Kalmar TL165 TERMINAL TRACTOR

Trainer Name : WONG FOOK LIM

Job Title : Product Support Engineer (SINGAPORE)
Email : fooklim.wong@kalmarglobal.com
Contact : +65-91736080

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 TL165 (TCIT)

DAY 1

1 TL165 Introduction
2 Operator Manual
3 Hydraulic System
4 Pneumatics System
5 Electrical System
6 Q&A
DAY 2

1 Maintenance
2 Axles
3 Engine
4 Transmission
5 Parts Manual
6 Q&A
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Introduction TL165 (TCIT)

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Introduction TL165 (TCIT)

ENGINE

TRANSMISSION

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TL165 (TCIT)

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 TL165 (TCIT)

SAFETY VIDEO

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

• Daily Inspections performed by the driver are important to

ensure the safe and efficient operation of the machine.
• It is recommended that the driver or the person responsible
for maintenance of the machine carry out the inspections
before each shift.
• This way it can be ensured that the work does not commence
with a defective machine whose possible malfunctions are
not repaired.

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Operator Manual TL165 (TCIT)

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Operator Manual TL165 (TCIT)

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 TL165 (TCIT)

OPERATOR
MANUALS

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HYDRAULIC TL165 (TCIT)

• Hydraulic system
– For stationary fifth wheel, the hydraulic power used in
steering derive from the pump of engine. The pump was
cancelled for elevating fifth wheel.
– The pressure and volume flow required by the 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.

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HYDRAULIC TL165 (TCIT)

SK8363

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PNEUMATICS TL165 (TCIT)

• Pneumatic system
– Compressed air is supplied by a continuously operating
compressor which draws the air through the engine air filter.
System pressure is controlled by a pressure control valve which
directs the compressor output to the bypass line when the
system pressure reaches the set maximum.

– Moisture is removed from the compressed air by an air dryer

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PNEUMATICS TL165 (TCIT)

AS1680

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PNEUMATICS TL165 (TCIT)

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ELECTRICAL TL165 (TCIT)

• 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 Off position, power supply to
the electric system is totally shut off. The main switch
is not to be turned off while the engine is running
since the alternator supplies power to the electric
system and the electric components can be damaged
by overvoltage.

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ELECTRICAL TL165 (TCIT)

Electrical SK8440 &

SK8490

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ELECTRICAL TL165 (TCIT)

example

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 TL165 (TCIT)

QUESTION ??

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Maintenance TL165 (TCIT)

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Maintenance TL165 (TCIT)

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Maintenance TL165 (TCIT)

Lubrication

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Maintenance TL165 (TCIT)

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Axles TL165 (TCIT)

Front axle
The front axle is equipped with spring
suspension, drum brakes,
steering joint and wheel hub.

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Axles TL165 (TCIT)

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Axles TL165 (TCIT)

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Axles TL165 (TCIT)

• Rear axle
– The drive axle (rear axle) is equipped with solid
mounting, drum brakes, differential, central
speed reducer, wheel side speed reducer, wheel
hub and planetary drive.

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Axles TL165 (TCIT)

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Axles TL165 (TCIT)

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Axles TL165 (TCIT)

Oil grade: 85W/140 in the tropical area -

temperature over 30 °C;

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Engine TL165 (TCIT)

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Engine TL165 (TCIT)

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Engine TL165 (TCIT)

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Engine TL165 (TCIT)

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Engine TL165 (TCIT)

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Engine TL165 (TCIT)

• All the electrical engines produced by Dongfeng

Cummins, including QSB engines for industry
market, were updated to use three-stage filters
system. The new system has benefit to enhance
fuel adaptability of engine and increase market
competition ability. It has no harm but benefit
compared to single fuel-water separator, the
engine remains good performance even the fuel
quality is not good enough.

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Engine TL165 (TCIT)

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Engine TL165 (TCIT)

Check Coolant Level

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Transmission TL165 (TCIT)

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Transmission TL165 (TCIT)

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Transmission TL165 (TCIT)

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Transmission TL165 (TCIT)

• PROGNOSTICS
– A Prognostics system, consisting of control valve
module hardware, shift selector, and Transmission
Control Module (TCM) calibration is available to
monitor fluid life, fluid filter life, and clutch life.
– Prognostics Features Availability. The vehicle
manufacturer specifies whether they want Allison
Prognostics Feature Package to be made available in
the calibration and in what configuration, for example
defaulted on or off.
• The Oil Life Monitor (OM), Filter Life Monitor (FM), and
Transmission Health Monitor (TM) are the individual
functions included in the Allison Prognostics Feature
Package.

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Transmission TL165 (TCIT)

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Transmission TL165 (TCIT)

• Accessing oil level, Prognostics, and DTCs using a keypad

pushbutton shift selector
– Select N (Neutral) and apply the parking brake
– Simultaneously press the ↑ (Upshift) and ↓ (Downshift) arrows once
to access oil level information
– Simultaneously press the ↑ (Upshift) and ↓ (Downshift) arrows again
to access the Oil Life Monitor (OM) (if Prognostics is available)
– Simultaneously press the ↑ (Upshift) and ↓ (Downshift) arrows again
to access the Filter Life Monitor (FM) (if Prognostics is available)
– Simultaneously press the ↑ (Upshift) and ↓ (Downshift) arrows again
to access the Transmission Health Monitor (TM) (if Prognostics is
available)
– Simultaneously press the ↑ (Upshift) and ↓ (Downshift) arrows again
to access the DTCs
– To exit DTC mode, press any range button, D (Drive), N (Neutral). R
(Reverse). After approximately 10 minutes of inactivity at the
pushbutton shift selector, the diagnostic mode automatically exits and
returns to normal operating mode

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Transmission TL165 (TCIT)

• Displaying Diagnostic Trouble Codes (DTCs). Up to five

DTCs may be displayed one at a time from the selector
once the diagnostic display mode has been initiated.
Each DTC is 5 characters in length. The DTC status
active or inactive is shown below the DTC

• Press the MODE button to read the next DTC in the

queue (if any) or requests to exit diagnostics mode.
The diagnostics mode times out and returns the
selector to normal operating mode after approximately
10 minutes of inactivity
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Transmission TL165 (TCIT)

• TRANSMISSION FLUID CHECK

– Manual Fluid Check Procedure

– Cold Check Procedure. The purpose of the cold check

is to determine if the transmission has enough fluid to
be operated safely until a hot check can be made

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Transmission TL165 (TCIT)

– Complete a COLD CHECK procedure using the dipstick

as follows:
• Park the vehicle on a level surface, put the transmission in N
(Neutral) and set the parking brake.
• With the engine idling (500–800 rpm), shift to D (Drive) and
then to R (Reverse) to clear air from the hydraulic circuits.
• Run the engine at idle (500–800 rpm) in N (Neutral) for
about one minute.
• Clean debris from around the end of the fill tube before
removing the dipstick.
• Remove the dipstick and wipe it clean.

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Transmission TL165 (TCIT)

– Complete a COLD CHECK procedure using the

dipstick as follows: (Con’t)
• Insert the dipstick into the fill tube, pushing down until
it stops, but still in its loose or unscrewed position.
• Remove the dipstick and observe the fluid level. If the
fluid on the dipstick is within the COLD CHECK band
(Figure 2–6), the fluid level is satisfactory. If the fluid
level is not within this band, add or drain as necessary
to bring the level within the COLD CHECK band.
• Perform a hot check at the first opportunity after the
normal operating sump temperature of 71°C93° C
(160°F200° F) is reached.

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Transmission TL165 (TCIT)

– Hot Check Procedure

• To complete a HOT CHECK procedure using the dipstick
do the following:
– Be sure fluid has reached normal operating temperature of
71-93° C (160-200° F). If a transmission temperature gauge
is not present, measure fluid level when the engine water
temperature gauge has stabilized.
– Park the vehicle on a level surface and shift to N (Neutral).
– Apply the parking brake and allow the engine to idle (500-
800rpm).
– Clean debris from around the end of the fill tube before
removing the dipstick.
– Remove the dipstick and wipe it clean.
– Insert the dipstick into the fill tube, pushing down until it
stops, but still in its loose or unscrewed position.

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Transmission TL165 (TCIT)

– Hot Check Procedure

• To complete a HOT CHECK procedure using the dipstick
do the following: (Con’t)
– Remove the dipstick and observe the fluid level. The safe
operating level is anywhere within the HOT RUN band on
the dipstick.
– If the fluid level is not within the HOT RUN band, add
and/or drain as necessary to bring the fluid level to within
the HOT RUN band.
– Measure fluid level more than once. Be sure fluid level
measurements are consistent. If readings are not
consistent, be sure the transmission breather is clean and
not clogged.

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Transmission TL165 (TCIT)

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Parts TL165 (TCIT)

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Parts example TL165 (TCIT)

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 TL165 (TCIT)

QUESTION ??

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