Kalmar Ottawa terminal tractors — Troubleshooting and warning lights: technical cards
General guidance only — always follow the operation and maintenance manual for your specific machine.
Short answers to precise questions on the indicator lights, error codes, brake, steering, boom and cab faults of the Kalmar Ottawa terminal tractor, one fact per card, each with its source stated in the text. For the overall picture, see the Kalmar Ottawa terminal tractors technical legacy guide.
Kalmar Ottawa T2: what do the centre-row indicator lights mean?
Brake Air warns of brake system air pressure at 70 psi (4.83 bar) or lower and Low Fuel of 1/8 tank or less, according to the Ottawa T2 operator's manual (2014 edition), as recorded by the HIT SRL technical desk. The same manual gives Check Engine and Stop Engine as calls to shut the tractor down at once and have it serviced, as HIT SRL's technical desk reads it. Check Transmission asks for a check of the transmission and its fluid level, according to the 2014 operator's manual. On DOT/EPA tractors the manual states that the malfunction indicator lamp signals an engine malfunction that has to be checked.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-indicator-lights-centre-row · HIT ref KTT-240 · fingerprint 3f4271 · see HIT ref KTT-246, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-indicator-light-layout
Kalmar Ottawa T2: which indicator lights sit on the left and on the right?
On the left are the left turn signal, Charger, Water-in-fuel, ATC, Trailer ABS and Tractor ABS lights, according to the Ottawa T2 operator's manual (2014 edition), as logged by the HIT SRL technical desk. The same manual places Wait to Start, Seat Belt, the right turn signal, High Exhaust System Temperature, DPF Regen Needed and Service on the right, as recorded at HIT SRL. The manual describes Charger as a charging system not working properly with low battery power, and Service as a call for immediate service. Operating the tractor while the tractor or trailer ABS warning lights stay on is forbidden by the 2014 operator's manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-indicator-lights-left-and-right · HIT ref KTT-241 · fingerprint 40f168 · see HIT ref KTT-240, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-indicator-lights-centre-row
Kalmar Ottawa T2: what does the DEF lamp signal?
A solid DEF lamp means the DEF level is low and a flashing one that it has dropped below a critical level, according to the Ottawa T2 operator's manual (2014 edition), as HIT SRL's technical desk reads it. The same manual reads a flashing DEF lamp together with the Warning or Check Engine lamp as a critically low level with loss of power, as recorded by the HIT SRL technical desk. If the engine has been shut down, or has idled for one hour, after the DEF tank ran dry, the 2014 operator's manual states that the Stop Engine lamp also comes on. The tractor is then limited to 5 mph (8 km/h) until DEF is refilled, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-def-lamp · HIT ref KTT-242 · fingerprint 11a0c8 · see HIT ref KTT-243, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-dpf-lamp
Kalmar Ottawa T2: what does the DPF Regen Needed lamp ask for?
A lit DPF Regen Needed lamp means the filter must regenerate within the next 2-6 hours of operation, according to the Ottawa T2 operator's manual (2014 edition), as set out in the HIT SRL technical cards. The manual allows this through at least 20 minutes of more demanding duty or through a stationary regeneration, the HIT SRL technical desk notes. A flashing lamp calls for regeneration within 1-2 hours, with possible power reduction, and a flashing lamp with Check Engine for an immediate stationary regeneration, according to the same manual. If that is not done, the 2014 operator's manual states that the red Stop Engine lamp comes on and the tractor is stopped at the first safe opportunity.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-dpf-lamp · HIT ref KTT-243 · fingerprint 202310 · see HIT ref KTT-242, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-def-lamp
Kalmar Ottawa T2: what if the low-air warning stays on after start-up?
If the low-air warning light and buzzer are still on at least 5 minutes after start-up, the engine is shut down and the reason the air system is not charging is found, according to the Ottawa T2 operator's manual (2014 edition), as logged by the HIT SRL technical desk. The same manual states that the air restriction indicator pops up when the air filter needs changing, as recorded at HIT SRL. The indicator is reset by pushing the button back down, according to the manual. The procedure to follow on a given machine is the one in the tractor's own manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-low-air-after-start-up · HIT ref KTT-244 · fingerprint 1debfc · see HIT ref KTT-248, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-brake-and-air-diagnosis
Kalmar Ottawa T2: where are the engine and transmission error codes found?
In the engine and transmission manufacturers' manuals, according to the Ottawa T2 maintenance manual, as recorded by the HIT SRL technical desk. The same manual states that its own error code section does not apply to this vehicle. For the optional ABS, the maintenance manual has diagnosis and fault code clearing carried out through the ABS electronic control unit.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-error-codes · HIT ref KTT-245 · fingerprint 7ff40a · see HIT ref KTT-247, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-gauge-diagnosis
Kalmar Ottawa T2: how are the indicator lights laid out on the gauge panel?
Along the top of the main gauge panel in three groups, left, centre and right, according to the Ottawa T2 maintenance manual, the HIT SRL technical desk notes. On the left the manual lists turn signal, charger, water-in-fuel, ATC, trailer ABS and tractor ABS. The centre group, according to the same manual, holds low DEF level, high beam, brake air, low fuel, the malfunction indicator lamp (MIL), check engine, stop engine and check transmission, as set out in the HIT SRL technical cards. On the right the manual places wait to start, seat belt, turn signal, high exhaust system temperature and DPF regeneration needed, both on DOT/EPA tractors only, and service. The start regen switch, the idle increase/decrease switch, the diagnostic switch and the on-board diagnostic plug port sit on the lower left dash panel, according to the manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-indicator-light-layout · HIT ref KTT-246 · fingerprint 5df28e · see HIT ref KTT-240, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-indicator-lights-centre-row
Kalmar Ottawa T2: how are instrument panel faults traced?
By matching replacement gauges and senders to each other and to the vehicle voltage, 12 VDC or 24 VDC, inspecting the wiring and checking that the sender housing is properly seated, according to the Ottawa T2 maintenance manual, as recorded at HIT SRL. The same manual then runs a grounded sender test: with the sender wire grounded and power applied briefly, the pointer should move to the far right of the scale, as logged by the HIT SRL technical desk. Otherwise the manual has the gauge replaced. A jumping, overshooting or oscillating pointer is read by the manual as an intermittent sender connection, and with sound connections the gauge cluster is replaced, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-gauge-diagnosis · HIT ref KTT-247 · fingerprint dd52e6 · see HIT ref KTT-246, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-indicator-light-layout
Kalmar Ottawa T2: what do the brake and air system diagnosis tables list?
Pulling to one side is linked to brake adjustment, front end alignment, unequal tire pressure or tread, uneven loading or loose front wheel bearings, according to the brake diagnosis tables of the Ottawa T2 maintenance manual, as HIT SRL's technical desk reads it. The same tables give grease or oil on the linings, out-of-round drums, defective valves or binding linkages for grabbing brakes, as recorded by the HIT SRL technical desk. For an air pressure that does not reach normal, the manual lists among the causes open reservoir drain cocks, system leakage, governor adjustment and a faulty gauge or compressor. A saturated desiccant cartridge is given in the tables as a cause of water in the reservoirs.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-brake-and-air-diagnosis · HIT ref KTT-248 · fingerprint 909db8 · see HIT ref KTT-244, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-low-air-after-start-up
Kalmar Ottawa T2: what causes hard steering?
An overloaded axle (checked against the GAWR), underinflated tires, front end misalignment, worn linkages, damaged king pins or tie rods, a binding steering column or weak pump flow, according to the Ottawa T2 maintenance manual, as set out in the HIT SRL technical cards. The same manual traces inconsistent steering pressure to air in the system or low fluid, the HIT SRL technical desk notes. Where one pump serves steering and boom, the manual states that a pump giving less than 4-1/2 to 5 GPM at idle may have a priority valve sticking from contamination. That valve is removed, cleaned with solvent and refitted, and the pump is replaced if its performance does not change, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-steering-diagnosis · HIT ref KTT-249 · fingerprint 5bf67a · see HIT ref KTT-250, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-boom-diagnosis
Kalmar Ottawa T2: how is a boom that is slow to lift tested?
With a 3000 psi gauge on the test port at the back of the boom platform and the cylinders deadheaded at full length, according to the Ottawa T2 maintenance manual, as logged by the HIT SRL technical desk. At maximum engine rpm the manual expects a reading of 2000 psi, adjusted at the control valve under the acorn nut with a 5/16 Allen wrench in 1/4-turn steps, clockwise to increase, as recorded at HIT SRL. The same manual then expects 3-1/2 to 5 GPM of flow at idle and 23-25 GPM at maximum rpm. When that flow cannot be reached, the manual has the pump replaced, checking the splines of the pump shaft and inside the PTO for wear. The test to run on a given machine is the one in the manual of the specific tractor.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-boom-diagnosis · HIT ref KTT-250 · fingerprint 5f6774 · see HIT ref KTT-249, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-steering-diagnosis
Kalmar Ottawa T2: what are the causes of a cab tilt fault?
If the cab tilt motor runs but the cab does not tilt, the causes are low fluid or line leakage, according to the Ottawa T2 maintenance manual, as recorded by the HIT SRL technical desk. An inoperative tilt motor, or a raised cab that does not return, points in the same manual to the 20 A stop/tilt circuit breaker, the tilt pump control switch, the tilt pump solenoid or valve, or the wiring, as HIT SRL's technical desk reads it. The manual states that the cab tilt system is self-bleeding. After work on the pump or the cylinder the cab is raised and lowered to bleed the air, and the fluid level in the hydraulic tank is then checked, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-cab-tilt-diagnosis · HIT ref KTT-251 · fingerprint 7d6fa9 · see HIT ref KTT-252, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-cab-leveling-check
Kalmar Ottawa T2: how is the cab leveling valve checked?
The Ottawa T2 maintenance manual has the cab entry handle held down while the time the air spring needs to bring the cab up to ride height is measured, the HIT SRL technical desk notes. The same manual reads 2 to 10 seconds as a good valve, and under 2 or over 10 seconds as a damaged valve or a clogged filter, as set out in the HIT SRL technical cards. For the ride height adjustment the manual asks for at least 100 psi in the air system. The same manual then calls for one inch (25.4 mm) between the channel under the cab deck and the suspension stop bumpers, set by changing the length of the leveling valve linkage rod.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-cab-leveling-check · HIT ref KTT-252 · fingerprint f12c7d · see HIT ref KTT-251, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-cab-tilt-diagnosis
Kalmar Ottawa T2: what does the frame diagnosis table give as causes of buckled rails?
Raising the fifth wheel to maximum while maneuvering a loaded trailer, load shift in a loaded trailer, fire, collision and equipment added beyond the vehicle capacity, according to the frame diagnosis table of the Ottawa T2 maintenance manual, as recorded at HIT SRL. The same table has broken Huck bolts replaced with 5/8, grade 8 bolts, as logged by the HIT SRL technical desk. The manual repairs a crack by drilling a 1/2-inch (12.7 mm) hole at its far end and V-grinding it, then opening the bottom 1/16 inch (1.6 mm). The weld is made with the proper electrode and ground smooth on both sides, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-frame-diagnosis · HIT ref KTT-253 · fingerprint 90e835 · see HIT ref KTT-250, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-t2-boom-diagnosis
Kalmar TL2: where does troubleshooting start?
By checking that battery voltage is available and the fuses are intact, according to the TL2 maintenance manual (2018 edition), as HIT SRL's technical desk reads it. The 2018 manual then has the engine oil, coolant, fuel and hydraulic oil levels checked for normal readings. Only after those checks does the same manual turn to the function description of the system concerned and to its circuit diagram.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-troubleshooting-order · HIT ref KTT-254 · fingerprint dfb8df · see HIT ref KTT-255, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-signal-tracing
Kalmar TL2: how is a fault traced along the signal chain?
By checking first the component or actuator that receives the signal, according to the TL2 maintenance manual (2018 edition), as set out in the HIT SRL technical cards. If that actuator is not defective, the 2018 manual moves on to the component that should send the control signal, the HIT SRL technical desk notes. The same manual follows the function description and the diagrams to find where in the chain the signal or the reaction is wrong.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-signal-tracing · HIT ref KTT-255 · fingerprint 7c105d · see HIT ref KTT-254, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-troubleshooting-order
Kalmar TL2: how are the engine error codes listed?
Each fault is listed by its description with SPN and FMI numbers, according to the Cummins engine error code table of the TL2 maintenance manual (2018 edition), as logged by the HIT SRL technical desk. Examples in the 2018 manual are Engine Oil Pressure Low – Warning (SPN 100, FMI 18) and Engine Oil Pressure Low – Critical (SPN 100, FMI 1), as recorded at HIT SRL. The same table gives Water in Fuel Indicator High – Maintenance as SPN 97, FMI 15. The 2018 manual does not describe how the codes are read in the cab or what corrective action to take.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-engine-error-codes · HIT ref KTT-256 · fingerprint dc7543 · see HIT ref KTT-257, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-transmission-error-codes
Kalmar TL2: how are the transmission error codes listed?
Each diagnostic code is paired with a short description, according to the transmission error code table of the TL2 maintenance manual (2018 edition), as recorded by the HIT SRL technical desk. Examples given in the 2018 manual are P0218 for transmission fluid over temperature, P088A for a deteriorated filter and P088B for a very deteriorated filter.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-transmission-error-codes · HIT ref KTT-257 · fingerprint 802b81 · see HIT ref KTT-256, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-engine-error-codes
Kalmar TL2: what charging voltage should the alternator give?
No less than 27 VDC in normal operation, according to the TL2 maintenance manual (2018 edition), the HIT SRL technical desk notes. The 2018 manual states that the charging indicator light comes on when the battery voltage is higher than the voltage supplied by the alternator. If the light stays on with the engine running, the same manual gives the alternator as faulty.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-alternator-check · HIT ref KTT-258 · fingerprint f27e0f · see HIT ref KTT-259, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-oil-pressure-after-oil-change
Kalmar TL2: how soon must oil pressure show after an engine oil change?
Within 15 seconds of starting, according to the TL2 maintenance manual (2018 edition), as recorded at HIT SRL. If the gauge shows no pressure by then, the 2018 manual has the engine switched off immediately. The oil level in the oil pan is then checked, according to the same manual.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-oil-pressure-after-oil-change · HIT ref KTT-259 · fingerprint 3cfaf6 · see HIT ref KTT-258, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-tl2-alternator-check
Kalmar terminal tractor before the T2: which warning lights are on the standard indicator strip?
A high transmission temperature light, lit when the fluid is above 300 °F, and a low air pressure light that comes on with the buzzer below 70 psi, according to the earlier Kalmar tractor operator's manual, as HIT SRL's technical desk reads it. The same manual places this standard indicator strip on dash panels 1 and 2, as recorded by the HIT SRL technical desk. If the low air warning is still on 5 minutes after start-up, the manual has the engine shut down and the charging fault traced. A warning that comes on while driving means stopping the vehicle at once and keeping it out of use until the air system is repaired, according to the same manual. The maintenance check section of the same manual gives instead 90 psi as the pressure below which buzzer and light must come on.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-earlier-warning-lights · HIT ref KTT-260 · fingerprint 6ef11f · see HIT ref KTT-261, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-earlier-abs
Kalmar terminal tractor before the T2: how is the optional ABS monitored?
Through a warning light in dash panel 1, according to the earlier Kalmar tractor operator's manual, as set out in the HIT SRL technical cards. Tractors with ABS produced after March 2002 also check the trailer ABS after coupling and light a trailer warning lamp on a fault, according to the same manual, the HIT SRL technical desk notes. Troubleshooting and fault code clearing are done at the EC module in the left front wheel well, the manual states. The manual forbids operating the vehicle while the tractor or trailer ABS lights stay on.
Source: HIT SRL technical desk — https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-earlier-abs · HIT ref KTT-261 · fingerprint 3c32bc · see HIT ref KTT-260, https://www.hitsrl.it/technical-resources/guides/kalmar-terminal-tractors/troubleshooting/#hit-ktt-earlier-warning-lights