q 576052000 STUD GD2000 WE 2 gt gt s lt CONVEX MIRROR CONVEX MIRROR CONNECTOR ale CONNECTOR LEFT RIGHT 58 tr a MIRROR DASH 2 MIRRORS CONNECTOR MIRROR z a HEAT SWITCH a MIRRORS MR1001 OE A MR1001 OE 1 ruf GD2000 WE KE GD2000 WE MR1000 RD KE MR1000 RD 5 ACC 2 85 56 e 1001 BN SEV TU POSITIVE S PASS THRU E PR STUD 5 Mirrors Heated Optional a CONNECTOR Heated Mirror Circuit Components Circuit Breaker Optional Accessory Heater Switch
150. tteries 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 per sonal injury and property damage Maintenance manual Ottawa 4x2 6x4 1 5 Vehicle Towing 1 Introduction 9 1 5 Vehicle Towing 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 Connect towing equipment to main structural parts of the vehicle 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 Fol low 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 with out adequate safety stands Do NOT attempt towing operations that will jeopardize the safety of other motorists bystanders or the tow ing 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
151. uit breaker as needed Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 59 5 2 4 Accessories and Options Accessory Relay Components Accessory Circuit Breakers e Accessory Relay lgnition Switch Accessory Relay Circuit Diagnosis Observation Cause Action One accessory inoperative Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed All accessories inoperative Defective relay Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Air Dryer Components lgnition Circuit Breaker 30A Ignition Switch Air Dryer Circuit Diagnosis Observation Cause Action Inoperative heater Circuit breaker open Reset Repair short as needed Re place circuit breaker as needed Defective ignition switch Replace Defective wiring Inspect connections and wires Test circuits Repair or replace as needed Maintenance manual Ottawa 4x2 6x4 60 5 2 Electrical 5 Diagnostic Procedures 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 Cause Action Inoperative motor Circuit breaker open Defective tilt pump control s
152. witch Defective tilt pump solenoid Defective wiring Reset Repair short as needed Re place circuit breaker as needed Replace Replace Inspect connections and wires Test circuits Repair or replace as needed Raised cab does not return Circuit breaker open Defective tilt pump control switch Defective tilt pump valve Reset Repair short as needed Re place circuit breaker as needed Replace Replace Motor operates cab does not rise Refer to Hydraulic section Maintenance manual Ottawa 4x2 6x4 5 2 Electrical 5 Diagnostic Procedures 61 Heater Air Conditioning Optional Components AC High Pressure Switch Normally Closed AC Low Pressure Switch Normally Open AC On Off Switch Blower Motor Cold Control Heater AC Relay Heater Resistor Block Heater Switch Ignition Switch Heater Air Conditioning Circuit Diagnosis Observation Cause Action Inoperative blower Circuit breaker open Reset Repair short as needed Re place 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 Defective blower motor Replace Blower operates at one or two Defective resistor Replace Speeds only Defective heater switch Replace Maintenance manual Ottawa 4x2 6x4 62 5 2 Ele
153. xhausting from the tilt cylinder The effect of this restriction is to provide a slow controlled return to the Down position for the cab Cab Latch One hydraulic cylinder and one mechanical lock ing 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 Maintenance manual Ottawa 4x2 6x4 32 ATTENTION Cab Tilt Control Switch and Lanyard 3 2 Chassis 3 Description and Operation S N latch cylinder and the tilt cylinder receive hydraulic un der 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 cyl inder will extend raising the cab Cab Tilt Safety Prop An additional mechanical safety de vice is used to ensure that the cab cannot be inadvertently low ered 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 Power Steering Components The standard power steeri

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