Kalmar Ottawa Operator's Manual

Download

KALMAR

OPERATOR’S MANUAL

Section Title Page Preﬁx

OWNER INFORMATION..................................................4

OPERATION....................................................................12

MAINTENANCE..............................................................40

NOTE The information in this manual was current at the time of publication. Contents of this manual are subject to change at publishers discretion.

DO NOT REMOVE THIS MANUAL FROM THE VEHICLE. STUDY THIS MANUAL. READ AND COMPLY WITH ALL WARNINGS IN THIS MANUAL. IF THE VEHICLE IS SOLD, GIVE THIS MANUAL TO THE NEW OWNER.

Kalmar Industries Corp.

415 East Dundee Street Ottawa, Kansas USA (785) 242-2200 Fax (785) 242-6177

FROM KALMAR

TO THE OWNER:

The manufacturer of these trucks cannot create a single manual that would cover every option available.

We have tried to cover all the information that would be included in a normally conﬁgured truck.

For information on some major components you will need to refer to the manufacturer’s literature.

CONTENTS

Section “A”

INTRODUCTION ...............................................................................................4

CAUTIONS AND WARNINGS ............................................................................4

NOTES ................................................................................................................4

SERVICE ASSISTANCE .........................................................................................4

VEHICLE MODIFICATIONS ................................................................................5

SAFETY CHECKS AND PRECAUTIONS ...............................................................5

Axle - Front ...................................................................................................6

Axle -Rear ....................................................................................................6

Brake System .........................................................................................6

Cab ........................................................................................................6

Electrical ................................................................................................7

Exhaust System ......................................................................................7

Frame .....................................................................................................7

Fuel System ............................................................................................7

Propeller Shaft ..........................................................................................7

Steering ..................................................................................................7

Suspension .............................................................................................7

Transmission ...........................................................................................8

Wheels ...................................................................................................8

ADDITIONAL MANUALS AND SAFETY INFORMATION ....................................8

SAMPLE PRE-OPERATION SAFETY CHECKLIST ..................................................9

VEHICLE WARRANTY .......................................................................................10

Owner Information

CAUTIONS & WARNINGS

Throughout this manual you will find Warnings and Cautions:

DANGER - Warning will indicate a potentially hazardous situation that could lead to serious injury

of death.

WARNING - Failure of the operator of this vehicle to read and be aware of all the

warnings published in this manual may lead to serious injury or death. READ THIS MANUAL!

CAUTION - Cautions will indicate procedures or situations that could result in vehicle and/or property

damage.

NOTES

NOTE — Throughout this manual you will see notes. Notes will be used to show special procedures or point out important facts. Notes will also designate important information regarding this manual and its use.

SERVICE ASSISTANCE

Kalmar Industries Corp. has an established dealer network throughout the country. Whenever assistance is needed contact local dealer ﬁrst. For the number of your nearest dealer visit our web site at www. kalmarind-northamerica.com or contact Kalmar sales.

INTRODUCTION

The intention of this section is to provide basic information on the safe operation of the Kalmar tractor.

The ﬁrst section, “To The Operator”, con- tains important information on the use of Warnings, Cautions, and Notes that are found throughout this manual. This section also contains important safety and service support information.

The second section, “Operation”, covers basic safety and operating information on the tractor itself.

The third section, “Maintenance”, covers basic operator maintenance and lubrication information.

Remember that the safe operation of the Kalmar tractor depends entirely on the operator. The operator of this vehicle must be properly trained and fully knowledgeable BEFORE attempting to operate it. Read this manual carefully and pay close attention to all warnings, cautions and notes. Keep this manual in the vehicle and make sure it goes to the new owner if the truck is sold.

NOTE — Because of the many variations and options associated with the Kalmar tractors, some optional equipment on your vehicle may not be covered in this manual. If there are any questions regarding the speciﬁc options or variations not covered in this manual, contact your nearest Kalmar dealer for assistance.

NOTE — The Kalmar tractor may also be referred to throughout this manual as “vehicle” “the vehicle”. Throughout this manual reference is made to “Operator”. In the context of this manual the “Operator” refers to the actual driver of the vehicle.

Owner Information

SAFETY-CHECKS AND PRECAUTIONS

All spotting applications are demanding on the vehicle. Maintenance is critical for the continued SAFE performance of your tractor. Before operating your Kalmar it is extremely important that the vehicle is in proper and safe working condition.

The following section is intended to provide a basic knowledge of important safety check procedures and what to look for. These checks must be performed regularly to ensure safe vehicle operation. The frequency of these checks depends on the application of the vehicle.

In general, the best time to make the following safety checks would be during normal maintenance and during daily Pre-Operation Safety Inspections.

Kalmar Industries Corp. highly recommends that all operators complete a Pre-Operation Safety Inspection before climbing into the drivers seat. This “WalkAround” is a good way to prevent potential problems. A sample “Pre-Operation Safety Checklist is provided on page A-6 of this section. Use this as a guide to come up with an appropriate checklist for your individual vehicle.

During each scheduled maintenance interval or at least once a month, a qualiﬁed mechanic should inspect all of the following areas:

NOTE - If the vehicle is used in a severe application, such as a rail yard operation or in 24 hour operations, a more frequent schedule may be required.

When parts or service are required always have the serial number of the vehicle ready before contacting your Kalmar dealer. The serial number is located on an ID plate inside of the cab.

Kalmar is proud to have been the leader in the Port and Terminal Tractor Industry for over 40 years. We strive to serve our customers in every way possible. Thank you for buying our Kalmar tractor. We know it will serve you well for many years.

If, for any reason, you are not able to obtain assistance from any Kalmar dealer, feel free to contact Kalmar Industries Corp. directly.

For Assistance Call: Kalmar Industries Corp. Service Department 785-242-2200

VEHICLE MODIFICATIONS

Do not make modiﬁcations to your tractor without written approval from Kalmar Industries Corp.. Your vehicle has been designed and manufactured with safety and reliability in mind. Any modiﬁcations by the operator or owner could decrease the safety and reliability of your vehicle. Any unauthorized vehicle modiﬁcations may also void the Kalmar Industries Corp. Limited Warranty. Do not risk personal safety or vehicle reliability by making unauthorized modiﬁcations to your Kalmar tractor. Contact Kalmar concerning any proposed modiﬁcations to this vehicle.

SAFETY-CHEC KS AND

Owner Information

AXLE-FRONT

Maintaining correct front axle alignment is critical and should be performed by a qualiﬁed mechanic.

Check to ensure that the axle mounting bolts are securely tightened. Regularly check the front axle for damage, binding or worn parts, and adequate lubrication. Pay special attention to the axle stops and rubber snubbers. Do not operate the vehicle without the proper axle stops in place.

AXLE - REAR

Check to ensure that the axle mounting bolts are securely tightened. Regularly check the rear axle for damage and oil leaks. Unusual noises and signs of extreme heat may indicate axle damage.

BRAKE SYSTEM

Check the following:

1. Check brake controls for proper operation. Make sure the foot operated treadle in the cab is operating smoothly and is not damaged.

2. Visually inspect the brake drums, brake chambers, and slack adjusters. Check for loose, missing or broken components. Check brake chambers and slack adjusters for cracks and other signs of sever wear.

3. Listen for air leaks in the cab and underneath the chassis. Check air pressure regularly using the dash mounted gauge. Be alert for any sudden drops in pressure while operating the vehicle and after the engine is shut off. A minimum air pressure

of 70 PSI is required to operate this vehicle.

4. Visually check hoses and pneumatic lines for damage and chafﬁng.

5. Check the operation of both the service and parking brake systems. Be alert for any reduction in braking performance or unusual noises while braking.

CAB

Defroster - Operate the defroster to make

sure sufﬁcient air is being directed against the windshield. Make sure the blower is operating before the weather requires the defroster.

Door Latches - Check for positive closing, latching and locking.

Walkways/Side Step - Check to ensure that all factory installed walkways, platforms and steps are installed on vehicle securely and are not damaged or loose.

Handholds/Grab Handles - Check to ensure all handholds are installed and are not loose or damaged.

Glass - Check for cracked, broken, scratched or dirty glass.

Cleaning instructions for optional plastic glazing - Wash window with a clean

sponge or soft cloth using lukewarm water and mild detergent or window cleaner. Rinse with clean water. Do not use abrasive highly alkaline cleaners. Never scrape with squeegees, razor blades, or other sharp instruments. Remove ice and frost with the cab heater/defroster or by applying heat.

Mirrors - Check to be certain all mirrors are installed and that they are clean, un-

Owner Information

Seat Belts - Check entire seat belt system for wear and proper operation. Make sure anchor mountings are tight.

ELECTRICAL

Horn - Operate steering wheel mounted

horn to check operation. (Check optional air horns if equipped)

Instruments - Check operation of all instruments and gauges.

Lights - Check to make sure all lights (interior, exterior, headlights, etc.) function properly. Make sure gauge and dash backlighting is working properly.

Wiring - Check to ensure all wiring is properly secured and protected. Replace worn, cracked or chaffed wires and looms. Make sure factory wiring has not been compromised by improper splicing or modiﬁcations.

FRAME

Check for cracks and signs of damage. Pay close attention to highly stressed areas of the frame such as the boom pivot area. Contact your dealer for instructions on frame repair. Do not weld on frame rails unless directed to do so by your Kalmar dealer or by the factory.

FUEL SYSTEM

Frequently check throttle linkage for signs of binding and wear. Throttle should operate smooth and with minimal effort. Always replace damaged throttle components with factory replacement parts.

PROPELLER SHAFT

Check universal joints for wear. If propeller shaft vibrations occur, stop the vehicle immediately to prevent serious damage to the vehicle drivetrain.

STEERING

Be alert to any change or feel in steering while driving the vehicle. This change or feel may include a change in steering effort, unusual sounds when turning, excessive wheel play or pulling to either side.

If a problem is suspected or felt, check steering components for loose, damaged or worn parts. All steering components such as the tie rod and drag link must be tight.

Check power steering system for leaks and hose chafﬁng. Repair any problems before operating the vehicle. Regularly inspect all steering linkages.

WARNING - If any of the above are evident have the vehicle repaired by a quali-

ﬁed steering technician. Do not operate this vehicle with broken, damaged, worn, or non OEM steering system components.

SUSPENSION

Check condition of front and optional rear (if installed) suspension components such as mounting brackets and bushings. Check for worn and damaged parts.

Check and maintain the speciﬁed torque

Owner Information

on all mounting bolts and nuts. Check springs and replace broken or distorted springs.

TRANSMISSION

Follow transmission manufacturer’s guidelines for proper maintenance.

WHEELS

Check condition and maintain speciﬁed torque on all wheel mounting nuts. Replace missing or broken studs and nuts. Check tire inﬂation and wear. Do not operate this vehicle with badly worn or damaged tires.

NOTE - Because of the many options available on Kalmar tractors, it is critical that the owner be aware of all options that may affect the safe operation of the vehicle and take appropriate measures to maintain his/her speciﬁc vehicle. Always contact your Kalmar dealer if any questions arise regarding safe operation of this vehicle.

ADDITIONAL MANUALS AND SAFETY INFORMATION

“OTTO Shows and Tells” booklet

Do not forget to read your safety booklet that is provided with your Kalmar tractor. This little manual is ﬁlled with important operating tips. “OTTO” makes important procedures easy to remember with pictures and simple explanations. If you did not receive your “OTTO Shows and Tells” booklet, contact your dealer for a copy or contact Kalmar Industries Corp. directly.

Operator Orientation Video

Kalmar Industries Corp. offers an Operator Orientation Video CD. This video covers important information that all Kalmar operators must know. The video should be used in conjunction with the “Otto Shows and Tells” booklet and this manual to instruct the operator on the proper operation of the Kalmar tractor. Shipped with every truck, this video is also available through your Kalmar dealer or directly from Kalmar Industries Corp..

SAMPLE PRE-OPERATION CHECKLIST

(Walk Around Inspection)

________ Check tires for damage and proper inﬂation

________ Check cab hold down latch (air suspension unit) for proper latching

________ Check all ﬂuid levels: engine oil, hydraulic, and coolant

________ Drain any moisture from air tanks

________ Check cab doors and latches for proper operation

________ Ensure that all steps, walkways and handholds are installed and in good working order

________ Start engine and check transmission ﬂuid level with parking brake

applied and transmission shift selector in “neutral”

________ Check windshield wiper for proper operation

________ Check steering system for any binding. Make sure steering effort is smooth and light

________ Check accelerator for proper operation. Should operate smoothly and without any binding.

________ Check all rear view mirrors, adjust and clean if needed

________ Check cab and frame for any structural damage or cracks

________ Inspect trailer electrical cable and trailer air lines for damage. Make sure both air lines are installed

________ Clean all windows if needed

________ Check transmission shift lever for any binding

________ Check boom control lever for proper operation

________ Check all lights for proper operation: headlights, turn signals, brake lights, hazard lights, and marker lights

________ Check horn(s) for proper operation

________ Check and ﬁll fuel tank

Kalmar Terminal Tractor

North American Warranty Policy

KALMAR INDUSTRIES CORP (hereafter KALMAR) warrants to the original owner that each new KALMAR Terminal Tractor will be free from defects in material or workmanship under normal use and service for a period not to exceed Three Hundred Sixty Five (365) days or Three Thousand (3,000) hours, whichever occurs ﬁrst, from commencement of service. The ﬁrst 182 days or 1,500 hours both labor and parts will be warranted. The remaining 183 days or 1,500 hours parts only will be warranted.

In addition, KALMAR warrants, to the original owner and in only the original approved application, that each new KALMAR Terminal Tractor mainframe will be free from defects in material or workmanship for a period of seven (7) years. This extended frame warranty applies if, and only if: a) the tractor is being used by the original owner; b) the failure cannot be attributed to lack of routine maintenance; c) the tractor has not been involved in an accident; d) the tractor is being used in the original KALMAR Terminal Tractor approved application; e) the tractor has not been used in an application where the requirements of which are greater than the speciﬁcation published at the time of manufacture; f) the tractor frame has not been modiﬁed by welding on, cutting into or drilling into the original structure.

The repair or replacement of defective parts or workmanship under the terms of this warranty will be made by KALMAR or KALMAR Terminal Tractor authorized Parts and Service Dealer, without charge for parts or labor, if the defect occurs within the ﬁrst 182 days of service and if the prepaid returned parts are judged by KALMAR to be faulty or defective. If the defect occurs between 183 and 365 days of service KALMAR or KALMAR Terminal Tractor authorized Parts and Service Dealer will repair or replace parts only and will not reimburse for any labor charges. KALMAR will not honor invoices for parts purchased from outside sources, unless written authorization is ﬁrst given by the KALMAR Terminal Tractor Service Department. Further, KALMAR will not honor invoices for labor charges, unless the rate per hour charged and the number of hours involved are ﬁrst authorized by KALMAR.

THE OBLIGATION OF KALMAR UNDER THIS WARRANTY IS LIMITED SOLELY AND EXCLUSIVELY TO REPAIRING OR REPLACING, AS KALMAR MAY ELECT, ANY PART OR PARTS WHICH ARE RETURNED TO US, TRANSPORTATION PREPAID, AND WHICH, UPON EXAMINATION, ARE DETERMINED BY KALMAR OR THE SUPPLIER TO BE DEFECTIVE IN MATERIAL AND/OR WORKMANSHIP. IN NO EVENT, SHALL KALMAR BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES.

Excluded from this warranty are engines, Transmissions, Tires and batteries or ant other components which have warranties covered by their manufactures.

The provisions of this warranty do not apply to the prime product or any component part thereof, which has been subject to misuse, or damaged through negligence or accident, or has been repaired or altered by anyone other than KALMAR or KALMAR Terminal Tractor authorized Parts and Service dealer. Further excluded, are such parts as ﬁlters, belts, brake linings, lights, breakers, and lubricants which are part of normal maintenance service replacements. The KALMAR warranty does not cover towing charges or rental replacements.

A Warranty Registration form is mailed for every tractor. It is the obligation of the purchaser to complete and sign the Warranty Registration form and return it to KALMAR Terminal Tractor within 30 days after receipt of the tractor.

THIS WARRANTY IS A LIMITED WARRANTY AND IS IN LIEU OF

ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, OF ANY KIND OR

NATURE WHATSOEVER.

KALMAR reserves the right, at any time, to make changes in the design, material, and/or speciﬁcation of this product, or accessories thereof, without thereby becoming liable to make similar changes in such equipment or accessories previously manufactured.

KALMAR INDUSTRIES CORP.

415 East Dundee Street

Ottawa, Kansas 66067 USA

785 242 2200

CONTENTS

Section “B”

INTRODUCTION ...............................................................................................14

VEHICLE ENTRY AND EXIT ................................................................................14

OCCUPANT RESTRAINT SYSTEM ....................................................................14

Seat Belt Operation ..............................................................................15

Suspension Type Seats ...........................................................................15

Seat Adjustment .................................................................................... 15

INSTRUMENT PANELS AND CONTROLS ........................................................16

Control and Display Location ...............................................................17

Control and Display Description ..........................................................18

STARTING THE VEHICLE ...............................................................................22

Ignition Switches ................................................................................22

Key Type Ignition ................................................................. .. 22

Push Button Starter ...............................................................22

PARKING THE VEHICLE ................................................................................ 23

AIR BRAKE SYSTEM ............................................................................... 23

Low Air Pressure Indicators .......................................................... .......24

Service Brakes ....................................................................................... 24

ABS .....................................................................................................25

Traction Control ..................................................................................26

PARKING BRAKE ............................................................................................26

Parking Brake and Trailer Air Supply Controls .....................................26

MANUALLY RELEASING TRACTOR SPRING BRAKES (CAGING) ..................... 26

TRAILER BRAKES .............................................................................................28

Trailer Air Lines ....................................................................................28

Operation

ENGINE .........................................................................................................28

Starting the Engine ................................................................................29

Starting Procedure ......................................................... .. 29

Engine Shut Down ..............................................................................30

Shut Down Procedure .........................................................30

Engine Oil ............................................................................30

TRANSMISSION ...........................................................................................30

Parking with an Automatic Transmission .............................................31

HYDRAULIC FIFTH WHEEL LIFTING SYSTEM ..............................................31

Hydraulic Boom Operation ...............................................................31

Fifth Wheel Unlatch Control Valve .....................................................32

BASIC TRAILER SPOTTING STEPS ................................................................32

TOWING THE VEHICLE ...................................................................................34

Towing vehicle with front wheels suspended .....................................34

Towing vehicle with rear wheels suspended .......................................35

AXLES .............................................................................................................35

Axle operating temperature .................................................................35

Rear axles with locking or limited slip differentials ............................35

CAB TILTING AND LOWERING .....................................................................36

To tilt cab ............................................................................................ 36

To lower cab ........................................................................................37

ELECTRICAL ...................................................................................................38

Accessory connections ........................................................................38

Breakers, Relays and Fuses .................................................................. 38

Operation

VEHICLE ENTRY AND EXIT

The Kalmar tractor is designed for easy entry and exit. The walkways, steps, and handholds are designed with operator safety in mind. As with any vehicle of this type, care must be taken when climbing in or out of your Kalmar tractor. Remember, be careful!

WARNING - Never remove factory installed walkways, steps or handholds. Do

not operate your Kalmarunless all of the factory installed steps, walkways and handholds are installed and in good working condition.

WARNING - Failure to exercise caution when entering and exiting this vehicle can result in

personal injury.

1. Entry and exit should be made slowly and carefully

2. A three-point stance should be used. Three out of the four extremities (hands and feet) should be in contact with the vehicle at all times.

3. Face inward toward steps when entering and exiting.

4. Keep steps, walkways and handholds in good condition.

5. Keep steps, handholds, walkways and shoes free of grease, mud, dirt, fuel, ice and snow.

6. Use extra care during bad weather, especially when steps and handholds may be icy or wet.

INTRODUCTION

The following section on OPERATION should be read carefully. It covers important information that every operator must know before operating any Kalmar tractor.

This manual is intended to cover the standard Kalmar tractor and some of the most common options. Not all of the customer ordered optional equipment or systems are covered in this manual. If the operation of any component or system on your vehicle is not covered in this manual, call your Kalmar dealer for assistance.

CAUTION - Kalmar Industries Corp. highly recom-

mends that all individuals that operate this vehicle have a valid drivers license and have sufﬁcient training to operate this type of vehicle. Although most Kalmar tractors are not sold as highway legal vehicles, this does not mean they are intended to be operated by untrained personnel. This manual is not intended to be a training guide for Yard Tractor operators. It is the operator’s responsibility to obtain sufﬁcient training in order to operate this vehicle safely. DO NOT ATTEMPT TO OPERATE THIS VEHICLE WITHOUT ADEQUATE TRAINING.

Operation

OCCUPANT RESTRAINT SYSTEM

THE KALMAR TRACTOR IS EQUIPPED WITH SEAT BELTS. THEY SHOULD BE USED WHENEVER THE VEHICLE IS IN OPERATION.

SEAT BELT OPERATION

The seat belt system used on Kalmar tractors is a lap type restraint with an automatic retractor.

Before fastening the seat belt, be sure to adjust the seat to a comfortable driving position. To fasten the belt, pull the belt low across the hips and insert the tongue into the buckle.

To release the seat belt, press the button on the buckle and the belt will retract automatically.

SUSPENSION TYPE SEATS

All Kalmar tractors have a suspension type seats as standard equipment.

WARNING—Due to the vertical travel of suspension seats, the operator must in-

sure that there is adequate head clearance when the seat is at the top of its upward travel.

Operation

SEAT ADJUSTMENT

Refer to seat manufacturer’s information packet provided with the vehicle or to the decal located on the seat base. Your local Kalmar dealer can assist with any questions.

Adjust the seat to the comfortable position for the operator to have full control of all cab controls and displays. This position is obtained by changing the air pressure in the suspension, which changes the height. The fore and aft position is obtained by moving the seat cushion and back on its slides. Once this position is achieved, tighten the seat belt tether securely on both sides. The tether will restrain the seat from raising above this position. Now, the seat air suspension may be adjusted to operator’s desired ﬁrmness.

WARNING - Do not adjust drivers seat unless vehicle is parked. The seat could

move suddenly and unexpectedly and cause loss of control of the vehicle.

WARNING - The Kalmar tractor is designed and equipped to carry

only the driver (unless built with a 2 man cab). Never allow anyone to ride anywhere inside or outside of the cab. Carrying a passenger is extremely dangerous and can result in serious injury or death. NEVER CARRY PASSENGERS WITH YOUR KALMAR.

Operation

POS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

42-52

53 54 55 56 57 58

59 60 61 62 63 65 66

NAME

WATER TEMP GAUGE TACHOMETER OIL PRESSURE GAUGE SPEEDOMETER FUEL GAUGE AIR DIFFUSER HEADLIGHT SWITCH PANEL LTS DIMMER INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT INDICATOR LIGHT STOP ENGINE IND LIGHT INDICATOR LIGHT LH TURN SIGNAL IND LT

VOLT METER HOUR METER A/C SWITCH WASHER SWITCH BEACON LT SWITCH OPTIONAL SWITCH FLOOD LIGHT SWITCH ETHER START IGNITION SWITCH PUSH BUTTON START HEATER CONTROLS HEATER CONTROLS HEATER CONTROLS HI BEAM INDICATOR LT RH TURN SIGNAL IND LT INDICATOR LIGHT HEATER FAN CONTROL INDICATOR LIGHT TRANS TEMP IND LIGHT BRAKE AIR INDICATOR LT WIPER SWITCH

GAUGE

STANDARD AIR GAUGE 2nd AIR GAUGE TRACTOR PARK CONTROL GAUGE TRAILER PARK CONTROL GAUGE

SHIFTER CONTROL 5th WHEEL CONTROL 5th WHEEL LATCH DOLLY MASTER LOAD GAUGE INTER AXLE DIFF LOCK DIFFERENTIAL LOCK

STD

OFF HWY

s a s a s s s a n u n u n u n u n s n s

s s a a a u s a s a s s s s s u s u s s s

s a s u s u

a s s a a a a

CUMMINGS

ISB/ISC

s a s s s s s s u s u s u s u s u s u s

s s a a a u s a s a s s s s s u s u s s s

s a s u s u

a s s a a a a

CATERPILLAR

3126

s a s s s s s s u u u s u s u s u s u s

s s a a a u s a s a s s s s s u s u s s s

s a s u s u

a s s a a a a

DETROIT

DIESEL S40 E

s a s s s s s s u u u s u u u s u s u s

s s a a a u s a s a s s s s s u s u s s s

s a s u s u

a s s a a a a

s=standard a=assigned options u=unassigned options n=not available

Operation

Ignition Switch ..........................17

Indicator Light Strip...................20

Optional Gauges.......................17

Optional Controls.....................17

Optional Switches.....................17

Parking Brake Control................21

Speedometer (optional).............20

Tachometer (optional)................20

Trailer Air Supply Control..........21

Transmission Shift Selector........21

Warning Light...........................20

Turn Signal Control...................21

Voltmeter..................................19

Windshield Wiper Control.........17

Windshield Washer...................17

Air-conditioner Switch ..............20

Air Pressure Gauge...................21

Beacon Switch (optional)..........17

Boom Control Lever..................21

Coolant Temperature Gauge......19

Engine Oil Pressure Gauge.......19

Emergency 4 Way Flasher.........21

Fan Control (heater/air-conditioner) 20

Fifth Wheel Unlatch Control.....21

Floodlight Switch......................20

Fuel Gauge...............................19

Headlight Control Switch..........19

Heater Controls........................20

High Beam Indicator.................20

High Beam Switch....................21

Hour Meter...............................19

CONTROL AND DISPLAY DESCRIPTION

Transmission Temp.

Operation

PANELS 1 and 2

1. Dash Panel Light Dimmer

2. Headlight/Running Light Control This switch controls headlights and running lights on the tractor and trailer. This switch also activates the interior dash and gauge lights when either the headlights or the running lights are on. The switch has three positions.

3. Fuel Gauge Indicates the level of fuel in the fuel tank in 1/4 increments.

4. Engine Oil Pressure Gauge Indicates the engine oil pressure in P.S.I.

5. Coolant Temperature Gauge Indicates the temperature of the engine coolant in degrees Fahrenheit.

6. Voltmeter (Ammeter Optional) Indicates the status of the charging system in volts. If the engine is running the gauge indicates the alternator output voltage. If the engine is not running the voltmeter indicates the output voltage of the battery.

7. Hour Meter Indicates engine operating hours.

Operation

8. Heater Control This lever controls the heater temperature. The full down position shuts off the heater. The lever can be adjusted to provide the desired amount of heat by moving it up from the OFF position.

9. Fan Speed ON/OFF Switch The switch has four positions. Full counterclockwise is the OFF position.

10. Windshield Wiper Control This control operates the windshield wiper. Turning the control clockwise increases the speed of the wiper. Turning the control counterclockwise completely will park the wiper.

11. Floodlight Control Activates a normally rear facing ﬂood light. The switch is two position, up (ON) and down (OFF).

12. Air-conditioner Switch (Optional) This switch activates the air-conditioning compressor when the optional air-conditioning is installed.

13. Tachometer (Optional) Indicates engine R.P.M.

14. Speedometer (Optional) Indicates vehicle speed in M.P.H. or K.P.H. This gauge may also come with an odometer feature built in.

15. Heater/Air-Conditioner Duct Directional and closeable duct for the heater and air-conditioner.

Indicator Light Strip

The indicator lights are located along the top of dash panels 1 and 2. These panels contain the 5 STANDARD indicators and any optional indicators. The 5 standard indicators are listed below:

1. Left Turn Signal Indicator (green arrow) Indicates left hand turn signal is on when ﬂashing.

2. Right Turn Signal Indicator (green arrow) Indicates right hand turn signal is on when ﬂashing.

3. High Beam Indicator (blue light symbol) Indicates high beams are on when illuminated.

4. High Transmission Temperature (trans temp) Indicates transmission ﬂuid temperature is above 300° F. when illuminated.

5. Low Air Pressure (brake air) Indicates system air pressure is below 70 P.S.I. when illuminated.

Operation

1. Standard Air Gauge Indicates air pressure in the air system in P.S.I.

2. 2nd Air Gauge Indicates air pressure in the air system in P.S.I.

3. Transmission Shift Selector This control selects the operating range of the transmission. (See page 30, Transmission)

4. Boom Control Lever This control operates the hydraulic boom and ﬁfth wheel. (See page 31, Hydraulic Boom Operation)

5. Fifth Wheel Unlatch Control This control engages the ﬁfth wheel jaw locking mechanism. (See page 32, Fifth Wheel Unlatch Control)

6. Parking Brake Control This control operates the parking brakes on the vehicle and trailer. (See page 26, Parking Brakes)

7. Trailer Air Supply This control activates the trailer air supply. (See page 26, Parking Brake and Trailer Air Supply)

Figure 1 A High Beam Switch B Turn Signal Lever C Emergency Flasher Switch

The column mounted control on the Kalmar tractor has three functions. It is located on the left hand side of the steering column (Fig. 1).

1. Moving the lever (Fig. 1, B) forward activates the right turn signal. Moving the lever to the rear activates the left turn signal. The turn signal is not self canceling and must be returned to the center (off) position manually after it is engaged. The green arrows on the dash panel light up and ﬂash when the switch is activated.

2. The button on the end of the lever operates the high beam lights (Fig. 1, A). The headlights must be on for the switch to work. When the high beam headlights are on, the high beam indicator on the dash will light up.

3. The pull out switch under the lever activates the emergency ﬂashers (Fig. 1, C). Pulling out on the switch turns the ﬂashers on. To turn the ﬂashers off, move the turn signal lever forward or backwards.

PANELS 4 and 5

TURN SIGNAL, HIGH BEAM AND EMERGENCY FLASHER CONTROL

Operation

KEY TYPE IGNITION

There are three positions; OFF, ACCESSORY and RUN/START. The full left (counterclockwise) position is the OFF position. The second position to the right (clockwise) is the ACCESSORY position. The third position to the right (clockwise) is the RUN/START position.

The RUN/START position is used to engage the starter motor. Moving the switch to the full right position engages the starter and upon release of the key, the switch automatically stays in the RUN position.

The ACCESSORY position activates the tractor’s electrical accessory circuit.

The OFF position cuts all power to the electrical system and shuts down the engine.

NOTE - The Off position on the standard three position key type switch is designed to function as the engine stop. There is no other engine stop device other than the ignition switch on the standard Kalmar tractor.

PUSH BUTTON STARTER

Push button starters are optional on Kalmar tractors. There are two basic types of toggle ignition switches, three position and two position.

The three position type functions like the standard key type with OFF, ACCESSORY and RUN positions. The button engages the starter when the switch is in the RUN position only.

The two position switch has only the OFF and RUN positions. It has no provision for and ACCESSORY position. The button engages the starter in the RUN position only.

DRIVER CONTROLLED DIFFERENTIAL LOCK

(Optional on drive axles)

Drive axles may be equipped with a driver controlled differential lock. This is an air

actuated traction device that can be manually controlled inside the cab by the operator. By actuating a dash mounted control, the operator can lock or unlock the differential.

NOTE: When this differential is fully locked the vehicle will have reduced steering capability. The driver must limit the use of the differential to slow speeds. Also, the differential must not be engaged when traveling down steep grades when traction is limited. Refer to axle manufacturer for operational & maintenance procedures.

STARTING THE VEHICLE

(See page 29, Starting The Engine)

IGNITION SWITCHES

The standard ignition switch on the Kalmar tractor is a key type, similar to the kind found on automobiles. Push button and other types of ignition switches are installed as optional equipment.

Operation

ing it in gear. Always place the transmission shifter selector in the “Neutral” position.

3. Never park a tractor trailer combination unless the trailer parking brakes are operational and applied.

NOTE - If the vehicle is parked in gear, the vehicle will not start.

AIR BRAKE SYSTEM

DANGER - Brakes must be kept in proper working condition. Operating a

vehicle with poorly maintained, brakes or worn out brakes can cause a loss of vehicle control. This may lead to serious injury or death. Never operate the vehicle unless the brakes are working properly.

CAUTION - Do not allow

moisture to collect in the

air tanks. The air tanks must

be drained daily. Failure to drain the air tanks can damage the air brake system.

Kalmar tractors come equipped with pneumatic (air) brake systems. This system has two basic parts, the service brakes, and the spring parking brakes.

The service brakes are the part of the system that the driver uses when he operates the foot operated treadle valve (or foot pedal) in the cab (Fig.1 page 24).

CAUTION - If the engine does not start within 30

seconds, release the starter switch and wait 3 minutes to allow the starter motor to cool. If after 3 repeated attempts, the engine still fails to start, stop and determine the cause. The starter motor may be damaged by repeated attempts to start the engine.

NOTE - Some vehicles may be equipped with optional shut down systems or optional starter switches. Contact your Kalmar dealer if you have any questions regarding the operation of any optional starter switches or shut down systems.

PARKING THE VEHICLE

(See page 30, Transmission) (See page 26, Parking Brake)

Standard Kalmar tractors are equipped with an Allison automatic transmission and spring operated parking brakes. Allison transmissions are unlike an automobile transmission in one important regard. They do not have a park position.

When parking your Kalmar tractor there are some important rules that must be followed.

DANGER - Failure to observe the following rules when parking the vehicle may result in serious injury

or death.

1. Always apply the parking brake.

2. Never park the vehicle by leav-

Operation

air pressure in the system. The warning buzzer will shut off after air pressure has reached 70 P.S.I.. (See page 21)

If the warning light and buzzer do not shut off at least 5 minutes after start-up, shut the engine down and determine why the air system is not charging.

If the Low Air indicator light or buzzer indicates a loss of air pressure while driving, the vehicle should be stopped immediately. The vehicle should not be operated until the air system is repaired and functioning properly.

Danger - Do not operate the vehicle if the air brake system is not working properly.

SERVICE BRAKES

The Service Brake system is controlled by a foot operated treadle valve (foot pedal) in the cab. This is the left hand pedal, located to the right of the steering column (Fig. 1, page 24). The amount of foot pedal pressure determines the amount of air pressure delivered to the brakes. The more pressure on the treadle valve (pedal), the more braking force applied. The service brakes should be applied in smooth constant applications. They should not be pumped or fanned while slowing or stopping the vehicle. Even in an emergency stop situation, the service brakes should not be rapidly “pumped”.

NOTE - Air brakes do not respond like the brakes in a car, and pumping them in an emergency stop is not advised. Rapidly “pumping” the brakes is more likely to use up all of the air in the system and cause the spring brakes to apply and lock the rear wheels. This will cause an out of control skid.

Figure 1 A Accelerator Pedal B Brake Treadle/Pedal

The service brakes are the primary brakes used by the operator. The service brakes require air to operate. If there is insufﬁcient air in the system, the service brakes will not operate.

The spring brakes are used for parking the vehicle. They are also called the parking brakes because the parking brake control applies the spring brakes. The spring brakes use the mechanical force of a spring to operate. They do not need air to operate, but they do need air to be released. If there is a loss of pressure in the system, these brakes will automatically apply. This is why the spring brakes are sometimes called “emergency” brakes. Remember, if there is no air in the system the spring (parking) brakes will not fully release.

LOW AIR PRESSURE INDICATORS

When air pressure in the brake system is below 70 P.S.I., the warning buzzer will sound and the LOW AIR warning indicator on the dash panel will light up. The air pressure gauges should indicate low

Operation

braking ability of the tractor trailer combination and creates a serious hazard. This increases the possibility of an accident and could result in serious injury or death.

WARNING - Never operate the vehicle when system air pressure is

below 70 P.S.I. There may not be enough air in the system to stop or slow the vehicle. Have the brake system checked by a certiﬁed air brake mechanic if there is any doubt about the brake system performance.

A.B.S.

Some trucks may be equipped with the Antilock Braking System (A.B.S.). The A.B.S. system is designed to prevent wheel lock up during hard braking.

Trucks equipped with A.B.S. have an indicator light located in dash panel number one. The indicator light will warn the operator if there is a potential problem in the system.

Trucks should not be operated if the indicator light is on. Contact your nearest Kalmar dealer for qualiﬁed service on the A.B.S. system.

Trucks built with A.B.S. after March of 2002 will have the capability to check the trailer for a properly operating system. After connecting a trailer to the truck, the system will run a diagnostics check. If a problem is detected with the trailer side of the A.B.S. system, a trailer warning indicator light on the dash will illuminate.

While the engine is running, the air compressor replenishes the brake system air supply. This air supply provides the pressure necessary to operate the service brakes.

The service brakes require at least 70 P.S.I. to operate effectively. If the system is not up to at least 70 P.S.I., there may not be enough air in the system to stop the vehicle. Several hard brake applications can quickly deplete the pressure in the air system and could possibly cause the pressure to drop below 43 P.S.I.. If this happens the spring brakes will apply automatically, possibly causing the operator to loose control of the vehicle.

The service brake system is integrated with the parking brake system. Should the service brake system fail because of a lack of air pressure (below 43 P.S.I.), the spring brakes will automatically be applied for emergency braking.

WARNING - Rapid successive brake application and release, sometimes

referred to as “fanning” or “pumping” the brakes, should be avoided. This is an inefﬁcient way to slow or stop a vehicle with air brakes and may use up all of the air in the system before the vehicle is stopped or slowed completely. This could result in serious injury or death.

WARNING - Always

connect both trailer air

lines when towing a trailer. Failure to connect both the trailer service (BLUE), and the trailer supply (RED) air lines greatly reduces

Operation

Trouble-shooting or clearing fault codes is performed at the EC module mounted in the left front wheel well.

TRACTION CONTROL

Automatic traction control (A.T.C.) is available as an option on trucks equipped with the Antilock Braking System. When activated, the A.T.C. active/warning lamp will be on and the system will limit wheel spin during hard acceleration. The system is activated by turning on the A.T.C. enable/disable switch located on the dash. During activation, the warning lamp will blink to advise the driver that drive-wheel spin is occurring.

A.T.C. can be disabled while the vehicle is stationary or in motion. However, A.T.C. will not re-enable until the vehicle comes to a complete stop, even with the switch turned to the enable position.

Danger - Never operate the vehicle if the truck or trailer A.B.S. warning (indicator) lights remain

illuminated.

PARKING BRAKE

Otttawa tractors are equipped with spring brakes of parking. The parking system is operated manually by a cab mounted parking brake control valve (Fig 1) (Also see page 21, Items 6 and 7)

The purpose of the parking (spring) brakes are to hold the vehicle while in the parked position.

(RED)

(YELLOW)

WARNING-Never apply the parking brake during normal driving. Doing this

will lock the rear wheels, possibly causing an uncontrolled stop.

PARKING BRAKE AND TRAILER AIR SUPPLY CONTROLS

NOTE - Air pressure in the system must be at least 70 P.S.I. before the Parking Brake Control or the Trailer Air Supply Control can be pushed in (releasing the spring brakes).

NOTE - If the tractor air system is completely discharged, the Trailer Parking Brake Controls will be applied. The trailer parking brake should not be released until the tractor brakes are rolling.

Figure 1

Parking Brake and Trailer

Air Supply Controls

MANUALLY RELEASING TRACTOR SPRING BRAKES (CAGING)

When air pressure in the system drops below approximately 43 P.S.I., the spring

Operation

1. Shut the engine off and remove the key.

2. BLOCK ALL wheels front and rear to prevent the vehicle from rolling forward and backwards.

3. Determine whether the chamber has an internal (FIGURE 1) or external (FIGURE

2) caging tool. Proceed to step 4 with an externally mounted tool. Step 8 for internal types.

4. Remove the access plug from the brake canister.

5. Insert the caging tool into the access hole, “T” end ﬁrst.

Figure 2

6. Turn the caging tool 1/4 turn to engage with the slot on the pressure plate.

7. Try to pull the caging tool out, it should not pull out. If it does repeat steps 5 and 6.

8. Thread the nut and washer down onto the threaded end of the caging tool all the way to the canister.

9. Tighten the nut until the threaded portion of the release tool is out. It should extend approximately 3” out of the nut.

3.00 inches - Type 2430 and 3030 Chambers

4.00 inches - Type 3036 and 3636 Chambers

parking brakes will apply automatically. To release the spring brakes, the air pressure must be returned to 70 P.S.I.. If the system cannot be recharged and the vehicle must be moved, the spring parking brakes can be released manually (caged).

To release the spring brakes, the actual spring in the brake canisters must be mechanically compressed. A release stud, or spring caging tool, must be used to manually compress the brake chamber.

DANGER - Never manually release (cage) the spring breaks before the wheels

are properly blocked. If the wheels are not properly blocked before releasing the spring brakes, the vehicle may move unexpectedly. This could result in serious injury or death.

Figure 1

The following steps can be used to release the standard brake chambers used on most Kalmar tractors. If your vehicle is equipped with other optional brake chambers, refer to that manufacturer’s operation or service manual.

Operation

CAUTION - Never use an

impact wrench to tighten

the nut onto the release

bolt. Never exceed the above lengths and never exceed 50 lbs-ft. of torque on the release nut or the chamber may be damaged.

TRAILER BRAKES

Kalmar tractors are designed to use the trailer’s brakes when towing trailers. All Kalmar tractors are equipped with a trailer Supply air line and a trailer Service air line. The service line is BLUE. The supply line is RED.

When the vehicle is towing a trailer and the service and supply line are connected to the trailer, the trailer brakes become part of the tractor’s brake system. The tractor service brakes control the trailer service brakes. The tractor parking brake control operates the tractor and trailer spring brakes. This is why it is critical that the operator always connect both air lines to the trailer.

TRAILER AIR LINES

The service air line (blue hose) operates the trailer service brakes. The supply air line (red hose) only supplies air to the trailer spring brakes to release them. If only the supply air line is attached to the trailer, the trailer service brakes will not operate. The tractor service brakes will be doing all the braking for the combination and braking distances will be dramatically increased. Without the trailer service brakes working, jack-kniﬁng and loss of vehicle control is much more likely during heavy braking.

WARNING - Always

connect both trailer air

lines when towing a trailer.

Failure to connect both the trailer service (BLUE), and the trailer supply (RED) air lines greatly reduces braking ability of the tractor trailer combination and creates a serious hazard. This increases the possibility of an accident and could result in serious injury of death.

ENGINE

Kalmar tractors come equipped with a variety of engines. Kalmar provides the engine manufacturer’s operation manual with each vehicle. It is the operators responsibility to read the engine operation manual and follow all instructions provided by the engine manufacturer.

Engine performance is very important to the efﬁcient operation of the Kalmar tractor. Failure to properly maintain and operate any engine can lead to very costly repairs and extensive down time. KNOW YOUR ENGINE AND

MAINTAIN IT!

NOTE - This manual only contains basic information on engine operation that apply speciﬁcally to the Kalmar tractor, or is applicable to all diesel engines.

If you did not receive an engine operation manual, contact your Kalmar dealer.

CAUTION - Failure to read and follow engine manufacturer’s instructions regarding

engine operation may lead to severe engine damage. Read the Engine Operation Manual before operating this vehicle.

Operation

To start a vehicle equipped with the standard electrical starting system, follow these steps:

STARTING PROCEDURE

NOTE - All Kalmar tractors are designed to start in NEUTRAL ONLY. The starter should not operate if the vehicle is in any other gear.

1. Set the parking brake.

2. Place the transmission control in NEUTRAL.

3. Apply the service brakes using the ﬂoor mounted treadle valve and hold the brakes in the position.

4. Insert the ignition key into the switch and rotate the key clockwise to the RUN position.

5. Wait for the “Wait to Start” light on the dash to go out if the vehicle is equipped with one.

6. Turn the key to the start position. When engine starts, release the key and allow the switch to remain in the Run position.

CAUTION - If the engine

does not start within 30

seconds, release the starter

switch and wait 3 minutes

to allow the starter motor to cool. If after 3 repeated attempts, the engine still fails to start, stop and determine the cause. The starter motor may be damaged by repeated attempts to start the engine.

STARTING THE ENGINE

(See page 22, Starting the Vehicle)

WARNING - Always set parking brake and place shifter in neutral before

attempting to start engine. Failure to do so may cause the vehicle to move suddenly and unexpectedly when the starter is engaged.

WARNING - All Kalmar

tractors are designed to

start in NEUTRAL ONLY. If

the vehicle you are operating starts while it is in gear, DO NOT OPERATE THE VEHICLE. Shut the vehicle down and have the neutral lock-out switch repaired before operating the vehicle.

DANGER - Never attempt to start the vehicle from any position other than the

driver’s seat. Attempting to start the vehicle while standing, outside of the cab, or in the engine compartment may cause the vehicle to move uncontrolled and cause serious injury or death.

The following is provided as general guideline information. Always follow all instructions provided in the engine manufacturer’s operation manual. Different makes and models of engines have different operating characteristics and requirements. There are some important guidelines to follow when starting any Kalmarequipped with a diesel engine. These are listed below.

Operation

ENGINE OIL

Always refer to the engine operation manual for complete information on engine oil requirements. Service intervals, oil types and reﬁll quantities are all covered in the engine operation manual. READ IT!

TRANSMISSION

Standard tractors are equipped with an Allison Automatic Transmission, RDS series. These heavy duty transmissions are designed for stop and go operation. An Allison Transmission operator’s manual is provided with every Kalmar. This manual provides important information on operation of the RDS series transmissions.

The following information can be found in your Allison Operator’s Manual:

1. Gear Selection

2. Shifting the Transmission

3. Driving Tips

4. Care and Maintenance

5. Check oil level w/shifter

6. Check/clear fault codes

WARNING - The operator of this vehicle must read and follow the instructions

in the Allison Operator’s Manual. Failure to do so may lead to serious vehicle damage and personal injury.

The forward to reverse shifts of the transmission are controlled by the “ECM”.

ENGINE SHUT DOWN

Diesel engines generate large amounts of heat. Internal engine parts on any diesel engine need to cool down before the engine is shut off. The operator should allow the engine to idle for at least 3 minutes prior to shutting the engine down. This cool down period allows the coolant to dissipate internal engine heat. Shutting a hot engine down without a cool down period may cause an immediate and excessive increase in engine temperature. This could severely damage internal engine components.

NOTE - Always refer to the engine operation manual for complete information on engine shut down procedures.

SHUT DOWN PROCEDURE

1. Place transmission in neutral.

2. Set parking brake.

3. Allow engine to idle at low idle for at least 3 minutes.

4. Turn ignition switch to OFF position (if your vehicle is not equipped with an ignition operated engine shut down then use the engine shut down button or control to stop engine).

5. Make sure all electrical accessories and lights are off and the vehicle is in neutral.

CAUTION - Failure to follow engine manufacturers

guidelines regarding engine shut down procedures may cause severe engine damage.

Operation

is located on the console to the right of the seat and next to the shift lever (Page 21).

Figure 1

A - Fifth Wheel Plate

B - Boom

DANGER - Never raise or lower the boom while the tractor and trailer combina-

tion are moving. Raising the boom while the tractor and trailer are moving creates a “roll over” hazard and may cause the vehicle to roll over. Possibly resulting in injury of death. DO NOT OPERATE THE BOOM CONTROL LEVER WHILE THE VEHICLE IS MOVING A TRAILER.

To Raise Fifth Wheel: To raise the boom the engine must be running. Pushing the lever to the “UP” position, indicated on the boom operating lever, raises the ﬁfth wheel. To increase the rate of travel of the boom, the engine may be idled higher while the vehicle is in NEUTRAL ONLY.

To Lower Fifth Wheel: To lower the boom, the engine must be running, the transmission in NEUTRAL. Pulling the boom control lever to the “DOWN” position,

PARKING WITH AN AUTOMATIC TRANSMISSION

The Allison RDS series transmissions do not have a “PARK” position like an automobile transmission. For information on how to properly park your Kalmar, see the following sections in this manual:

Page 23, Parking the Vehicle Pages 26 thru 28, Parking Brake

HYDRAULIC FIFTH WHEEL LIFTING SYSTEM

The standard ﬁfth wheel lifting system on Kalmar tractors is hydraulically operated. A P.T.O. and hydraulic pump mounted on the transmission provide the hydraulic power to operate the Hydraulic Fifth Wheel Lifting System. The Fifth Wheel is mounted to a hydraulically operated “Boom” (ﬁg. 1). This “Boom” assembly is attached to the frame at a pivot behind the cab. The system operates like a large hydraulic ﬂoor jack.

The following are general operating instructions and may not apply to you particular vehicle. If there are any questions regarding the operation of your vehicle or a particular option, contact your Kalmar dealer.

HYDRAULIC BOOM OPERATION

The hydraulically operated boom is controlled by a lever inside the cab. The lever

Operation

marked on the boom operating lever, lowers the boom and ﬁfth wheel. To increase the rate of travel of the boom, the engine may be idled higher while the vehicle is in NEUTRAL ONLY. Standard conﬁguration of the boom allows both power up and down capability.

FIFTH WHEEL UNLATCH CONTROL VALVE

The Kalmar tractor comes standard with an air operated ﬁfth wheel unlatch cylinder. The cylinder is operated by a “push type” valve located on the right hand console behind the shifter (Page 21). Pressing the ﬁfth wheel unlatch valve opens the king pin jaws in the ﬁfth wheel. After the jaws are opened, they remain open until the ﬁfth wheel is connected to a trailer kingpin.

NOTE - When pulling out from under a trailer, the control must be depressed and held until the ﬁfth wheel is clear of the trailer king pin.

BASIC TRAILER SPOTTING STEPS

NOTE - The following information is for reference only. Kalmar Industries Corp. highly recommends using the following information to create procedures that match your particular application and vehicle. It is the operator’s responsibility to ensure that proper trailer moving procedures are used for a particular situation and vehicle application.

1. Maintain optimum tractor air pressure (120 PSI). The ﬁfth wheel should be in the FULL DOWN position. Be absolutely positive that the ﬁfth wheel jaws are in the UNLATCH position by depressing the unlatch control valve located to the right of the shifter. (See page 21).

2. Line the tractor up to the front of the trailer by centering the ﬁfth wheel to the center line of the trailer. Make sure that the tail of the ﬁfth wheel is BELOW the trailer skid ramp.

3. Back the tractor UNDER the trailer until the ENTIRE ﬁfth wheel DISAPPEARS UNDER the front edge of the trailer ﬂoor/skid plate.

4. With your foot ﬁrmly on the brake treadle and the tractor shift lever in NEUTRAL, move the boom control lever to the UP position and raise the trailer until the trailer support is JUST OFF THE GROUND. DO NOT raise the trailer any more than a few inches to provide clearance between the trailer landing gear and the ground at this step.

5. After you have obtained adequate ground clearance at the trailer landing gear, place the shift selector in REVERSE, release your foot from the brake treadle and back FIRMLY into the kingpin jaws until you feel full engagement. REMEMBER, the latching jaws in the ﬁfth wheel MUST BE FULLY IN THE UNLATCH POSITION BEFORE attempting kingpin engagement.

6. Place the transmission shift lever into a forward drive gear and give a “TUG” at the kingpin to ensure positive lock of the jaws around the kingpin. BE PREPARED to stop if the ﬁfth wheel jaws have not fully latched to avoid pulling out from under the trailer and dropping it.

7. Place the shift lever in the NEUTRAL position and raise the boom using the boom control lever. Raise the ﬁfth wheel to the necessary height to maintain ground clearance while towing the trailer to the new location. Be aware of potential overhead damage to a trailer if it is

Operation

raised too high.

8. Once proper trailer height is reached, apply the tractor parking brake. Now hook BOTH the trailer emergency and service airlines to the trailer (blue & red airlines) and plug in the trailer electrical cable.

9. With the brake treadle FULLY applied, push in BOTH the parking brake control (yellow) and the trailer air supply (red), this will charge the trailer air supply and release the trailer spring/parking brakes.

10. After the tractor air system is fully charged, move the transmission shift lever to the proper gear and release pressure on the foot operated brake treadle and allow the vehicle to roll a VERY SHORT distance and then depress the brake treadle again to stop the vehicle. This procedure will insure that the service brakes on the trailer are working properly. NOW, and ONLY NOW, are you ready to move (“SPOT”) the trailer.

11. Once the trailer is relocated and the vehicle combination is completely stopped, place the shift lever in NEUTRAL and pull out on the trailer air supply control (red). This will apply the trailer parking brakes only. The parking brake control (yellow) should remain “in”, with the tractor parking brake released.

12. Using the boom control lever, lower the trailer until the trailer supports are resting completely on the ground.

13. Disconnect and STORE the air lines and electrical cable.

14. DEPRESS and HOLD the ﬁfth wheel unlatch control valve as you slowly pull away from the trailer. Once the ﬁfth wheel is completely clear of the kingpin, release

the ﬁfth wheel unlatch control and go the next trailer.

WARNING - When the tractor is operated on public streets or highways, the

5th wheel manual secondary lock MUST be engaged. The secondary lock is engaged by removing the hairpin clip on the lock handle allowing the lock to pivot behind the locking yoke. The ﬁfth wheel MUST be in the DOWN position to operate the vehicle on public streets or highways.

WARNING - Never raise

or lower the boom while

the vehicle has a trailer at-

tached and is in motion.

WARNING - DO NOT

EXCEED 15 MPH WHEN

TOWING TRAILERS. Op-

erating at speeds in excess of 15 MPH may lead to loss of vehicle control. NEVER take turns at excessive speeds, this may cause the vehicle and trailer to roll over. The majority of roll over accidents are caused by excessive cornering speed. ALWAYS SLOW WHEN CORNERING. Roll over accidents may lead to serious injury or death.

WARNING - Never tow

trailers without BOTH the

service and emergency brake

lines connected to the trailer. Never tow trailers without functioning service and emergency brake systems. Operating the vehicle while towing trailers without functioning trailer brake systems may lead to loss of control of the vehicle, serious injury or death.

Operation

TOWING VEHICLE WITH FRONT WHEELS SUSPENDED

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

WARNING - Always obey the following when towing a Kalmar tractor with the front wheels lifted and the

rear wheels on the road.

1. Always use a rigid towing bar or properly restrain the towed vehicle. Using a chain or cable to tow the vehicle is not recommended.

2. Always disconnect the drive line to the rear drive axle(s), or remove all axle shafts from all rear drive

axles.

3. Always cage the spring brakes on

all rear drive wheels. (See page B-14, Manually Releasing Spring Brakes) A loss of air pressure could occur while towing the vehicle. This would apply the spring/parking brakes and lock the rear wheels on the towed vehicle.

WARNING - When manually releasing spring brakes, make sure that the vehicle

wheels are properly blocked. If the wheels are not blocked, the vehicle could move suddenly when the spring brakes are released and cause sever injury.

WARNING - Never tow a trailer above the minimum height required to clear

the landing gear from the ground. Lifting the ﬁfth wheel and trailer too high drastically raises the center of gravity of the trailer and increases the chance of a roll over.

TOWING THE VEHICLE

Towing a vehicle requires special equipment and training. Kalmar Industries Corp. recommends that a professional towing service be used when towing a disabled Kalmar.

The best way to tow a Kalmar tractor is with the rear wheels lifted off the road. This prevents any possible damage to the transmission and drivetrain. Towing the vehicle with the rear wheels lifted avoids having to disconnect the driveline or axle shafts. Also, towing with the rear wheels lifted does not require the spring brakes to be caged unless there are spring brakes on the front wheels.

If it is impossible to tow the vehicle with the rear wheels lifted, be sure to follow the steps listed below, “Towing Vehicle with Front Wheels Suspended”.

CAUTION - Some Kalmars

are equipped with “Off

Highway” tires. Tire damage

may occur if towed on road.

Operation

Fahrenheit (37 deg. Celsius) above ambient temperature. Operating temperatures above 230 deg. F signiﬁcantly increase the rate of lubricant oxidation and shortens the effective life of the lubricant. This makes more frequent changes necessary.

REAR AXLES WITH LOCKING DIFFERENTIALS

Kalmar tractors may be equipped with a variety of special axle and differential combinations. Because of the effect of special differentials on vehicle operation, it is important to understand how your particular differential operates. Locking or limited slip differentials are not standard on Kalmar tractors. If you do not know if your vehicle is equipped with a special axle and differential, contact your Kalmar dealer.

“NO SPIN” POSITIVE LOCKING DIFFERENTIAL

Kalmar tractors may be equipped with an optional “No Spin” differential. This locking differential has very special operating characteristics. IT IS VERY IMPORTANT FOR THE OPERATOR OF A VEHICLE EQUIPPED WITH THIS FEATURE TO OBTAIN AND FOLLOW ALL OF THE OPERATION AND MAINTENANCE INFORMATION PROVIDED BY THE DIFFERENTIAL MANUFACTURER. Contact your Kalmar dealer for assistance on operating and maintaining this differential.

WARNING - If the disabled vehicle is connected to a tow vehicle before the

spring brakes are released, make sure that the tow vehicle’s parking brakes are applied and it’s wheels are blocked to prevent movement.

TOWING VEHICLE WITH REAR WHEELS SUSPENDED

The recommended way to tow a disabled vehicle is with the rear wheels lifted off of the ground. The steering axle must be locked in the straight ahead position. If there are spring brakes on the front axle, the springs must be caged. (See page 26, Manually Releasing Spring Brakes).

AXLES

Kalmar tractors may be ordered with a variety of axle conﬁgurations, makes and models. It is important to refer to the axle manufacturer’s information for your speciﬁc axles. You can obtain axle operation and maintenance information from your local Kalmar dealer. The following is general axle information and may not apply to your particular axle.

NOTE - This manual does not contain complete operational information on any axle. The operator must obtain and refer to the axle manufacturer’s information on operation, service, and maintenance.

AXLE OPERATING TEMPERATURE

Normally, axle operating temperatures will not exceed more that 100 degrees

Operation

to fully extend the cylinder past 45 degrees can cause pump and motor damage. Check cab tilt cylinder and bracket mounting bolt for proper torque and for wear!

Figure 1

A - Cab Tilt Control Switch

B - Safety Prop Release Cable

TO TILT CAB

In most cases, the cab tilt control switch is located on the left hand frame rail (Fig.1). The safety prop release cable is located on the left hand rail, within reach of the tilt switch.

WARNING - Ensure that no part of the body is under the cab while tilting. Stand

clear of the rear of the cab and ensure that the cab does not strike you when it is being raised.

WARNING - Ensure that

the safety prop is properly

engaged before working under the cab. The safety prop must be able to move freely to engage automatically. Always check the safety prop before working under

CAB TILTING AND LOWERING

The tractor comes equipped with an electrically operated cab tilt system as standard equipment. Under power assist, the cab can be tilted to 45 degrees. At 45 degrees the safety prop is automatically engaged.

The cab can be tilted MANUALLY TO 90 degrees if needed. This requires that the tilt cylinder be disconnected, and that a suitable hoist be used to tilt the cab all the way to the 90 degree position.

All tractors come standard with a cab air suspension. These units are designed to work with the power cab tilt, and unlatch automatically. If the unit is not equipped with cab air suspension as an option, the cab hold down latches will also operate automatically when titling the cab.

The electric cab tilt is designed to tilt the cab to 45 degrees at which point the cab safety prop is automatically engaged. The tilt system is not designed to provide a safety prop at any point other than 45 degrees. Figure 2 shows proper engage-

ment of the Cab Safety Prop.

DANGER - Never work under the cab unless the safety prop is properly en-

gaged. The cab could fall and cause serious injury or death. (See Figures 2 and 3)

CAUTION - Only tilt the cab far enough past the 45 degree point to engage the safety bar. Attempting

Operation

the cab and make sure to properly

maintain this important safety system.

1. Locate the cab tilt control switch and safety prop release cable.

2. Pull the safety prop release cable and hold the cable to the rear.

3. While holding the cable to the rear move the tilt control switch to the “UP” position.

4. After the cab has traveled about 15 inches, release the safety prop cable and continue tilting the cab.

5. As the cab approaches the 45 degree position, watch for the safety prop to drop over the tilt cylinder on the driver’s side of the frame. (Fig. 2 and 3) STOP!

6. After the safety prop has dropped over the cylinder, move the tilt control switch to the “DOWN” position (Page 38, Fig. 1) and lower the cab slightly until the safety prop rests fully on the top of the tilt cylinder (Fig. 2).

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

TO LOWER CAB

1. Move the cab tilt switch to the “UP”

position and raise the cab slightly

until the safety prop is free from the top of the tilt cylinder.

2. Pull the safety prop release cable to the rear and hold in the rearward position.

3. Move the tilt switch to the “DOWN” position with the safety prop disengaged and allow the cab to lower onto the rear cab latch.

4. Hold the cab tilt switch in the down position for 5 seconds after the cab has come to a rest on the lower latch units to ensure that the mechanical cab latches are fully engaged.

CAB SAFETY PROP IS ENGAGED

CORRECTLY

Figure 2

A Tilt Cylinder B Safety Prop C Safety Prop Release Cable The Safety Prop (B) is resting ﬂush

against the Tilt Cylinder (A). The Safety Prop is properly engaged.

Operation

ELECTRICAL ELECTRICAL

ACCESSORY CONNECTIONS

The wiring harness in the Kalmar is designed to support many vehicle options. These options may or may not already be on your vehicle. If any electrical equipment is installed on the vehicle after it leaves the factory, contact your Kalmar dealer ﬁrst. Your dealer can provide you with information on proper electrical modiﬁcations and installations. Generally, there will be an accessory location on the harness where you will need it. Do not risk damaging your vehicle or voiding the warranty by making improper and poor electrical modifications, contact your Kalmar dealer ﬁrst.

RELAYS / BREAKERS / FUSES

The Kalmar is equipped with an easily accessible fuse panel. This panel is located below and to the left of the steering column, underneath the dash (Page 39, Fig. 1)

Trucks equipped with an electronic engine will have an additional relay panel located directly above the main fuse panel. (The relay panel can be accessed by removing the ﬁrst dash panel.)

The fuse panel has a removable cover. A decal showing the relay locations can be found on the back of the cover. If the cover is missing refer to Figures 1 and 2 for fuse and relay locations.

CAB SAFETY PROP IS NOT

ENGAGED CORRECTLY

Figure 3

Safety Prop (B) is NOT resting ﬂush

against Tilt Cylinder (A). The Safety

Prop is NOT properly engaged.

WARNING - Ensure that the cab latch is fully engaged after lowering

the cab. If the cab latch is not properly locked down, the cab could tilt while the vehicle is in motion.

NOTE - The safety prop is designed to act as a secondary cab hold down in case of cab latch failure or a tilt system malfunction. Ensure that the release cable is operating freely and that the safety prop rests against the tilt cylinder when the cab is in the lowered and latched position.

Operation

Figure 1a - Standard fuse conﬁguration

Figure 1b - QSB fuse conﬁguration

Figure 2 - Relay Location

Operation

CONTENTS

Section “C”

INTRODUCTION ...........................................................................................41

LUBRICATION AND FLUIDS .........................................................................41

Automatic Transmission Fluid ............................................................ 42

Axle Lubricant ...................................................................................42

Coolant / Anti-freeze .........................................................................42

Fuel ....................................................................................................43

Engine Oil ..........................................................................................44

Hydraulic System Fluid ......................................................................44

Mulit-purpose Grease ........................................................................44

FILTERS ...........................................................................................................44

MAINTENANCE ............................................................................................. 45

CHASSIS LUBRICATION DIAGRAM ..............................................................56

LUBRICATION CHART ...................................................................................57

BOOM AND FIFTH WHEEL LUBRICATION DIAGRAM .................................58

Maintenance

DANGER - A vehicle that has not been properly maintained, may not be

safe to operate. The operator of an Kalmar must be satisﬁed that his/her vehicle has been properly maintained and is in safe working condition, before operating that vehicle. Operating an improperly maintained vehicle may lead to loss of vehicle control, which could severely injure or kill the operator.

LUBRICATION AND FLUIDS

This section contains basic ﬂuid and lubricant requirements and their minimum service intervals for the Standard Kalmar tractor. It also contains basic information on ﬁlter change intervals. If your vehicle has any optional or special factory installed equipment, such as planetary axles or a central lube system, contact your Kalmar dealer for speciﬁc lubrication requirements for your vehicle.

The ﬂuids and lubricants covered in this section are listed below. If a speciﬁc lubricant or ﬂuid used on your vehicle is not covered in this section, contact your Kalmar dealer for the information.

Automatic Transmission Fluid Axle Differential Lubricant Coolant / Anti-freeze Diesel Fuel Engine Oil Multi-purpose Grease Hydraulic System Fluid

The Lubrication Diagrams on pages 56 and 58 show the location of speciﬁc lubrication and ﬂuid points for easy reference. The Preventive Maintenance Form

INTRODUCTION

The key to safe and dependable operation of your Kalmar tractor is proper maintenance. Yard tractors are used in very abusive operations. Moving trailers through rough yards 10 to 24 hours a day can take a toll on even the best built piece of equipment. It is the operator’s job to ensure that every time he or she climbs into the cab, that the vehicle is ready to roll, safely and reliably.

Because all spotting applications are not he same, it is critical that a good “Total Maintenance Program” is developed for your particular vehicle and application. A vehicle that runs 24 hours a day in a railroad yard will need a more intensive maintenance program than a vehicle running 8 hour days in a smooth, paved lot.

If you need assistance on determining a good maintenance program, call your Kalmar dealer for assistance.

NOTE - The pre-operation checklist, or “walk around” ensures that there are no obvious problems with the vehicle (a sample checklist is provided on page 9). This is no substitute for a good Preventative Maintenance program, though.

WARNING - Vehicle maintenance, other than routine operator maintenance

(checking ﬂuids, cleaning, ﬁlling fuel tank), should only be performed by a professional, trained mechanic. Many maintenance procedures requires special training and tools to be done safely. Attempting to perform maintenance procedures without proper training and equipment may lead to serious injury or death.

Maintenance

(See page 45) indicates services that need to be performed at every 250, 500, 1000 and 2000 hour interval. The chart also indicates the type of lubricant or ﬂuid required or indicates the page number where that information can be found.

CAUTION - The mainte-

nance and service intervals

in this manual are provided

for a reference. These intervals are the maximum allowable on a vehicle used in a normal operation. These intervals may not apply to your speciﬁc vehicle application. It is the operator’s responsibility to ensure that the vehicle is properly maintained. Failing to maintain a vehicle properly may lead to serious vehicle damage and possibly to an unsafe vehicle.

NOTE - Never add any type of ﬂuid or lubricant unless it is the same grade and type which is currently being used. Mixing of difference lubricant and ﬂuid grades or types should be avoided. If the grade or type of ﬂuid is unknown, the system must be drained and ﬂushed before the new ﬂuid or lubricant is added.

AUTOMATIC TRANSMISSION FLUID

All Kalmar tractors come with an Transmission Operator’s Manual, provided by the manufacturer. This manual covers the speciﬁc transmission in your vehicle. Refer to this Transmission Operator’s Manual for transmission ﬂuid requirements and service intervals.

CAUTION - Kalmar Industries Corporation

requires that the operator of any Kalmar tractor comply with the transmission manufacturer’s transmission ﬂuid requirements. Failure to comply with the transmission manufacturer’s requirements for transmission ﬂuid may void the warranty on the transmission and cause severe transmission damage. Contact your Kalmar dealer if you did not receive a Transmission Operator’s Manual with your new Kalmar.

AXLE LUBRICANT

Axle lubricant requirements vary with make of axle and customer requirements. Refer to the axle manufacturers operator’s manual for required speciﬁcations and operating information.

NOTE - Synthetic gear lubricant is available as an option. Contact your Kalmar dealer if you need more information.

NOTE - Front axles equipped with optional “WET” wheel seals require the lubricant described previously. They do not use the lithium based grease used on standard front hubs. The ﬂuid in these front hubs needs to be checked every 250 hours.

COOLANT / ANTI-FREEZE

The Cooling system of a new Kalmar is ﬁlled at the factory with the following solution:

50% ethyl-glycol heavy-duty antifreeze with rust inhibitor

Maintenance

CAUTION - The coolant

should be tested every 250

hours and replaced every

2000 hours at the very minimum. Exceeding these intervals may damage the cooling system.

NOTE - A coolant mixture below 30% does not provide adequate corrosion protection and may lead to radiator damage. A coolant mixture above 68% does not provide proper freeze protection and reduces heat transfer capabilities of the solution.

FUEL

All Kalmar tractors come with an Engine Operator’s Manual provided by the engine manufacturer. This manual is for the speciﬁc engine in your vehicle. Refer to this Engine Operator’s Manual for fuel requirements.

DANGER - Never mix

diesel fuel with gasoline,

gasohol, and/or alcohol.

This practice creates an extreme ﬁre hazard and may cause an explosion which could result in serious injury or death.

CAUTION - Kalmar Indus-

tries Corp. requires that

the operator of any Kalmar

tractor comply with the engine manufacturer’s fuel requirements. Failure to comply with engine manufacturer’s fuel requirements may cause severe engine damage and void the warranty on the engine. Contact your Kalmar dealer if you did not receive an Engine Operator’s Manual with your new Kalmar.

50% Water Coolant system additive must be aluminum compatible.

Proper level of ﬁll for the cooling system is indicated by the presence of coolant in the sight glass of the radiator top tank. It is not necessary to ﬁll the top tank to the ﬁller neck.

A 50/50 mixture provides freeze protection down to -34 degrees F. and maintains proper heat transfer properties. This is the recommended solution mixture.

Always refer to the Engine Operator’s Manual before changing the factory recommended anti-freeze to water ratio in the coolant mixture. Some engine manufacturers have specific coolant mixture requirements needed to satisfy engine warranty requirements. Remember to check and maintain the anti-freeze solution in your Kalmar tractor regularly. Contact your Kalmar dealer if you need more information.

Some engines, specifically “sleeved” engines, require the use of supplemental coolant additives to prevent liner cavitation. Refer to the engine operator’s manual for more information.

WARNING - Never attempt to open the radiator when

the engine is hot. Always allow the engine and coolant to cool completely before opening the radiator. Failure to allow the coolant to cool, will cause hot coolant to spray from the radiator when it is opened. This could cause severe burns or blindness.

Maintenance

NOTE - The ﬂuid in the hydraulic system and the ﬁlter must both be replaced at least once a year at the very minimum. Never exceed this interval.

MULTI-PURPOSE GREASE

The following ﬂuids are recommended:

1. API Grade 1

2. Any high quality Lithium based grease that has extreme pressure properties, is water resistant and is recommended for use in automotive and heavy-duty applications.

3. Base Oil Timken 40 rating minimum.

FILTERS

Refer to your Kalmar Parts Manual for the required part numbers. Remember, your parts manual is custom built to match your speciﬁc vehicle. If you are in doubt of the correct part numbers, contact your Kalmar dealer for help.

The preventative maintenance form (see page 45) for the recommended MAXIMUM ﬁlter replacement intervals. These intervals are the absolute maximum allowable under normal conditions. Intervals for your vehicle may be shorter due to actual vehicle operating conditions. Operating a vehicle in harsh conditions, or for extended periods of heavy use will make more frequent ﬁlter changes necessary.

CAUTION - Never exceed the maximum time intervals. Doing so may lead to

vehicle damage and void the vehicle and component warranties.

ENGINE OIL

CAUTION - Kalmar Industries Corp. requires that the operator of any Kalmar

tractor comply with the engine manufacturer’s engine oil requirements. Failure to comply with the engine manufacturer’s requirements for engine oil may void the warranty on the engine and cause severe engine damage. Contact your Kalmar dealer if you did not receive and Engine Operator’s Manual with your new Kalmar.

HYDRAULIC SYSTEM FLUID

Proper ﬂuid level can be checked using the gauge found on the outside of the hydraulic tank. Add ﬂuid to keep it level with the “Full Cold” line. The level should be checked after moving the boom to the down position with the engine running.

Three systems requiring hydraulic ﬂuid operate out of a single, high capacity reservoir located on the frame rail. The three systems are:

1. Boom Lift

2. Power Steering

3. Cab Tilt

DEXTRON III should be used whenever replenishing or replacing the ﬂuid.

Maintenance

KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM

ELECTRONIC ENGINES (Except QSB-155) – RDS TRANSMISSION WITH NON-SYNTHETIC LUBE

TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE

EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION.  = SATISFACTORY  = ADJUSTMENT NECESSARY  = REPAIRS NEEDED. “A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVALS, “B” INSPECTIONS AT 500 HOUR INTERVALS, “C” INSPECTIONS AT 1000 HOUR INTERVALS, AND “D” INSPECTIONS AT 2000 HOUR INTERVALS.

OPERATION A B C D

CAB – INTERIOR

UNDER VEHICLE

CHECK OPERATION OF NEUTRAL START

CHECK STEERING GEAR

CHECK OPERATION OF ALL GAUGES

CHECK BRAKE LININGS AND DRUMS

CHECK LOW AIR BUZZER AND LIGHT

CHECK SPRINGS

CHECK WINDSHIELD WIPER OPERATION

CHECK SHOCK ABSORBERS (IF APP.)

CHECK WINDSHIELD WASHER OPERATION (IF APP.)

TORQUE FRONT AXLE MOUNTING BOLTS

CHECK ACCELERATOR FOR FREE OPERATION

TORQUE KING PIN DRAW KEY NUT(S)

CHECK HORN(S) OPERATION

CHECK POWER STEERING PUMP

CHECK AIR SYSTEM FOR MAXIMUM 120 PSI

CHECK HYDRAULIC PUMP

CHECK AIR SYSTEM FOR LEAK DOWN

CHECK STARTER MOUNTING AND CONNECTIONS

CHECK OPERATION OF BACK UP ALARM

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK OPERATION OF SHIFT LOCK OUT

CHANGE ENGINE OIL AND FILTER

CHECK HVAC SYSTEM

CHANGE TRANSMISSION EXTERNAL FILTER

BLOWER MOTOR OPERATION

CHANGE TRANSMISSION FLUID

TEMPERATURE CONTROL

CHECK ENGINE AND TRANSMISSION MOUNTS

AUXILIARY FAN(S) (IF APP.)

CHECK WHEEL SEALS FOR LEAKS

A/C OPERATION (IF APP.)

CLEAN REAR AXLE BREATHER

DEFROSTER OPERATION

CHECK DIFFERENTIAL FOR LEAKS

CHECK OPERATION OF PTO CONTROL (IF APP.)

CHECK DIFFERENTIAL OIL LEVEL

CHECK 5TH WHEEL UNLATCH CONTROL

CHANGE DIFFERENTIAL OIL

CHECK OPERATION OF BOOM

CHECK LIFT CYLINDERS FOR LEAKS

CHECK FIRE EXTINGUISHER CHARGE (IF APP.)

CHECK OTTO-RIDE RUBBER ISOLATOR (IF APP.)

CHECK SEAT BELT OPERATION

TORQUE REAR AXLE MOUNTING BOLTS

CHECK SIDE DOOR LATCH OPERATION

CHASSIS

CHECK REAR DOOR LATCH OPERATION

CHECK FRONT AXLE OIL LEVEL (IF APP.)

CHECK DOME LIGHT OPERATION

REPACK FRONT WHEEL BEARINGS (IF APP.)

CHECK ALL GLASS AND MIRRORS

CHECK BATTERY CABLES & HOLDDOWNS

CHECK OPERATION OF WINDOWS

CHECK BATTERIES FOR CRACKS OR ACID DAMAGE

CAB DOWN – EXTERIOR

CLEAN BATTERY CABLE CONNECTIONS

CHECK CAB ACCESS STEPS AND HANDLES

CHECK BATTERY BOX COVER HOLDDOWNS

CLEAN HEATER / AC FILTER (IF APP.)

DRAIN WATER FROM AIR TANKS

CHECK REAR DOOR ROLLER / SLIDE ADJUSTMENT

CHECK AND TORQUE ALL WHEEL NUTS

CHECK GLADHAND SEALS AND TRAILER AIR LINES

CHECK WHEELS

CHECK TRAILER LIGHT CORD

CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION

CHECK HEADLIGHTS / MARKER LIGHTS

CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)

CHECK TURN SIGNALS

INSPECT CATWALK

CHECK STROBE LIGHT (IF APP.)

CHECK FRAME FOR CRACKS

CHECK SPOTLIGHTS

CHECK MUD FLAPS / FENDERS (IF APP.)

CHECK WIPER BLADES

CHANGE HYDRAULIC SYSTEM FILTER

CHECK WINDSHIELD WASHER FLUID LEVEL

CHECK HYDRAULIC FLUID LEVEL

CAB UP

CHANGE HYDRAULIC FLUID

CHECK OPERATION OF CAB TILT PUMP

CLEAN HYDRAULIC TANK VENT

CHECK CAB SAFETY PROP

LUBRICATION

CHECK CAB SUSPENSION AND LATCH

CHECK / LUBRICATE SIDE DOOR HINGES

CHECK INTAKE DUCTING FOR LEAKS

CHECK / LUBRICATE REAR DOOR ROLLERS

CHECK RADIATOR FOR LEAKS

CHECK / LUBRICATE CAB HINGE PINS

CHECK RADIATOR MOUNTS

CHECK / LUBRICATE HOOD HINGE

CHECK COOLANT LEVEL AND CONCENTRATION

CHECK / LUBRICATE STEERING SLIP JOINT

CHECK AND ADJUST COOLANT ADDITIVE (IF APP.)

CHECK / LUBRICATE STEERING U-JOINTS

CHANGE ENGINE COOLANT

CHECK / LUBRICATE KING PINS AND TIE ROD ENDS

CHECK COOLANT HOSES AND CLAMPS

CHECK / LUBRICATE DRAG LINK

CHECK FAN CLUTCH FOR OPERATION (IF APP.)

CHECK / LUBRICATE SLACK ADJUSTERS

CHECK ENGINE COOLING FAN FOR CRACKS

CHECK / LUBRICATE SPRING PINS AND BUSHINGS

CHECK ENGINE BELT(S) AND TENSIONER

CHECK / LUBRICATE DRIVELINE U-JOINTS

CHANGE ENGINE COOLANT FILTER (IF APP.)

CHECK AND LUBE LOWER BOOM CYLINDER BEARING

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)

DRAIN FUEL WATER SEPARATOR

ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.)

CHANGE FUEL FILTER / FUEL WATER SEPARATOR

CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS

CHECK AIR RESTRICTION GAUGE (IF APP.)

CHECK AND LUBRICATE 5TH WHEEL TOP PLATE

CHANGE AIR FILTER AS NEEDED

CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS

CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED

CHECK AND LUBRICATE BOOM PIVOT BEARINGS

CHECK EXHAUST SYSTEM

CHECK AND LUBE UPPER BOOM CYLINDER BEARING

CHECK TRANSMISSION FLUID LEVEL

CHECK AND LUBRICATE HYDRAULIC PUMP DRIVE

CLEAN TRANSMISSION BREATHER

TEST DRIVE

TORQUE CAB TO DECK MOUNTING BOLTS

DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION

Maintenance

KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM

QSB-155 – RDS TRANSMISSION WITH NON-SYNTHETIC LUBE

TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE

OPERATION A B C D

CAB – INTERIOR

UNDER VEHICLE

CHECK OPERATION OF NEUTRAL START

CHECK STEERING GEAR

CHECK OPERATION OF ALL GAUGES

CHECK BRAKE LININGS AND DRUMS

CHECK LOW AIR BUZZER AND LIGHT

CHECK SPRINGS

CHECK WINDSHIELD WIPER OPERATION

CHECK SHOCK ABSORBERS (IF APP.)

CHECK WINDSHIELD WASHER OPERATION (IF APP.)

TORQUE FRONT AXLE MOUNTING BOLTS

CHECK ACCELERATOR FOR FREE OPERATION

TORQUE KING PIN DRAW KEY NUT(S)

CHECK HORN(S) OPERATION

CHECK POWER STEERING PUMP

CHECK AIR SYSTEM FOR MAXIMUM 120 PSI

CHECK HYDRAULIC PUMP

CHECK AIR SYSTEM FOR LEAK DOWN

CHECK STARTER MOUNTING AND CONNECTIONS

CHECK OPERATION OF BACK UP ALARM

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK OPERATION OF SHIFT LOCK OUT

CHANGE ENGINE OIL AND FILTER

CHECK HVAC SYSTEM

CHANGE TRANSMISSION EXTERNAL FILTER

BLOWER MOTOR OPERATION

CHANGE TRANSMISSION FLUID

TEMPERATURE CONTROL

CHECK ENGINE AND TRANSMISSION MOUNTS

AUXILIARY FAN(S) (IF APP.)

CHECK WHEEL SEALS FOR LEAKS

A/C OPERATION (IF APP.)

CLEAN REAR AXLE BREATHER

DEFROSTER OPERATION

CHECK DIFFERENTIAL FOR LEAKS

CHECK OPERATION OF PTO CONTROL (IF APP.)

CHECK DIFFERENTIAL OIL LEVEL

CHECK 5TH WHEEL UNLATCH CONTROL

CHANGE DIFFERENTIAL OIL

CHECK OPERATION OF BOOM

CHECK LIFT CYLINDERS FOR LEAKS

CHECK FIRE EXTINGUISHER CHARGE (IF APP.)

CHECK OTTO-RIDE RUBBER ISOLATOR (IF APP.)

CHECK SEAT BELT OPERATION

TORQUE REAR AXLE MOUNTING BOLTS

CHECK SIDE DOOR LATCH OPERATION

CHASSIS

CHECK REAR DOOR LATCH OPERATION CHECK FRONT AXLE OIL LEVEL (IF APP.)

CHECK DOME LIGHT OPERATION

REPACK FRONT WHEEL BEARINGS (IF APP.)

CHECK ALL GLASS AND MIRRORS CHECK BATTERY CABLES & HOLDDOWNS

CHECK OPERATION OF WINDOWS

CHECK BATTERIES FOR CRACKS OR ACID DAMAGE

CAB DOWN – EXTERIOR

CLEAN BATTERY CABLE CONNECTIONS

CHECK CAB ACCESS STEPS AND HANDLES

CHECK BATTERY BOX COVER HOLDDOWNS

CLEAN HEATER / AC FILTER (IF APP.)

DRAIN WATER FROM AIR TANKS

CHECK REAR DOOR ROLLER / SLIDE ADJUSTMENT

CHECK AND TORQUE ALL WHEEL NUTS

CHECK GLADHAND SEALS AND TRAILER AIR LINES

CHECK WHEELS

CHECK TRAILER LIGHT CORD

CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION

CHECK HEADLIGHTS / MARKER LIGHTS

CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)

CHECK TURN SIGNALS

INSPECT CATWALK

CHECK STROBE LIGHT (IF APP.)

CHECK FRAME FOR CRACKS

CHECK SPOTLIGHTS

CHECK MUD FLAPS / FENDERS (IF APP.)

CHECK WIPER BLADES

CHANGE HYDRAULIC SYSTEM FILTER

CHECK WINDSHIELD WASHER FLUID LEVEL

CHECK HYDRAULIC FLUID LEVEL

CAB UP

CHANGE HYDRAULIC FLUID

CHECK OPERATION OF CAB TILT PUMP

CLEAN HYDRAULIC TANK VENT

CHECK CAB SAFETY PROP

LUBRICATION

CHECK CAB SUSPENSION AND LATCH

CHECK / LUBRICATE SIDE DOOR HINGES

CHECK INTAKE DUCTING FOR LEAKS

CHECK / LUBRICATE REAR DOOR ROLLERS

CHECK RADIATOR FOR LEAKS

CHECK / LUBRICATE CAB HINGE PINS

CHECK RADIATOR MOUNTS

CHECK / LUBRICATE HOOD HINGE

CHECK COOLANT LEVEL AND CONCENTRATION

CHECK / LUBRICATE STEERING SLIP JOINT

CHECK AND ADJUST COOLANT ADDITIVE (IF APP.)

CHECK / LUBRICATE STEERING U-JOINTS

CHANGE ENGINE COOLANT

CHECK / LUBRICATE THROTTLE SHAFT

CHECK COOLANT HOSES AND CLAMPS

CHECK / LUBRICATE KING PINS AND TIE ROD ENDS

CHECK FAN CLUTCH FOR OPERATION (IF APP.)

CHECK / LUBRICATE DRAG LINK

CHECK ENGINE COOLING FAN FOR CRACKS

CHECK / LUBRICATE SLACK ADJUSTERS

CHECK ENGINE BELT(S) AND TENSIONER

CHECK / LUBRICATE SPRING PINS AND BUSHINGS

CHANGE ENGINE COOLANT FILTER (IF APP.)

CHECK / LUBRICATE DRIVELINE U-JOINTS

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK AND LUBE LOWER BOOM CYLINDER BEARING

DRAIN FUEL WATER SEPARATOR

CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)

CHANGE FUEL FILTER / FUEL WATER SEPARATOR

ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.)

CHECK AIR RESTRICTION GAUGE (IF APP.)

CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS

CHANGE AIR FILTER AS NEEDED

CHECK AND LUBRICATE 5TH WHEEL TOP PLATE

CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED

CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS

CHECK EXHAUST SYSTEM

CHECK AND LUBRICATE BOOM PIVOT BEARINGS

CHECK TRANSMISSION FLUID LEVEL

CHECK AND LUBE UPPER BOOM CYLINDER BEARING

CLEAN TRANSMISSION BREATHER

CHECK AND LUBRICATE HYDRAULIC PUMP DRIVE

TORQUE CAB TO DECK MOUNTING BOLTS

TEST DRIVE

DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION

Maintenance

KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM

ELECTRONIC ENGINES (Except QSB-155) – RDS TRANSMISSION WITH “TRANSYND” LUBE AND ALLISON FILTERS

TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE

OPERATION A B C D

CAB – INTERIOR

UNDER VEHICLE

CHECK OPERATION OF NEUTRAL START

CHECK STEERING GEAR

CHECK OPERATION OF ALL GAUGES

CHECK BRAKE LININGS AND DRUMS

CHECK LOW AIR BUZZER AND LIGHT

CHECK SPRINGS

CHECK WINDSHIELD WIPER OPERATION

CHECK SHOCK ABSORBERS (IF APP.)

CHECK WINDSHIELD WASHER OPERATION (IF APP.)

TORQUE FRONT AXLE MOUNTING BOLTS

CHECK ACCELERATOR FOR FREE OPERATION

TORQUE KING PIN DRAW KEY NUT(S)

CHECK HORN(S) OPERATION

CHECK POWER STEERING PUMP

CHECK AIR SYSTEM FOR MAXIMUM 120 PSI

CHECK HYDRAULIC PUMP

CHECK AIR SYSTEM FOR LEAK DOWN

CHECK STARTER MOUNTING AND CONNECTIONS

CHECK OPERATION OF BACK UP ALARM

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK OPERATION OF SHIFT LOCK OUT

CHANGE ENGINE OIL AND FILTER

CHECK HVAC SYSTEM

CHANGE TRANSMISSION EXTERNAL FILTER

BLOWER MOTOR OPERATION

CHANGE TRANSMISSION FLUID

TEMPERATURE CONTROL

CHECK ENGINE AND TRANSMISSION MOUNTS

AUXILIARY FAN(S) (IF APP.)

CHECK WHEEL SEALS FOR LEAKS

A/C OPERATION (IF APP.)

CLEAN REAR AXLE BREATHER

DEFROSTER OPERATION

CHECK DIFFERENTIAL FOR LEAKS

CHECK OPERATION OF PTO CONTROL (IF APP.)

CHECK DIFFERENTIAL OIL LEVEL

CHECK 5TH WHEEL UNLATCH CONTROL

CHANGE DIFFERENTIAL OIL

CHECK OPERATION OF BOOM

CHECK LIFT CYLINDERS FOR LEAKS

CHECK FIRE EXTINGUISHER CHARGE (IF APP.)

CHECK OTTO-RIDE RUBBER ISOLATOR (IF APP.)

CHECK SEAT BELT OPERATION

TORQUE REAR AXLE MOUNTING BOLTS

CHECK SIDE DOOR LATCH OPERATION

CHASSIS

CHECK REAR DOOR LATCH OPERATION

CHECK FRONT AXLE OIL LEVEL (IF APP.)

CHECK DOME LIGHT OPERATION

REPACK FRONT WHEEL BEARINGS (IF APP.)

CHECK ALL GLASS AND MIRRORS

CHECK BATTERY CABLES & HOLDDOWNS

CHECK OPERATION OF WINDOWS

CHECK BATTERIES FOR CRACKS OR ACID DAMAGE

CAB DOWN – EXTERIOR

CLEAN BATTERY CABLE CONNECTIONS

CHECK CAB ACCESS STEPS AND HANDLES

CHECK BATTERY BOX COVER HOLDDOWNS

CLEAN HEATER / AC FILTER (IF APP.)

DRAIN WATER FROM AIR TANKS

CHECK REAR DOOR ROLLER / SLIDE ADJUSTMENT

CHECK AND TORQUE ALL WHEEL NUTS

CHECK GLADHAND SEALS AND TRAILER AIR LINES

CHECK WHEELS

CHECK TRAILER LIGHT CORD

CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION

CHECK HEADLIGHTS / MARKER LIGHTS

CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)

CHECK TURN SIGNALS

INSPECT CATWALK

CHECK STROBE LIGHT (IF APP.)

CHECK FRAME FOR CRACKS

CHECK SPOTLIGHTS

CHECK MUD FLAPS / FENDERS (IF APP.)

CHECK WIPER BLADES

CHANGE HYDRAULIC SYSTEM FILTER

CHECK WINDSHIELD WASHER FLUID LEVEL

CHECK HYDRAULIC FLUID LEVEL

CAB UP

CHANGE HYDRAULIC FLUID

CHECK OPERATION OF CAB TILT PUMP

CLEAN HYDRAULIC TANK VENT

CHECK CAB SAFETY PROP

LUBRICATION

CHECK CAB SUSPENSION AND LATCH

CHECK / LUBRICATE SIDE DOOR HINGES

CHECK INTAKE DUCTING FOR LEAKS

CHECK / LUBRICATE REAR DOOR ROLLERS

CHECK RADIATOR FOR LEAKS

CHECK / LUBRICATE CAB HINGE PINS

CHECK RADIATOR MOUNTS

CHECK / LUBRICATE HOOD HINGE

CHECK COOLANT LEVEL AND CONCENTRATION

CHECK / LUBRICATE STEERING SLIP JOINT

CHECK AND ADJUST COOLANT ADDITIVE (IF APP.)

CHECK / LUBRICATE STEERING U-JOINTS

CHANGE ENGINE COOLANT

CHECK / LUBRICATE KING PINS AND TIE ROD ENDS

CHECK COOLANT HOSES AND CLAMPS

CHECK / LUBRICATE DRAG LINK

CHECK FAN CLUTCH FOR OPERATION (IF APP.)

CHECK / LUBRICATE SLACK ADJUSTERS

CHECK ENGINE COOLING FAN FOR CRACKS

CHECK / LUBRICATE SPRING PINS AND BUSHINGS

CHECK ENGINE BELT(S) AND TENSIONER

CHECK / LUBRICATE DRIVELINE U-JOINTS

CHANGE ENGINE COOLANT FILTER (IF APP.)

CHECK AND LUBE LOWER BOOM CYLINDER BEARING

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)

DRAIN FUEL WATER SEPARATOR

ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.)

CHANGE FUEL FILTER / FUEL WATER SEPARATOR

CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS

CHECK AIR RESTRICTION GAUGE (IF APP.)

CHECK AND LUBRICATE 5TH WHEEL TOP PLATE

CHANGE AIR FILTER AS NEEDED

CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS

CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED

CHECK AND LUBRICATE BOOM PIVOT BEARINGS

CHECK EXHAUST SYSTEM

CHECK AND LUBE UPPER BOOM CYLINDER BEARING

CHECK TRANSMISSION FLUID LEVEL

CHECK AND LUBRICATE HYDRAULIC PUMP DRIVE

CLEAN TRANSMISSION BREATHER

TEST DRIVE

TORQUE CAB TO DECK MOUNTING BOLTS

DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION

Maintenance

KALMAR TRUCK PREVENTATIVE MAINTENANCE FORM

QSB-155 – RDS TRANSMISSION WITH “TRANSYND” LUBE AND ALLISON FILTERS

TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE

EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION.

 = SATISFACTORY  = ADJUSTMENT NECESSARY  = REPAIRS NEEDED.

“A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVALS, “B” INSPECTIONS AT 500 HOUR INTERVALS, “C” INSPECTIONS AT 1000 HOUR INTERVALS, AND “D” INSPECTIONS AT 2000 HOUR INTERVALS.

OPERATION A B C D

CAB – INTERIOR

UNDER VEHICLE

CHECK OPERATION OF NEUTRAL START

CHECK STEERING GEAR

CHECK OPERATION OF ALL GAUGES

CHECK BRAKE LININGS AND DRUMS

CHECK LOW AIR BUZZER AND LIGHT

CHECK SPRINGS

CHECK WINDSHIELD WIPER OPERATION

CHECK SHOCK ABSORBERS (IF APP.)

CHECK WINDSHIELD WASHER OPERATION (IF APP.)

TORQUE FRONT AXLE MOUNTING BOLTS

CHECK ACCELERATOR FOR FREE OPERATION

TORQUE KING PIN DRAW KEY NUT(S)

CHECK HORN(S) OPERATION

CHECK POWER STEERING PUMP

CHECK AIR SYSTEM FOR MAXIMUM 120 PSI

CHECK HYDRAULIC PUMP

CHECK AIR SYSTEM FOR LEAK DOWN

CHECK STARTER MOUNTING AND CONNECTIONS

CHECK OPERATION OF BACK UP ALARM

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK OPERATION OF SHIFT LOCK OUT

CHANGE ENGINE OIL AND FILTER

CHECK HVAC SYSTEM

CHANGE TRANSMISSION EXTERNAL FILTER

BLOWER MOTOR OPERATION

CHANGE TRANSMISSION FLUID

TEMPERATURE CONTROL

CHECK ENGINE AND TRANSMISSION MOUNTS

AUXILIARY FAN(S) (IF APP.)

CHECK WHEEL SEALS FOR LEAKS

A/C OPERATION (IF APP.)

CLEAN REAR AXLE BREATHER

DEFROSTER OPERATION

CHECK DIFFERENTIAL FOR LEAKS

CHECK OPERATION OF PTO CONTROL (IF APP.)

CHECK DIFFERENTIAL OIL LEVEL

CHECK 5TH WHEEL UNLATCH CONTROL

CHANGE DIFFERENTIAL OIL

CHECK OPERATION OF BOOM

CHECK LIFT CYLINDERS FOR LEAKS

CHECK FIRE EXTINGUISHER CHARGE (IF APP.)

CHECK OTTO-RIDE RUBBER ISOLATOR (IF APP.)

CHECK SEAT BELT OPERATION

TORQUE REAR AXLE MOUNTING BOLTS

CHECK SIDE DOOR LATCH OPERATION

CHASSIS

CHECK REAR DOOR LATCH OPERATION

CHECK FRONT AXLE OIL LEVEL (IF APP.)

CHECK DOME LIGHT OPERATION

REPACK FRONT WHEEL BEARINGS (IF APP.)

CHECK ALL GLASS AND MIRRORS

CHECK BATTERY CABLES & HOLDDOWNS

CHECK OPERATION OF WINDOWS

CHECK BATTERIES FOR CRACKS OR ACID DAMAGE

CAB DOWN – EXTERIOR

CLEAN BATTERY CABLE CONNECTIONS

CHECK CAB ACCESS STEPS AND HANDLES

CHECK BATTERY BOX COVER HOLDDOWNS

CLEAN HEATER / AC FILTER (IF APP.)

DRAIN WATER FROM AIR TANKS

CHECK REAR DOOR ROLLER / SLIDE ADJUSTMENT

CHECK AND TORQUE ALL WHEEL NUTS

CHECK GLADHAND SEALS AND TRAILER AIR LINES

CHECK WHEELS

CHECK TRAILER LIGHT CORD

CHECK TIRE AIR PRESSURE, TREAD DEPTH & CONDITION

CHECK HEADLIGHTS / MARKER LIGHTS

CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)

CHECK TURN SIGNALS

INSPECT CATWALK

CHECK STROBE LIGHT (IF APP.)

CHECK FRAME FOR CRACKS

CHECK SPOTLIGHTS

CHECK MUD FLAPS / FENDERS (IF APP.)

CHECK WIPER BLADES

CHANGE HYDRAULIC SYSTEM FILTER

CHECK WINDSHIELD WASHER FLUID LEVEL

CHECK HYDRAULIC FLUID LEVEL

CAB UP

CHANGE HYDRAULIC FLUID

CHECK OPERATION OF CAB TILT PUMP

CLEAN HYDRAULIC TANK VENT

CHECK CAB SAFETY PROP

LUBRICATION

CHECK CAB SUSPENSION AND LATCH

CHECK / LUBRICATE SIDE DOOR HINGES

CHECK INTAKE DUCTING FOR LEAKS

CHECK / LUBRICATE REAR DOOR ROLLERS

CHECK RADIATOR FOR LEAKS

CHECK / LUBRICATE CAB HINGE PINS

CHECK RADIATOR MOUNTS

CHECK / LUBRICATE HOOD HINGE

CHECK COOLANT LEVEL AND CONCENTRATION

CHECK / LUBRICATE STEERING SLIP JOINT

CHECK AND ADJUST COOLANT ADDITIVE (IF APP.)

CHECK / LUBRICATE STEERING U-JOINTS

CHANGE ENGINE COOLANT

CHECK / LUBRICATE THROTTLE SHAFT

CHECK COOLANT HOSES AND CLAMPS

CHECK / LUBRICATE KING PINS AND TIE ROD ENDS

CHECK FAN CLUTCH FOR OPERATION (IF APP.)

CHECK / LUBRICATE DRAG LINK

CHECK ENGINE COOLING FAN FOR CRACKS

CHECK / LUBRICATE SLACK ADJUSTERS

CHECK ENGINE BELT(S) AND TENSIONER

CHECK / LUBRICATE SPRING PINS AND BUSHINGS

CHANGE ENGINE COOLANT FILTER (IF APP.)

CHECK / LUBRICATE DRIVELINE U-JOINTS

CHECK ENGINE AND TRANSMISSION FOR LEAKS

CHECK AND LUBE LOWER BOOM CYLINDER BEARING

DRAIN FUEL WATER SEPARATOR

CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)

CHANGE FUEL FILTER / FUEL WATER SEPARATOR

ADD GREASE TO AUTOLUBE RESERVOIR (IF APP.)

CHECK AIR RESTRICTION GAUGE (IF APP.)

CLEAN, CHECK, ADJUST AND LUBE 5TH WHEEL JAWS

CHANGE AIR FILTER AS NEEDED

CHECK AND LUBRICATE 5TH WHEEL TOP PLATE

CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED

CHECK AND LUBRICATE 5TH WHEEL PIVOT PINS

CHECK EXHAUST SYSTEM

CHECK AND LUBRICATE BOOM PIVOT BEARINGS

CHECK TRANSMISSION FLUID LEVEL

CHECK AND LUBE UPPER BOOM CYLINDER BEARING

CLEAN TRANSMISSION BREATHER

CHECK AND LUBRICATE HYDRAULIC PUMP DRIVE

TORQUE CAB TO DECK MOUNTING BOLTS

TEST DRIVE

DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION

Cab Interior

Check Operation of Neutral Start – Move the gear selector to any position other than “N” and attempt to start the engine. The engine should not crank with the selector in any position other than “N”.

Check Operation of All Gauges – With the engine is running verify that all gauges are functional.

Check Low Air Buzzer and Light – Apply and release the brake pedal until air pressure drops below 90

PSI. At that point, the low air buzzer and dash warning light should come on.

Check Windshield Wiper Operation – Turn on the windshield wiper on and confirm full and smooth travel of the wiper arm. Listen for any noises that might indicate a worn wiper motor.

Check Windshield Washer Operation (If Applicable) – Depress the washer button and confirm the flow and pattern of the washer fluid.

Check Accelerator for free operation – Depress and release the foot throttle and check for binding and ease of operation.

Check Horn(s) Operation – Sound electric and air horns (if applicable) to confirm proper operation.

Check Air System for Maximum 120 PSI – Start engine and run at fast idle. Governor should limit

system air pressure to 120 psi.

Check Air System for Leak Down – Disconnect the gladhands from any trailer. Run engine at fast idle and allow air pressure to stabilize at 120 psi for at least one minute. Shut off engine and observe dash gauge(s) for 2 minutes. The drop in pressure should not exceed 2 psi over the two-minute period.

Check Operation of Back Up Alarm – With engine running, move the gear selector to reverse and listen for back up alarm.

Check Operation of Shift Lock Out – With engine running, air pressure above 90 psi, and the parking brake set, attempt to move the gear selector from any drive gear to reverse without depressing the brake pedal. You should not be able to select reverse.

Check HVAC System

Blower Motor Operation – With the key on, insure that the blower motor operates at each

position of the blower speed switch.

Temperature Control – Confirm proper operation of the temperature control switch.

Auxiliary Fan(s) (If Applicable) – With the key on turn on the auxiliary fans and confirm

operation.

Air Conditioner Operation – With the engine running and the air conditioner control turned on, confirm cooled airflow from the defroster vents.

Defroster Operation – With the engine running and the defroster control turned on, confirm airflow from the defroster vents.

Check Operation of PTO Control (If Applicable) – With the truck running apply the parking brake and move the gear selector to any drive gear. Confirm that the PTO engages and disengages when the dash control is activated.

Check 5

Wheel Unlatch Control – With system air pressure above 100 psi confirm that the 5th wheel

jaws unlatch when the dash control is activated.