Terminal Tractor Service Bulletin Subject: T2 Chassis Power Distribution Center Replacement Product: Medium Terminal Tractor

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Rolf Ray
5 years ago
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Page 1 of 14 Units Affected: Kalmar Ottawa T2 Terminal s built prior to November 14, 2016.

Exposure to the elements can result in failure of the chassis PDC.

1 Page 1 of 14 Units Affected: Kalmar Ottawa T2 Terminal s built prior to November 14, Possible Situation: The original power distribution center (PDC) was not protected from the environment. Exposure to the elements can result in failure of the chassis PDC. Solution: Replace the original chassis PDC with the new design using waterproof components per the following instructions. Start by raising the cabin and the boom. This will allow access to the chassis harness inside the left frame rail. Next, remove the boom platform and frame platforms.

2 Page 2 of 14 Disconnect the battery positive cables. (If you have a battery disconnect switch, you must remove the cable that runs from the batteries to the power board completely.) Remove the cover and unplug the two chassis harness connectors from the circuit board and remove the ground wires from the chassis board. Next unplug the chassis harness connections. (tail-lights, back-up alarm, cabin tilt, air tank pressure senders, transmission power, etc ) The number of connections

3 Page 3 of 14 will depend on options. Clip all the wire ties that secure the harness inside the frame rail.

4 Page 4 of 14 Unplug the main chassis harness bulkhead connector that is located just below the hydraulic control valve. Bulkhead connector Unplug the cab connector located by the side of the radiator. Cab connector

5 Page 5 of 14 Unhook all the ground wires on the side of the chassis board mounting plate. Make sure to label them or tie them together. Ground cables and ground stud on bracket The harness can now be removed, pay attention to how the harness comes out so the new harness can be reinstalled later using the same routing.

6 Page 6 of 14 Clip wire ties on the battery cables at the solenoids. Unhook the cables going to the solenoids. Grid heater solenoid Starter solenoid and cable Cabin tilt solenoid and cable Unhook the positive and negative battery cables and cabin power lead from the circuit board. Cabin power lead connection Positive battery cable connection

Page 7 of 14 Unhook the main battery cables from the terminal strip on the side

Unbolt the chassis board mounting bracket bolt from the transmission mounting

Remove the chassis board mounting bracket along with all of its components.

By leaving it you will not have to reset the transmission mount.

7 Page 7 of 14 Unhook the main battery cables from the terminal strip on the side of the chassis board mounting plate. Unbolt the chassis board mounting bracket bolt from the transmission mounting bracket. Unbolt the rest of the chassis board mounting bracket bolts. Remove the chassis board mounting bracket along with all of its components. You will need to reuse the tilt pump switch harness. Do not remove this bracket. By leaving it you will not have to reset the transmission mount. Install the Chassis harness in the truck following the routing of the old harness. The harness should go under and behind the air lines going to the boom unlatch

Page 8 of 14 cylinder, and should also be routed behind and under the hydraulic hoses going from the

Cab Tilt 5 th wheel Air Pressure Ground Engine Harness Cab Tail-Lights ABS New power center Starter

8 Page 8 of 14 cylinder, and should also be routed behind and under the hydraulic hoses going from the tank to the control valve. Cab Tilt 5 th wheel Air Pressure Ground Engine Harness Cab Tail-Lights ABS New power center Starter Solenoid Back-up Alarm Engine Specific Reconnect all the connectors that were unhooked in the removal of the chassis harness. (tail lights, air pressure sensors, cabin tilt, transmission power, etc ) Do not wire tie the harness until after the chassis power center is completely installed. Remove the exhast system bracket from the curb side of the truck. Remove this bracket and discard.

Page 9 of 14 Pre-assemble the brackets loosely for

And then install the bracket to the exhaust and

Tighten these bolts last Frame rail bottom edge

Make sure to slide this under and behind all the

Be careful not to pinch any of the harnesses.

9 Page 9 of 14 Pre-assemble the brackets loosely for each side of the frame. And then install the bracket to the exhaust and the frame. Tighten these bolts last Frame rail bottom edge clamp. Make sure to slide this under and behind all the cables and hoses. Be careful not to pinch any of the harnesses. This bolt will need to be loosened from the fuel tank mounting before installation of the bracket. This bolt will need to be either added, or loosened from the trailer stop before installation of the bracket.

10 Page 10 of 14 Once the bolts to the frame are tightened, then you can tighten the clamp bolts. This should clamp on the bottom edge of the frame rail. Install the chassis power center sub-assembly..

Page 11 of 14 Plug the chassis harness into the

11 Page 11 of 14 Plug the chassis harness into the new power distribution center. Install and route the Low Current Battery Power harness (CTT ) from the chassis power center to the positive battery post. Do not install this to the battery at this time. Route inside frame rail Route to battery box

Page 12 of 14 Route inside battery box to positive

Install all battery cables to the terminal strip.

side of the bracket, rotate each cable to allow

12 Page 12 of 14 Route inside battery box to positive stud on battery. Install all battery cables to the terminal strip. Only 2 cables per terminal, one from the top and one from the bottom. Install all the negative cables to the post on the side of the bracket, rotate each cable to allow them to be stacked and still maintain good connection. Positive cable from battery Ground stud Positive cable for cabin

coating the connections with die-electric grease. Start the truck and ensure no codes are present. Tie up all the harnesses.

13 Page 13 of 14 Hook up the grid heater, cabin tilt and starter solenoids. Grid heater cable Starter cable - route cable under the power center Cabin tilt solenoid - route cable under the power center Once all installations have been completed, hook up the batteries after coating the connections with die-electric grease. Start the truck and ensure no codes are present. Tie up all the harnesses. Make sure to check clearances at the boom pivot points and boom arm to insure that the harness will not be damaged as the boom moves up and down. Also check to make sure the hydraulic control valve has clearance for it to move without causing damage to any of the harnesses. Make sure all connections are tight. Make sure all cables are coated with anti-corrosion spray where the connection will be exposed to the weather. Reinstall all the platforms. Install the battery box cover. Installation should now be complete.

14 Page 14 of 14 Warranty: The following expenses are covered using the standard Kalmar warranty policy: Travel up to 3 hours round trip unless approved for additional time prior to the repair Labor 3.5 Claim Submission: Parts Parts vary by truck serial number. Either contact the Kalmar parts department or use the following link to determine what parts are needed. To submit a claim select: o Location code o Failure code o Work code 26 Recalls and Campaigns Campaign 26.4 o Hours claimed 3.5

Subject: Chassis and Cab Power Distribution Center Nylon Washers Product: Medium Terminal Tractor. Date: 24-JUN-2016

Subject: Chassis and Cab Power Distribution Center Nylon Washers Product: Medium Terminal Tractor. Date: 24-JUN-2016 Page 1 of 11 Units Affected: All Kalmar Ottawa T2 model terminal tractors built prior to October 13, 2015. Possible Situation: The fasteners for the cab and chassis power distribution boards may abrade