TL2 Operator's Manual

Terminal Tractor
Kalmar TL2
Operator’s Manual
2018
All variants
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”
3
1 Foreword 5
1.1 About the Operator’s Manual 5
1.2 About the Documentation Kit 7
1.3 Inspection and maintenance 8
2 Safety 9
2.1 Safety and Warning Equipment 9
3 Overview 13
3.1 Description 13
3.2 Plates 16
4 Instruments and controls 23
4.1 Locations of controls in the cab 23
4.2 Warning and indicator lights 27
4.3 Instruments 30
4.4 Ignition 33
4.5 Switches 36
4.6 Gear and Multi-function Lever 37
4.7 Control Lever 44
4.8 Pedals 45
4.9 Operator's Seat 46
4.10 Heating/Air Conditioning 47
5 Handling 49
5.1 Running-in 49
5.2 Daily Inspection 51
5.3 Handling Error Codes 52
5.4 Operating 53
5.5 Load handling 59
6 Inspection and maintenance 63
6.1 Daily Inspection 64
6.2 Maintenance 67
6.3 Service 74
7 Transport of machine 77
7.1 Towing 77
7.2 Lifting and Transporting Machine 79
7.3 Service Position 80
7.4 Long-term Storage 81
8 Environment 83
Standards 87
9 Specifications 89
Specifications and dimensional drawing 89
Oil, grease and fluid volumes and quality 94
Tightening torques, units of measurement and conversion tables 98
Appendixes 103
Index
4
1 Foreword – 1.1 About the Operator’s Manual 5
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 reli‐
ability 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 custom‐
er’s needs, requirements, and expectations, to develop, manufac‐
ture, and provide products and associated services in a way that
makes sure that always ensures the full satisfaction of our cus‐
tomer.
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
415 East Dundee Street
Ottawa, Kansas USA 66067
tel. +1-785-242-2200
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 oper‐
ations.
TL2 Operator's Manual

566 004 Default
6 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, empha‐
sises operational safety.
Information on variations
This manual is a general manual for the terminal tractor model Kal‐
mar 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
This symbol indicates an accessory or optional describing the equipment.
equipment. The symbol is clearly distinguished from the text, and it is placed
next to the text and picture representing the equipment.

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1 Foreword – 1.2 About the Documentation Kit 7
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 manufacturer’s spare parts
department.
Refer to the type and serial number of the tractor when placing the
order.

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8 1 Foreword – 1.3 Inspection and maintenance
1.3 Inspection and maintenance
General
Chapter 6, Inspection and maintenance, 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 in6 Inspection and maintenance.
The recommended service items and instructions are specified in 6
Inspection and maintenance.
Do not hesitate to contact the maintenance staff at manufacturer or
an authorised service outlet if you need further information on main‐
tenance.

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2 Safety – 2.1 Safety and Warning Equipment 9
2 Safety
General
This chapter contains general instructions for the driver to make
sure 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 opera‐
tion.
• Regularly perform all maintenance according to the programme
defined in the Chapter 6. Professionally performed mainte‐
nance makes sure 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 mainte‐
nance 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 bat‐
tery.
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.

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10 2 Safety – 2.1 Safety and Warning Equipment
Tilting the cab for maintenance
• Prior to tilting the cab to the maintenance position, make sure

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!
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!
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 tyres.
Check the maximum speed for each load from the tyre manu‐
facturer.
• 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 uncou‐
pling the trailer from the fifth wheel to avoid damaging the
equipment.

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2 Safety – 2.1 Safety and Warning Equipment 11
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 condi‐
tion.
Fifth wheel and lift boom
• Tow a load only when the kingpin is locked and the green indi‐
cator light on the dashboard panel is illuminated.
• 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.

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12 2 Safety – 2.1 Safety and Warning Equipment

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3 Overview – 3.1 Description 13
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 descri‐
bed, the application must be approved in writing by the manufac‐
turer.
3.1.1 Main components

General
This chapter describes the location of the terminal tractor main com‐
1
ponents indicated in the picture below as well as a general descrip‐
tion of these components and their operation.
10
1. Cab
2. Battery box (under the steps)
3. Hydraulic tank
4. Lift boom
2
5. Fifth wheel
3 Rear axle
6.
4 5 7. Fuel tank
8. Steering axle
9. Transmission
10. Engine
9 8
Engine
7
Engine is a low-emission turbocharged diesel engine with inter‐
6 cooler. 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.
Rear axle
The rear axle is equipped with drum or disc brakes. Differential,
planetary drive and differential lock are available as options.

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14 3 Overview – 3.1 Description
Brakes
The terminal tractor axles are equipped with common-circuit pneu‐
matic 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. King‐
pin 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.
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. 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 pump. The pump is con‐
nected 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.
Hydraulic oil flow for hoist cylinders is controlled by a valve on the
frame. The valve directs oil to the cylinders. Over-center valves pre‐
vent 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 cirquits are deenergized. ECM cirquits are
powered even if main switch is switched off.

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3 Overview – 3.1 Description 15
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 con‐
trolled 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 stand‐
ard behind the cab. Different types of options are available.
Cab
The cab can be tilted to the maintenance position. The cab is con‐
nected 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 direc‐
tion and to the entire working area of the terminal tractor. Controls
for the terminal tractor and any equipment attached to it are ergo‐
nomically positioned on the steering column, dashboard panels, and
in some cases, at the driver's seat.

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16 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 sys‐
tems 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 the
A inside of the cab side door.

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3 Overview – 3.2 Plates 17
Information decal locations in the machine
B
C
C
D
E
F
G
H
Fig. : 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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C
E
G
Fig. : Decals from the right side

C Keep lear of cab
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 invard
while entering or exiting vehicle. Use handrail for maximum sup‐
port.
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 ventila‐

ted 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 bat‐
tery, then disconnect harness from electronic control modules.

566 004 Default
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 com‐
pletely 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. 1: DO NOT OPERATE THIS VEHICLE WITHOUT REVIEW‐

ING THE OPERATOR'S MANUAL
2. 2: NEVER PARK VEHICLE WITHOUT PARKING BRAKE
APPLIED AND TRANSMISSION PLACED IN NEUTRAL.
3. 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. 4: STOP MACHINE BEFORE SHIFTING FROM FORWARD
TO REVERSE OR FROM REVERSE TO FORWARD.
5. 5: TO COUPLE TO LOW TRAILERS:
A) A: LOWER 5TH WHEEL AND DRIVE UNDER TRAILER
UNTIL 5TH WHEEL PLATE IS JUST COVERED BY
TRAILER NOSE.
B) B: RAISE 5TH WHEEL APPROX. 5 INCHES.
C) C: FINISH DRIVING UNDER TRAILER UNTIL 5TH
WHEEL LATCHES .
K Warning: No riders
WARNING
No riders on a moving machine.
J 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 – 4.1 Locations of controls in the cab 23
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 con‐
trols, do not hesitate to ask your supervisor or a 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 column adjustment may
C
cause you to lose control of the machine.
Lever D releases the steering column for adjustment.
Adjusting the steering column

1. Turn the lever (D) up to release the adjustment.
D 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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24 4 Instruments and controls – 4.1 Locations of controls in the cab
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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4 Instruments and controls – 4.1 Locations of controls in the cab 25
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

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26 4 Instruments and controls – 4.1 Locations of controls in the cab
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

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4 Instruments and controls – 4.2 Warning and indicator lights 27
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 the mainte‐
nance of the terminal tractor.
STOP
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 indi‐
cate 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.
! 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 mainte‐
nance of the terminal tractor.

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28 4 Instruments and controls – 4.2 Warning and indicator lights
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.
Low fuel
Indicates that the fuel level is too low.

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4 Instruments and controls – 4.2 Warning and indicator lights 29
Check trans
Indicates a fault in the transmission system.
Brake air
Indicates a fault in a brake air system, when the warning light stays
lit.

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30 4 Instruments and controls – 4.3 Instruments
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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4 Instruments and controls – 4.3 Instruments 31
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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32 4 Instruments and controls – 4.3 Instruments
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 Instruments and controls – 4.4 Ignition 33
4.4 Ignition
General
Prior to starting the engine, turn on the power to the ignition key lock
with the main switch.
Main switch
The switch is located on the main dashboard switch panel.
0
The main switch is used to turn the power supply from the batteries
to the tractor electric devices on or off.
0 Power Power from the batteries to the electric devices is off.

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

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.
Psition S Starting position.

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34 4 Instruments and controls – 4.4 Ignition
Engine start push button

The button is located on the main dashboard switch panel.
START The push button is used to start the engine.
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 Turn the main switch ON.
5 Insert the ignition key into the switch and rotate the key clock‐
wise to the position I.
6 Wait for the “Wait to Start” light on the dash to go out if the
vehicle is equipped with one.
7 Press the engine start push button.
NOTE
Do not run a cold engine at high speed!
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.

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4 Instruments and controls – 4.4 Ignition 35
CAUTION
Always apply the parking brake. Never park the vehicle by leaving it
in gear. Always place the transmission shifter selector in the “neu‐
tral” position.
Never park a tractor trailer combination unless the trailer parking
brakes are operational and applied.

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36 4 Instruments and controls – 4.5 Switches
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
0 1 Position 0 The lights are off.
Position 1 The forward-facing work lights are on.
Air conditioner
A /C
0 1 Position 0 The air conditioner is not activated.
Position 1 The air conditioner is activate.

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4 Instruments and controls – 4.6 Gear and Multi-function Lever 37
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.

566 004 Default
38 4 Instruments and controls – 4.6 Gear and Multi-function Lever
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.
4.6.1 Oil level and diagnostic

Checking fluid levels
Use following procedure to display oil level information if the trans‐
mission 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 director selector press the DISPLAY MODE/
DIAGNOSTIC button once.
3 Correct fluid level is displayed as shown in adjacent figure.

566 004 Default
4 Low fluid level is displayed and the number indicates the num‐
ber 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 tempera‐
ture.

566 004 Default
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

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 personell 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 and clutch
maintenance monitoring. Allison Approved TES 295 transmission
fluid and high capacity filters are required to engage the prognos‐
tics.

566 004 Default
Prognostic features
When the prognostics are enabled the wrech 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

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 immediatelly.
99 4 The OIL LIFE may be reset back to 99% by holding the DIS‐
PLAY MODE/DIAGNOSTIC button for 10 seconds, while OIL
LIFE information is displayed.

Filter life monitor
MODE
1 Press the DISPLAY MODE/DIAGNOSTIC button three times

on the driving director selector.

566 004 Default
2 Display shows filters condition.

3 The FILTER LIFE automatically resets once the new filters
have been installed.
FILTERS The FILTER LIFE can also be reset manually by holding the
OK DISPLAY MODE/DIAGNOSTIC button for 10 seconds, while

FILTER LIFE information is displayed.
REPLACE
FILTERS
Transmission health monitor
MODE
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 resets
when appropriate conditions are detected. TRANSMISSION
TRANSHEALTH HEALTH can only be manually reset using Allison DOC for
OK PC–Service Tool. When resetting with the service tool, individ‐

ual clutches or all clutches can be reset. Operator reset
through the shift selector is not allowed.
TRANSHEALTH
LO

566 004 Default

MODE

566 004 Default
44 4 Instruments and controls – 4.7 Control Lever
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
NOTE
L
UP
When lowering the fifth wheel, ensure that there are no obstructions!

566 004 Default
4 Instruments and controls – 4.8 Pedals 45
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.

566 004 Default
46 4 Instruments and controls – 4.9 Operator's Seat
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

566 004 Default
4 Instruments and controls – 4.10 Heating/Air Conditioning 47
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/C MAIN SWITCH
A B C
A/C main switch (A) is used to control the blower speed.
A/C MAIN SWITCH DEFROSTING SWITCH HEAT SWITCH
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.

566 004 Default
48 4 Instruments and controls – 4.10 Heating/Air Conditioning

566 004 Default
5 Handling – 5.1 Running-in 49
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 driv‐
ing conditions to prevent safety hazards to the people or equipment
on the site.
In addition to the instructions in this manual, observe any local driv‐
ing 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 side or 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.
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 pres‐
sure gauges must be observed during operation and the engine

566 004 Default
50 5 Handling – 5.1 Running-in
must be shut down IMMEDIATELY if the readings deviate from nor‐

mal 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 runin
period are specified in detail in the maintenance information for this
machine.

566 004 Default
5 Handling – 5.2 Daily Inspection 51
5.2 Daily Inspection
General
Daily inspections performed by the driver are important to 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 com‐
mence with a defective machine whose possible malfunctions are
not repaired.
Instructions for the daily inspections can be found in section 6 of this
manual.

566 004 Default
52 5 Handling – 5.3 Handling Error Codes
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 chapter4.2 Warning and indica‐
tor lights.
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 dur‐
ing operation, the engine must, in most cases, be stopped IMMEDI‐
ATELY 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.

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5 Handling – 5.4 Operating 53
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.
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 pla‐
ces 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.

566 004 Default
54 5 Handling – 5.4 Operating
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.
Psition S Starting position.
Starting the engine

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 clock‐
wise 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
Starting the engine with Start push button

As an optional function the tractor can be equipped with keyless
ignition.
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 Turn the main switch ON.
OFF 5 Wait for the “Wait to Start” light on the dash to go out if the
ON vehicle is equipped with one.

566 004 Default
6 Press the engine start push button on the dash panel.

START
NOTE
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 col‐
our, 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 bat‐
teries installed on the tractor.
7 Disconnect the jump-start cables in reverse order of connec‐
tion.
DANGER
If electrolyte is spilled on the eyes or skin, flush the area immedi‐
ately 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.

566 004 Default
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 “neu‐
tral” 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

566 004 Default
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.
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 mechanically and 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 into the steering system, and steering is very slow and
limited.

566 004 Default
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 the trailer.
As a standard the brake system is a single circuit brake system.
Optionally the tractor can be equipped with a dual circuit brake sys‐
tem. With the dual circuit brake system, one circuit remains func‐
tional even if the other circuit fails due to, for example, an air leak.
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.
The switch operates the parking brakes on the vehicle and trailer:
PARKING
BRAKE • 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 engag‐
ing the parking brake while the tractor is moving subjects the trans‐
mission 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 selec‐
tor. 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.

566 004 Default
5 Handling – 5.5 Load handling 59
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 .1. Specifica‐
tions.
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 lift‐
ing 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 trac‐
tor 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 driv‐
ing gear. Make sure that the transmission of the tractor does not
need to change gear on a ramp.

566 004 Default
60 5 Handling – 5.5 Load handling
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 instru‐
ment 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 indi‐
cator light remains lit to indicate that the fifth wheel jaws are open.

566 004 Default
5 Handling – 5.5 Load handling 61
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 engage‐
ment.
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 whil 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 park‐
ing 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 th transmis‐
sion 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.

566 004 Default
62 5 Handling – 5.5 Load handling

566 004 Default
6 Inspection and maintenance – General 63
6 Inspection and
maintenance
General
This chapter describes the following issues regarding inspection
and maintenance:
• Daily inspections
The Daily inspections section specifies the inspection proce‐
dures which the driver or the person responsible for the main‐
tenance of the machine carries 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 sched‐
uled maintenance since these are specified and presented in
the maintenance manual of this machine.
DANGER
The engine must always be stopped for maintenance and inspec‐
tion.
Only a person who has been familiarised with the machine's con‐
trols and devices may be in the cab during inspection and mainte‐
nance.
DANGER
Fuel is highly flammable.
Do not smoke or use an open flame when refuelling and servicing
the fuel system.
CAUTION
Avoid skin contact with oils and lubricants. Use protective gloves
during maintenance.

566 004 Default
64 6 Inspection and maintenance – 6.1 Daily Inspection
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 com‐
mence with a defective machine.
DANGER
If an issue requiring service or repair is detected in the daily inspec‐
tion, 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 Visually

and visible damage
Shields and doors Visually
• Closed and locked

correctly
1 Engine
Unusual system noise By listening
Fuel level from the fuel Visually Fill with high-quality diesel see: 6.2.6. Fuel system
gauge fuel if necessary.
Lubrication oil level Dipstick Add the recommended oil if see: 6.2.1. Engine
necessary. lubrication system
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
level is too low. recommended coolant, if
The level can be visually necessary.
checked.

566 004 Default
6 Inspection and maintenance – 6.1 Daily Inspection 65
4 Brakes
Operation of brakes Brake test immediately after Also test the operation of
moving. the parking brake.
5 Steering
Operation of the steering Turn the wheels to the At the same time, check
logic valve opposite position. also 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
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
Operation of the fifth wheel Visually Lubricate the fifth wheel

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

566 004 Default
66 6 Inspection and maintenance – 6.1 Daily Inspection
9 Frame, cab, and accessories
Examine the mounting of Visually Walk around the machine

the 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 testing Add the recommended see: 6.2.7. Windscreen
washer fluid to the washer washer
fluid reservoir if necessary.
10 Common hydraulics
Oil level in the hydraulic oil Sight glass If necessary, add the see: 6.2.8. Hydraulic system
tank recommended oil to the
tank.
12 Common pneumatics
Drain moisture from the air Pull the drain plug cord from see: 6.2.9. Pneumatic
pressure tanks the air pressure tanks system

566 004 Default
6 Inspection and maintenance – 6.2 Maintenance 67
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.
Using the lubricants and fluids specified in this manual as well as
original filters and other service parts makes sure that the safety
and reliability of the machine is maintained.
Safety
• Always stop the engine prior to performing maintenance proce‐

dures unless they require that the engine is running.
• Maintenance may only be performed by a trained and profes‐
sional persons to make sure that the safety and reliability of the
machine is maintained at the intended level.
• Do not service the machine unless you are absolutely sure
about the instructions and regulations on performing the proce‐
dures 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
the 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!

566 004 Default
68 6 Inspection and maintenance – 6.2 Maintenance
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.
To tilt cab
The tractor is equipped with electric tilt pump control unit. The con‐
trols are located on the side of the battery box.
Cab hold-down latch is automatic and works hydraulically with prior‐
ity valve.
1 Turn on the main switch to operate the tilt pump.
2 Pull firmly from the safety prop release cable (A) and then
hold the switch (B) in the UP position.
B 3 After the cab has traveled about 15 inches (381 mm), release
the safety prop cable (A) and continue tilting 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.
5 To tilt the cab back to the operating position pull first firmly
C from the safety prop release cable (A) to release the safety
A 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.
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.

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1 Clean the dipstick before the oil level examination.

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

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6.2.3 Cooling system

Examine the coolant level
The cooling system expansion tank is equipped with coolant recov‐
B
ery 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.
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 mainte‐
nance. 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 working only
A 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.
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 sys‐
tem.
The fuel tank is located on the right side of the tractor.

566 004 Default
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.
6.2.7 Windscreen washer
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 level.
2 If necessary, add the recommended hydraulic oil through the
B
filler cap (B).
NOTE
If you have to add oil to the hydraulic oil tank, be careful to keep the
oil free of other fluids or impurities. Impurities damage the hydraulic
system. Filter the oil before adding it into the tank.
A
6.2.9 Pneumatic system

Drain the air tanks
The air tanks are located under the chassis.

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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.

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74 6 Inspection and maintenance – 6.3 Service
6.3 Service
General
For the operational safety and reliability of the machine, it is
extremely important that the inspections and maintenance proce‐
dures 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 make sure that the operational safety and reliability
of the machine is maintained at the intended level.
It is recommended that servicing be performed by the maintenance
division of Cargotec Oy, 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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6 Inspection and maintenance – 6.3 Service 75
Lubrication
4,5,6
8
14
9 4,5,6
11
12
10
13
Explanation of the symblos:
Manual lubrication (at intervals of 250 running

hours).
If the machine is equipped with central lubrication,

check only.

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76 6 Inspection and maintenance – 6.3 Service
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 (4 pcs.)
6 Lubricating the brake shoe anchor pins (4 pcs.) Lubrication only once
a year.
5 Steering
7 Lubricating the tie rod joints (2 pcs.)
8 Lubricating the steering cylinder ends (4 pcs.)
6 Suspension
9 Lubricating the rear 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 pcs.) Holland FW 35
13 Lubricating the lifting cylinder ends (4 pcs.)
9 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 77
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 pres‐
sure 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).
The propeller shaft between the transmission and axle of the towed
tractor must be removed before towing to prevent damage to the
transmission during towing due to insufficient lubrication.

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78 7 Transport of machine – 7.1 Towing
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 com‐
presses 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 anti‐
clockwise 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 Transport of machine – 7.2 Lifting and Transporting Machine 79
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 compo‐
nents 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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80 7 Transport of machine – 7.3 Service Position
7.3 Service Position
General
The tractor service position is used while performing maintenance
procedures.
The tractor is in 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
Make sure that the fifth wheel is unloaded and the lift boom is sup‐
ported mechanically if it must be in the upper position during main‐
tenance or repair.
Prior to tilting the cab to maintenance position, make sure that the
radiator grille at the front of the cab is lifted up, the cab door is prop‐
erly closed, and any loose items are removed from the cab.
Working under the cab without a mechanical safety stop that pre‐
vents the cab from lowering is strictly prohibited!

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7 Transport of machine – 7.4 Long-term Storage 81
7.4 Long-term Storage
General
If the tractor is stored for an extended period of time, contact your
local Cargotec dealer for detailed storage instructions.

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82 7 Transport of machine – 7.4 Long-term Storage

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8 Environment – Environmental awareness 83
8 Environment
General
Increasing industrialisation has a significant effect on our environ‐
ment 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 com‐
mon environment.
Environmental policy
The management of environmental issues at the manuacturing fac‐
tory 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 environ‐
ment, 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 fac‐
tory management looks at the main environmental concerns, deter‐
mines 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. React‐
ing to possible environmental abnormalities and taking the neces‐
sary corrective actions is the responsibility of the entire staff. Manu‐
facturing factory adheres to the current legislation and regulations in
its operations. Our operations comply with the international environ‐
mental system standard ISO 14001 and the principles of sustaina‐
ble development set by the International Chamber of Commerce.
Environmental awareness
Aim to define your own environmental awareness. Ask your supervi‐
sor 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 pro‐
vide 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

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84 8 Environment – Environmental problems
in exceptional cases. Follow the maintenance and adjustment

schedules carefully. Use the designated oils and other liquids.
Check that the oil levels are correct. In general, when using the
machine, make sure that it works properly and that is in the appro‐
priate 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 uninter‐
rupted. 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. Pre‐
ventive 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 main‐
tenance 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 influ‐
enced 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 emis‐
sions. Regular maintenance and immediate repair work when nec‐
essary are a prerequisite for optimal machine operation. Pay special
attention to starting the machine from cold and the instructions
given for this.

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8 Environment – Complete overhaul or disposal 85
Effects of exhaust gases

Diesel engine emissions are the cause of both health and environ‐
mental 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 emis‐
sions, nitrous oxide (NOx) forms nitric 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 pri‐
marily the result of poor combustion of the fuel-air mixture in the die‐
sel 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 hydro‐
carbons 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 performeded 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 uti‐
lize 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, labeled receptacles. The most effec‐
tive 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. Recy‐
cling saves approximately half of the energy that would be con‐
sumed 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

566 004 Default
86 8 Environment – Problem waste
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 compo‐
nents. The safety bulletins of various liquids and materials contain
instructions for disposal. You can also consult the suppliers of com‐
ponents and the product manufacturer for disposal and sorting.
Problem waste
Deliver materials that are classified as problem waste, such as bat‐
teries, 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 environ‐
ment.
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, immedi‐
ately contact your supervisor or the person responsible for environ‐
mental 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 green‐
house effect. Refrigerant must not be discharged from the air condi‐
tioning system into the atmosphere.
NOTE
The air conditioning system must be serviced only by skilled service
personnel qualified to service refrigeration equipment.

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8 Environment – Standards 87
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 accord‐
ing to the laws and regulations established for those conditions.
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 com‐
ponents 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 cabi‐
nets 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 com‐
pany and its employees.
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.

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88 8 Environment – Standards
Noise levels
Maximum noise level inside the cabin is 75 dB(A) LpAZ , according
to the standard SFS-EN 12053 + AC. Maximum 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 inter‐
ference to other electric devices or be exposed to the electromag‐
netic 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 regard‐
less 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 refer‐
ence 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 – Specifications and dimensional drawing 89
9 Specifications
Specifications and dimensional
drawing
General
This chapter includes the dimensional drawing of the machine, a
summary of component specifications and settings, and specifica‐
tions 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 measure‐
ments.
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]

566 004 Default
90 9 Specifications – Specifications and dimensional drawing
Specifications
Cummins engines
Model Cummins QSB 6.7 EPA Tier 3 / EU Stage 3A
Operating Low-emission, turbocharged diesel engine with

principle direct injection and intercooler.
Number of 6
cylinders
Capacity 6.7 dm3
Power 129 kW / 2200 rpm

(ISO 3046,
net)
Maximum 164 kW (220 hp) 2000rpm

power
Torque 952 Nm / 1400 rpm

(ISO 3046)
Engine speeds Idle speed 700 rpm

Maximum speed 2500
Alternator 70 A
Starting 2 x 12 V
batteries
Transmission
Model Allison 3000im
Operating Automatic transmission with torque converter

principle
Front axle
Hande 5.5
Front axle Hande 5.5
Rated axle 5500 kg

load
Brake Size 410 mm x 160 mm
Steering Mechanical steering arm

566 004 Default
Hande 7.5
Front axle Hande 7.5
Rated axle 7500 kg

load
Brake Size 410 mm x 160 mm
Steering Mechanical steering arm
Rear axles
Hande 11.98
Rear axle Hande 11.98
Rated axle 16 000 kg

load
Drive flange 180 mm
Final drive 11.98:1

ratio
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 Hydraulic power assisted steering with

system 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.

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92 9 Specifications – Specifications and dimensional drawing
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 capacies 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
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

566 004 Default
Pneumatic system
Operating A compressor coupled to the engine generates

principle 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 3 tanks: 89 litres.

air tank volume

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94 9 Specifications – Oil, grease and fluid volumes and quality
Oil, grease and fluid volumes and

quality
Cummins engine fluids

Cummins engine lubrication oil specification
Lubrication oil quantity 17.2 l
Lubrication oil quality Diesel engine oil SAE 15W-40
Ambient temperature -15 °C - +45 °C
Classification API CJ-4/SL or CES-20081
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.
Diesel fuel
Fuel tank volume 300 l
Fuel quality High-quality ultra-low sulphur

diesel fuel
Classification EN590

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9 Specifications – Oil, grease and fluid volumes and quality 95
Transmission fluid
Automatic transmission fluid
Automatic transmission fluid 21 l

quantity
Automatic transmission fluid Automatic transmission fluid

quality (ATF)
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
Cab tilt hydraulics

Cab tilt pump hydraulic oil
Cab tilt pump reservoir volume 1,9 l
Hydraulic oil quality Hydraulic oil, Dextron III

566 004 Default
96 9 Specifications – Oil, grease and fluid volumes and quality
Classification ISO VG 32
Common hydraulics
Common and working hydraulics oil
Hydraulic tank volume 75,7 l
Hydraulic oil quality Hydraulic oil, Dextron III
Classification ISO VG 32
Windscreen washer fluid

Windscreen washer fluid
Windscreen washer fluid 3.5 l

volume
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
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

566 004 Default
9 Specifications – Oil, grease and fluid volumes and quality 97
Pneumatic system
Air system pressure
Nominal air pressure 8,3 - 8,9 bar

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98 9 Specifications – Tightening torques, units of measurement and conversion tables
Tightening torques, units of

measurement and conversion tables
Units of measurement and their abbreviations
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/ m2 )
kPa x 4.0 = in. H2O x 0.249 = kPa
kPa x 0.30 = in. Hg x 3.38 = kPa

566 004 Default
9 Specifications – Tightening torques, units of measurement and conversion tables 99
SI unit Conversion factor Other than SI Conversion factor SI
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp / cm2 x 14.22 = psi x 0.070 = kp/cm2
N/ mm2 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/s2 x 3.28 = ft/s2 x 0.305 = m/s2
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 (dm3 / min) x 0.264 = US gal / min x 3.785 = l/min
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

566 004 Default
Unit cm m km in ft yd mile
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 cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a , 1 mile2 = 259 ha = 2.59 km2
Conversion table, volume
Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3(l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)

566 004 Default
9 Specifications – Tightening torques, units of measurement and conversion tables 101
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/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/ m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm

566 004 Default

566 004 Default
Appendixes 103
Appendixes

566 004 Default
104 Appendixes

566 004 Default
105
Index
About the Documentation Kit 7 Standards 87

About the Operator’s Manual 5 Starting the engine 53
Appendixes 103 Steering 57
Brakes 58 Stickers 19
Charging system for batteries 70 Stopping the engine / parking 58
Control Lever 44 Switches 36
Cooling system 70 Tightening torques, units of measurement and
Daily Inspection 51 conversion tables 98
Daily Inspection 64 Towing 77
Description 13 Transmission lubrication system 69
Diagnostics 40 Transporting a trailer 59
Engine air filter 71 Transport of machine 77
Engine lubrication system 68 Warning and indicator lights 27
Environment 83 Warning symbols 52
Foreword 5 Windscreen washer 72
Fuel system 71
Gear and Multi-function Lever 37
Handling 49
Handling Error Codes 52
Heating/Air Conditioning 47
Hydraulic system 72
Ignition 33
Inspection and maintenance 8
Inspection and maintenance 63
Instruments 30
Instruments and controls 23
Lifting and Transporting Machine 79
Load handling 59
Locations of controls in the cab 23
Long-term Storage 81
Main components 13
Maintenance 67
Oil, grease and fluid volumes and quality 94
Oil level and diagnostic 38
Operating 53
Operator's Seat 46
Overview 13
Parking brake system 58
Pedals 45
Plates 16
Pneumatic system 72
Prognostic features 40
Reading the manual 5
Releasing the parking brake mechanically 78
Running-in 49
Safety 9
Safety and Warning Equipment 9
Selecting driving direction and gear 56
Service 74
Service Position 80
Specifications 89
Specifications 90
Specifications and dimensional drawing 89
106
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.
www.kalmarglobal.com
Kalmar is part of Cargotec. Cargotec’s sales totalled approximately EUR 3.4 billion in 2014 and it
employs approximately 11,000 people. Cargotec’s class B shares are quoted on NASDAQ OMX
Helsinki Ltd under symbol CGCBV. www.cargotec.com
Kalmar
415 East Dundee Street
Ottawa, Kansas USA 66067
tel. +1-785-242-2200
Published by Kalmar, part of Cargotec. Copyright ©Cargotec 2015. All rights reserved. No part of this publication may be copied
or reproduced without permission of the copyright owner. The content of this document is provided “as is”, without warranties of
any kind with regards to its accuracy or reliability and excluding all implied warranties. We reserve the rights to make changes to
any of the items described in this document without prior notice. The content of each service contract and availability of particular
services may vary.

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Terminal Tractor

1.1.1 Reading the manual