Terminal Tractor

Kalmar TL2
Operator’s Manual
All variants

UMTT0005EN.01
September/2024
Original Instructions
 EQUIPMENT CONNECTIVITY
Kalmar General Sales Terms and Conditions (“Terms”)

“Kalmar, or a third party designated by Kalmar, shall have the right,

notwithstanding any other terms and conditions of this agreement, to install remote
diagnostic tools into the equipment and gather and store equipment related data
during and after the term of this agreement including, but not limited to information
concerning efficiency, availability, condition and downtime of the equipment. Such
information may be used for optimizing the equipment or the related services as
well as for Kalmar’s internal business purposes. Kalmar shall be responsible for
complying with applicable laws and regulations”
 Table of Contents 5

Table of Contents
1 Foreword................................................................................................................................. 7
1.1 About the Operator's manual.......................................................................................................................... 7
1.1.1 Reading the manual................................................................................................................................. 7
1.2 About the Documentation Kit.......................................................................................................................... 9
1.3 Inspection and maintenance.........................................................................................................................10

2 Safety.....................................................................................................................................11
2.1 Safety and Warning Equipment.....................................................................................................................11
2.1.1 In Case of Emergency............................................................................................................................15

3 Overview................................................................................................................................19
3.1 Description....................................................................................................................................................19
3.1.1 Main components...................................................................................................................................19
3.2 Plates............................................................................................................................................................22
3.2.1 Stickers...................................................................................................................................................25

4 Instruments and controls....................................................................................................... 29

4.1 Locations of controls in the cab.................................................................................................................... 29
4.2 Warning and indicator lights..........................................................................................................................33
4.3 Instruments................................................................................................................................................... 36
4.4 Ignition.......................................................................................................................................................... 39
4.5 Switches........................................................................................................................................................41
4.6 Gear and Multi-function Lever.......................................................................................................................42
4.6.1 Oil level and diagnostic.......................................................................................................................... 43
4.6.2 Diagnostics.............................................................................................................................................45
4.6.3 Prognostic features................................................................................................................................ 45
4.7 Control Lever................................................................................................................................................ 49
4.8 Pedals...........................................................................................................................................................50
4.9 Operator's Seat.............................................................................................................................................51
4.10 Heating/Air Conditioning............................................................................................................................. 52

5 Handling................................................................................................................................ 53
5.1 Running-in.....................................................................................................................................................55
5.2 Daily Inspection.............................................................................................................................................56
5.3 Handling Error Codes................................................................................................................................... 57
5.3.1 Warning symbols....................................................................................................................................57
5.4 Operating...................................................................................................................................................... 58
5.4.1 Starting the engine................................................................................................................................. 59
5.4.2 Selecting driving direction and gear....................................................................................................... 62
5.4.3 Steering..................................................................................................................................................63
5.4.4 Brakes.................................................................................................................................................... 63

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6 Table of Contents

5.4.5 Parking brake system.............................................................................................................................64

5.4.6 Stopping the engine / parking.................................................................................................................64
5.5 Load handling............................................................................................................................................... 65
5.5.1 Transporting a trailer.............................................................................................................................. 65

6 Inspection and maintenance..................................................................................................69

6.1 Daily Inspection.............................................................................................................................................70
6.2 Maintenance................................................................................................................................................. 73
6.2.1 Engine lubrication system...................................................................................................................... 76
6.2.2 Transmission lubrication system............................................................................................................ 76
6.2.3 Cooling system.......................................................................................................................................77
6.2.4 Charging system for batteries................................................................................................................ 77
6.2.5 Engine air filter....................................................................................................................................... 78
6.2.6 Fuel system............................................................................................................................................79
6.2.7 Windscreen washer................................................................................................................................79
6.2.8 Hydraulic system....................................................................................................................................80
6.2.9 Pneumatic system..................................................................................................................................80
6.3 Service..........................................................................................................................................................81

7 Transport of machine.............................................................................................................85
7.1 Towing...........................................................................................................................................................85
7.1.1 Releasing the parking brake mechanically.............................................................................................86
7.2 Lifting and transporting machine...................................................................................................................87
7.3 Service position.............................................................................................................................................88
7.4 Long-term storage.........................................................................................................................................89

8 Environment.......................................................................................................................... 91
8.1 Standards......................................................................................................................................................95

9 Specifications........................................................................................................................ 97
9.1 Specifications and dimensional drawing.......................................................................................................97
9.2 Oil, grease and fluid volumes and quality .................................................................................................. 101
9.3 Tightening torques, units of measurement and conversion tables..............................................................105

A. Appendixes.........................................................................................................................113

Index....................................................................................................................................... 115

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1 Foreword - 1.1 About the Operator's manual 7

1 Foreword

1.1 About the Operator's manual

General
Read the operating instructions in this manual carefully, and
follow them strictly when operating the machine so that the
safety and reliability of the machine will be maintained.
Contact your superior if some parts of this manual lead to
questions or some important information seems to be missing.
We thank you for selecting Kalmar, as the provider of your
machine. We believe that we can fulfil your expectations with
regard to the operational features and availability of
maintenance services.

Operating policy
The business philosophy of manufacturer, is, based on the
customer’s needs, requirements, and expectations, to develop,
manufacture, and provide products and associated services in a
way that always ensures the full satisfaction of our customers.
Plant management utilises a certified quality system in
compliance with the ISO 9001:2008, ISO 14001:2004 and
OHSAS 18001:2007 standards.

Storage
Keep the manual in good condition, and store it in a place
where it is always available to the operator or service
personnel.

Copyright
This document may not be copied, presented, or delivered to a
third party without our explicit permission, or used for purposes
other than those allowed by us.
We reserve the right to alter the adjustment values, equipment,
and service and repair instructions for the machine without prior
notice.
Kalmar Corporation
Kalmar Head Office
Street address: Itämerenkatu 25, FI-00180, Helsinki, Finland
eMail: [email protected]

1.1.1 Reading the manual

Information on possible safety hazards

This manual includes three types of warnings containing
instructions on how to avoid situations that may compromise
the safety of operations.

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8 1 Foreword - 1.1 About the Operator's manual

DANGER
Warns about a situation that involves an immediate risk
of personal injury or death unless the safety
instructions provided are observed.

WARNING
Warns about a situation that may cause personal injury,
death, and/or substantial damage to the machine or
other property unless the safety instructions provided
are observed.

CAUTION
Warns about a situation that may cause moderate
personal injury and/or damage to the product or other
property unless the safety instructions provided are
observed.

Important information
The word NOTE is used to emphasise aspects of the machine’s
operational safety or operation instructions that the driver must
pay particular attention to when working with the machine.
An example of how the word NOTE appears is presented
below.

NOTE
Calls the reader’s attention to an instruction that, for example,
emphasises operational safety.

Information on variations
This manual is a general manual for the terminal tractor model
Kalmar T2. Some content in the book has several variations
based on the different equipment options available for the
machine. These variations are marked with the component
manufacturer models to clarify which component variations the
instructions are specific to.

Optional equipment
The machine can be equipped with various accessories or
optional equipment. The equipment is marked with the symbol
seen on the left. The symbol is always accompanied by text
representing and describing the equipment.

This symbol indicates an accessory or The symbol is clearly distinguished from the text, and it is
optional equipment. placed next to the text and picture representing the equipment.

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1 Foreword - 1.2 About the Documentation Kit 9

1.2 About the Documentation Kit

Manual package
The following manuals are included in the machine delivery as
ordered:
• Operator’s manual
• Maintenance manual
• Spare parts catalogue
If extra copies of instruction manuals or the spare parts
catalogue for the machine are needed, they can be ordered
separately.

Ordering the manuals

The manuals can be ordered from the manufacturer’s spare
parts department.
Refer to the type and serial number of the tractor when placing
the order.

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10 1 Foreword - 1.3 Inspection and maintenance

1.3 Inspection and maintenance

General
Chapter 6 Inspection and maintenance on page 69, contains
instructions on daily inspection and maintenance tasks that
must be carried out at the beginning of each shift.

Maintenance
Regular maintenance is carried out according to the
maintenance programme defined in 6 Inspection and
maintenance on page 69.
The recommended service items and instructions are specified
in 6 Inspection and maintenance on page 69.
Do not hesitate to contact the maintenance staff at
manufacturer or an authorised service outlet if you need further
information on maintenance.

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2 Safety - 2.1 Safety and Warning Equipment 11

2 Safety
General
This chapter contains general instructions for the driver to
ensure that the machine is used safely and as intended. Safety
instructions on use and maintenance of the machine can also
be found in the chapters of the manual concerning these
subjects.
• Carefully study the operating instructions and the
functioning of the control devices. Do not use the
machine if you are not familiar with the instructions and
regulations concerning its safe operation. If required,
ask your supervisor for guidance.
• Clean the machine regularly to ensure correct and safe
operation.
• Regularly perform all maintenance according to the
programme defined in the chapter 6 Inspection and
maintenance on page 69. Professionally performed
maintenance ensure that the machine operates safely
and as intended.
• When the machine is in use, passenger transport is not
allowed, except for the occupational training carried out
by the supervisor.
• Notify your superior or the person responsible for the
maintenance of the machine IMMEDIATELY of any
malfunctions or other repairs that are necessary.
• OBSERVE any site-specific work and safety
instructions on the operation of the machines in
addition to the instructions in this manual.

WARNING
Never use open flame to check the fluid level in the fuel
tank or battery.
Fuel fumes from the fuel tank and hydrogen gas from
the batteries may ignite and explode.

WARNING
Always turn of the engine before refuelling.
Fuel spilled on hot engine components may ignite.

2.1 Safety and Warning Equipment

General
This chapter describes safety instructions concerning the
operation of the terminal tractor. While operating the terminal
tractor, strictly follow the general instructions on the safe
operation of the machine in section 2 Safety on page 11.

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Normal Operation
• Perform normal procedures before driving such as
checking fluids, tyres, and for any possible damage.
• Never drive a faulty or damaged tractor.
• Always wear the seat belt provided.
• Brake smoothly to avoid sudden jolts and wear on the
braking system.
• Always connect air and electrical lines to the trailer.
• Periodically check gauges and warnings and confirm
they are normal operating levels.

Driving speed
• The maximum driving speed of the terminal tractor is to
be used ONLY when driving straight on a smooth
surface.
• Never exceed the maximum allowed driving speed and
load of the tractor’s and trailer’s tires.
Check the maximum speed for each load from the tire
manufacturer.
• ALWAYS decrease driving speed prior to turning the
terminal tractor or driving on an inclined surface, and
ALWAYS when visibility is limited.
• While driving the terminal tractor, avoid sudden
braking and acceleration and drive slowly when
cornering.
• Always drive slowly when coupling the terminal tractor's
fifth wheel to the trailer to be moved. This applies also
to uncoupling the trailer from the fifth wheel to avoid
damaging the equipment.

Parking brake
• When leaving the terminal tractor cab, set the driving
direction selector to neutral and always engage the
parking brake.
• If the parking brake has been released mechanically
due to, for example, towing, work with the terminal
tractor may not be resumed until the braking system
is restored to working condition.

General Precautions
• Heed all warning signs posted on machine.
• Exhaust surfaces may be hot. Keep away.
• Keep Flammable substances and material away from
the exhaust.
• When washing, carefully aim any wash hose as high
pressure water can damage seals and electrical
components.

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Fifth wheel and lift boom

• Tow a load only when the kingpin is locked and the
green indicator light on the dashboard panel is
illuminated, if equipped.
• Never go near a loaded terminal tractor if the fifth
wheel is up.
• Always turn the main switch to the off position for
repairing the lift boom and fifth wheel.
• The fifth wheel must be unloaded and the lift boom
must be supported mechanically if the lift boom needs
to be in the upper position during repair.
• Prior to lowering the lift boom, check that its’ path is
free of obstructions and any mechanical supports.

Tilting the cab for maintenance

The inspection table specifies the inspection procedures for
which the cab must be tilted to the maintenance position as
shown in the picture.
• Prior to tilting the cab to the maintenance position,
ensure that the cab door is properly closed and any
loose items are removed from the cab.
• Prior to lowering the cab, check that the cab path is
free of obstructions.
• If the tilting hydraulics hoses or fittings are to be
replaced, use only original spare parts and accessories
available from our spare parts department.

DANGER
Working under the cab without the mechanical safety
stop A that prevents the cab from lowering is strictly
prohibited!

DANGER
Only tilt the cab when the tractor is parked on a level
surface. Tilting the cab when the tractor is parked on an
unlevel surface may cause damage to the cab tilt system
and result the cab to fall and cause serious injury or
death.

DANGER
Ensure the front of the cab is clear of personnel before
tilting cab.

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CAUTION
Only tilt the cab far enough to engage the safety bar.
Attempting to fully extend the cylinder can cause pump
and motor damage. Check the cab tilt cylinder and
bracket mounting bolt for proper torque and wear!
Failure to check and operate the cab tilt system
correctly can result in injury.

Belts and driveshafts

DANGER
When checking the operation of a running engine with
the cab tilted to the maintenance position, pay special
attention to the rotating belts and driveshafts.
Pieces of clothing can be easily caught in a rotating part
and when wrapped and tightened around the part may
cause personal injury!

Pressure Systems
• Hydraulic, air, tyres, HVAC, and fuel lines can be
pressurized. Never use bare hands to check for a leak.
• Damaged system components can cause serious
failures. Check components regularly.
• If the steering pump has a failure, tractor will still be
steerable but with a large increase in effort.
• If engine stops while driving, note there will be a large
increase in steering effort.
• Immediately report any leaks to proper maintenance
personnel.

Machine Fluids
• Take precaution when working around fluids including
coolant, refrigerant, diesel fuel, DEF (Ad Blue), grease,
hydraulic oil, and engine oil.
• Avoid inhaling fumes and make sure there is adequate
ventilation.
• Avoid skin contact.
• Many fluids are flammable, keep away from heat or
flame.
• Use care when opening tanks, especially if the truck
has been running, pressure build up can cause
splashing or spraying.
• Immediately report any leaks to proper maintenance
personnel.

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2 Safety - 2.1 Safety and Warning Equipment 15

Fire and Explosion Risk

• Always store fuel and oil in approved and sealed
containers.
• Do not transport fuel or oil inside the cab.
• Make sure there are no ignition sources near
flammable or explosive substances.

2.1.1 In Case of Emergency

Leaving the cab

Should an emergency occur, the driver can leave the cab
quickly from the rear door. If the rear door is inaccessible, the
front windshield is designed to be kicked out. Some models are
also equipped with a side door that can be used for exiting.

Smoke or Fire
Should an alert to fire or smoke occur, the tractor should be
stopped immediately. The ignition should be turned off and
leave the cab in the safest way possible. The main power
switch should be turned off if safe to do so.

Fire extinguisher
If the tractor is equipped with an optional fire extinguisher, it is
attached on the front curb side mudguard near the exhaust
stack or inside the cabin.

DAFO Vehicle Fire Suppression System

If the truck is equipped with an optional DAFO system the alarm
panel is located to the left of the door just behind the operator's
seat. The system is always automatically active. It is equipped
with an audible alert that activates with the test functions and
fire alarm. There is an internal backup power battery in case the
primary power circuit is interrupted.
What to Do in Case of a Fire:
• If necessary, evacuate the vehicle immediately!
• Discharge VFSS either manually from the Alarm Panel
or from the outside of the vehicle if not automatically
discharged.
If safe to do so, complete the following:
• Stop the engine, set the brake and ground any
hydraulics
• Turn off master switch
• Cut fuel supply if possible
• Be prepared with a portable extinguisher in case of re-
ignition
• Avoid inhaling fumes

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Description of LEDs and buttons on the control panel when

the system is running on external power source.

1 1. Manual Actuation Button: Break wire seal, lift clear

plastic guard and hold for a minimum of 1 sec. for
2
actuation
3
2. Fire Alarm LED: Flashes at alarm and after release
4
5 3. Fault Actuator LED: Indicates a fault in Actuator Circuit
6 4. Fault Detector LED: Indicates fault in Detector Circuit
7 5. Manual LED: System is operating in manual only mode
6. On LED: Solid light indicates system is on
8
7. Test/Reset Button: for system and alarm devices
Reset of system after fire/fault
Reset of shut down/control functions if connected
Silencing of sounder, hold for 3 seconds
8. Alarm Panel with clear plastic guard: Normally secured
with wire
Automatic internal battery status indication
1. If the Alarm Panel shows scrolling lights on the 3 yellow
LEDs (3-5) and the green operating LED (6) is solid the
internal battery power is too low and should be
replaced by your Authorized Dafo Distributor.
2. If some of the yellow LEDs (3-5) are in active mode
(i.e., fault present) the other yellow LEDs flash when
internal battery power is low.
If the Alarm Panel shows any of the following, contact your
Authorized Dafo Distributor for service or contact Dafo US,
Technical Support line at, 1-910-769-6299, Ext. 3.
• Any of the yellow Fault LEDs illuminated either flashing
or solid
• The green “On” LED is flashing and not solid
Secondary Manual Activation Points:
The vehicle is also equipped with two secondary manual
activation points. The first is located below back side of the cab
on the driver’s side. The second manual activation point is
located opposite the driver’s side on the exterior fender.
To Manually Actuate the system:
1. Pull the yellow guard on the right-side bracket marked
“Extinguishing System Release”.
2. Forcefully push down on the Red Push-button.
Operators Daily Check:
1. Verify that the green power “ON” LED is illuminated
solid
2. Press the Test/Reset button for 1 second while
observing the alarm panel.
a. The Alarm Panel LEDs should flash, and the
sounder should annunciate several times. If the
system does not react as described, contact your
Authorized Dafo Distributor for service or contact
Dafo US, Technical Support line at,
1-910-769-6299, Ext. 3.

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2 Safety - 2.1 Safety and Warning Equipment 17

Operators Monthly Check:

1. Perform the Daily Check above.
2. Walk over the vehicle and observe that all the systems
hoses, distribution lines, tanks and cables appear
undamaged. Verify that the yellow safety pull-ring is in-
place on the manual release station. If the system
appears damaged or does not react as described,
contact your Authorized Dafo Distributor for service or
contact Dafo US, Technical Support line at,
1-910-769-6299, Ext. 3
Service and Maintenance:
1. At minimum the system should be inspected and
serviced by an Authorized Dafo Distributor annually.
Contact your Authorized Dafo Distributor for service or
contact Dafo US, Technical Support line at, 1-
910-769-6299, Ext. 3.
2. At 5-year and 10-year intervals certain components will
need to be replaced or rebuilt. Contact your Authorized
Dafo Distributor for service or contact Dafo US,
Technical Support line at, 1-910-769-6299, Ext. 3.

CAUTION
The VFSS should be disabled prior to performing
pressure washing or steam cleaning. Use caution to
avoid damaging the Linear Detection Line. Damage to
the linear detection line could cause unintentional
system discharge. The system should be enabled by a
Dafo Certified Technician.

CAUTION
The VFSS should be disconnected from the vehicles
battery prior to any welding, jumpstarting, recharging of
the vehicles batteries or work on the vehicle electrical
system. Failure to do so may cause an unintentional
system discharge.

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 3 Overview - 3.1 Description 19

3 Overview

3.1 Description
About models
The two-wheel drive TT terminal tractors are designed mainly
for moving trailers at locations with relatively level surfaces.
We also manufacture terminal tractors for ro-ro-applications in
ports where a powerful machine is required for loading ships by
pushing and pulling loads up on ramps and for heavy industry
to meet their in-plant cargo transportation needs.
If this terminal tractor will be used for applications other than
described, the application must be approved in writing by the
manufacturer.

3.1.1 Main components

General

1 This chapter describes the location of the terminal tractor main

components indicated in the picture below as well as a general
description of these components and their operation.
10
1. Cab
2. Battery box (under the steps)
3. Hydraulic tank
2 4. Lift boom
3
5. Fifth wheel
4 5
6. Rear axle
7. Fuel tank
8. Steering axle
9 8
9. Transmission
7
10. Engine
6
Engine
Engine is a low-emission turbocharged diesel engine with
intercooler. The engine drives the transmission, hydraulic and
pneumatic systems.

Transmission
The automatic transmission features four speeds for forward
and one for reverse.

Front axle
The front axle is equipped with drum brakes, steering linkage
and power steering. The front axle has leaf spring suspension.

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Rear axle
The rear axle is equipped with drum or disc brakes. Differential,
planetary drive and differential lock are available as options.

Brakes
The terminal tractor axles are equipped with common-circuit
pneumatic brakes and split-circuit pneumatic brakes are
available as option.
In standard tractors, the parking brake mechanism is located at
the rear axle.

Lift boom
The lift boom is attached to the terminal tractor frame at its front
end with two pivot pins. The lift boom rear end is attached with
pivot pins to the single or double-acting lift cylinders. The lift
cylinders are attached to the terminal tractor frame with pivot
pins.
Tractor doesn't have a lift boom if it's equipped with static fifth
wheel.

Fifth wheel
The fifth wheel is attached to the lift boom with two pivot pins.
Kingpin unlocking is actuated with a pneumatic cylinder. In case
of a pneumatic system malfunction, the kingpin locking can be
released with the mechanical lever at the fifth wheel.

Fuel tank
For fuel tank capacity, see section 9, chapter 9 Specifications
on page 97.
For RHD the fuel tank is located on the left side.
For LHD the fuel tank is located on the right side.

Hydraulic oil tank

For hydraulic oil tank capacity, see section 9 Specifications on
page 97. As a standard assembly the tank is equipped with a
sight glass for oil level. Oil filter has a replaceable filter element.
For RHD, the tank and the valve assembly controlling the
hydraulic functions, are located on the right side.
For LHD, the tank and the valve assembly controlling the
hydraulic functions, are located on the left side.

Hydraulic system
The pressure and volume flow required by the terminal tractor
hydraulic system is generated by a fixed displacement pump.
The pump is connected to the power take-off on the
transmission.
A priority valve is integrated in to the pump and it primarily
directs the pump output for the tractor steering. The flow for the
steering is determined by the load information coming from the
steering device. If steering is not in operation, no hydraulic oil
flow is directed to the steering cylinders.

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Hydraulic oil flow for hoist cylinders is controlled by a valve on

the frame. The valve directs oil to the cylinders. Over-center
valves prevent the boom from falling in the event of a hose
failure.

Electric system
The electric system voltage is 24 Vdc. While the engine is
running, the batteries are charged by the alternator coupled to
the engine.
The main switch is located near the batteries. When the main
switch is in the 0 position, most circuits are deenergized. ECM
circuits are powered even if main switch is switched off.
The main switch is not to be turned off while the engine is
running since the alternator supplies power to the electric
system and the electric components can be damaged by
overvoltage.
The terminal tractor is EMC tested and certified.

Pneumatic system
Compressed air is supplied by a engine driven compressor
which draws the air through the engine air filter. System
pressure is controlled by a pressure control valve. Moisture is
removed from the compressed air by an air dryer.
All air tanks have safety valves to protect against overpressure.

Trailer connecting
The pneumatic connections between the terminal tractor and a
trailer are palm type couplings in accordance with ISO 1728
standard behind the cab. Different types of options are
available.

Cab
The cab can be tilted to the maintenance position. The cab is
connected to the frame by means of two rubber mounts at the
front and one air-suspended mount at the rear. Cushioned cab
mounting, large window area, interior heater and air
conditioning provide a quiet and pleasant working environment.
From the cab, the driver has excellent visibility in the driving
direction and to the entire working area of the terminal tractor.
Controls for the terminal tractor and any equipment attached to
it are ergonomically positioned on the steering column,
dashboard panels, and in some cases, at the driver's seat.

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22 3 Overview - 3.2 Plates

3.2 Plates
Warning and information plates
The following figures show the warning plates and information
plates that are located on the machine. The operator should be
aware of the warnings and follow the instructions and
information given on the plates.
Make sure that the warning and information symbols on the
machine and its components are always easy to see and
legible. Plates that have been damaged, illegible or painted
over must be replaced immediately.

Vehicle data plate

Each terminal tractor has a vehicle data plate attached to the
cab frame. Plate text: "The standards and laws governing motor
vehicles operated on public roads requires brake, lighting and
restraint systems which are different from the equipment on this
vehicle. This vehicle is not designed for use on a public road or
highway, and operation on a public road or highway may
increase the risk of injury or collision and may violate state or
federal laws."

Item A indicates the location of the data plate. The Plate is on A

A
the rear door frame.

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Information decal locations in the machine

B
C

C
D
E
F
G
H

Figure 3.1 Decals seen from the left side

B Warning: Fall hazard

C Caution: Keep clear of cab

D Caution: Battery compartment

E Warning: Rotating shaft

F Use dextron III only

G Do not step

H Attention: Cab tilt lock

I Caution: Jaw lock control

J Read operating instructions

K Warning: No riders

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24 3 Overview - 3.2 Plates

C
E
G

Figure 3.2 Decals from the right side

C Keep lear of cab

E Warning: Rotating shaft

G Do not step

L Use diesel fuel only

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3.2.1 Stickers
B Warning: Fall hazard

WARNING
Fall Hazard. Keep hands free, hold rails, do not jump.
Face inward while entering or exiting vehicle. Use
handrail for maximum support.

C Caution: Keep clear of cab

CAUTION
Keep clear. Keep personnel from underneath cab when
raising or lowering. If not avoided injury may result.

D Caution: Battery compartment

CAUTION
BATTERY COMPARTMENT
• This compartment contains batteries.
Compartment is ventilated but explosive gas
may be present.
• Avoid sparks and fire in or near compartment.
• Shield eyes during installation or removal of
batteries.
• Before welding, remove all wires and battery
cables from battery, then disconnect harness
from electronic control modules.

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E Warning: Rotating shaft

WARNING
Rotating shafts are dangerous and can catch clothes,
skin, hair or hands, which can cause serious injury or
death.

To avoid serious injury or death from a rotating shaft:

1. Do not go under the vehicle when the engine is
running.
2. Do not work on a power take off or shaft when the
engine is running.
3. Do not engage or disengage the power take off or
driven equipment by hand from under the vehicle when
the engine is running.
Always shut the engine off before working on or near the
system.
F Use Dexron III only
Use only Dexron III (SAE 20W/ISO 46) hydaulic oil.

G Do not step
Do not step on the surface.

H Attention: Cabin tilt control

NOTE
Pull release cable before activating cab tilt switch.
Hold switch in the down position for 5 seconds after the cab is
completely lowered to fully engage hold-down hooks.

I Caution: Jaw lock operation

CAUTION
To prevent serious injury.
Never operate jawlock control or allow anything to touch
it while the truck is in motion.

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J Operating instructions
OPERATING INSTRUCTIONS
1. DO NOT OPERATE THIS VEHICLE WITHOUT
REVIEWING THE OPERATOR'S MANUAL.
2. NEVER PARK VEHICLE WITHOUT PARKING BRAKE
APPLIED AND TRANSMISSION PLACED IN
NEUTRAL.
3. WHEN CRANKING ENGINE, DO NOT LEAVE
STARTER ENGAGED OVER 20 SECONDS, WAIT 1
TO 2 MINUTES BEFORE RE-ENGAGING STARTER
FOR ANOTHER 20 SECONDS MAXIMUM CRANKING
PERIOD.
4. STOP MACHINE BEFORE SHIFTING FROM
FORWARD TO REVERSE OR FROM REVERSE TO
FORWARD.
5. TO COUPLE TO LOW TRAILERS:
A. LOWER 5TH WHEEL AND DRIVE UNDER
TRAILER UNTIL 5TH WHEEL PLATE IS JUST
COVERED BY TRAILER NOSE.
B. RAISE 5TH WHEEL APPROX. 5 INCHES.
C. FINISH DRIVING UNDER TRAILER UNTIL 5TH
WHEEL LATCHES.

K Warning: No riders

WARNING
No riders on a moving machine.

L Use diesel fuel only

Use diesel fuel only.

CAUTION
Do not use any other type of fuel. Use of other fuels may
damage the engine.

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4 Instruments and controls

General
This chapter contains general information about the terminal
tractor controls. All controls required for operating the tractor
are located in the cab.
The controls consist of various steering devices, a display
panel, switches, and pedals.
Study the location and operation of all controls carefully prior to
commencing work with the tractor.
If you need additional information about the operation of the
controls, do not hesitate to ask your supervisor or the person
responsible for maintenance of the tractor.

4.1 Locations of controls in the cab

Steering column

A B
CAUTION
Never release the steering column adjustment switch
when the machine is moving. Releasing the steering
C
column adjustment may cause you to lose control of the
machine.

Lever D releases the steering column for adjustment.

Adjusting the steering column
D 1. Turn the lever (D) up to release the adjustment.
2. Adjust the steering wheel to preferred position by
pushing or pulling and
3. Lock the steering column in position by by pushing the
lever (D) down to lock position.
A. Driving light and flashers control switch
B. Windscreen wiper and washer control switch
C. Keyed ignition switch
D. Steering column adjustment lever

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Front dashboard panel 1

F G H I J K

D E

X 100r/min Km/h

A B

A. Tachometer gauge
B. Speedometer gauge
C. Engine oil pressure gauge
D. Hour meter gauge
E. Coolant temperature gauge
F. Stop engine indicator light
G. Wait to start indicator light
H. Engine water temperature indicator light
I. Engine warning indicator light
J. Engine oil pressure indicator light
K. Turn right indicator light

NOTE
More detailed function of the instruments, controls and indicator
lights is explained later in the manual.

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Front dashboard panel 2

I J K L M N

A B

A. Main switch
B. Start push button
C. Emergency flashers switch
D. Work lights switch
E. Air conditioner switch
F. Heating/Air conditioning control panel
G. Fuel gauge
H. Voltmeter gauge
I. Head light indicator light
J. Turn left indicator light
K. Transoil temperature indicator light
L. Low fuel indicator light
M. Check trans indicator light
N. Brake air indicator light

NOTE
More detailed function of the instruments, controls and indicator
lights is explained later in the manual.

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Middle dashboard panel

A A. Transmission oil temperature gauge

NOTE
More detailed function of the instruments, controls and indicator
lights is explained later in the manual

Left dashboard panel

DN
+ 5th
W
H
E
E
- L

UP

TRAILER PARKING
AIR SUPPLY BRAKE

A B C D E

A. Fifth Wheel unlatch control

B. Driving direction selector
C. Boom control lever
D. Trailer air supply control switch
E. Parking brake control switch
F. Air pressure gauge

NOTE
More detailed function of the instruments, controls and indicator
lights is explained later in the manual.

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4.2 Warning and indicator lights

Stop engine
Indicates that the engine is not operating properly.
If the warning light comes on during operation, STOP THE
ENGINE IMMEDIATELY and notify the person responsible for
STOP the maintenance of the terminal tractor.

Wait to start
The indicator light comes on during engine start up and should
go off when engine is running.
If the indicator light flashes when the engine is running, it may
indicate a fault with the glow plug circuitry or the engine itself.

Engine water temperature

Indicates that the engine is overheating.
If the light comes on during operation, drive the machine away
from the traffic lane and stop the engine. Notify the person
responsible for the maintenance of the machine.

Engine warning
Indicates that the engine is not operating properly.
If the light comes on during operation, drive the machine away

!
from the traffic lane and stop the engine. Notify the person
responsible for the maintenance of the machine.

Engine oil pressure

Indicates that the engine oil pressure is too low.
If the warning light comes on during operation, STOP THE
ENGINE IMMEDIATELY and notify the person responsible for
the maintenance of the terminal tractor.

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Turn right signal

Indicates that the right-hand turn signal is on when flashing.

Turn left signal

Indicates that the left-hand turn signal is on when flashing.

Head lights
Indicates that the head lights are on.

Transoil temperature
Indicates that the temperature of the transmission fluid is too
high.
If the light comes on during operation, drive the machine away
from the traffic lane and stop the engine. Notify the person
responsible for the maintenance of the machine.

Low fuel
Indicates that the fuel level is too low.

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Check trans
Indicates a fault in the transmission system.
If the light comes on during operation, drive the machine away
from the traffic lane and stop the engine. Notify the person
responsible for the maintenance of the machine.

Brake air

Indicates a fault in a brake air system, when the warning light

stays lit.
If the light comes on during operation, drive the machine away
from the traffic lane and stop the engine. Notify the person
responsible for the maintenance of the machine.

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4.3 Instruments
Air pressure gauge
Indicates air pressure in the air system.

Coolant temperature gauge

Indicates the temperature of the engine coolant.

Engine oil pressure gauge

Indicates the engine oil pressure.

Fuel gauge
Indicates the level of fuel in the fuel tank.

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Hour meter gauge

Indicates engine operating hours.

Speedometer gauge
Indicates the speed of the machine.

Km/h

Tachometer gauge
Indicates engine R.P.M.

X 100 r/min

Transmission oil temperature gauge

Indicates the temperature of the transmission oil.

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Voltmeter gauge
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.

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4.4 Ignition
General
Prior to starting the engine, turn on the power to the ignition key
lock with the main switch.

Main switch

0 The switch is located on the main dashboard switch panel.

The main switch is used to turn the power supply from the
batteries to the tractor electric devices on or off.

0 Power off Power from the batteries to the electric devices

1 is off.
1 Power on Power from the batteries to the electric devices
is on.

CAUTION
Do not turn the main switch off when the engine is
running. After shutting down the engine wait at least 30
seconds before turning off the main switch.

Ignition switch
The switch is located on the dash panel.

Position 0 Circuits are turned off.

The ignition key can be removed from the lock in
this position only.

Position I Power to cabin circuits is switched on and

accessory in the cabin can be operated.

Position II Power to all circuits is switched on and the

engine may be started.

Position S Starting position.

Engine start push button

START The button is located on the main dashboard switch panel.

The push button is used to start the engine.

NOTE
See section 5.4.1 Starting the engine on page 59 for
instructions to start the engine.

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Stopping the engine

Engage the parking brake. 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. Stop
the engine by turning the ignition key to position 0.
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
The tractor transmission does not have a parking position. Use
the parking brake when parking.

CAUTION
Always apply the parking brake. Never park the vehicle
by leaving it in gear. Always place the transmission
shifter selector in the “neutral” position.
Never park a tractor trailer combination unless the
trailer parking brakes are operational and applied.

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4.5 Switches
Emergency flashers

Position 0 The emergency flashers are off.

Position 1 The emergency flashers are on and the indicator

0 1 light on the switch blinks.

Work lights
The switch is located on the main dashboard switch panel.

Position 0 The lights are off.

0 1
Position 1 The forward-facing work lights are on.

Air conditioner
The switch is located on the main dashboard switch panel.

A /C Position 0 The air conditioner is not activated.

0 1
Position 1 The air conditioner is activate.

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4.6 Gear and Multi-function Lever

General
The driver selects the driving direction of the tractor with the
driving direction selector.

Driving direction selector

MODE

SELECT
E R
N C
M D
L

MONITOR

A. Bump lever
B. Mode button
C. Mode indicator display
D. Display Mode/Diagnostic button
E. Shift selector:

Position Range Description

R Reverse Selects Reverse gear.

N Neutral Must be selected prior to starting the

engine.

D Drive Selects the highest available forward

range.

L Low Selects the lowest available forward

range range.

M Manual Moving the lever from the Drive position

select into the Manual Select position allows the
operator to select a lower or higher
forward gear range.

Do not move off if the gauge readings are not normal or any of
the warning symbols is lit.

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Select the desired driving direction with the bump lever (A).
The current gear is indicated in the gear selector display (C).
The tractor moves off by increasing the engine speed. Move off
with a gear corresponding to the load; the heavier the load, the
lower the gear.

4.6.1 Oil level and diagnostic

Checking fluid levels

Use following procedure to display oil level information if the
transmission is equipped with the option.

NOTE
The fluid level reading may be delayed until the following
conditions are met:
• The engine is at idle (below 1000 rpm).
• The fluid temperature is between 40°C and 104°C.
• Transmission is in Neutral.
• The vehicle has been stationary for approximately two
minutes to allow the fluid to settle.
When fluid level check is delayed, a countdown timer in
minutes and seconds appears in the selector graphics display.

1. Park the vehicle on a level surface, shift to N and apply

the parking brake and allow the engine to idle (500 –
800 rpm).

2. On the driving direction selector press the DISPLAY

MODE/ DIAGNOSTIC button once.

3. Correct fluid level is displayed as shown in adjacent

figure.

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4. Low fluid level is displayed and the number indicates

the number of quarts of fluid the transmission requires.

NOTE
Confirm a low fluid level condition by making a manual
fluid level examination.

5. High fluid level is displayed followed by a number and

the number indicates the number of quarts the
transmission is overfilled.

NOTE
If fluid level is too high, the fluid can aerate, causing
the transmission to shift erratically or overheat.

6. If there is a measuring fault, measuring is interrupted

and the display shows error codes according to the
following table:

Code Cause of code

SETTLING / OK Settling time too short

ENG RPM / TOO LOW Engine rpm too low

ENG RPM TOO HIGH Engine rpm too high

MUST BE / IN NEU N(Neutral) must be selected

OIL TEMP / TOO LOW Sump fluid temperature too low

OIL TEMP / TOO HIGH Sump fluid temperature too high

VEH SPD / TOO HI Output shaft speed

SENSOR FAILED Sensor failure

7. To exit the fluid level display mode, press the DISPLAY

MODE/DIAGNOSTIC button two times on the driving
direction selector.

NOTE
The sensor display and the transmission dipstick may not
agree exactly because the oil level sensor compensates for
fluid temperature.

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CAUTION
Incorrect fluid level can damage the transmission.

4.6.2 Diagnostics

General
If there aren't any active faults, the display shows two lines.
When a fault is active, the display shows the code.

Diagnostic procedure
1. Park the vehicle on a level surface, shift to N and apply
the parking brake.

2. Press the DISPLAY MODE/DIAGNOSTIC button five

times on the driving director selector.

3. An example of an error code

Errors can be browsed with the mode button.

PO71A The code is the actual error code. P071A for example
means “RELS Input Failed On.”
INACTIVE Record all codes for maintenance personnel before
clearing them.
4. The error log is cleared by keeping the mode button
pressed down for 10 seconds.

5. Exit by pressing the MODE button once or by moving

the bump lever to any range.

NOTE
MODE Transmission error code lists are included in the last
pages of this manual.

4.6.3 Prognostic features

General
Allison 5th generation gearboxes includes transmission
prognostics features. These include oil quality, oil filter condition

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and clutch maintenance monitoring. Allison Approved TES 295

transmission fluid and high capacity filters are required to
engage the prognostics.

Prognostic features
When the prognostics are enabled the wrench icon illuminates
briefly on the shift selector display arter the system power has
been turned on.
Exit by pressing the mode button.

Oil life monitor

1. Park the vehicle on a level surface, shift to N and apply
the parking brake.

2. Press the DISPLAY MODE/DIAGNOSTIC button two

times on the driving director selector.

3. An OIL LIFE appears on the shift selector display

followed by number from 0-99.

OIL LIFE 99 means that 99% of oil life is remaining and 0 means
that fluid change is required immediately.

99 4. The OIL LIFE may be reset back to 99% by holding the

DISPLAY MODE/DIAGNOSTIC button for 10 seconds,
while OIL LIFE information is displayed.

5. Exit by pressing the MODE button once or by moving

the bump lever to any range.

MODE

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Filter life monitor

1. Press the DISPLAY MODE/DIAGNOSTIC button three
times on the driving director selector.

2. Display shows filters condition.

FILTERS
3. The FILTER LIFE automatically resets once the new
filters have been installed.

OK
The FILTER LIFE can also be reset manually by
holding the DISPLAY MODE/DIAGNOSTIC button for
10 seconds, while FILTER LIFE information is
displayed.

REPLACE
FILTERS
4. Exit by pressing the MODE button once or by moving
the bump lever to any range.

MODE

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Transmission health monitor

1. Press the DISPLAY MODE/DIAGNOSTIC button four
times on the driving director selector.

2. Display shows condition of the clutch.

3. The TRANSMISSION HEALTH feature automatically
TRANSHEALTH resets when appropriate conditions are detected.

OK
TRANSMISSION HEALTH can only be manually reset
using Allison DOC for PC–Service Tool. When resetting
with the service tool, individual clutches or all clutches
can be reset. Operator reset through the shift selector
is not allowed.

TRANSHEALTH
LO
4. Exit by pressing the MODE button once or by moving
the bump lever to any range.

MODE

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4.7 Control Lever

Load handling control

Backward: The fifth wheel is raised.

Forward: The fifth wheel is lowered.

DN
5th
W
H
E
E
L NOTE
UP
When lowering the fifth wheel, ensure that there are no
obstructions!

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4.8 Pedals
Accelerator pedal
The tractor is equipped with an electronic accelerator pedal.

Brake pedal
The brake pedal is pneumatic and it is used to control the
brakes at the steering and drive axles.

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4.9 Operator's Seat

Adjusting the seat
A. Rear cushion adjustment
B. Chugger lock out
C. Horizontal adjustment
D. Front cushion adjustment

A B C D

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4.10 Heating/Air Conditioning

Adjusting the heating and air conditioning
The temperature, blowing speed, and direction of the air flowing
into the cab can be adjusted in the main dashboard switch
panel.
A B C
A/C MAIN SWITCH
A/C MAIN SWITCH DEFROSTING SWITCH HEAT SWITCH A/C main switch (A) is used to control the blower speed.
DEFROSTING SWITCH
Defrosting switch (B) is used to control the ventilation between
the cabin and windows.
HEAT SWITCH
Heat switch (C) is used to turn the cabin heater on/off.
A/C SWITCH
D A/C switch (D) is used to turn the Air Conditioner on/off.

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5 Handling
General
Use the terminal tractor according to the instructions in this
manual and STUDY THE INSTRUCTIONS CAREFULLY so
that the safety and reliability of the machine will be maintained.
The driver must also be very familiar with the working area and
driving conditions to prevent safety hazards to the people or
equipment on the site.
In addition to the instructions in this manual, observe any local
driving and work instructions.

WARNING
Never operate your vehicle under the influence of
alcohol or drugs that have impaired your ability to
operate. Alcohol and certain drugs delay reaction time,
impair judgment and reduce coordination, which could
lead to an accident that could result in death or serious
injury.

WARNING
Always drive defensively. Anticipate mistakes that other
operators, drivers or pedestrians might make and be
ready to avoid accidents.

Safety
Read this information before you operate the machine.
Leaving the cab in an emergency
Should an emergency occur, the driver can leave the cab
quickly from the rear door.
Fire extinguisher
If the tractor is equipped with an optional fire extinguisher, it is
attached on the front curb side mudguard near the exhaust
stack or inside the cabin.

DAFO Vehicle Fire Suppression System

If the truck is equipped with an optional DAFO system the alarm
panel is located to the left of the door just behind the operator's
seat. The system is always automatically active. It is equipped
with an audible alert that activates with the test functions and
fire alarm. There is an internal backup power battery in case the
primary power circuit is interrupted.
What to Do in Case of a Fire:
• If necessary, evacuate the vehicle immediately!
• Discharge VFSS either manually from the Alarm Panel
or from the outside of the vehicle if not automatically
discharged.

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If safe to do so, complete the following:

• Stop the engine, set the brake and ground any
hydraulics
• Turn off master switch
• Cut fuel supply if possible
• Be prepared with a portable extinguisher in case of re-
ignition
• Avoid inhaling fumes
Secondary Manual Activation Points:
The vehicle is also equipped with two secondary manual
activation points. The first is located below back side of the cab
on the driver’s side. The second manual activation point is
located opposite the driver’s side on the exterior fender.
To Manually Actuate the system:
1. Pull the yellow guard on the right-side bracket marked
“Extinguishing System Release”.
2. Forcefully push down on the Red Push-button.

NOTE
See section 2.1.1 In Case of Emergency on page 15 for
additional information on the DAFO system.

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5.1 Running-in
General
To make sure that the engine and transmission are durable, it is
important that the engine is not operated under high load and at
high speed for extended periods of time during the first 300
hours of operation. The engine and transmission temperature
and oil pressure gauges must be observed during operation
and the engine must be shut down IMMEDIATELY if the
readings deviate from normal values.
However, the engine may not be loaded at too low a speed nor
the engine allowed to idle for extended periods of time.
During the run-in period, the oils should be changed and filters
be replaced at shorter intervals than normally, before the
scheduled operation hours are reached. Maintenance
procedures for the run-in period are specified in detail in the
maintenance information for this machine.

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5.2 Daily Inspection

General
Daily inspections performed by the driver are important to make
sure that the machine operates safely and efficiently.
It is recommended that the driver or the person responsible for
maintenance of the machine carries out the inspections before
each shift. This way it can be made sure that the work does not
commence with a defective machine whose possible
malfunctions are not repaired.
Instructions for the daily inspections can be found in section 6
Inspection and maintenance on page 69 of this manual.

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5.3 Handling Error Codes

General
An illuminated warning light or STOP symbol in the instrument
panel and a buzzer indicate malfunctions in the tractor’s
components or systems. For warning symbols, see chapter 4.2
Warning and indicator lights on page 33.
If a warning light comes on and/or the buzzer is activated during
operation, locate and correct the malfunction causing the alarm
before you continue working.

5.3.1 Warning symbols

General
The warning symbols provide the driver with information about
any device and system faults in the machine.
If any of the warning symbols in the instrument panel come on
during operation, the engine must, in most cases, be stopped
IMMEDIATELY and the cause of the problem determined.
The warning lights and their operation are described in more
detail in chapter 4.2 Warning and indicator lights on page 33.

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5.4 Operating
About safety

DANGER
Keep the seat belt fastened during operation.
Be careful when entering and leaving the machine.

WARNING
During operation, a loaded fifth wheel must be lifted at
least 50 mm from the lowest position. This way the fifth
wheel is supported by the lifting cylinders.
Direct load on the mechanical limiters during operation
may cause severe fractures in the lift boom and tractor
frame.

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WARNING
While operating the tractor, the coupled trailer usually
limits visibility from the cab to the driving surface.
During operation, pay attention to the following issues:
• Before moving, make sure that there are no
people in the way of the machine.
• Adjust your driving speed according to the
visibility, coupled load, and condition of the
driving surface.
• Switch the work lights on if the lighting
conditions require it. Sufficient lighting is a
prerequisite for safe traffic in the working area.
• Beware of areas near the edges of routes where
the edge may collapse and the machine can tip
over or fall.
• Pay attention to the total weight of the machine
and the load. Do not drive on surfaces with
insufficient load capacity.
• Never go near a loaded terminal tractor if the
fifth wheel is up.
• Always turn the main switch off for servicing or
repairing the lift boom or fifth wheel.
• Pay attention to the overhead clearance signs.
Be aware of the total height of your vehicle
combination before you drive in places with
restricted height.
• Be particularly careful when working in the
vicinity of power lines, piers, ramps, doors and
gateways.

5.4.1 Starting the engine

General
As a standard the engine is started from the keyed ignition
switch.

Ignition switch
The switch is located on the dash panel.

Position 0 Circuits are turned off.

The ignition key can be removed from the lock in
this position only.

Position I Power to cabin circuits is switched on and

accessory in the cabin can be operated.

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Position II Power to all circuits is switched on and the

engine may be started.

Position S Starting position.

Starting the engine

Terminal tractors are designed to start in N (neutral) only. The
starter should not operate if the vehicle is in any other gear.
1. Prior to starting the engine, 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.

NOTE
Do not run a cold engine at high speed!

Starting the engine with Start push button

As an optional function the tractor can be equipped with keyless
ignition.
Terminal tractors are designed to start in N (neutral) only. The
starter should not operate if the vehicle is in any other gear.
1. Prior to starting the engine, 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.

OFF 4. Turn the main switch ON.

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

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6. Press the engine start push button on the dash panel.

START NOTE
Do not run a cold engine at high speed!

Starting with auxiliary batteries

If the charge level of the batteries has decreased or the
batteries are drained, the tractor engine can be started using
24-volt auxiliary batteries according to the following instructions:
1. If the auxiliary batteries are on another vehicle, ensure
that the vehicles are not touching each other.
2. Connect one end of the positive (+) jump-start cable to
the positive terminal of the auxiliary battery (marked
with red colour, the letter ’P’, or a plus sign). Ensure
that the clamps are securely connected to prevent
sparking.
3. Connect the other end of the positive (+) jump-start
cable to the positive terminal of the drained battery (the
cable to the starter motor is connected to this terminal).
4. Connect one end of the negative (-) jump-start cable to
the negative terminal of the auxiliary battery (marked
with blue colour, the letter ’N’, or a minus sign) and
connect the other end of the cable securely to, for
example, the negative engine cable of the vehicle with
the drained battery.
5. Start the engine. Ensure that the cables do not touch
each other while starting.
6. While starting, do not cut off the circuit going through
the batteries installed on the tractor.
7. Disconnect the jump-start cables in reverse order of
connection.

DANGER
If electrolyte is spilled on the eyes or skin, flush the area
immediately with large quantities of water and consult a
doctor.

Stopping the engine

Engage the parking brake. 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. Stop
the engine by turning the ignition key to position 0.
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.

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NOTE
The tractor transmission does not have a parking position. Use
the parking brake when parking.

CAUTION
Always apply the parking brake. Never park the vehicle
by leaving it in gear. Always place the transmission
shifter selector in the “neutral” position.
Never park a tractor trailer combination unless the
trailer parking brakes are operational and applied.

5.4.2 Selecting driving direction and gear

Driving direction selector

MODE

SELECT
E R
N C
M D
L

MONITOR

A. Bump lever
B. Mode button
C. Mode indicator display
D. Display Mode/Diagnostic button
E. Shift selector:

Position Range Description

R Reverse Selects Reverse gear.

N Neutral Must be selected prior to starting the

engine.

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Position Range Description

D Drive Selects the highest available forward

range.

L Low Selects the lowest available forward

range range.

M Manual Moving the lever from the Drive position

select into the Manual Select position allows
the operator to select a lower or higher
forward gear range.

Do not move off if the gauge readings are not normal or any of
the warning symbols is lit.
Select the desired driving direction with the bump lever (A).
The current gear is indicated in the gear selector display (C).
The tractor moves off by increasing the engine speed. Move off
with a gear corresponding to the load; the heavier the load, the
lower the gear.

5.4.3 Steering

General
The tractor is equipped with hydraulic power assisted steering
with mechanical backup. The front wheels and the steering
wheel are mechanically connected.
The movements of the steering wheel are conveyed to the front
axle wheels hydraulically.

DANGER
Never let the tractor roll downhill if the engine is not
running.
When the engine is not running, the hydraulic pump
does not supply pressure to the steering system and
steering is very slow and limited.

5.4.4 Brakes

General
The pneumatic brake system is controlled with the brake pedal.
If a trailer is coupled to the tractor, the trailer brakes are also
controlled with the brake pedal if the pneumatic connections are
connected between the tractor and trailer.
As a standard the brake system is a single circuit brake system.
Optionally the tractor can be equipped with a dual circuit brake
system.With the dual circuit brake system, one circuit remains
functional even if the other circuit fails due to, for example an air
leak.

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Brake firmly but smoothly to reduce tyre and brake wear.

Decrease the brake pedal pressure slightly prior to stopping to
stop the tractor and trailer (if coupled) in a controlled manner.

5.4.5 Parking brake system

Parking brake control switch

Parking brake control switch is located on the left dashboard
panel.
PARKING The switch operates the parking brakes on the vehicle and
BRAKE
trailer:
• PULL to apply the parking brakes.
• PUSH to release the parking brakes.

NOTE
Prior to getting up from the driver’s seat, ensure that the
parking brake is engaged.
The parking brake is not to be used as a service brake, since
engaging the parking brake while the tractor is moving subjects
the transmission and brake system components to heavy
loads!

5.4.6 Stopping the engine / parking

Stopping the engine

Put the gear to neutral by pressing the N button on the gear
selector. Engage the parking brake with the lever. Let the
engine to run on idle for three minutes so the engine
temperature can stabilise.
Stop the engine by turning the ignition key to position 0.
Turn the main switch to the off position when leaving the
machine.

CAUTION
Do not turn the main switch to the off position while the
engine is running as it may damage the alternator and
cause error codes.

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5.5 Load handling

General
In this context, load handling means transporting various trailers
with the tractor.
The load handling instructions presented in this section are
general guidelines only and not intended for work instructions
as such. The tractor may be operated only by a trained driver.
Local conditions and loads can cause exceptions to these
instructions. Maximum fifth wheel load and lifting capacity are
listed in section 9 Specifications on page 97.

WARNING
When transporting a trailer along a steep ramp, always
drive under the trailer.
Push behind the trailer when going upwards and pull in
front of the trailer when going downwards. Otherwise
the front end of the tractor may rise off the surface
causing loss of control of the machine.

CAUTION
During operation, loaded Fifth wheel must be lifted at
least 50mm from the lowest position. This way fifth
wheel is supported by the lifting cylinders.
Direct load on the mechanical limiters during operation
may cause severe fractures to the lift boom and tractor
frame.

5.5.1 Transporting a trailer

General
Keeping the driving surface clean is essential for the safety and
durability of the tractor.
When driving, select the driving speed so that any driving
surface irregularities or inclination do not pose a safety hazard
and the tractor structure is not unnecessarily stressed.
When moving off and stopping, accelerate and brake smoothly.

WARNING
When transporting a trailer along a ramp, make sure that
there is enough power in the tractor to pull a load by
using a selected driving gear. Make sure that the
transmission of the tractor does not need to change
gear on a ramp.

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Transporting a trailer
Back the tractor under the trailer to be transported so that the
fifth wheel is coupled to the kingpin.
Connect the tractor brake hoses to the trailer brake fittings and
run the engine at high rpm until the brake system pressure
reaches the normal level and the trailer brakes are released.
Lift the trailer so that, if necessary, its support legs can be
cranked to the fully retracted position, or hinged support legs
can be turned and secured parallel to the trailer bed. While
lifting the trailer, be careful not to damage any other vehicles
possibly parked in the vicinity.
Transport the trailer into confined spaces by pushing.

WARNING
When driving to a loading ramp, use gear that is low
enough.

When the trailer is in the correct position, lower the trailer onto
its support legs or trailer horse and disconnect the brake hoses.
Release the kingpin from the fifth wheel by pushing the kingpin
release switch until the red kingpin lock indicator light on the
instrument panel is lit. Hold the switch while the indicator light is
lit and pull the tractor clear of the parked trailer.
Release the switch when the tractor is clear of the trailer. The
indicator light remains lit to indicate that the fifth wheel jaws are
open.

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Detailed trailer spotting instructions

1. Maintain optimum tractor air pressure (8,3bar). 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.
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 raised too high.
8. Once proper trailer height is reached, apply the tractor
parking brake. Now hook BOTH the trailer emergency
and service air lines to the trailer (blue and red air
lines) 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. Allow the
vehicle to roll a VERY SHORT distance and then
depress the brake treadle again to stop the vehicle.
This procedure will ensure that the service brakes on
the trailer are working properly. NOW, and ONLY NOW,
are you ready to move (“SPOT”) the trailer.

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6 Inspection and
maintenance
General
This chapter describes the following issues regarding inspection
and maintenance:
• Daily inspections
The Daily inspections section specifies the inspection
procedures which the driver or the person responsible
for maintenance of the machine carry out the before
each shift.
• Maintenance
The Maintenance section contains instructions on
performing the daily inspections and associated
maintenance procedures.
• Service
This section does not include procedures concerning
scheduled maintenance since these are specified and
presented in the maintenance manual of this machine.

DANGER
The engine must always be stopped for maintenance
and inspection.
Only a person who has been familiarised with the
machine's controls and devices may be in the cab
during inspection and maintenance.

DANGER
Fuel is highly flammable.
Do not smoke or use an open flame when refueling and
servicing the fuel system.

CAUTION
Avoid skin contact with oils and lubricants. Use
protective gloves during maintenance.

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6.1 Daily Inspection

General
Daily inspections and any required maintenance carried out by
a professional and trained person make sure that the
operational safety and reliability of the machine are maintained.
It is recommended that the driver or the person responsible for
the maintenance of the machine carries out the inspections
before each shift. This way it can be made sure that the work
does not commence with a defective machine.

DANGER
If an issue requiring service or repair is detected in the
daily inspection, do not start working with the machine
until the service or repair has been carried out.

Daily inspection table

General

Item Inspection method Note Reference

Any oil, fluid, or air leaks and Visually

visible damage

Shields and doors Visually

• Closed and locked
correctly

1 Engine

Item Inspection method Note Reference

Unusual system noise By listening

Fuel level from the fuel Visually Fill with high-quality diesel See: 6.2.6 Fuel system on
gauge fuel if necessary. page 79

Lubrication oil level Dipstick Add the recommended oil if See: 6.2.1 Engine lubrication
necessary. system on page 76

Coolant level in the Indicator light is lit in the Tilt the cab to the service See: 6.2.3 Cooling system
expansion tank CANpanel when the coolant position and add the on page 77
level is too low. recommended coolant, if
necessary.
The level can be visually
checked.

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4 Brakes

Item Inspection method Note Reference

Operation of brakes Brake test immediately after Also test the operation of the
moving. parking brake.

5 Steering

Item Inspection method Note Reference

Operation of the steering Turn the wheels to the At the same time, check also
logic valve opposite position. that the operation of the
lights corresponds with the
driving direction.
In case of a logic valve
malfunction, contact the
person responsible for
maintenance of the
machine.

6 Suspension and wheels

Item Inspection method Note Reference

Wheel attachment Visually Pay special attention to the

wheels since they are only
attached to the axle by the
friction force between the rim
seating surface and
mounting nuts.

Tyre pressure and condition Visually Moreover, pay attention to

any surface damage (for
example, deep cuts in the
tire surface).

7 Load handling

Item Inspection method Note Reference

Operation of the fifth wheel Visually Lubricate the fifth wheel

and lift boom surface and kingpin locking
components with the
recommended grease if
necessary.

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8 Frame, cab, and accessories

Item Inspection method Note Reference

Examine the mounting of the Visually Walk around the machine

protective plates and and inspect that all the
additional devices protective covers, ladders
and additional devices are
properly attached.

Controls, instruments, and Visually Examine operation before

indicator lights and after starting the engine.

Cab lock pins in the rear Visually Working is prohibited unless

brackets the lock pins are in place in
the rear brackets.

Operation of beacons and Visually / by listening

buzzers

Windscreen washer Visually / by listening Add the recommended see: 6.2.7 Windscreen
washer fluid to the washer washer on page 79
fluid reservoir if necessary.

9 Common hydraulics

Item Inspection method Note Reference

Oil level in the hydraulic oil Sight glass If necessary, add the see: 6.2.8 Hydraulic system
tank recommended oil to the on page 80
tank.

11 Common pneumatics

Item Inspection method Note Reference

Drain moisture from the air Pull the drain plug cord from see: 6.2.9 Pneumatic system
pressure tanks the air pressure tanks on page 80

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6.2 Maintenance
General
This section contains instructions on performing the daily
inspection and maintenance procedures specified in the
inspection table.

IMPORTANT
To maintain machine warranty, use only the oils,
greases, and fluids specified in chapter 9, as well as
original filters and other service parts available from our
spare parts department.
By using the lubricants and fluids specified in this
manual and original filters and other service parts it can
be ensured that the safety and reliability of the machine
will be maintained.

Safety
• Always stop the engine prior to performing
maintenance procedures unless they require the
engine to be running.
• Maintenance may only be performed by trained and
professional persons to ensure that the safety and
reliability of the machine will be maintained at the
intended level.
• Do not service the machine unless you are absolutely
sure about the instructions and regulations on
performing the procedures safely. If necessary, ask
your work instructor or our maintenance department for
guidance on the issues regarding safety in
maintenance.
• Do not dispose of the waste oil, grease, and fluids in
the drain or on the ground. Clean any fluid leaks from
the machine and ground.
• Take responsibility for the environment!

NOTE
If you wash the machine with a pressure washer, do not direct
the water jet directly towards the radiator, electric devices,
bearings, and shaft seals since they can be damaged!

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Tilting the cab

The inspection table specifies the inspection procedures for
which the cab must be tilted to the maintenance position as
shown in the picture.
• Prior to tilting the cab to the maintenance position,
ensure that the cab door is properly closed and any
loose items are removed from the cab.
• Prior to lowering the cab, check that the cab path is
free of obstructions.
• If the tilting hydraulics hoses or fittings are to be
replaced, use only original spare parts and
accessories.

DANGER
When checking the operation of a running engine with
the cab tilted to the maintenance position, pay special
attention to the rotating belts and driveshafts.
Pieces of clothing can be easily caught in a rotating part
and when wrapped and tightened around the part may
cause personal injury!

DANGER
Working under the cab without the mechanical safety
stop that prevents the cab from lowering is strictly
prohibited!

DANGER
Only tilt the cab when the tractor is parked on a level
surface. Tilting the cab when the tractor is parked on an
unlevel surface may cause damage to the cab tilt system
and result the cab to fall and cause serious injury or
death.

DANGER
Ensure the front of the cab is clear of personnel before
tilting cab.

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CAUTION
Only tilt the cab far enough to engage the safety bar.
Attempting to fully extend the cylinder can cause pump
and motor damage. Check the cab tilt cylinder and
bracket mounting bolt for proper torque and wear!
Failure to check and operate the cab tilt system
correctly can result in injury.

To tilt cab
The tractor is equipped with electric tilt pump control unit. The
controls are located on the side of the battery box.
Cab hold-down latch is automatic and works hydraulically with
priority valve.
1. Turn on the main switch to operate the tilt pump.
2. Pull firmly from the safety prop release cable (A) and
B then hold the switch (B) in the UP position.
3. After the cab has traveled about 15 inches (381 mm),
release the safety prop cable (A) and continue tilting
A the cab.

4. Make sure the cab is fully tilted and the safety stop (C)
is engaged to the cylinder before working under the
cab.
C
5. To tilt the cab back to the operating position pull first
A firmly from the safety prop release cable (A) to release
the safety stop (C) and then hold the switch (B) in the
down position.
6. Hold the switch in the down position for couple of
seconds after the cab is completely lowered to fully
engage hold-down hook.

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6.2.1 Engine lubrication system

Examine oil level (Cummins)

The engine oil dipstick (A) is located behind the cab and it is
attached to the guard rail next to the steps with the transmission
oil dipstick.

A 1. Clean the dipstick before the oil level examination.

2. Examine the oil level when the engine has been
stopped for at least a few minutes.
The engine oil level is correct when the level is
between the MIN and MAX marks on the dipstick.

3. If necessary, tilt the cab and add the recommended oil

B through the filler cap (B).

6.2.2 Transmission lubrication system

Examine the transmission oil level

The transmission oil dipstick (A) is located behind the cab and it
is attached to the guard rail next to the steps.
The transmission oil level is correct when the level is between
the MIN and MAX marks on the dipstick.

B 1. Clean the dipstick before the oil level examination.

2. Examine the oil level when the engine has been
stopped for at least a few minutes.
A 3. If necessary, add the recommended oil through the
filler cap (B).

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6.2.3 Cooling system

Examine the coolant level

B The cooling system expansion tank is equipped with coolant

recovery tank (A).
1. Check the level from the recovery tank (A). The coolant
level must be close to the Cold fill mark.
2. If necessary, tilt the cab and add the recommended
coolant to the expansion tank through the filler cap (B).

NOTE
A If you have to add coolant to the tank, be careful to keep the
fluid free of any impurities. Impurities in coolant damage the
coolant pump and impair engine coolant circulation. The right
coolant mix and type can be found from section 9
Specifications on page 97.

CAUTION
Allow the engine to cool down for a while and open the
cap carefully if you have to add coolant to the tank.
Steam or hot coolant may be discharged from the
expansion tank and cause burns.

6.2.4 Charging system for batteries

Examine the alternator belt

Replace the alternator belt (A) if it is clearly worn, oily, or visibly
cracked.
The alternator belt is equipped with an automatic tensioner.

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6.2.5 Engine air filter

Cummins engine air filter

The air filter in the housing (A) is changed during scheduled
maintenance. Depending on the operating conditions, the air
filter may clog during a relatively short operating period.
The air filter is under the engine hood.
Contact the person responsible for maintenance if the filter
clogging indicator that the filter needs to be changed. Continue
A working only after the filter has been replaced.

Air filter clog indicator

The air filter clogging indicator is directly behind the
maintenance hatch on the curbside of the tractor.

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6.2.6 Fuel system

Fill the fuel tank

DANGER
Fuel is highly flammable.
Do not smoke or use an open flame when refuelling and
servicing the fuel system.

NOTE
Never allow the fuel tank to run completely empty since this
allows air to enter the fuel system and it becomes necessary to
bleed the system.

The fuel tank is located on the right side of the tractor.

1. Examine the fuel level from the fuel gauge in the cab
while the machine power is switched on.
2. Fill the tank with high-quality diesel fuel through the
filler cap (A). Leave the fuel level approximately 10%
from the top.
A

6.2.7 Windscreen washer

Fill the windscreen washer fluid reservoir

The washer fluid reservoir is located under the front fender.
1. Examine the washer fluid level in the reservoir. If
necessary, add the recommended washer fluid through
the filler cap.
Remember to consider the ambient temperature and
required anti-freezing properties when determining the
appropriate washer fluid mixture.
2. Examine the condition of the windscreen wipers.

NOTE
Make sure that the visibility from the machine cab to the
working environment is always unobstructed.

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6.2.8 Hydraulic system

Examine the hydraulic oil level

The hydraulic oil tank is located:
• for RHD on the right side of the machine,
• for LHD on the left side of the machine.
1. Inspect the oil level from the sight glass (A).
Make sure the lift boom is down when inspecting the
B level.
2. If necessary, add the recommended hydraulic oil
through the filler cap (B).

NOTE
If you have to add oil to the hydraulic oil tank, be careful to
A keep the oil free of other fluids or impurities. Impurities damage
the hydraulic system. Filter the oil before adding it into the tank

6.2.9 Pneumatic system

Drain the air tanks

The air tanks are located under the chassis.
1. Drain the water from the reservoirs by pulling the cord
(A) attached to the valve ring at the bottom of the
reservoir. The exiting compressed air forces the water
out.
A

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6.3 Service
General
For the operational safety and reliability of the machine, it is
extremely important that the inspections and maintenance
procedures are carried out according to the maintenance
programme defined in the maintenance manual of this machine.
Inspections and maintenance carried out by a professional and
trained person ensure that the operational safety and reliability
of the machine will be maintained at the intended level.
It is recommended that servicing be performed by the
maintenance division of Kalmar, or an authorised service outlet.

IMPORTANT
Following the maintenance programme defined in the
maintenance manual of this machine is a prerequisite
for maintaining the machine warranty.

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Lubrication

4,5,6
8

14

9 4,5,6

11
12
10
13

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Explanation of the symbols:

Manual lubrication (at intervals of 250 running hours).
If the machine is equipped with central lubrication, check
only.

Number Maintenance item Lubrication Note Reference

3 Axles

1 Lubricating the universal shaft joints (2

pcs.)
2 Lubricating the front axle kingpins (4
pcs.)

3 Lubricating the driveline slip yoke

4 Brakes

4 Lubricating the brake lever (4 pcs.)

5 Lubricating the S-cam bearings (6

pcs.)
6 Lubricating the brake shoe anchor Lubrication only once a
pins (4 pcs.) year.
5 Steering

7 Lubricating the tie rod joints (2 pcs.)

8 Lubricating the steering cylinder ends

(4 pcs.)
6 Suspension

9 Lubricating the axle rocker bearing (2

pcs.)
7 Load handling

10 Lubricating the lifting frame bearing (2

pcs.)
11 Fifth wheel: grease nipples, jaws, slide The number of the
grease nipples varies
depending on the
customer.

12 Lubricating the fifth wheel joints (2 Holland FW 35

pcs.)

13 Lubricating the lifting cylinder upper

end (2 pcs.)

8 Frame, body, cab, and accessories

14 Lubricating the cab tilt latch

15 Lubricating the cab door locks (2 pcs.)

16 Lubricating the cab door hinges

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7 Transport of machine

7.1 Towing
General
Starting the tractor by towing or pushing is not possible.
If the engine cannot run while towing, the towed tractor must be
attached to the towing tractor with a tow bar.
The brakes operate normally as long as the pneumatic system
pressure remains over 5 bar. The parking brake is engaged
gradually by the springs in the brake cylinder while the system
pressure drops from 5 bar to 0 bar. If the tractor is towed when
the brake system pressure is below 5 bar, the parking brake
must be released mechanically (for detailed instructions, see
section 7.1.1 Releasing the parking brake mechanically on
page 86).
The propeller shafts between the transmission and axles of the
towed tractor must be removed at the appropriate locations
before towing to prevent damage to the transmission during
towing due to insufficient lubrication.

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7.1.1 Releasing the parking brake

mechanically

General
The spring-actuated parking brake is located in the same brake
1 chamber assembly as the service brake pneumatic chamber.
The spring-actuated parking brake is at the rear axle as
standard, and available as an option at the front axle.
Releasing the parking brake
Turn the nut (item 1) on the top side of the rear axle spring
brake chamber clockwise until the screw going through the nut
compresses the coil spring in the cylinder and the brakes
release.
Release the front axle parking brake, if fitted, as described
above.

DANGER
Prior to releasing the parking brake mechanically,
ensure that the tractor cannot move by, for example,
chocking the wheels.

Resetting the parking brake

When the brake system pressure reaches the normal level, turn
the spring brake cylinder release nuts at the front and rear axles
anticlockwise until the release screws going through the nuts
are flush with the nut top surface.
Prior to commencing work with the tractor, test the operation of
the parking brake by parking the machine on a slope.

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7.2 Lifting and transporting machine

General
Attach the lifting slings to the front bumper and to the lifting ears
at the rear section of the frame. When lifting, select the length
of the lifting slings so that the tractor is balanced both
lengthwise and crosswise. Lifting slings can not touch the
windscreen when lifting.
Pay special attention to protecting the cab and attached
components to prevent damage to them while lifting.

DANGER
Never go under a suspended load while the machine is
lifted.

Transport
Engage the parking brake and secure the tractor to the cargo
bed with, for example, chains so that the load cannot shift and
cause hazard to other road users and the tractor remains intact
during transportation.

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7.3 Service position

General
The tractor service position is used while performing
maintenance procedures.
The tractor is in the service position when the following
conditions are met:
• The tractor is parked, and the parking brake is
engaged.
• The main power is switched off with the main switch.

DANGER
Ensure that the fifth wheel is unloaded and the lift boom
is supported mechanically if it must be in the upper
position during maintenance or repair.
Prior to tilting the cab to the maintenance position,
ensure that the radiator grille at the front of the cab is
lifted up, the cab door is properly closed, and any loose
items are removed from the cab.
Working under the cab without the mechanical safety
stop that prevents the cab from lowering is strictly
prohibited!

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7.4 Long-term storage

General
If the tractor is to be stored for an extended period of time,
contact local Kalmar dealer for detailed storage instructions.

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 8 Environment - 91

8 Environment
General
Increasing industrialisation has a significant effect on our
environment on a global scale. Nature, animals, and people are
every day exposed to risks caused by exposure to various
chemicals.
In this light, the long-term objective is to develop chemicals that
are environmentally friendly. Many chemicals in current use,
such as oils, greases, and coolants, are classified as problem
waste.
By using appropriate tools and procedures, we can reduce the
impact on the environment.
When the machine is serviced according to the maintenance
plan described in the service manual for this machine, the
machine is safe for the operator and places the smallest
possible burden on the environment.
By observing these instructions, you can help conserve our
common environment.

Environmental policy
The management of environmental issues at the manufacturing
factory is based on the manufacturer's operational policy, to
which this environmental policy is a supplement. Our operations
are based on making continual improvements to prevent
pollution of the environment, and on developing environmentally
friendly products and services. The operations of the factory are
developed in accordance with the principles of sustainable
development. Each year, the factory management looks at the
main environmental concerns, determines its environmental
objectives and develops an environmental management
program to meet the objectives. The management will keep
track of the environmental objectives and corrective actions by
conducting internal audits as part of the operations system.
Reacting to possible environmental abnormalities and taking
the necessary corrective actions is the responsibility of the
entire staff. Manufacturing factory adheres to the current
legislation and regulations in its operations. Our operations
comply with the international environmental system standard
ISO 14001 and the principles of sustainable development set by
the International Chamber of Commerce.

Environmental awareness
Aim to define your own environmental awareness. Ask your
supervisor for more training if required. After the training, make
sure that you can adapt the information received to your
everyday tasks. Product manuals also contain environmental
information about the product. Make sure that you have
sufficient general knowledge about the matters that have to do
with your tasks. You can improve your product knowledge by
studying user manuals and spare parts lists provided by the
manufacturer. The manufacturer will also provide the necessary
user training when needed. Find out about the environmental
and safety instructions for using, servicing and repairing the
machine. What is most important is to know how to act in
exceptional cases. Follow the maintenance and adjustment
schedules carefully. Use the designated oils and other liquids.

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92 8 Environment -

Check that the oil levels are correct. In general, when using the
machine, make sure that it works properly and that is in the
appropriate condition for the job.Try to decrease emissions and
the amount of waste produced as best you can. Do not take any
risks, work with care. Try to do the right things in the right way.

Environmental problems
By environmental problems, we mean faults detected in
machine operation that will or might be harmful to the
environment. The most common of these are oil and other liquid
spills, toxic waste, leaks and fires. If seals on cabs are
damaged or worn, this can also lead to an environmental
problem, in case it causes the operator to be exposed to noise
levels which are too high. If there are possible environmental
problems, immediately contact your supervisor or the person
responsible for environmental issues. Continuous monitoring of
the machine operation along with preventive maintenance and
repairs makes sure that the use of the product is safe and
uninterrupted. Follow the maintenance instructions diligently so
as not to jeopardize the machine and its user. By blocking up
leaks and checking the joints and pipe installations, you can
make sure that no unwanted liquids are released from the
machine.

Laws and regulations

There are several laws and regulations that have to do with
using the machine. It is the employer’s responsibility to make
sure that the requirements are met in the work. Environmental
issues have become increasingly important. It is important to be
aware of the current requirements, but it is equally important to
follow up on the changes in the requirements. The requirements
tend to become tighter all the time.

Use of materials and energy

Reasonable and appropriate use of materials can yield
surprisingly high savings in costs and also decrease
environmental load. Preventive maintenance has a decisive
influence on decreasing machine downtime. User and
maintenance manuals are intended to teach how to use the
machine correctly and safely. Always use spare parts
recommended by the manufacturer, and perform maintenance
and repairs in accordance with the instructions. Follow all fluid
changing intervals. Use environmentally friendly materials when
possible. Also try to use recycled materials. In this way, you will
achieve the best possible results both for the environment and
safety. When using a machine, energy consumption is most
influenced by the condition of the machine and the machine
operator’s skills. The manufacturer has installed and set the
adjustable values of your machine to the optimal level for both
consumption and emissions. Regular maintenance and
immediate repair work when necessary are a prerequisite for
optimal machine operation. Pay special attention to starting the
machine from cold and the instructions given for this.

Effects of exhaust gases

Diesel engine emissions are the cause of both health and
environmental problems. The most serious environmental
problem is soil acidification, which is manifested in problems in
tree growth and plant formation as well as eutrophication. Of
the diesel engine emissions, nitrous oxide (NOx) forms nitric

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acid when in contact with water, and sulfur dioxide forms

sulfuric acid. Both of these are strong acids that have an effect
on plant formation by decreasing the ability of roots to absorb
water and minerals. Particles are primarily the result of poor
combustion of the fuel-air mixture in the diesel engine. They
consist of small carbon particles (<10 μm) on which toxic
hydrocarbons have concentrated. These come from the fuel
and lubricating oil. The particles are released into the air along
with the exhaust gases, and the mutagenic and carcinogenic
hydrocarbons may then enter human lungs. Hazardous
emissions are mainly the result of incorrect adjustment of the
motor and lack of maintenance. For this reason, it is essential
that adjustments and maintenance are performed in the
instruction manuals.

Recycling
The primary goal of environmental protection is to decrease the
amount of waste produced. If waste is produced, you must try
to utilize it as a material or as a source of energy. Appropriate
and safe processing must be arranged for all kinds of waste.
The sorting of the waste created in our operations is influenced
by the legislation, environmental factors and general tidiness,
among other things. The amount of waste driven to the landfill
can be decreased by sorting the waste in the appropriate,
labelled receptacles. The most effective way of protecting the
environment is to save material and energy and use to
environmentally friendly methods and products. Become
familiar with the waste disposal and recycling instructions of
your unit. Metal waste can be collected, sorted and delivered to
the industry for use as a raw material and alloying element.
Recycling saves approximately half of the energy that would be
consumed if the same amount of metal were obtained from a
mine. Toxic waste means waste that can be hazardous to
health or the environment because of some chemical or other
property. When collecting and handling toxic waste, these
health and environmental risks need to be taken into account.
Toxic waste typically includes batteries and accumulators,
paints, solvents, other special liquids, fuel waste, coolant waste,
aerosols and used fluorescent tubes. Sort all toxic waste and
make sure that it is treated appropriately.
Deliver the used or discarded materials for example, packing
waste, clean metal parts, electric components to a recycling
centre or another suitable location to be destroyed.

Complete overhaul or disposal

As the lifetime of the machine draws to a close, there are two
options for dealing with the machine: complete overhaul or
disposal. If complete overhaul is selected, use the
manufacturer's expertise to determine the amount of repairs
needed. This also make sure that any new environmental and
safety requirements will be taken into account. In the case of
complete overhaul, the product needs to be equipped to meet
the new requirements. This is the responsibility of the person
conducting the repair work. Environmental load can be reduced
by sorting materials and components. Note that the machine
mostly consists of various iron structures, which are mainly
recyclable. As to the disposal of toxic waste, you must find out
the appropriate methods of disposing of liquids, materials and
components. The safety bulletins of various liquids and
materials contain instructions for disposal. You can also consult
the suppliers of components and the product manufacturer for
disposal and sorting.

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Problem waste
Deliver materials that are classified as problem waste, such as
batteries, used filters, plastic parts, and other problematic
components, to a problem waste collection point.
Discard the problem waste according to the laws and
environmental regulations that are in effect for the machine's
operating environment.

Oils and fluids

The main consideration for the environment is to prevent oil and
other toxic liquids from entering ground water and surface water
courses. Even small oil spills can cause significant damage to
water courses. Pay attention to any possible spills on your
machine. Make sure that the hoses are in good condition in
order to prevent unpleasant surprises. When there is a spillage,
absorb the spilled oil, for example, in sawdust, and remove the
contaminated sawdust according to your site instructions. In
case of an accident, immediately contact your supervisor or the
person responsible for environmental issues.
Use appropriate containers, an oil collection basin, a pump, a
hose, and so on, when removing oils and other fluids from the
machine. Let companies specialising in recycling of problem
waste take care of discarding the used oils and other fluids.
Pay special attention to fluid leaks. If any oil has leaked onto
the ground, absorb this oil in sawdust or a similar material and
deliver the contaminated sawdust to the problem waste
collection point.
Properly address the cause of the leak, and replace damaged
parts before you carry on working with the machine!

Air conditioning
The refrigerant of the cab's air conditioner accelerates the
greenhouse effect. Refrigerant must not be discharged from the
air conditioning system into the atmosphere.

NOTE
The air conditioning system must be serviced only by skilled
service personnel qualified to service refrigeration equipment.

Occupational health and safety

Pay attention to your working environment. Perform the
necessary maintenance and repair work to prevent sickness or
accidents caused by vibration, noise or other factors.
Recognize the needs for safety training, and get to know the
safety bulletins of the hazardous substances you have to work
with.

Working in an environment that is hazardous to

health
If the machine must be operated in an environment that poses
health hazards, it must be equipped, operated, and serviced
according to the laws and regulations established for those
conditions.

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Environments that are hazardous to health include premises

where asbestos particles or other dust fills the air.
When the machine has been used in such an environment, take
special care when discarding the cabin's and the engine's air
filters.
If the machine has been operated in environments such as
those mentioned above, the discarded filters must be kept in
appropriate waste containers and delivered to the problem
waste collection point.

Remember these
Being tidy and systematic is the most important consideration.
Remember the following things:
• Act according to instructions.
• Check that all liquids are filled correctly.
• Check for leaks.
• Make sure that everything is functioning correctly.
• Return the tools used for maintenance and repair work
to their right place.
• Store unused components appropriately.
• Recognize environmental problems.
• Sort the waste that is produced.
• Clear up the environment after finishing work.
• Keep the working areas, emergency exits and electric
cabinets clear and unobstructed.
• Report all abnormal events.
• Contact your supervisor or the person responsible for
environmental issues if necessary.
Keeping your own working environment tidy and in good order
is your personal responsibility. Tidiness and orderliness
influence how the workplace functions, decrease the number of
accidents at work, and contribute to the positive image of the
company and its employees.

8.1 Standards
Vibration affecting the hands
Measured at the steering wheel in accordance with standard
SFSENV 25349: the vibration affecting the hands does not
exceed 2.5 m/s2 at normal operation.

Vibration affecting the whole body

Measured at the driver's seat in accordance with standard ISO
2631: the vibration affecting the whole body when working with
the terminal tractor does not exceed 0.5 m/s2 at normal
operation.

Noise levels
Maximum noise level inside the cabin is 75 dB(A) LpAZ ,
according to the standard SFS-EN 12053 + AC. Maximum

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noise level outside the cabin is 85 dB(A) LAeq, measured from

the side at 7.5 m, with the engine running at full power speed.
Optionally, the maximum noise level outside the cabin is 80
dB(A) LAeq, measured from the side at 7.5 m, with the engine
running at full power speed.

EMC Electromagnetic Compatibility

In some conditions, the machine's electric devices may cause
interference to other electric devices or be exposed to the
electromagnetic radiation emitted by other electric devices. This
may pose safety hazards for the operation of the machines
involved.
The devices and systems of this machine operate normally
regardless of the electromagnetic radiation in the working
environment.
In the electromagnetic compatibility (EMC) directive
2004/104/EC the performance characteristics related to
electromagnetic radiation and safety required of the device are
set forth. The directive's reference values are expressed
according to the international standards. A machine or device
that complies with these standards can be CE marked.
The EMC directive is included in this machine's CE marking and
Declaration of Conformity.
If the machine is equipped with auxiliary devices other than
those manufactured and approved by manufacturer, they must
be CE marked and compatible with other electric devices.

Exhaust gas emissions

The exhaust gas and particle emissions from this machine do
not exceed the limit values specified in Stage 4 of the directive
2004/26/EC and U.S. 40 CFR 89 Tier 4 final for machines
delivered in EU and US.
Machines delivered outside the EU or US are available with Tier
3/ Stage 3A engines.

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9 Specifications

9.1 Specifications and dimensional

drawing
General
This chapter includes the dimensional drawing of the machine,
a summary of component specifications and settings, and
specifications for the recommended oils, fluids, and greases to
be used.
At the end of the chapter there is a table of the most common
units and their abbreviations, as well as conversion tables for
the SI units and length, area, volume, weight, mass, and
pressure measurements.

Dimensional drawing

R 83.59
[2123.19]
TO CAB REAR DOOR

103.19
[2621.09] 98
[2489.2]

R 56.7
[1440.26]
TO REAR AXLE BRKT
187.4
[4760]

9.6
[243.94] UP
5.49
[139.57] DOWN
126.42
[3211.05]

63.56
[1614.39] UP
46.37
[1177.88] DOWN

74.02
[1880]
46.39 116 0.98 80.43 REAR
[1178.25] [2946.4] [25.01] [2043]

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Specifications

Cummins engines

Model Cummins QSB 6.7 EPA Tier 3 / EU Stage 3A

Operating Low-emission, turbocharged diesel engine

principle with direct injection and intercooler.
Number of 6
cylinders
Capacity 6.7 dm3

Power (ISO 3046, 129 kW / 2200 rpm

net)
Maximum power 164 kW (220 hp) 2000rpm

Torque (ISO 3046) 952 Nm / 1400 rpm

Engine speeds Idle speed 700 rpm

Maximum speed 2500 rpm

Alternator 70 A

Starting batteries 2 x 12 V

Transmission

Model Allison 3000im

Operating Automatic transmission with torque converter

principle
Front axle

Hande 5.5

Front axle Hande 5.5

Rated axle load 5500 kg

Brake Size 410 mm x 160 mm

Steering Mechanical steering arm

Hande 7.5

Front axle Hande 7.5

Rated axle load 7500 kg

Brake Size 410 mm x 160 mm

Steering Mechanical steering arm

Rear axles

Hande 11.98

Rear axle Hande 11.98

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Rated axle load 16 000 kg

Drive flange 180 mm

Final drive ratio 11.98:1

Track width 1860 mm

Brake size 420 mm x 185 mm

Brakes

Operating Pneumatic spring brake chamber actuates the

principle brake lever which turns the S-cam causing the
brake shoes to make contact with the brake
drum and generate brake torque.
Service brake Dual circuit drum brakes.

Parking brake Spring-loaded drum brake at the rear axle,

controlled with an electric switch in the cab.
Steering

Hydraulic power assisted steering

Steering system Hydraulic power assisted steering with

mechanical backup.
Suspension

Front axle Leaf springs, attached with pivot pins to the

tractor frame and with clamps to the axle.
Rear axle On the standard tractors, the rear axle is
bolted rigidly to the tractor frame.
Wheels

Tyre size 11R22.5

Tyre pressure 10 bar

Rim size 22.5 X 8.25 X 6.5

Fifth wheel

Model Holland FW35

Maximum load 32,000 kg

Lifting capacities and heights

The following lifting boom and cylinder types are available, with the
capacities and lifting heights noted.

Lifting capacity 20 000 kg

Lifting height 430 mm

Lift cylinder Double acting, single stage

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Lifting capacity 28 000 kg

Lifting height 430 mm

Lift cylinder Double acting, single stage

Hydraulics

Operating The pressure and volume flow required by the

principle terminal tractor hydraulic system is generated
by a fixed pump which is actuated by the PTO
- on the transmission.
A priority valve is integrated in the pump and it
primarily directs the pump output for the
tractor steering. The flow for the steering is
determined by the load information coming
from the steering device. If steering is not in
operation, no hydraulic oil flow is directed to
the steering cylinders.

Steering 100 bar

hydraulics
pressure value
Pneumatic system

Operating A compressor coupled to the engine

principle generates the required volume flow for the
pneumatic system.
The pressure control valve at the compressor
directs the compressor output to the by-pass
line when the system pressure exceeds 8.0
bar.

Compressor Approximately 500 litres per minute (Depends

output on engine type and RPM).
Compressed air 3 tanks: 89 litres.
tank volume

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9.2 Oil, grease and fluid volumes and

quality
Cummins engine fluids
Cummins engine lubrication oil specification

Lubrication oil quantity 14.2 l

Lubrication oil quality Diesel engine oil SAE 15W-40

Ambient temperature -15 °C - +45 °C

Classification API CJ-4/SL or CES-20086

NOTE
The two types of coolant may never be mixed with each other
as this will affect the anti-corrosion properties.
Never mix more than 60% concentrate in the coolant.

Cummins engine cooling fluid specification

Cooling fluid quantity 30.3 l

Cooling fluid quality 50% concentrated coolant and

50% water. The fluids must be
thoroughly mixed before they
are added to the cooling
system.
Classification ASTM4985 or ASTM D6210

Diesel fuel

NOTE
Never fill the fuel tank to more than 90% of the capacity.

Fuel tank volume 300 l

Fuel quality High-quality ultra-low sulphur

diesel fuel

Classification EN590

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Transmission fluid
Automatic transmission fluid

Automatic transmission fluid 21 l

quantity

Automatic transmission fluid Automatic transmission fluid

quality (ATF)

Ambient temperature -30 °C - +30 °C

Classification Allison Transynd TES-295

Approved transmission fluid

Maximum fluid temperature 120°C

Front axle
Front axle lubrication grease

Lubrication grease quality EP multipurpose grease, for

example, ESSO Beacon EP1,
MOBIL Mobilgrease HP222,
Shell Alvania EP1, or CASTROL
APS 2.

Classification NLGI 1
Temperatures below -10 °C,
use NLGI 0

Rear axle
Rear axle lubrication oil

Differential oil volume 13 l

Wheel end planetary gear oil 2.8 l each

volume

Lubrication oil quality (depends Over 30°C: SAE 85W140

on environmental temperature)
-10°C to 30°C: SAE 85W90
-30°C to -10°C: SAE 80W90
Below -30°C: SAE 75W

Classification GL-5

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Cab tilt hydraulics

Cab tilt pump hydraulic oil

Cab tilt pump reservoir volume 1.9 l

Hydraulic oil quality Hydraulic oil, Dextron III

Ambient temperature -30 °C - +10 °C

Classification ISO VG 32

Common hydraulics
Common and working hydraulics oil

Hydraulic tank volume 75.7 l

Hydraulic oil quality Hydraulic oil, Dextron III

Ambient temperature 30 °C - +10 °C

Classification ISO VG 32

Windscreen washer fluid

Windscreen washer fluid

Windscreen washer fluid volume 3.5 l

Fluid quality Isopropyl washer fluid

Winter mixture 1:3

Summer mixture 1:6

Air conditioner
Air conditioner refrigerant

Refrigerant quantity 900 g

Refrigerant quality R134A

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Lubrication grease
General lubrication grease

Lubrication grease quality EP multipurpose grease, for

example, ESSO Beacon EP1,
MOBIL Mobilgrease HP222,
Shell Alvania EP1, or CASTROL
APS 2

Classification NLGI 1
Temperatures below -10 °C,
use NLGI 0

Pneumatic system
Air system pressure

Nominal air pressure 8.3 - 8.9 bar

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9.3 Tightening torques, units of

measurement and conversion tables
Tightening torques, recommendations
The tightening torques in the following table are
recommendations when tightening:
• screw, washer and nut
• screw, washer and untreated steel
General tolerances of specified torques is ±10%.
For soft materials (lower hardness than 200 HB), use washer
under both bolt head and nut. As an alternative, use flange bolt
or flange nut.
Recommended tightening torque varies depending on surface
treatment.

State Bolt Nut/thread Washer

A Steel ZnNi Steel ZnNi Steel untreated Steel ZnNi

B Steel ZnNi Steel ZnNi Steel untreated Nord Lock

C Steel galv Steel galv Steel untreated Steel galv

D Steel flZn Steel fiZn Steel untreated Steel flZn

E Steel flZn Steel flZn Steel untreated Nord lock

ZnNi = Zinc nickel coating

flZn = Zinc flake coating
galv = hot-galvanised

Quality 8.8 10.9 12.9

State A B C D E D E

M-thread Tightening torque in Nm

M4 2 3 3 3 4 4 5

M5 5 6 7 6 8 7 9

M6 8 11 11 10 14 12 16

M8 21 26 28 24 34 29 39

M10 40 52 54 47 68 57 76

M12 69 89 94 82 116 98 130

M16 169 220 229 201 288 242 322

M20 329 426 448 393 563 472 628

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Quality 8.8 10.9 12.9

State A B C D E D E

M-thread Tightening torque in Nm

M24 566 727 770 675 966 810 1080

M30 1131 1453 1539 1351 1935 1621 2160

M36 1969 2537 2679 2351 3375 2818 3762

Quality 8.8 10.9 12.9

Fine M-thread Tightening torque in Nm

M4x0.5 3 3 4 3 5 4 5

M5x0.5 5 7 7 6 10 7 10

M6x0.75 9 11 12 11 16 12 18

M8x1 22 28 29 26 37 31 41

M10x1.25 42 54 57 50 72 60 80

M12x1.25 75 96 102 89 128 107 142

M16x1.5 179 230 243 214 307 257 342

M18x1.5 262 337 357 312 448 372 500

M20x1.5 365 471 496 436 626 523 698

M24X2 617 794 839 736 1058 883 1179

M30x2 1247 1613 1697 1489 2142 1789 2385

M36x3 2081 2683 2831 2486 3569 2986 3983

Tightening torque, ORFS connections

Table 9.1 Pipe and hose coupling

Pipe diameter Tightening torque

mm inch Nm

6 1/4 23–25

8 5/16 33–38

10 3/8

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Pipe diameter Tightening torque

mm inch Nm

12 1/2 51–57

14 — 80–90

15 —

16 5/8

18 3/4 120–130

20 —

22 7/8 150–170

25 1”

28 — 180–200

30 —

32 1” 1/4

35 — 200–240

38 1” 1/2

Wrench size Tightening torque

mm inch Nm

17 11/16 23–25

22 13/16 33–38

24 15/16 51–57

36 13/8 120–130

41 15/8 150–170

Table 9.2 Goods coupling

UNF-UN Metric-ISO BSSP

Thread (inch) Tightening Thread (mm) Tightening Thread (inch) Tightening

torque (Nm) torque (Nm) torque (Nm)

7/16-20 21 10x1 20 1/8-28 20

1/2-20 27 12x1.5 35 1/4-19 35

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UNF-UN Metric-ISO BSSP

Thread (inch) Tightening Thread (mm) Tightening Thread (inch) Tightening

torque (Nm) torque (Nm) torque (Nm)

9/16-18 40 14x1.5 45 3/8-19 70

3/4-16 78 16x1.5 55 1/2-14 100

7/8-14 110 18x1.5 68 3/4-14 190

1"1/16-12 180 20x1.5 80 1"-11 300

1"3/16-12 230 22x1.5 98 1"1/4-11 330

1"5/16-12 285 26x1.5 170 1"1/2-11 400

1"5/8-12 320 27x2 180

1"7/8-12 400 33x2 310

42x2 330

48x2 400

Tightening torque, connections for air

conditioning unit

Table 9.3 O-ring coupling cooling coils

Hose diameter Thread Tightening torque

mm inch inch Nm

6 1/4" 7/16" 7-13 Nm

10 3/8" 5/8" 14-20 Nm

10 3/8" 11/16" 14-20 Nm

12 1/2" 3/4" 14-26 Nm

16 5/8" 7/8" 27-41 Nm

19 3/4" 11/16" 34-46 Nm

Pressure switch 3/8" 7/16" 7-13 Nm

The above values should be considered guidelines and may

vary depending on installation.

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Unit explanations

Unit Abbreviation

Newton-metre Nm

Kilopond-metre kpm

Kilopascal kPa

Megapascal MPa

Kilowatt kW

Kilojoule kJ

British thermal unit Btu

Calorie ca

Inch in

Foot ft

Yard yd

Mile mile

Centimetre cm

Metre m

Kilometre km

Conversion table, SI units

SI unit Conversion factor Other than SI Conversion factor SI

Torque

Nm x 10.2 = kg·cm x 0.8664 = lb·in

Nm x 0.74 = lbf·ft x 1.36 = Nm

Nm x 0.102 = kg·m x 7.22 = lb·ft

Pressure (Pa = N/ m 2 )

kPa x 4.0 = in. H 2O x 0.249 = kPa

kPa x 0.30 = in. Hg x 3.38 = kPa

kPa x 0.145 = psi x 6.89 = kPa

bar x 14.5 = psi x 0.069 = bar

kp / cm 2 x 14.22 = psi x 0.070 = kp/cm 2

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SI unit Conversion factor Other than SI Conversion factor SI

N/ mm 2 x 145.04 = psi x 0.069 = bar

MPa x 145 = psi x 0.00689 = MPa

Power (W = J/s)

kW x 1.36 = hp (cv) x 0.736 = kW

kW x 1.34 = bhp x 0.746 = kW

kW x 0.948 = Btu/s x 1.055 = kW

W x 0.74 = ft·lb/s x 1.36 =W

Energy (J = Nm)

kJ x 0.948 = Btu x 1.055 = kJ

J x 0.239 = calorie x 4.19 =J

Speed and acceleration

m/s 2 x 3.28 = ft/s 2 x 0.305 = m/s 2

m/ s x 3.28 = ft/s x 0.305 = m/s

km/ h x 0.62 = mph x 1.61 = km/h

Horsepower/ torque

Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp

Temperature

ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32

Flow factor

l / min (dm 3 / min) x 0.264 = US gal / min x 3.785 = l/min

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Conversion table, length

Unit cm m km in ft yd mile

cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006

m 100 1 0.001 39.37 3.2808 1.0936 0.00062

km 100000 1000 1 39370.7 3280.8 1093.6 0.62137

in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015

ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189

yd 91.44 0.9144 0.000914 36 3 1 0.000568

mile 160930 1609.3 1.6093 63360 5280 1760 1

1 mm = 0.1 cm, 1 mm = 0.001 m

Conversion table, area

Unit cm 2 m2 km 2 a ft 2 yd 2 in 2

cm 2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000

m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000

km 2 - 1000000 1 10000 1076400 1195800 -

a 0.01 100 0.0001 1 1076.4 119.58 -

ft 2 - 0.092903 - 0.000929 1 0.1111 144.000

yd 2 - 0.83613 - 0.008361 9 1 1296.00

in 2 6.4516 0.000645 - - 0.006943 0.000771 1

1 ha = 100 a , 1 mile 2 = 259 ha = 2.59 km 2

Conversion table, volume

Unit cm 3 = cc m3 l in 3 ft 3 yd 3

cm 3= ml 1 0.000001 0.001 0.061024 0.000035 0.000001

m3 1000000 1 1000 61024 35.315 1.30796

dm 3(l) 1000 0.001 1 61.024 0.035315 0.001308

in 3 16.387 0.000016 0.01638 1 0.000578 0.000021

ft 3 28316.8 0.028317 28.317 1728 1 0.03704

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Unit cm 3 = cc m3 l in 3 ft 3 yd 3

yd 3 764529.8 0.76453 764.53 46656 27 1

1 gal (US) = 3785.41 cm 3= 231 in 3= 0.83267 gal (UK)

Conversion table, mass

Unit g kg t oz lb

g 1 0.001 0.000001 0.03527 0.0022

kg 1000 1 0.001 35.273 2.20459

t 1000000 1000 1 35273 2204.59

oz 28.3495 0.02835 0.000028 1 0.0625

lb 453.592 0.45359 0.000454 16 1

1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table, pressure

Unit kp/cm 2 bar Pa=N/m 2 kPa lbf/in 2 lbf/ft 2

kp /cm 2 1 0.98067 98066.5 98.0665 14.2233 2048.16

bar 1.01972 1 100000 100 14.5037 2088.6

Pa=N/ m 2 0.00001 0.001 1 0.001 0.00015 0.02086

kPa 0.01020 0.01 1000 1 0.14504 20.886

lbf/in 2 0.07032 0.0689 6894.76 6.89476 1 144

lbf/ft 2 0.00047 0.00047 47.88028 0.04788 0.00694 1

kg/cm 2 = 735.56 Torr (mmHg) = 0.96784 atm

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A. Appendixes

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114 A. Appendixes -

TL2 Operator's Manual

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 Index

Index
A M
About the Documentation Kit 9 Main components 19
About the Operator's manual 7 Maintenance 73
Appendixes 113
O
B
Oil level and diagnostic 43
Brakes 63 Oil, grease and fluid volumes and quality 101
Operating 58
Operator's Seat 51
C Overview 19
Charging system for batteries 77
Control Lever 49 P
Cooling system 77
Parking brake system 64
Pedals 50
D Plates 22
Daily Inspection 56, 70 Pneumatic system 80
Description 19 Prognostic features 45
Diagnostics 45
R
E Reading the manual 7
Engine air filter 78 Releasing the parking brake mechanically 86
Engine lubrication system 76 Running-in 55
Environment 91
S
F Safety 11
Foreword 7 Safety and Warning Equipment 11
Fuel system 79 Selecting driving direction and gear 62
Service 81
Service position 88
G Specifications 97
Specifications and dimensional drawing 97
Gear and Multi-function Lever 42
Standards 95
Starting the engine 59
H Steering 63
Stickers 25
Handling 53 Switches 41
Handling Error Codes 57
Heating/Air Conditioning 52
Hydraulic system 80 T
Tightening torques, units of measurement and conversion
I tables 105
Towing 85
Ignition 39 Transmission lubrication system 76
In Case of Emergency 15 Transport of machine 85
Inspection and maintenance 10, 69 Transporting a trailer 65
Instruments 36
Instruments and controls 29
W
L Warning and indicator lights 33
Warning symbols 57
Lifting and transporting machine 87 Windscreen washer 79
Load handling 65
Locations of controls in the cab 29
Long-term storage 89

115
Kalmar offers the widest range of cargo handling solutions and services to ports, terminals,
distribution centres and to the heavy industry. Kalmar is the industry forerunner in terminal automation
and in energy efficient container handling, with one in four container movements around the globe
being handled by a Kalmar solution. Through its extensive product portfolio, global service network
and ability to enable a seamless integration of different terminal processes, Kalmar improves the
efficiency of every move.
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Published by Kalmar. Copyright ©Kalmar Corporation 2024. All rights reserved. No part of this publication may be copied or
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