Property of American Airlines Maintenance · Orig CD402-Maint Chapter 1 MA Tow Tractor Table of...

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Chapter 1MA Tow Tractor Table of Contents

CHAPTER 1: MAINTENANCE

TABLE OF CONTENTS

SECTION 1: SERVICING .......................................................................................................... 1-1-1A. Preparation For Use ............................................................................................. 1-1-1

1. Fuel System.............................................................................................. 1-1-12. Battery ...................................................................................................... 1-1-13. Brakes ...................................................................................................... 1-1-14. Engine and Transmission ......................................................................... 1-1-15. Rear Axle and Reduction Gear Box .......................................................... 1-1-26. Tire Inflation ............................................................................................... 1-1-27. Vehicle Drive ............................................................................................. 1-1-28. Units Equipped with Cummins B3.3 Engine ............................................. 1-1-2

B. Periodic Maintenance Schedule ........................................................................... 1-1-31. FOR UNITS WITH PERKINS 1104C-44 (Tier II) .............................................. 1-1-3

(a). Daily ....................................................................................................................................... 1-1-3(b). Weekly or 50 Hours ............................................................................................................... 1-1-4(c). Monthly or 200 Hours ............................................................................................................. 1-1-5(d). Two (2) Months or 500 Hours................................................................................................ 1-1-6(e). Six (6) Months or 1000 Hours ................................................................................................ 1-1-6(f). One (1) year or 2000 Hours .................................................................................................... 1-1-6(g). Every 1.5 years or 3000 Hours .............................................................................................. 1-1-7(h). Every 2 years or 4000 Hours ................................................................................................. 1-1-7(i). Every 3 years or 6000 Hours.................................................................................................. 1-1-7

2. FOR UNITS WITH DEUTZ Tier 4i .................................................................... 1-1-7(a). Daily ....................................................................................................................................... 1-1-7(b). Weekly or 50 Hours ............................................................................................................... 1-1-8(c). Monthly or 200 Hours ............................................................................................................. 1-1-9(d). Two (2) Months or 500 Hours............................................................................................... 1-1-10(e). Six (6) Months or 1000 Hours .............................................................................................. 1-1-11(f). Yearly or 2000 Hours............................................................................................................. 1-1-11(g). Each 18 months or 3000 Hours ........................................................................................... 1-1-12(h). Each 2 years or 4000 Hours ................................................................................................ 1-1-12(i). Each 2.5 years or 5000 Hours .............................................................................................. 1-1-12(j). Each 3 years or 6000 Hours ................................................................................................. 1-1-12(k). Each 6 years or 12000 Hours .............................................................................................. 1-1-12

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Chapter 1Table of Contents MA Tow Tractor

3. FOR UNITS WITH DEUTZ 2.9L4 ................................................................... 1-1-13

(a). Daily ..................................................................................................................................... 1-1-13(b). Weekly or 50 Hours ............................................................................................................. 1-1-14(c). Monthly or 200 Hours ........................................................................................................... 1-1-15(d). Two (2) Months or 500 Hours............................................................................................... 1-1-16(e). Six (6) Months or 1000 Hours .............................................................................................. 1-1-16(f). Yearly or 2000 Hours............................................................................................................. 1-1-17(g). Each 2 years or 4000 Hours ................................................................................................ 1-1-17(h). Status dependent ................................................................................................................. 1-1-17

4. FOR UNITS WITH FORD 2.5L4 .................................................................... 1-1-18(a) .Daily ..................................................................................................................................... 1-1-18(b). Weekly or 50 Hours ............................................................................................................. 1-1-19(c). Two-weekly or 100 Hours .................................................................................................... 1-1-19(d). Monthly or 200 Hours ........................................................................................................... 1-1-20(e). Two (2) Months or 400 Hours.............................................................................................. 1-1-21(f). Six (6) Months or 1000 Hours ............................................................................................... 1-1-21(g). Yearly or 2000 Hours ............................................................................................................ 1-1-22(h). Every 4 years. ...................................................................................................................... 1-1-22

5. FOR UNITS WITH CUMMINS ENGINE ........................................................... 1-1-22(a). Daily ..................................................................................................................................... 1-1-22(b). Weekly or at 50 Hours ......................................................................................................... 1-1-23(c). Bi-Weekly or 100 Hours ....................................................................................................... 1-1-24(d). Monthly or 200 Hours .......................................................................................................... 1-1-24(e). Every Two Months or 400 Hours .......................................................................................... 1-1-26(f). Every Five Months or 1000 Hours ......................................................................................... 1-1-26(g). Every Six Months or 1200 Hours .......................................................................................... 1-1-26(h). Every Ten Months or 2000 Hours ......................................................................................... 1-1-27(i). Yearly or 2400 Hours ............................................................................................................. 1-1-27

6. FOR UNITS WITH KUBOTA ENGINE ............................................................. 1-1-27(a). Daily ..................................................................................................................................... 1-1-27(b). Weekly or at 50 Hours ......................................................................................................... 1-1-28(c). Monthly or 200 Hours .......................................................................................................... 1-1-29(d). Every Two Months or 400 Hours .......................................................................................... 1-1-30(e). Every Five Months or 1000 Hours ........................................................................................ 1-1-31(f). Every Six Months or 1200 Hours ........................................................................................... 1-1-31(g). Yearly or 2000 Hours ............................................................................................................ 1-1-31(h). Each 18 months or 3000 Hours ........................................................................................... 1-1-31 (i). Each 2 years or 4000 Hours ................................................................................................ 1-1-32

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C. Lubrication Charts .............................................................................................. 1-1-32Figure 1-1. MA Lubrication Schematic ............................................................... 1-1-33

D. Adjustment Instructions ...................................................................................... 1-1-381. Service Brake Adjustment ....................................................................... 1-1-382. Park Brake Adjustment ........................................................................... 1-1-38

- for units with Ford engine and C6 transmission ................................... 1-1-38- for units with Ford engine and 4L70 transmission .............................. 1-1-38

3. Vertical Headlight Adjustment .................................................................. 1-1-384. Horizontal Headlight Adjustment ............................................................. 1-1-385. Cab Door Adjustment .............................................................................. 1-1-396. Toe-In Adjustment ................................................................................... 1-1-397. Steering Gear Box Adjustment ................................................................ 1-1-40

SECTION 2: TROUBLESHOOTING ........................................................................................ 1-2-1A. Loss of Power ...................................................................................................... 1-2-1B. Rear Axle .............................................................................................................. 1-2-2C. Twelve (12 ) Volt System ...................................................................................... 1-2-3

1. Headlights ................................................................................................. 1-2-32. Stop Lights ................................................................................................ 1-2-43. Back-Up Lights ......................................................................................... 1-2-54. Turn Signal Lights ..................................................................................... 1-2-65. Cab Marker Light ....................................................................................... 1-2-76. Wiper Motor .............................................................................................. 1-2-87. Horn .......................................................................................................... 1-2-98. Electric Fan............................................................................................. 1-2-10

D. Steering............................................................................................................... 1-2-11E. Brake System ..................................................................................................... 1-2-15F. Alternator ............................................................................................................ 1-2-18G. Battery ................................................................................................................ 1-2-19H. Diagnostic Trouble Code (DTC) Charts (gasoline engines only) ........................ 1-2-20i. Diagnostic Trouble Code (DTC) Charts ( DEUTZ 2.9L) .................................... 1-2-23

Figure 2-1. Display System Error by Flash Code .............................................. 1-2-24J. Diagnostic Trouble Code ( 4L70 Transmission) ................................................ 1-2-31K. Electrical Schematics ......................................................................................... 1-2-37

Figure 2-2. Electrical Schematic, Perkins 2011 (Tier II) Diesel Engine,Page 1 of 3 ......................................................................................................... 1-2-37

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Figure 2-2. Electrical Schematic, Perkins 2011 (Tier II) Diesel Engine,Page 2 of 3 ......................................................................................................... 1-2-38Figure 2-2. Electrical Schematic, Perkins 2011 (Tier II) Diesel Engine, Page 3 of 3 ........................................................................................................ 1-2-39Figure 2-3. Electrical Schematic, Deutz (Tier 4i) Diesel Engine, Page 1 of 3 .... 1-2-40Figure 2-3. Electrical Schematic, Deutz (Tier 4i) Diesel Engine, Page 2 of 3 .... 1-2-41Figure 2-3. Electrical Schematic, Deutz (Tier 4i) Diesel Engine, Page 3 of 3 .... 1-2-42Figure 2-4. Electrical Schematic, Deutz 2.9 L4 (Tier 4) Diesel Engine,Page 1 of 6 ......................................................................................................... 1-2-43Figure 2-4. Electrical Schematic, Deutz 2.9 L4 (Tier 4) Diesel Engine,Page 2 of 6 ......................................................................................................... 1-2-44Figure 2-4. Electrical Schematic, Deutz 2.9 L4(Tier 4) Diesel Engine,Page 3 of 6 ......................................................................................................... 1-2-45Figure 2-4. Electrical Schematic, Deutz 2.9 L4 (Tier 4) Diesel Engine,Page 4 of 6 ......................................................................................................... 1-2-46Figure 2-4. Electrical Schematic, Deutz 2.9 L4 (Tier 4) Diesel Engine, of 6 ......................................................................................................... 1-2-47Figure 2-4. Electrical Schematic, Deutz 2.9 L4 (Tier 4) Diesel Engine,Page 6 of 6 ......................................................................................................... 1-2-48Figure 2-5. Electrical Schematic, Ford 2.5L Gasoline Engine With C6Transmission, Page 1 of 3 .................................................................................. 1-2-49Figure 2-5. Electrical Schematic, Ford 2.5L Gasoline Engine With C6Transmission, Page 2 of 3 .................................................................................. 1-2-50Figure 2-5. Electrical Schematic, Ford 2.5L Gasoline Engine With C6Transmission, Page 3 of 3 ................................................................................. 1-2-51Figure 2-6. Electrical Schematic, Ford 2.5L Gasoline Engine With 4L70 Transmission, Page 1 of 4 ................................................................................. 1-2-52Figure 2-6. Electrical Schematic, Ford 2.5L Gasoline Engine With 4L70Transmission, Page 2 of 4 .................................................................................. 1-2-53Figure 2-6. Electrical Schematic, Ford 2.5L Gasoline Engine With 4L70 Transmission, Page 3 of 4 ................................................................................. 1-2-54Figure 2-6. Electrical Schematic, Ford 2.5L Gasoline Engine With 4L70Transmission, Page 4 of 4 .................................................................................. 1-2-55Figure 2-7. Electrical Schematic, Ford 2.5L LP Engine With C6Transmission, Page 1 of 3 .................................................................................. 1-2-56Figure 2-7. Electrical Schematic, Ford 2.5L LP Engine With C6Transmission, Page 2 of 3 .................................................................................. 1-2-57Figure 2-7. Electrical Schematic, Ford 2.5L LP Engine With C6Transmission, Page 3 of 3 .................................................................................. 1-2-58

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Figure 2-8. Electrical Schematic, Ford 2.5L LP Engine With 4L70Transmission, Page 1 of 4 .................................................................................. 1-2-59Figure 2-8. Electrical Schematic, Ford 2.5L LP Engine With 4L70Transmission, Page 2 of 4 .................................................................................. 1-2-60Figure 2-8. Electrical Schematic, Ford 2.5L LP Engine With 4L70Transmission, Page 3 of 4 .................................................................................. 1-2-61Figure 2-8. Electrical Schematic, Ford 2.5L LP Engine With 4L70Transmission, Page 4 of 4 .................................................................................. 1-2-62Figure 2-9. Electrical Schematic, Cummins B3.3 Diesel Engine, Page 1 of 3 .. 1-2-63Figure 2-9. Electrical Schematic, Cummins B3.3 Diesel Engine, Page 2 of 3 .. 1-2-64Figure 2-9. Electrical Schematic, Cummins B3.3 Diesel Engine, Page 3 of 3 .. 1-2-65Figure 2-10. Electrical Schematic, Kubota Diesel Engine, Page 1 of 3 ............. 1-2-66Figure 2-10. Electrical Schematic, Kubota Diesel Engine, Page 2 of 3 ............. 1-2-67Figure 2-10. Electrical Schematic, Kubota Diesel Engine, Page 3 of 3 ............. 1-2-68

L. Hydraulic Schematics ......................................................................................... 1-2-69Figure 2-11. Hydraulic Schematic, Perkins Diesel Engine ................................. 1-2-69Figure 2-12. Hydraulic Schematic, Deutz (Tier 4i) Diesel Engine ..................... 1-2-70Figure 2-13. Hydraulic Schematic, Deutz 2.9 L4 (Tier 4) Diesel Engine ........... 1-2-71Figure 2-14. Hydraulic Schematic, Deutz 2.9 L4 (Tier 4) Diesel EngineWith Power Steering ........................................................................................... 1-2-72Figure 2-15. Hydraulic Schematic, Ford 2.5L Gasoline Engine ........................ 1-2-73Figure 2-16. Hydraulic Schematic With Filter, Ford 2.5L Gasoline Engine....... 1-2-74Figure 2-17. Hydraulic Schematic, Cummins (Tier 4i) Diesel Engine .............. 1-2-75Figure 2-10. Hydraulic Schematic, Kubota V3600 Diesel Engine ...................... 1-2-75Figure 2-18. Hydraulic Schematic, Kubota V3600 Diesel Engine ...................... 1-2-76Figure 2-19. Hydraulic Schematic, Kubota V3600 Diesel Engine With Power Steering .................................................................................................. 1-2-77

SECTION 3: REMOVAL / INSTALLATION ................................................................................ 1-3-1A. Hood (diesel units) ................................................................................................ 1-3-1

1. Removal ................................................................................................... 1-3-12. Installation ................................................................................................. 1-3-1

B. Engine Compartment Side Panel (diesel units) .................................................... 1-3-11. Removal ................................................................................................... 1-3-12. Installation ................................................................................................. 1-3-1

C. Front Bumper ....................................................................................................... 1-3-21. Removal ................................................................................................... 1-3-22. Installation ................................................................................................. 1-3-2

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D. Front Fender / Running Board .............................................................................. 1-3-31. Removal ................................................................................................... 1-3-32. Installation ................................................................................................. 1-3-3

E. Radiator and Radiator Shroud Assembly .............................................................. 1-3-41. Removal ................................................................................................... 1-3-42. Installation ................................................................................................. 1-3-5

F. Rear Fender ......................................................................................................... 1-3-61. Removal ................................................................................................... 1-3-62. Installation ................................................................................................. 1-3-6

G. Seat Cushions ...................................................................................................... 1-3-71. Back Cushion ........................................................................................... 1-3-72. Bottom Cushion ........................................................................................ 1-3-7

H. Seat Assembly ...................................................................................................... 1-3-81. Removal ................................................................................................... 1-3-82. Installation ................................................................................................. 1-3-8

I. Battery .................................................................................................................. 1-3-81. Removal ................................................................................................... 1-3-82. Installation ................................................................................................. 1-3-9

J. Fuel Cell / Compartment Assembly ...................................................................... 1-3-91. Removal ................................................................................................... 1-3-92. Installation ............................................................................................... 1-3-10

K. Tires and Wheels................................................................................................ 1-3-101. Tire and Wheel Removal/Installation ....................................................... 1-3-102. Tire and Wheel Removal/Installation on Tractors Equipped with

Split Wheels ............................................................................................ 1-3-113. Tire and Wheel Removal/Installation on Tractors with Standard Wheels 1-3-12

L. Drive Shaft .......................................................................................................... 1-3-131. Removal ................................................................................................. 1-3-132. Installation ............................................................................................... 1-3-14

M. Drive Axle, Shocks and Mounting Assemblies .................................................... 1-3-141. Removal ................................................................................................. 1-3-142. Installation ............................................................................................... 1-3-15

N. Transmission/Torque Converter (Gasoline AND DIESEL) .................................. 1-3-161. Transmission Removal ........................................................................... 1-3-162. Transmission Installation ........................................................................ 1-3-16

O. Engine / Transmission ........................................................................................ 1-3-171. Removal ................................................................................................. 1-3-17

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2. Installation ............................................................................................... 1-3-19P. Perkins Diesel Engine / Transmission ................................................................ 1-3-21

1. Removal ................................................................................................. 1-3-212. Installation ............................................................................................... 1-3-22

Q. Shifter ................................................................................................................. 1-3-241. Removal ................................................................................................. 1-3-242. Installation ............................................................................................... 1-3-243. Adjustment .............................................................................................. 1-3-25

R. Accelerator Pedal and Throttle Control Cable (IF EQUIPPED) .......................... 1-3-251. Removal/Installation ................................................................................ 1-3-252. Throttle Control Cable Removal/Installation ............................................ 1-3-26

S. Tail Pipe / Muffler / Exhaust Pipe ......................................................................... 1-3-261. Removal ................................................................................................. 1-3-262. Installation ............................................................................................... 1-3-27

T. Steer Axle ............................................................................................................ 1-3-271. Removal ................................................................................................. 1-3-282. Installation ............................................................................................... 1-3-28

U. Steer Axle Leaf Springs and Spring Strap Arms .................................................. 1-3-291. Removal ................................................................................................. 1-3-292. Installation ............................................................................................... 1-3-30

V. Steering Linkage Rod (Drag Link) ....................................................................... 1-3-301. Removal ................................................................................................. 1-3-302. Installation ............................................................................................... 1-3-31

W. Sector / Column and Steering Wheel ................................................................. 1-3-311. Removal ................................................................................................. 1-3-312. Installation ............................................................................................... 1-3-32

X. Master Cylinder ................................................................................................... 1-3-331. Removal ................................................................................................. 1-3-332. Installation ............................................................................................... 1-3-33

Y. Brake Booster ..................................................................................................... 1-3-341. Removal ................................................................................................. 1-3-342. Installation ............................................................................................... 1-3-35

Z. Brake Pedal ........................................................................................................ 1-3-351. Removal ................................................................................................. 1-3-352. Installation ............................................................................................... 1-3-35

AA. Parking Brake, Linkage and Lever (FORD WITH C6 TRANSMISSION) ............. 1-3-361. Removal ................................................................................................. 1-3-362. Installation ............................................................................................... 1-3-37

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BB. Parking Brake, Linkage and Lever (FORD WITH GM 4L70 TRANSMISSION) ... 1-3-381. Removal ................................................................................................. 1-3-38

CC. Alternator ............................................................................................................ 1-3-401. Removal ................................................................................................. 1-3-402. Installation ............................................................................................... 1-3-40

DD. Starter Solenoid (Dieselunits only) ...................................................................... 1-3-401. Removal ................................................................................................. 1-3-402. Installation ............................................................................................... 1-3-40

EE. Temperature Sending Unit and Gauge ................................................................ 1-3-411. Temperature Sending Unit Removal/Installation ..................................... 1-3-412. Water Temperature Gauge Removal/Installation..................................... 1-3-41

FF. Oil Pressure Sending Unit and Gauge ................................................................ 1-3-411. Oil Pressure Sending Unit Removal/Installation ..................................... 1-3-412. Oil Pressure Gauge Removal/Installation ............................................... 1-3-42

GG. GAUGES............................................................................................................. 1-3-421. Removal ................................................................................................. 1-3-422. Installation ............................................................................................... 1-3-42

HH. Switches ............................................................................................................. 1-3-431. Ignition Switch Removal/Installation ........................................................ 1-3-432. Headlight Switch Removal/Installation .................................................... 1-3-433. Auxiliary Switch Removal/Installation ...................................................... 1-3-434. Brake Warning Light Removal/Installation ............................................... 1-3-445. Glow Plug Button Removal/Installation ................................................... 1-3-44

II. Headlights, Stop Lights, and Turn Signal Lights .................................................. 1-3-451. Headlight Removal/Installation ................................................................ 1-3-452. Stop Light Removal/Installation ............................................................... 1-3-453. Signal Light Removal/Installation ............................................................ 1-3-454. Back-Up Light Removal/Installation ........................................................ 1-3-46

JJ. Cab Assembly .................................................................................................... 1-3-461. Removal ................................................................................................. 1-3-462. Installation ............................................................................................... 1-3-46

KK. Door .................................................................................................................... 1-3-471. Removal ................................................................................................. 1-3-472. Installation ............................................................................................... 1-3-47Pro

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SECTION 4: SHIPPING ............................................................................................................. 1-4-1

A. Preparation ........................................................................................................... 1-4-11. Battery ...................................................................................................... 1-4-12. Radiator .................................................................................................... 1-4-13. Fuel Cell .................................................................................................... 1-4-14. Checks ..................................................................................................... 1-4-1

B. Preparation for Operation ..................................................................................... 1-4-21. Radiator .................................................................................................... 1-4-22. Fuel Cell .................................................................................................... 1-4-23. Battery ...................................................................................................... 1-4-2

SECTION 5: STORAGE ............................................................................................................ 1-5-1A. For One Month ...................................................................................................... 1-5-1

l. Engine ....................................................................................................... 1-5-12. Transmission ............................................................................................ 1-5-23. Axle and Reduction Gear Box ................................................................... 1-5-24. Tires .......................................................................................................... 1-5-25. Lubrication ................................................................................................ 1-5-26. Fluid Levels ............................................................................................... 1-5-27. Wheel Bearings ........................................................................................ 1-5-28. Battery ...................................................................................................... 1-5-2

B. Indefinite Period .................................................................................................... 1-5-31. Engine ....................................................................................................... 1-5-32. Transmission ............................................................................................ 1-5-43. Axle and Reduction Gear Box ................................................................... 1-5-44. Tires .......................................................................................................... 1-5-45. Lubrication ................................................................................................ 1-5-46. Fluid Levels ............................................................................................... 1-5-57. Wheel Bearings ........................................................................................ 1-5-58. Battery ...................................................................................................... 1-5-5

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Chapter 1MA Tow Tractor Section 1

SECTION 1: SERVICING

A. PREPARATION FOR USE

1. Fuel System

(a) Check all fuel line connections to make sure they are properly connected.

(b) Make certain fuel cell drain valve is closed.

(c) Fill fuel cell with correct fuel. Refer to the engine manual(s) included with thismanual to determine the correct fuel specifications.

2. Battery

(a) Check the battery fluid level. Top up with distilled or approved drinking water, asneeded.

(b) Connect the battery cables, if disconnected.

NOTE: Standard TUG batteries are maintenance free and do not requirethis step.

3. Brakes

(a) Check master cylinder fluid level.

(b) If low, check for leaks in brake lines.

(c) Check service brake to make sure it is working properly.

(d) Check park brake to make sure it is working properly.

4. Engine and Transmission

(a) Check engine oil level, add oil if needed. (See lubrication specifications later in thissection.)

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(b) Check radiator coolant/water mixture level. If coolant is needed, make sure radiatordrain valve is closed, then add required coolant/water mixture.

(c) Check transmission fluid level.

NOTE: This check is to determine if there is fluid in the transmission. If anyfluid shows on the dipstick, do not add transmission fluid until it is checkedwith the engine running, after the engine has reached normal operatingtemperature.

(d) Check transmission cooling lines for proper connections.

5. Rear Axle and Reduction Gear BoxCheck oil level in the rear axle and gear reduction box and add oil, if needed. The rear axleand reduction gear box are internally connected. (See lubrication specifications later in thissection.)

6. Tire Inflation

CAUTION: THE RECOMMENDED TIRE PRESSURES LISTED AREFOR THE 8.00 X 16.5 (DRIVE WHEELS) AND 6.9 X 9.0 (STEERWHEELS) TIRES THAT ARE STANDARD ON THE MA UNIT.OTHER OPTIONAL TIRES SHOULD BE INFLATED ACCORDINGTO THE TIRE MANUFACTURER SPECIFICATIONS.

Check air pressure in tires and add air, if needed:

Drive Wheels 45 psiSteer Wheels 60 psi

7. Vehicle DriveCheck that the tractor drives properly in both forward and reverse directions.

8. Units Equipped with Cummins B3.3 EngineIn cold weather, ensure that the engine preheat toggle switch, located on the engine side of thefirewall, is in the ON position. The switch may be turned off in warm weather climates.

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B. PERIODIC MAINTENANCE SCHEDULE

CAUTION: CHECK THE ENGINE OPERATION MANUAL FORSPECIFIC ENGINE MAINTENANCE.

The tractor should be maintained in accordance with the following schedules:

1. FOR UNITS WITH PERKINS 1104C-44 (Tier II)

(a). Daily

(1) Check that all controls are in good working order. Report a faulty TUG control and donot use until repaired.

(2) Check fuel level.

(3) Check oil level and top engine oil up if necessary.

(4) Check coolant level and top up if necessary with correct mixture.

(5) Walk-around inspection (visual inspection for oil, fuel or coolant leaks).

(6) Inspect, adjust, or replace alternator and fan belts.

(7) Inspect engine air cleaner service indicator.

(8) Drain Fuel system primary filter/water separator.

(9) Check the pressure of the pneumatic tires:

Drive Wheels 45 psi (310.3 kPa)Steer Wheels 60 psi (413.7 kPa)

WARNING: DO NOT CHANGE PNEUMATIC TIRE FOR CUSHIONTIRE OR VICE VERSA WITHOUT FIRST CONSULTING TUG.. TIRESOF A DIFFERENT TYPE OR MAKE, TREAD OR MATERIAL CANREDUCE THE LOAD CAPACITY OR AFFECT SAFETY.

(10) Check the tire treads for damage. Remove any stone, etc.

(11) Check the operation and aiming of the headlights.

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(12) Check the operation of backup, tail, stop and turn signal lights (if equipped).

(13) Check the operation of the cab marker lights, the heater, the wiper and cab light, ifequipped.

(14) Sound the horn.

(b). Weekly or 50 Hours

WARNING: LUG NUTS MUST BE RETIGHTENED TO 125 FT-LB(169.5 Nm) AFTER ANY CHANGE OF A WHEEL AND ANYTIME THELUG NUTS HAVE BEEN LOOSENED FOR ANY REASON, AND ATTHE INTERVALS SPECIFIED IN THIS PERIODIC MAINTENANCESECTION.

(1) Check that the wheel lug nuts are tightened to 125 ft-lb (169.5 Nm).

(2) Check the level of the brake fluid in the master cylinder. If low, top off as necessary.

(3) Check the battery charge.

(4) Check the drive axle U-bolts and tighten if required.

WARNING: TRANSMISSION FLUID MAY REACH HIGHTEMPERATURES AND THE CASE MAY BE UNDER PRESSURE.CARE MUST BE TAKEN WHEN REMOVING THE DIPSTICK TOAVOID BURNS.

(5) Check the transmission fluid level (with engine running at normal operatingtemperature).

(6) Check cylinder head bolt torque and all nuts and bolts for tightness. If required, torqueto specified torque with oiled threads.

(7) Check drive axle and reduction gear box oil level.

(8) Check king pins and steer pin for looseness.

(9) Check underneath for oil leaks and damage.

(10) Drain fuel tank water and sediment

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(11) Check neutral safety switch adjustment.

(12) Check power steering fluid level.

(c). Monthly or 200 Hours

(1) Check park brake operation. With the park brake handle in ‘lock’ position, the tractorshould not move on an 8% or less grade. If the tractor does not move, no adjustmentis necessary, but if the tractor rolls, then adjustment is advised. Follow therecommended adjustment instructions in this section.

(2) Check service brake operation.

(3) Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch (3.175mm).

(4) Change drive axle and reduction gear box oil.

NOTE: Only the initial change is required at the 200-hour maintenancelevel, change every six (6) months or 1200 hours thereafter.

(5) Lube the adjusting slides beneath the operator’s seat.

(6) Lube the service brake pedal pivot.

(7) Lube the drive shaft joints.

(8) Lube the parking brake lever pivots.

(9) Lube the throttle linkage.


(11) Lube all grease fittings.

(12) Lube the hood latches and hinges.

(13) Lube the cab door handles (if equipped).

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(d). Two (2) Months or 500 Hours

(1) Check the cooling system for dirt or rust in coolant.

(2) Inspect/Replace engine air cleaner element.

(3) Inspect/Clean engine ground

(4) Change engine oil and oil filter

(5) Replace fuel system primary filter (water separator) element

(6) Replace fuel system secondary filter

(7) Inspect/Replace hoses and clamps.

(8) Clean radiator.

(e). Six (6) Months or 1000 Hours

(1) Check the differential and reduction gear box bolts are tightened to 492 in-lb 55.6Nm).


NOTE: The initial change is required at the 200-hour maintenance level,change every six (6) months or 1200 hours thereafter.

(3) Check cylinder compression.

(4) Inspect/Adjust engine valve lash.

(5) Check battery and cable connectors.

(6) Check fastenings, hose unions/clips (renew if damaged).

(f). One (1) year or 2000 Hours

(1) Inspect aftercooler core.

(2) Inspect alternator.

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(3) Inspect engine mounts.

(4) Inspect starting motor.

(5) Inspect turbocharger.

(6) Inspect water pump

(7) Adjust automatic transmission band.

(8) Change transmission fluid and filter.

(9) Drain, flush, refill and bleed the hydraulic brake system.

(g). Every 1.5 years or 3000 Hours

(1) Test/Change fuel injector.

(2) Change cooling system coolant.

(h) .Every 2 years or 4000 Hours

(1) Clean/Test aftercooler core.

(i). Every 3 years or 6000 Hours

Add cooling system coolant extender (ELC).

2. FOR UNITS WITH DEUTZ Tier 4i

(a). Daily



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(4) Check oil bath (lube oil quality, TC0199-99-3002/Dry type filter).

(5) Check radiator coolant/water level.

(6) Check/drain water separator. (If equipped)











(1) Check that the wheel lug nuts are tightened to 125 ft-lb (169.5Nm).


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(9) Check voltmeter for charging


(11) Check exhaust system for leaks and holes.


(13) Check power steering fluid level




(3) Check the fan and alternator belts; tighten, if necessary.

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(4) Inspect radiator hoses and clean radiator exterior.

(5) Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch.



(7) Lube the adjusting slides beneath the operator's seat.




(11) Lube the throttle linkage

(12) Lube the steering axle, king pins, and pivot points.

(13) Lube the sliding bushings on the rear brake calipers.



(16) Lube the cab door handles (If equipped)


(1) Replace BFL20011 lube oil, see TC0199-99-3002

(2) Replace oil filter catridge BFL2011

(3) Check battery and cable connectors

(4) Check the cooling system for dirt or rust in coolant.

(5) Inspect front wheel bearings; clean and repack.

(6) Check ball joints and tie rod ends looseness.

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(7) Check hydraulic pressure relief valve; adjust to 850 psi (5860.5 kPa) if needed.


(1) Check the differential and reduction gear box bolts are tightened to 492 in-lb(55.6Nm).




(4) Check the intake manifold bolts and tighten, if necessary.

(5) Replace FL2011 lube oil (see TC 0199-99-3002).

(6) Clean oil bath (lube oil quality (see TC 0199-99-3002/Dry type filter).

(7) Replace oil filter catridge FL2011.

(8) Replace fuel filter catridge.

(9) Clean or change fuel pump/strainer if necessary.

(10) Check flexible fuel leakage lines (see TC0138-21-9300).

(11) Clean fuel pre-cleaner

(12) Check Intake air cleaner (if aviable, maintain according to maintenance indicator)

(13) Adjust valve clearance.

(14) Adjust V-belt

(15) Check engine mounts (replace if damaged)

(f). Yearly or 2000 Hours


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(g). Each 18 months or 3000 Hours

(1) Check injection valve.

(2) Check crankcase pressure vent valve.

(3) Replace timing belt, extreme-duty, see adjacent table (Deutz Operation Manual).

(h). Each 2 years or 4000 Hours

(1) Replace flexible fuel leakage lines (see TC 0138-21-9300).

(2) Replace intake air cleaner (if aviailable, maintain according to maintenance indicator).

(3) Replace V-belt.

(i). Each 2.5 years or 5000 Hours

Replace timing belt, heavy-duty, see adjucent table (Deutz Operation Manual).

(j). Each 3 years or 6000 Hours

Replace timing belt, light-duty, see adjacent table (Deutz Operation Manual).

(k). Each 6 years or 12000 Hours

(1) Replace oil bath (lube oil quality, see TC 0199-99-3992/Dry type filter).

(2) Replace injection valve.

(3) Make basic overhaul

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3. FOR UNITS WITH DEUTZ 2.9L4

(a). Daily




(4) Check coolant level (top up if necessary).

(5) Check engine tightness (visual inspection for leaks).

(6) Check and empty water tank in the pre-filter.









(13) Check exhaust system including exhaust aftertreatment components for leaks.

(14) Check suction air filter/dry air filter (maintain in accordance with maintenanceindicator)

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(2) Change engine oil.

NOTE: Only the intial change is required at the 50-hour maintenancelevel, change monthly or every 200 hours thereafter.













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(5) Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch(3.175mm).

NOTE: The intial change is required at the 50-hour maintenance level,change monthly or every 200 hours thereafter.












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(1) Check the cooling system (additive concentration).

(2) Change fuel catridge for filter.

(3) Check intake air pipes for damage.

(4) CheckV-belt




(8) Replace lubricating oil. A lubricating oil application/change strategy adapted optimallyto the individual engine application type can be created, for example, with the DEUTZoil diagnosis (Ask your DEUTZ partner).

(9) Replace lubricating oil filter/insert (every time the lubrication oil is changed)


(1) Check the differential and reduction gear box bolts are tightened to 492 in-lb (55.6Nm).




(4) Check the intake manifold bolts and tighten, if necessary.

(5) Check charge air cooler entry area (drain lube oil/condensate).


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(7) Check cold starting device.

(8) Check engine mounting (tighten, replace if damaged when necessary).


(10) Check V-rib belt and tensioning pulley.

(11) Replace filter insert for the fuel pre-filter. If the warning system responds (lamp/horn), the water trap bowl must be emptied immediately.

(12) Replace dry air filter.

(13) Replace V-belts

(f). Yearly or 2000 Hours




(4) Check engine monitor, warning system. Maintenance only to be carried out byauthorised service personnel.

(5) Replace fuel pre-filter.

(g). Each 2 years or 4000 Hours

(1) Replace coolant

(2) Replace timing belt, extreme-duty, see adjacent table (Deutz Operation Manual)

(h). Status dependent

Change diesel particle filter (the required exchange is displayed via an electronic display)

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4. FOR UNITS WITH FORD 2.5L4

(a). Daily




(4) Check coolant level and top up if necessary with correct mixture.

(5) Check engine tightness (visual inspection for oil, fuel or coolant leaks).

(6) Lubricate PTO release bearing.

(7) Check hot and cold starting functions.








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(10) Check coolant, oil, fuel, exhaust and vacuum hoses/pipes for leaks, damage,deterioration and correct routing. Chace all visible electrical wiring for security,correct routing and evidence of chafing or heat damage.



(c). Two-weekly or 100 HoursLubricate PTO bearings

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(d). Monthly or 200 Hours





(5) Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch (3.175mm).

NOTE: The intial change is required at the 50-hour maintenance level,change monthly or every 200 hours thereafter.













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(17) Check condition and adjust tension of drive belt(s).

(18) Check gasoline fuel filter element and renew as necessary (Depending upon thequality of the fuel used, it maybe necessary to renew the filter element morefrequently).

(19) Check dry filter elementand renew as necessary (Depending upon the quality of thefuel used, it maybe necessary to renew the filter element more frequently).

(e). Two (2) Months or 400 Hours

(1) Renew air filter element.

(2) Check spark plugs: Clean, adjust and test or replace.

(3) Check all nuts and bolts for tightness.

(4) Adjust PTO clutch release and shaft bearings.




(f). Six (6) Months or 1000 Hours





(4) Inspect PCV hoses, tubes and fittings.



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(g). Yearly or 2000 Hours

Adjust automatic transmission band.

(h). Every 4 years.

Clean coolant filler cap. Renew cap if seal has deteriorated.

5. FOR UNITS WITH CUMMINS ENGINE

(a). Daily

(1) Check that all controls and warning lights are in good working order. Report a faultyTUG and do not use until repaired.

(2) Check fuel level and odor of fuel.

(3) Check engine oil level.

(4) Check for leaks.

(5) Check for loosen or damaged parts.

(6) Check for worn or damaged belts.

(7) Check for worn or damaged low and high voltage harness.

(8) Look for any change in system appearence.

(9) Check for odor of electronic devices.

(10) Check transmission oil for signs of water or other contaminants. Check (smell) oil forsigns of burned oil (overheating). The fluid must be changed, the transmission flushedand the torque converter changed if the oil is contaminated with water (fluid is pink),has gone rancid with a foreign substance (smell), has clutch debris (the fluid has adark color) or burned (fluid smells burned). If these conditions exist, it may benecessary to remove and dismantle the transmission to flush and replace the torqueconverter. See the Transmission Service Manual in Chapter 4 for more information.

(11) Check radiator coolant/water level.

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(12) Check/drain water separator. (if equipped)

(13) Check voltmeter for charging.

CAUTION: THE RECOMMENDED TIRE PRESSURES LISTED AREFOR THE 8.00 X 16.5 (DRIVE WHEELS) AND 6.9 X 9.0 (STEERWHEELS) TIRES THAT ARE STANDARD ON THE MA UNIT.OTHER OPTIONAL TIRES SHOULD BE INFLATED ACCORDINGTO THE TIRE MANUFACTURER SPECIFICATIONS.


Drive Wheels 45 psiSteer Wheels 60 psi

WARNING: DO NOT CHANGE PNEUMATIC TIRE FOR CUSHIONTIRE OR VICE VERSA WITHOUT FIRST CONSULTING TUG. TIRESOF A DIFFERENT TYPE OR MAKE, TREAD OR MATERIAL CANREDUCE THE LOAD CAPACITY OR AFFECT SAFETY.

WARNING: LUG NUTS MUST BE RETIGHTENED TO 125 LB-FT(135.6 NM) AFTER ANY TIME THE LUG NUTS HAVE BEENLOOSENED FOR ANY REASON, AND AT THE INTERVALSSPECIFIED IN THIS PERIODIC MAINTENANCE SECTION.


(16) Check the operation of the headlights and if aimed correctly.

(17 Check the operation of backup, tail, stop and turn signal lights (if equipped).


(19) Sound the horn to verify proper operation.

(20) Visual cooling fan inspection

(b). Weekly or at 50 Hours

(1) Check the level of the brake fluid in the master cylinder. If low, top off as necessary.(See lubrication specifications later in this section.)

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(2) Check battery charge and fluid level.


(3) Check drive axle mounting bolts and tighten if required.


(4) Check transmission fluid level (with engine running and at normal operatingtemperature). If low, add fluid until level is within acceptable range as marked on thedipstick. (See lubrication specifications later in this section.)

(5) Check neutral safety switch adjustment (If equipped).




(c). Bi-Weekly or 100 Hours

Inspect cooler for signs of leakage, damage or loose mounting bolts.

(d). Monthly or 200 Hours

(1) Check the service brake pedal. The bottom of the pad on the pedal should be between4 and 5 inches above the floorboard. If it is, no adjustment is necessary; go to thenext item. If it is not, follow the recommended adjustment instruction in this section.

(2) Check the parking brake. With the parking brake handle in ‘lock’ position, the tractorshould not move on a 8% or less grade. If the tractor does not move, no adjustment isnecessary, but if the tractor rolls, then adjustment is advised. Follow therecommended adjustment instructions in this section.

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(4) Check brake pads; replace if pads are less than 1/8".

(5) Lubricate service brake pedal linkage pivots.

(6) Lubricate drive shaft joints.

(7) Lubricate parking brake lever pivots.

(8) Lubricate throttle linkage.

(9) Lubricate steering axle links, king pins, pivot points.

(10) Lubricate sliding bushings on the rear brake calipers.

(11) Lubricate all grease fittings.

(12) Lubricate hood latches and hinges.

(13) Lubricate cab door handles (if equipped).

(14) Check operator seat slides (if equipped).


(16) Check ball joints for looseness.

(17) Change drive axle and reduction gear box oil. (See lubrication specifications later inthis section.)


(18) Replace lubrication oil and filter. (See lubrication specifications later in this section.)

(19) Check air filter and air intake piping. Clean or replace (Cummins Operation andMaintenance Manual).

(20) Check radiator pressure cap (Cummins Operation and Maintenance Manual)..

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(e). Every Two Months or 400 Hours


(2) Check tie rod ends for looseness.

(3) Check fuel injection in-line pumps (Cummins Operation and Maintenance Manual).

(4) Change fuel filter.

(5) Check supplemental coolant additive and antifreeze concentration level(CumminsOperation and Maintenance Manual).


(f). Every Five Months or 1000 Hours

(1) Change transmission fluid and clean filter and screen within pan.

(2) Check transmission mounting bolts for tightness. Refer to the Transmission ServiceManual in Chapter 4 for torque specifications.

(3) Inspect and adjust drive belt. Replace if it has cracs, glazing, tears, cuts, or excessivewear (Cummins Operation and Maintenance Manual) .

(4) Check fuel supply lines.

(g). Every Six Months or 1200 Hours




(4) Check steering cylinder compression.

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(h). Every Ten Months or 2000 Hours

(1) Drain, flash and replace coolant (Cummins Operation and Maintenance Manual).

(i). Yearly or 2400 Hours




6. FOR UNITS WITH KUBOTA ENGINE

(a). Daily

(1) Check that all controls and warning lights are in good working order. Report a faultyTUG and do not use until repaired.


(3) Check engine oil level and contamination.

(4) Check for leaks.

(5) Check for damaged parts or loosened bolts and nuts.

(6) Check coolant level.

(7) Chect for dust in air cleaner dust cup.

(8) Check color of exhaust fumes.

(9) Check for unsual engine noise.

(10) Check engine start-up condition

(11) Check for slow-down and accelerator behavior.

(12) Check transmission oil for signs of water or other contaminants. Check (smell) oil for

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signs of burnt oil (overheating). The fluid must be changed, the transmission flushedand the torque converter changed if the oil is contaminated with water (fluid is pink),has gone rancid with a foreign substance (smell), has clutch debris (the fluid has adark color) or burned (fluid smells burned). If these conditions exist, it may benecessary to remove and dismantle the transmission to flush and replace the torqueconverter. See the Transmission Service Manual in Chapter 4 for more information.

(b). Weekly or at 50 Hours


(2) Check battery charge and fluid level.


(3) Check drive axle mounting bolts and tighten if required.


(4) Check transmission fluid level (with engine running and at normal operatingtemperature). If low, add fluid until level is within acceptable range as marked on thedipstick. (See lubrication specifications later in this section.)


(6) Check neutral safety switch adjustment (If equipped).


(8) Check fuel lines and band clamps.

(9) Drain water separatror.

(10) Change engine oil.

NOTE: The initial change is required at the 50-hour maintenance level,

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change every monthly or 200 hours thereafter.

(11) Change oil filter catridge

NOTE: The initial change is required at the 50-hour maintenance level,change every two (2) months or 400 hours thereafter.


(1) Check the service brake pedal. The bottom of the pad on the pedal should be between4 and 5 inches above the floorboard. If it is, no adjustment is necessary; go to thenext item. If it is not, follow the recommended adjustment instruction in this section.

(2) Check the parking brake. With the parking brake handle in ‘lock’ position, the tractorshould not move on a 8% or less grade. If the tractor does not move, no adjustment isnecessary, but if the tractor rolls, then adjustment is advised. Follow therecommended adjustment instructions in this section.

(3) Inspect radiator hoses, clamp bands and clean radiator exterior.

(4) Check brake pads; replace if pads are less than 1/8".

(5) Lubricate service brake pedal linkage pivots.

(6) Lubricate drive shaft joints.

(7) Lubricate parking brake lever pivots.

(8) Lubricate throttle linkage.

(9) Lubricate steering axle links, king pins, pivot points.

(10) Lubricate sliding bushings on the rear brake calipers.

(11) Lubricate all grease fittings.

(12) Lubricate hood latches and hinges.

(13) Lubricate cab door handles (if equipped).

(14) Check operator seat slides (if equipped).


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(16) Check ball joints for looseness.



(18) Clean air filter element. (Kubota Operator's Manual). Should be cleaned more oftenin dusty conditions than in normal conditions.

(19) Clean fuel filter

(20) Check fan belt tightness (Kubota Operator's Manual).

(21) Check air intake lines.

(d). Every Two Months or 400 Hours


(2) Check tie rod ends for looseness.

(3) Replace oil filter catridge.

NOTE: Only the initial change is required at the 50-hour maintenancelevel, change every two (2) months or 400 hours thereafter.

(4) Change fuel filter.

(5) Remove sediment in the fuel tank.

(6) Clean water jacket (radiator interior) (Kubota Operator's Manual) .

(7) Replace fan belt (Kubota Operator's Manual) .

(8) Clean water separator.

(9) Recharge battery.

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(e). Every Five Months or 1000 Hours

(1) Change transmission fluid and clean filter and screen within pan.

(2) Check transmission mounting bolts for tightness. Refer to the Transmission ServiceManual in Chapter 4 for torque specifications.

(3) Check valve clearance (Kubota Operator's Manual).

(f). Every Six Months or 1200 Hours




(3) Check the steering sector and adjust if necessary.

(4) Check steering cylinder compression.

(5) Check fuel injection nozzle injection pressure (Consalt your local KUBOTA Dealerfor this service).

(g). Yearly or 2000 Hours


(2) Replace air cleaner element (After 6 times of cleaning).

(h). Each 18 months or 3000 Hours

(1) Check injection pump (Consalt your local KUBOTA Dealer for this service).

(2) Check turbo charge (Consalt your local KUBOTA Dealer for this service).

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(3) Check fuel injection timer (Consalt your local KUBOTA Dealer for this service).

(i). Each 2 years or 4000 Hours

(1) Change radiator coolant (Kubota Operator's Manual).

(2) Replace battery.

(3) Replace radiator hoses and clamp bands.

(4) Replace fuel lines and clamp bands (Consalt your local KUBOTA Dealer for thisservice).

(5) Replace air intake line (Replace only if neccesary).

(6) Replace fan belt (or every 500 hours)

C. LUBRICATION CHARTS

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7

9

8

8

14

8

8

2

41

6 6

5

3

5

12b

15c

5b

12a

11

15d

15c

10

Figure 1-1. MA Lubrication Schematic

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Table 1-1. MA Lubrication Schematic Index

Item # Component/System Item # Component/System

1 Steering Gear Box (Manual Steering) 11 Hood Latch

2 Brake Pedal Linkage Pivots 12a Radiator Coolant (Ford, Cummins)

3 Automatic Transmission 12b Radiator Coolant (Perkins)

4 Hydraulic Brake System 13 Throttle Linkage

5 Steer Axle (King Pins, Links and Tie Rod Ends)

14 Adjusting Slides, Operator’s Seat

6 Steer Axle Hubs/Front Wheel Bearings 15a Hydraulic Reservoir (Power Steering)(Ford 300, Perkins)

7 Drive Shaft Joints 15b Hydraulic Reservoir (Power Steering)(Ford DSG-423 (2.3L))

8 Brake Calipers 15c Hydraulic Reservoir (Power Steering)(Deutz and Kubota)

9 Drive Axle and Reduction Gear Box 15d Hydraulic Reservoir (Power Steering)(Cummins B3.3)

10 Engine Oil 16 Hood Hinge

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Table 1-2. Component/System to Lubricant (Alphabetical by Component/System)

Component/System Lubricant Type or Specification

Adjusting Slides, Operator’s Seat Multi-Purpose Lithium-Based Grease

Brake Calipers Silicon-Based Grease

Brake Pedal Linkage Pivots Multi-Purpose Lithium-Based Grease

Drive Axle and Reduction Gear Box Hypoid Gear Oil, SAE 80W-90LS

Drive Shaft Joints Multi-Purpose Lithium-Based Grease

Engine Oil API Service Category CF-4 Plus (Diesel)

API Service Classification SJ (Gasoline)

Hood Hinge Multi-Purpose Lithium-Based Grease

Hood Latch Multi-Purpose Lithium-Based Grease

Hydraulic Brake System Brake Fluid, DOT 3, Extra Heavy Duty

Hydraulic Reservoir (Power Steering) Automatic Transmission Fluid, Dexron Type III

Parking Brake Linkage Multi-Purpose Lithium-Based Grease

Radiator Coolant Ethylene Glycol Based Antifreeze

Steer Axle (King Pins, Links and Tie Rod Ends) Multi-Purpose Lithium-Based Grease

Steer Axle Hubs/Front Wheel Bearings Multi-Purpose Lithium-Based Grease

Steering Gear Box (Manual Steering) Multi-Purpose Lithium-Based Grease

Throttle Linkage Multi-Purpose Lithium-Based Grease

Transmission, C6 Automatic Automatic Transmission Fluid, Dexron Type III

Transmission, 4L70 Automatic Automatic Transmission Fluid, Dexron Type VI

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Table 1-3. Lubricant to Component/System (Alphabetical by Lubricant)

Lubricant Type or Specification Component/System

API Service Category CF-4 Plus (15W40CJ-4) Diesel Engine Oil

API Service Classification SJ (5W-20SJ) Gasoline Engine Oil

Hydraulic Reservoir (Power Steering)

Transmission C6, Automatic

Automatic Transmission Fluid, Dexron Type VI Transmission 4L70, Automatic

Brake Fluid, DOT 3, Extra Heavy Duty Hydraulic Brake System

Ethylene Glycol Based Antifreeze (deloELC 50/50) Radiator Coolant

Hypoid Gear Oil, SAE 80W-90LS Drive Axle and Reduction Gear Box

Adjusting Slides, Operator’s Seat

Brake Pedal Linkage Pivots

Drive Shaft Joints

Hood Hinge

Hood Latch

Parking Brake Linkage

Steer Axle (King Pins, Links and Tie Rod Ends)

Steer Axle Hubs/Front Wheel Bearings

Steering Gear Box (Manual Steering)

Throttle LinkageSilicon-Based Grease Brake Calipers

Automatic Transmission Fluid, Dexron Type III

Multi-Purpose Lithium-Based Grease

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Table 1-4. Lubricant to Commercially Available Product

NOTE: For extreme cold or hot temperatures, use Chevron Delo SyntheticSAE 0W-30 or SAE 5W-40 or equivalent.Note

Lubricant Commercially Available Product

API Service Category CF-4 Plus (Diesel) Chevron Delo SAE 15W-40 or Equivalent (See Note)

API Service Classification SJ (Gasoline) Ford/Motorcraft "Formula E" SAE 5W-30 or Equivalent(Ford Specification WSS-M2C153-H)

Automatic C6 Transmission Fluid Texamatic Dexron III ATF Qualification No. D-20112 or Equivalent

Automatic 4L70 Transmission Fluid General Motors Dexron VI ATF Qualification GMN 10060 or Equivalent

Brake Fluid, DOT 3, Extra Heavy Duty NAPA Dot 3 Heavy Duty Brake Fluid (Part No. 35-032) or Equivalent

Ethylene Glycol Based Antifreeze Texaco Startex Anti-freeze/Summer Coolant or Equivalent

Hypoid Gear Oil, SAE 80W-90LS Texaco MGL SAE 80W-90LS or EquivalentMulti-Purpose Lithium-Based Grease Texaco Marfak Multipurpose 2 or EquivalentSilicon-Based Grease Ford Part No. D7AZ-19A-331-A or Equivalent

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D. ADJUSTMENT INSTRUCTIONS

1. Service Brake Adjustment

(a) Remove master cylinder.

(b) Measure the distance between the inner face of the piston to the tip of the push rod.This length should be 0.9" (+ 0.06"). Adjust the length as required to be withintolerance by turning the screw on the end of the push rod in or out.

2. Park Brake Adjustment

- for units with Ford engine and C6 transmission

The parking brake lever is connected by two straps to the parking brake drum on the end ofthe transmission. When the lever is in the “lock” position, the straps are pulled, pressing thedrum shoes against the drum and holding the tractor from moving. To adjust the parkingbrake, turn the knob on the lever to the right (clockwise) to tighten the brakes or turn it to theleft (cunterclockwise) to slacken the brakes.- for units with Ford engine and 4L70 transmission

The parking brake lever is connected by rod to the parking brake caliper on the input shaft ofthe rear axle. When the lever is in the “lock” position, the rod is pulled, actuating the caliperwhich squeezes the pads and holds the tractor from moving. To adjust the parking brake, turnthe knob on the lever to the right (clockwise) to tighten the brakes or turn it to the left(counterclockwise) to slacken the brakes. Also, the rod has adjustable yokes on each endwhich allow for more adjustment as the parking brake wears. This rod can be adjustedduring normal maintenance procedures while the unit is on a lift.

3. Vertical Headlight Adjustment

(a) Loosen the nut on the horizontal bolt.

(b) Aim headlight in desired position.

(c) Tighten the nut.

4. Horizontal Headlight Adjustment

(a) Loosen the nut on the vertical shaft that holds the entire headlight assembly to therail.

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(b) Aim headlight in desired direction.

(c) Tighten the nut.

5. Cab Door Adjustment

The adjustment of a cab door is accomplished by loosening the bolts on the hinges [(2) perhinge]. Hold door in desired position and secure by tightening the bolts.

6. Toe-In Adjustment

(a) A level piece of pavement that is flat and smooth for at least 20 ft is required. Driveahead slowly and, with the cross spoke of the steering wheel at center, run the tractorabsolutely straight without touching the steering wheel.

(b) Use the parking brake to stop the tractor at end of the run. Now the wheels arestraight, so don’t bounce the truck around.

(c) Using two flat sticks and a pencil, position yourself on your back with the two sticksheld together so you can measure the distance between the two front wheels; first at3 o’clock, then at 9 o’clock.

(d) Make the toe-in on the rim.

(e) Hold the ends of the sticks extended to reach both tire rims. Hold them togetherwhile you make a pencil mark where the sticks meet.

(f) Measure between the backs of the tire rims (9 o’clock). Make your mark for theback. The back mark should be 0" to 1/8" further than the front mark. In otherwords, the wheel should be 0" to 1/8" pigeon-toed.

(g) Turn the sticks over, measure again and make different marks to check yourself foraccuracy. If the back marks are 0" to 1/8" further apart than the front marks, yourtoe-in is adjusted correctly.

(h) To adjust toe-in, change the length of the tie-rod. Turn the tie rod clamps so the rodcan turn on the tie rod end.

(i) Turn the tie rod so it either increases the pigeon-toe or decreases it. Adjust the toe-inso it checks out right with the sticks: 0" to 1/8" longer in back.

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(j) Tighten the clamps to lock the tie rods so they cannot turn.

7. Steering Gear Box Adjustment

(a) Locate the adjustment screw opposite the Pitman arm spline on the right hand side ofthe steering gear box.

(b) Remove the drag link from the Pitman arm.

(c) Loosen the lock nut on the adjusting screw.

(d) Turn the adjusting screw clockwise or counterclockwise until the Pitman arm doesnot have any free play in it at the straight ahead position.

(e) Turn the adjusting screw an eighth to a quarter of a turn more in the same directionused to adjust it.

(f) Tighten lock nut on adjusting screw.

(g) Reinstall drag link.

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SECTION 2: TROUBLESHOOTING

A. LOSS OF POWER

Check engine per appendix

Reduction in pulling power

Check transmission Repair or adjust engine

Check rear axle Adjust or repair

ok not ok

ok not ok

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B. REAR AXLE

Check lubrication

Rear axle noise

Check axle magnetic plugsfor metal chips Overhaul dropbox

Check drive shaft Replace drive shaft or U-joint

ok not ok

ok not ok

Check drop box magneticplugs for metal chips Add lubricate

ok not ok

Check drive shaft aligment Shim transmission to align

ok not ok

Check bearings Overhaul axle

ok not ok

Tear down and inspect axleand drop box Replace bearings

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C. TWELVE (12 ) VOLT SYSTEM

1. Headlights

Check fuse or circuit breaker

Poor, intermittent, or no lights

Check sealed beam Replace fuse or circuitbreaker

Check headlight switch Replace sealed beams

ok not ok

ok not ok

Check wiring & groundconnections Replace headlight switch

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2. Stop Lights



Check bulbs or lamps Replace fuse or circuitbreaker

Check brake light switch Replace bulbs or lamps

ok not ok

ok not ok

Check wiring and groundconnections Replace brake light switch

ok not ok

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3. Back-Up Lights



Check bulbs or lamps Replace fuse or circuitbreaker

Check back-up light switch Replace bulbs or lamps

ok not ok

ok not ok

Check wiring and ground connections Replace back-up light switch

ok not ok

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4. Turn Signal Lights



Check relay Replace fuse or circuitbreaker

Check bulbs or lamps Replace relay

ok not ok

ok not ok

Check wiring, connections& grounds Replace bulbs or lamps

ok not ok

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5. Cab Marker Light



Check relay or switch Replace fuse

Check wiring & connections Replace relay or switch

ok not ok

ok not ok

Check sockets, bulbs or lamps;replace bulbs/lamps as required Repair wiring & connections

ok not ok

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6. Wiper Motor

Work intermittently, or will notwork

Replace circuit breaker

Check wiper control switch Repair wiring & ground connections

ok not ok

ok not ok

Check motor Replace wiper control switch

ok not ok

Check wiring and groundconnections

Check circuit breaker

Repair or replace wipermotor

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7. Horn

Check fuse

C heck re lay R eplace fuse

C heck w iring & horn button R eplace relay

ok not ok

ok not ok

W ork in term ittently, or nosound

C heck for shorted w irebetween horn button & relay

Check for a stuck hornbutton R epair w ire

Check re lay R epair or rep lace button

ok not ok

ok not ok

Horn sounds continuously

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8. Electric Fan

Check circuit breaker

Check wiring andground connections Replace circuit breaker

Check temperaturesensor

Repair wiring and groundconnections

ok not ok

ok not ok

Works intermittenly,or won't work

Check fan control circuitboard

Replace temperaturesensor

ok not ok

Check fan motor circuitboard

Replace fan control

ok not ok

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D. STEERING

Check lubrication

Steering difficult

Check connections Lubricate

Check steering connectionarm

Adjust as required

ok not ok

ok not ok

Check steering sector mounting Adjust or replace if damaged

ok not ok

Replace steering sector Correct installation

ok not ok

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Check lubrication

Check steering cylinder Lubricate

Check Charlynn valve,replace if damaged or faulty Adjust to get equal steering

ok not ok

ok not ok

Steering difficult (CharLynn)

Check studs and king pins

Check bearings and hubsrepair or replace as required

Tighten or replace studsand/or king pins

ok not ok

Front wheel appears to wobble

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Check lubrication of steeringsystem

Steering wanders or weaves

Check wheel bearings Lubricate

Check toe-in Adjust or replacewheel bearings

ok not ok

ok not ok

Check steering gear mountings Adjust toe-in

ok not ok

Check steering gear box forbacklash adjustments Adjust mounting or tighten bolts

ok not ok

Adjust steering gear box

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Check brakes

Vehicle pulls to one side

Check wheel bearings Repaire brakes

Check tire "match" andinflation

Adjust or replacewheel bearings

ok not ok

ok not ok

Check steering arm linkage,repaire as required Change tires or adjust inflation

ok not ok

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E. BRAKE SYSTEM

Check brakes pads forglazing or excessive wear

Check fluid level Replace brake pads

Bleed brakes Top off as necessary

ok not ok

ok not ok

Excessive stopping distance

Check brake pads and rotor

Check for seized pistons Replace pads or rotoras needed

ok not ok

Brakes drag or uneven pull

Check adjustment on vacuumshaft nut in booster Install new caliper assembly

ok not ok

Check for excessivevacuum boost Adjust

ok not ok

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Check fluid lines, fittings andmaster cylinder for leaks

Check for leaks and refillsystem

Tighten fittings, repair linesor overhaul master cylinder

Bleed brakes or refill system Repaire or replace calipers

ok not ok

ok not ok

Brake spongy or excessive travel

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Check hydraulic pressure reliesvalve is adjusted to 850 PSI

Hard pedal

Replace booster

ok

Check Lines Replace pads or rotor

ok not ok

Check booster forpressure or leaking

Adjust to 850 PSI(5860.5 kPa)

ok not ok

not ok

Inspect brake pads & rotor

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F. ALTERNATOR

Check mounting and pulleys

Replace alternator Adjust

ok not ok

Alternator noisy

Check battery for shorts orinadequate fluid level

Check wiring between batteryand alternator

Replace battery

ok not ok

Alternator outputconsistently high

Check alternator Repair wiring

ok not ok

Chrck fpr high current drawsin electric system Replace alternator

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G. BATTERY

Check specific gravity;check for shorted cell

Battery will not stay charged

Check alternator output &belts Replace battery

Replace alternator or adjustbelts

ok not ok

ok not ok

Check for breaks in wiring

Replace wiring

not ok

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H. DIAGNOSTIC TROUBLE CODE (DTC) CHARTS (GASOLINE ENGINES ONLY)

1. Some units are equipped with a malfunction indicator light (MIL) on the instrument panel. Thissection contains a list of all the DTCs that may be obtained by diagnostic software or theMIL. If this option is equipped, additional information can be found in the Ford service manuallocated in Chapter 5.

NOTE: When checking codes with the diagnostic software, the DTCterminal can NOT be grounded.

2. When diagnostic trouble codes are obtained by the MIL, the following sequence will flash:

(a) 123 will flash 3 times to indicate the beginning of the flash code display sequence.

(b) Any active DTCs will flash 3 times each.

(c) 123 will flash 3 times indicating the end of the code display sequence.

3. If code 123 is the only code present, the system does not have any active codes - all systemsare working fine.

4. If an active DTC is present, refer to the corresponding DTC Chart in the Ford service manuallocated in Chapter 5 (only if equipped). Begin with the lowest number code first.

5. If you have a symptom of the pedal not working, and no DTC is set, go to the voltage screenand check pedal voltage. If pedal voltage is .75-1.25V, and idle validation switch says the unitis at idle, replace the pedal.

Table 2-1. Diagnostic Trouble Codes (DTCs)

Note

Code Designation DTC 111 Closed Loop Multiplier High (LPG) DTC 112 HO2S Open/Inactive (Bank 1) DTC 113 HO2S Open/Inactive (Bank 2) DTC 121 Closed Loop Multiplier High Bank 1 (Gasoline) DTC 122 Closed Loop Multiplier Low Bank 1 (Gasoline) DTC 124 Closed Loop Multiplier Low (LPG) DTC 125 Closed Loop Multiplier High (Natural Gas) DTC 126 Closed Loop Multiplier Low (Natural Gas)

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Table 2-1. Diagnostic Trouble Codes (DTCs) (Cont'd)

Code Designation DTC 131 Closed Loop Multiplier High Bank 2 (Gasoline) DTC 132 Closed Loop Multiplier Low Bank 2 (Gasoline) DTC 141 Adaptive Lean Fault (High Limit Gasoline) DTC 142 Adaptive Rich Fault (Low Limit Gasoline) DTC 143 Adaptive Learn High (LPG) DTC 144 Adaptive Learn Low (LPG) DTC 145 Adaptive Learn High (Natural Gas) DTC 146 Adaptive Learn Low (Natural Gas) DTC 161 System Voltage Low DTC 162 System Voltage High DTC 211 IAT High Voltage DTC 212 IAT Low Voltage DTC 213 IAT Higher Than Expected 1 DTC 214 IAT Higher Than Expected 2 DTC 215 Oil Pressure Low DTC 221 CHT/ECT High Voltage DTC 222 CHT/ECT Low Voltage DTC 223 CHT Higher Than Expected 1 DTC 224 CHT Higher Than Expected 2 DTC 231 MAP High Pressure DTC 232 MAP Low Voltage DTC 234 BP High Pressure DTC 235 BP Low Pressure DTC 242 Crank Sync Noise DTC 243 Never Crank Synced At Start DTC 244 Camshaft Sensor Loss DTC 245 Camshaft Sensor Noise DTC 253 Knock Sensor Open DTC 254 Excessive Knock Signal DTC 311 Injector Driver #1 Open (2.5L) DTC 312 Injector Driver #1 Shorted (2.5L) DTC 313 Injector Driver #2 Open (2.5L) DTC 314 Injector Driver #2 Shorted (2.5L) DTC 315 Injector Driver #3 Open (2.5L) DTC 316 Injector Driver #3 Shorted (2.5L)

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Code Designation DTC 321 Injector Driver #4 Open (2.5L) DTC 322 Injector Driver #4 Shorted (2.5L) DTC 351 Fuel Pump Loop Open or High Side Short To Ground DTC 352 Fuel Pump High Side Shorted To Power DTC 353 MegaJector Delivery Pressure Higher than Expected DTC 354 MegaJector Delivery Pressure Lower than Expected DTC 355 MegaJector Communication Lost DTC 361 MegaJector Voltage Supply High DTC 362 MegaJector Voltage Supply Low DTC 363 MegaJector Internal Actuator Fault Detection DTC 364 MegaJector Internal Circuitry Fault Detection DTC 365 MegaJector Internal Communication Fault Detection DTC 411 Coil Driver #1 Open (2.5L) DTC 412 Coil Driver #1 Shorted (2.5L) DTC 413 Coil Driver #2 Open (2.5L) DTC 414 Coil Driver #2 Shorted (2.5L) DTC 511 FPP1 High Voltage DTC 512 FPP1 Low Voltage DTC 513 FPP1 Higher Than IVS Limit DTC 514 FPP1 Lower Than IVS Limit DTC 521 FPP2 High Voltage DTC 522 FPP2 Low Voltage DTC 531 TPS1 (Signal Voltage) High DTC 532 TPS1 (Signal Voltage) Low DTC 533 TPS2 (Signal Voltage) High DTC 534 TPS2 (Signal Voltage) Low DTC 535 TPS1 Higher Than TPS2 DTC 536 TPS1 Lower Than TPS2 DTC 537 Throttle Unable To Open DTC 538 Throttle Unable To Close DTC 545 Governor Interlock Failure DTC 551 Max Govern Speed Override DTC 552 Fuel Rev Limit DTC 553 Spark Rev Limit DTC 611 COP Failure DTC 612 Invalid Interrupt

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I. DIAGNOSTIC TROUBLE CODE (DTC) CHARTS ( DEUTZ 2.9L)

a. Diagnostic button

The diagnostic button allows the errors currently saved in the errror memory of the electronic enginecontrol to be visualised in the form of a flash code. The flash codes permit:

• Errors that may occur can be classified.• Clear display of the error as visual signal.

- The blink codes can only be interpreted by a DEUTZ partner.

b. Use of the diagnostic key

The flash code displays all errors in the error memory, this means astive as well as passive ones.

The control unit must be switched off to start the engine (ignition off). Then the diagnosis buttonshould be presed for aprox. 1s during the start (ignition on).

Then next error (i.e. the following one in the error memory) can be displayd by pressing the diagnostic key again. If the lash error was displaed the first error is displaed again by pressing the diagnostic key again.

After the display of the error flash code, the error lamp goes out for five seconds.

c. Display system error by flash code

Example:

Flash code 1-2-81 x short flash2 x long flash8 x short flash

Code Designation DTC 613 A/D Loss DTC 614 RTI 1 Loss DTC 615 Flash Checksum Invalid DTC 616 RAM failure DTC 631 External 5V Ref Lower Than Expected DTC 632 External 5V Ref Higher Than Expected DTC 655 RTI 2 Loss DTC 656 RTI 3 loss

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This flash code indicates a break or short circuit in the wiring of the charge air temperature sensor.The temporal sequence of the flash signals is shown in the illustration.

• The blink codes can only be interpreted by a Deutz codes ( shown in the table below)

d. DTC-List-EMR4. Diagnosis and Errorcodes

Error description

Short Destination

- Battery voltage: the voltage measured by ECU is uot of the target range, system reaction is initiated- Sensor error battery voltage; signal range check high, Battery voltage above warming threshold, Short cut to battery

KWP Code

SPN Code

FMI Code

Blink Code Designation

47 168 2 3-1-8 Battery voltage:system reaction initiated

Figure 2-1. Display System Error by Flash Code

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System Reaction

- Warning- Error lamp shows permanent light Entry in the ECU fault memory.- Measurement in case of error: not available

Power reduction

- No reduction

Possible reason for error

-Alternator defective, connecting cable damaged

Possible consequence

-Error lamp on, for permanent overvoltage, the ECU can be damaged.

Take actions for repair

-Check wiring, check alternator, check cables and repair or replace if necessary.

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Table 2-2. Diagnostic Trouble Codes

KWP CODE SPN FMI BLINK

CODE Identification

1014 51 6 5 - 9 - 4 Actuator error EGR-Valve: internal error1015 51 5 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error1016 51 7 5 - 9 - 4 Actuator error EGR-Valve; internal error1022 51 6 5 - 9 - 4 Actuator error EGR-Valve; internal error1023 51 5 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error1024 51 3 5 - 9 - 4 Actuator error EGR-Valve; internal error1025 51 4 5 - 9 - 4 Actuator error EGR-Valve; internal error1223 51 5 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) internal error1224 51 6 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error1226 51 3 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error1227 51 3 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error1228 51 4 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error1229 51 4 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6); internal error1230 51 6 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6); internal error1231 51 11 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error1232 51 4 5 - 9 - 4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error935 91 3 2 - 2 - 6 Sensor error accelerator pedal; signal range check high940 91 4 2 - 2 - 6 Sensor error accelerator pedal; signal is below the range976 91 11 2 - 2 - 6 Plausibility error between APP1 and APP2 or APP1 and idle switch472 94 3 2 - 1 - 6 Sensor error low fuel pressure; signal range check high473 94 4 2 - 1 - 6 Sensor error low fuel pressure; signal range check low474 94 1 2 - 1 - 6 Low fuel pressure; system reaction initiated464 97 3 2 - 2 - 8 Sensor error water in fuel; signal range check high465 97 4 2 - 2 - 8 Sensor error water in fuel; signal range check low

1157 97 12 2 - 2 - 8 Water in fuel level prefilter; maximum value exceeded732 100 3 2 - 2 - 4 Sensor error oil pressure; signal range check high733 100 4 2 - 2 - 4 Sensor error oil pressure sensor; signal range check low736 100 1 2 - 3 - 1 Low oil pressure; system reaction initiated737 100 1 2 - 3 - 1 Low oil pressure; system reaction initiated88 102 2 2 - 2 - 3 Charged air pressure; system reaction initiated89 102 2 2 - 2 - 3 Charged air pressure; system reaction initiated

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CODE Identification

776 102 3 2 - 2 - 3 Sensor error charged air pressure; signal range check high777 102 4 2 - 2 - 3 Sensor error charged air pressure; signal range check low994 105 3 1 - 2 - 8 Sensor error charged air temperature; signal range check high995 105 4 1 - 2 - 8 Sensor error charged air temperature; signal range check low996 105 0 2 - 3 - 3 Charged air cooler temperature; system reaction initiated997 105 0 2 - 3 - 3 Charged air cooler temperature; system reaction initiated752 107 0 1 - 3 - 6 Air filter differential pressure; system reaction initiated96 110 3 2 - 2 - 5 Sensor error coolant temperature; signal range check high97 110 4 2 - 2 - 5 Sensor error coolant temperature; signal range check low98 110 0 2 - 3 - 2 Coolant temperature; system reaction initiated99 110 0 2 - 3 - 2 Coolant temperature; system reaction initiated101 111 1 2 - 3 - 5 Coolant level too low877 157 3 1 - 4 - 7 Sensor error rail pressure; signal range check high878 157 4 1 - 4 - 7 Sensor error rail pressure; signal range check low45 168 3 3 - 1 - 8 Sensor error battery voltage; signal range check high46 168 4 3 - 1 - 8 Sensor error battery voltage; signal range check low47 168 2 3 - 1 - 8 Battery voltage; system reaction initiated

1180 168 0 3 - 1 - 8 Physikal range check high for battery voltage1181 168 1 3 - 1 - 8 Physikal range check low for battery voltage388 190 0 2 - 1 - 4 Engine speed above warning threshold (FOC-Level 1)389 190 0 2 - 1 - 4 Engine speed above warning threshold (FOC-Level 1)390 190 11 2 - 1 - 4 Engine speed above warning threshold (FOC-Level 2)391 190 14 2 - 1 - 4 Speed detection; out of range, signal disrupted419 190 8 2 - 1 - 2 Speed detection; out of range, signal disrupted420 190 12 2 - 1 - 2 Speed detection; out of range, signal disrupted421 190 2 2 - 1 - 3 Offset angle between crank- and camshaft sensor is too large422 190 8 2 - 1 - 2 Speed detection; out of range, signal disrupted423 190 12 2 - 1 - 2 Speed detection; out of range, signal disrupted376 630 12 2 - 8 - 1 Access error EEPROM377 630 12 2 - 8 - 1 Access error EEPROM378 630 12 2 - 8 - 1 Access error EEPROM

Table 2-2. Diagnostic Trouble Codes (Cont'd)

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CODE Identification

84 639 14 2 - 7 - 1 CAN-Bus 0 "BusOff-Status"568 651 5 1 - 5 - 4 Injector 1 (in firing order); interruption of electric connection580 651 3 1 - 5 - 4 Injector 1 (in firing order); short circuit569 652 5 1 - 5 - 5 Injector 2 (in firing order); interruption of electric connection581 652 3 1 - 5 - 5 Injector 2 (in firing order); short circuit570 653 5 1 - 5 - 6 Injector 3 (in firing order); interruption of electric connection582 653 3 1 - 5 - 6 Injector 3 (in firing order); short circuit571 654 5 1 - 6 - 1 Injector 4 (in firing order); interruption of electric connection583 654 3 1 - 6 - 1 Injector 4 (in firing order); short circuit956 677 3 5 - 1 - 2 Starter relay; short circuit957 677 4 5 - 1 - 2 Starter relay; short circuit958 677 5 5 - 1 - 2 Starter relay; no load error959 677 12 5 - 1 - 2 Starter relay; powerstage over temperature960 677 3 5 - 1 - 2 Starter relay; short circuit961 677 4 5 - 1 - 2 Starter relay; short circuit305 898 9 1 - 1 - 8 T imeout Error of CAN-Receive-Frame TSC1TE; Setpoint946 1079 13 2 - 8 - 2 Sensor supply voltage monitor 1 error (ECU)947 1080 13 2 - 8 - 2 Sensor supply voltage monitor 2 error (ECU)121 1109 2 3 - 4 - 1 Engine shut off demand ignored85 1231 14 2 - 7 - 1 CAN-Bus 1 "BusOff-Status"747 1237 2 1 - 4 - 5 Override switch; plausibility error825 523009 9 2 - 5 - 3 Pressure Relief Valve (PRV) reached maximun allowed opening count833 523009 10 2 - 5 - 3 Pressure relief valve (PRV) reached maximun allowed open time565 523350 4 1 - 5 - 1 Injector cylinder-bank 1; short circuit566 523352 4 1 - 5 - 2 Injector cylinder-bank 2; short circuit567 523354 12 1 - 5 - 3 Injector powerstage output defect826 523470 2 1 - 4 - 6 Pressure Relief Valve (PRV) forced to open827 523470 2 1 - 4 - 6 Pressure Relief Valve (PRV) forced to open828 523470 12 1 - 4 - 6 Pressure Relief Valve (PRV) forced to open; system reaction initiated829 523470 12 1 - 4 - 6 Pressure Relief Valve (PRV) forced to open; system reaction initiated830 523470 14 1 - 4 - 6 Pressure Relief Valve (PRV) is open


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CODE Identification

831 523470 11 1 - 4 - 6 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range832 523470 11 1 - 4 - 6 Rail pressure out of tolerance range876 523470 7 1 - 4 - 6 Maximum rail pressure in limp home mode exceeded (PRV)980 523550 12 5 - 1 - 5 T50 start switch active for too long948 523601 13 2 - 8 - 2 Sensor supply voltage monitor 3 error (ECU)387 523612 12 5 - 5 - 5 Internal software error ECU612 523612 12 5 - 5 - 5 ECU reported internal software error613 523612 12 5 - 5 - 5 ECU reported internal software error614 523612 12 5 - 5 - 5 ECU reported internal software error615 523612 12 5 - 5 - 5 ECU reported internal software error616 523612 12 5 - 5 - 5 ECU reported internal software error617 523612 12 5 - 5 - 5 ECU reported internal software error618 523612 12 5 - 5 - 5 ECU reported internal software error619 523612 12 5 - 5 - 5 ECU reported internal software error620 523612 12 5 - 5 - 5 ECU reported internal software error621 523612 12 5 - 5 - 5 ECU reported internal software error623 523612 12 5 - 5 - 5 ECU reported internal software error624 523612 12 5 - 5 - 5 ECU reported internal software error625 523612 12 5 - 5 - 5 ECU reported internal software error627 523612 12 5 - 5 - 5 ECU reported internal software error628 523612 12 5 - 5 - 5 ECU reported internal software error637 523612 12 5 - 5 - 5 ECU reported internal software error973 523612 14 5 - 5 - 5 Softwarereset CPU974 523612 14 5 - 5 - 5 Softwarereset CPU975 523612 14 5 - 5 - 5 Softwarereset CPU

1170 523612 12 5 - 5 - 5 ECU reported internal software error856 523613 0 1 - 3 - 4 Rail pressure disrupted857 523613 0 1 - 3 - 4 Rail pressure disrupted858 523613 0 1 - 3 - 4 Rail pressure disrupted859 523613 0 1 - 3 - 4 Rail pressure disrupted861 523613 1 1 - 3 - 4 Minimum rail pressure exceeded (RailMeUn3)


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CODE Identification

862 523613 0 1 - 3 - 4 Rail pressure disrupted864 523613 2 1 - 3 - 4 Setpoint of metering unit in overrun mode not plausible592 523615 5 1 - 3 - 5 Metering unit (Fuel-System); open load594 523615 3 1 - 3 - 5 Metering unit (Fuel-System); short circuit to battery595 523615 4 1 - 3 - 5 Metering unit (Fuel-System); short circuit to ground596 523615 3 1 - 3 - 5 Metering unit (Fuel-System); short circuit to battery597 523615 4 1 - 3 - 5 Metering unit (Fuel-System); short circuit to ground122 523698 11 5 - 9 - 1 Shut off request from supervisory monitoring function291 523776 9 1 - 1 - 9 T imeout Error of CAN-Receive-Frame TSC1TE - active292 523777 9 1 - 1 - 9 Passive T imeout Error of CAN-Receive-Frame TSC1TE; Setpoint

559 523895 13 7 - 0 - 6Check of missing injector adjustment value programming (IMA) injector 1 (in firing order)

560 523896 13 7 - 0 - 7check of missing injector adjustment value programming (IMA) injector 2 (in firing order)



834 523906 5 7 - 6 - 1 Electrical fuel pre - supply pump; open load835 523906 12 7 - 6 - 1 Electrical fuel pre - supply pump; powerstage over temperature836 523906 3 7 - 6 - 1 Electrical fuel pre - supply pump; short circuit to battery837 523906 4 7 - 6 - 1 Electrical fuel pre - supply pump; short circuit to ground360 523982 0 7 - 3 - 7 Powerstage diagnosis disabled; high battery voltage361 523982 1 7 - 3 - 7 Powerstage diagnosis disabled; low battery voltage

1505 524057 2 8 - 4 - 3 Electric fuel pump; fuel pressure build up error1669 524108 9 9 - 3 - 2 T imeout error of CAN-Transmit-Frame ComEGRTVActr1679 524109 9 9 - 3 - 3 T imeout error of CAN-Receive-Frame ComRxEGRTVActr


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J. DIAGNOSTIC TROUBLE CODE ( 4L70 TRANSMISSION)

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Figure 2-2. Electrical Schematic,Perkins 2011 (Tier II) Diesel Engine,

Page 1 of 3

K. ELECTRICAL SCHEMATICS

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Figure 2-3. Electrical Schematic,Deutz (Tier 4i) Diesel Engine,

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Figure 2-4. Electrical Schematic,Deutz 2.9 L4 (Tier 4) Diesel Engine,

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Figure 2-4. Electrical Schematic,Deutz 2.9 L4 Tier 4) Diesel ( Engine,

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Figure 2-5. Electrical Schematic,Ford 2.5L Gasoline Engine, With

C6 Transmission, Page 1 of 3

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Figure 2-5. Electrical Schematic,Ford 2.5L Gasoline Engine With


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Figure 2-5. Electrical Schematic,Ford 2.5L Gasoline Engine With


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Figure 2-6. Electrical Schematic,Ford 2.5L Gasoline Engine With4L70 Transmission, Page 1 of 4

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C4-8CHKTRNS<SHEET 1>

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Figure 2-7. Electrical Schematic,Ford 2.5L LP Engine With C6

Transmission, Page 1 of 3

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Figure 2-8. Electrical Schematic,Ford 2.5L LP Engine With 4L70


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Figure 2-9. Electrical Schematic,Cummins B3.3 Diesel Engine,

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Figure 2-10. Electrical Schematic,Kubota Diesel Engine, Page 1 of 3

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L. HYDRAULIC SCHEMATICS

Figure 2-11. Hydraulic Schematic,Perkins Diesel Engine

ITEM DESCRIPTIONPART

NUMBER REQ’D

1 T6-5011-101 PUMP & RESERVOIR ASSEMBLY 1

2 660-1-3028 CHARLYNN STEER VALVE 1

3 TM1--2-8032 STEERING CYLINDER 1

ENGINE

1000 PSI

4 GPM

PR

P

T

L R

3

2

1

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Figure 2-12. Hydraulic Schematic,Deutz (Tier 4i) Diesel Engine


NUMBER REQ’D

1 660-1-3028 CHARLYNN STEERING VALVE 1

2 TM1-ND-8084 HYDRAULIC PUMP 1

3 MT-2-1126 HYDRAUILC RESERVOIR 1

ENGINE

1000 PSI

4 GPM

PR

P

T

L R

4

1

2

3

4 TM1-2-8032 STEERING CYLINDER 1

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Figure 2-13. Hydraulic Schematic,Deutz 2.9 L4 (Tier 4) Diesel Engine

1

3

ENGINE

1000 PSI

4 GPM


NUMBER REQ’D

1 T6-4900-202 HYDROBOOST ASSEMBLY 1

2 T6-4700-527 HYDRAULIC PUMP 1

3 T6-4800-184 HYDRAULIC RESERVOIR 1

PR

4 T6-4800-186 HOSE, RESERVOIR TO PUMP 1

5 T6-4800-188 HOSE, PUMP TO HYDROBOOST 1

6 T6-4800-189 HOSE, HYDROBOOST PB TO RESERVOIR 1

7 T6-4800-190 HOSE, HYDROBOOST DRAIN TO RESERVOIR 1

4

5

7

6

8

8 T6-4800-187 HOSE, PUMP TO RESERVOIR, EXCESS FLOW 1

2

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Figure 2-14. Hydraulic Schematic,Deutz 2.9 L4 (Tier 4) Diesel Engine

With Power Steering

ENGINE

1000 PSI

4 GPM

PR

P

T

L R

5

4


NUMBER REQ’D


2 T6-4700-527 HYDRAULIC PUMP 1

3 T6-4800-184 HYDRAULIC RESERVOIR 1


1

3

5 TM1-2-8032 POWER STEERING CYLINDER 1

6 T6-4800-186 HOSE, RESERVOIR TO PUMP 1

7 T6-4800-188 HOSE, PUMP TO HYDROBOOST 1

8 T6-4800-190 HOSE, HYDROBOOST DRAIN TO RESERVOIR 1

9 T6-4900-134 HOSE, HYDROBOOST TO CHARLYNN VALVE 1

10 T6-4800-194 HOSE, STEER VALVE T TO RESERVOIR 1

11 T6-4800-187 HOSE, PUMP TO RESERVOIR, EXCESS FLOW 1

7

910

11

12

13

6

2

12 660-1-1338 HOSE, STEER VALVE L TO STEER CYLINDER DEAD SIDE 1

13 T6-5120-111 HOSE, STEER VALVE R TO STEER CYLINDER ROD SIDE 1

8

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Figure 2-15. Hydraulic Schematic,Ford 2.5L Gasoline Engine

2

1

ENGINE

1300 PSI

PT

L

R3

4


NUMBER REQ’D

1 1

2 ENG-MA-27-PS-2 HYDRAULIC PUMP 1

4

ENG-MA-27-PS-1

STEER CYLINDER 1

3 660-1-3028 CHARLYNN POWER STEERING VALVE 1

RESERVOIR

TM1-2-8032

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Figure 2-16. Hydraulic Schematic WithFilter, Ford 2.5L Gasoline Engine

2

1

ENGINE

1300 PSI

NOTES: CHARLYNN POWER STEERING WITH FILTER (OPT-BRA-028)

5

P

T

L R

4

3

6


NUMBER REQ’D

1 1

2 ENG-MA-27-PS-2 HYDRAULIC PUMP 1

4

ENG-MA-27-PS-1

STEER CYLINDER 1


RESERVOIR

TM1-2-8032

5 HYDROBOOST ASSEMBLY 1T6-4900-202

6 HYDRAULIC RETURN FILTER (10 MICRON) 1660-4-0010-10

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Figure 2-17. Hydraulic Schematic,Cummins (Tier 4i) Diesel Engine

1

NOTES:1. SCHEMATIC FOR MA-35 TOW TRACTOR W/ OPTIONS: SYSTEM INCLUDES CHARLYNN STEERING, HYDROBOOST BRAKES, AND HYDRAULIC FILTER AS STANDARD EQUIPMENT

5

P

T

L R

4

3

6


NUMBER REQ’D

1 1

2 MT-1-1330 HYDRAULIC PUMP 1

4

MT-2-1126

STEER CYLINDER 1


RESERVOIR

TM1-2-8032

5 HYDROBOOST ASSEMBLY 1T6-4900-202

6 HYDRAULIC RETURN FILTER (10 MICRON) 1660-4-0010-10

2

ENGINE

1000 PSI

4 GPM

PR

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Figure 2-18. Hydraulic Schematic,Kubota V3600 Diesel Engine

1

2

3

ENGINE

1000 PSI

4 GPM


NUMBER REQ’D



3 TM1-3-5003 HYDRAUILC RESERVOIR 1

PR

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Figure 2-19. Hydraulic Schematic,Kubota V3600 Diesel Engine With Power

Steering

ENGINE

1000 PSI

4 GPM

PR

P

T

L R

5

4


NUMBER REQ’D



3 TM1-3-5003 HYDRAUILC RESERVOIR 1


1

2

35 TM1-2-8032 POWER STEERING CYLINDER 1

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SECTION 3: REMOVAL / INSTALLATION

A. HOOD (DIESEL UNITS)

1. Removal

(a) Disconnect the two (2) hood latches at forward end of hood and place hood in anopen position.

(b) Remove the three (3) bolts attaching the hood hinge to the forward edge of the firewall and remove hood.

2. Installation

(a) Position hood in an open position on the tractor and mount the hood hinge to theforward edge of the fire wall with three (3) bolts.

(b) Place hood in the closed position and secure it with the two (2) hood latches.

B. ENGINE COMPARTMENT SIDE PANEL (DIESEL UNITS)

1. Removal

(a) Open hood and secure in the open position.

(b) Disconnect air filter hose from air filter assembly by removing hose clamp (ifapplicable).

(c) Remove the four (4) bolts of the side panel which connect the side panel to the firewall and the radiator shroud assembly.

(d) Remove air filter assembly from right side panel by removing the four (4) bolts andnuts (if applicable).

2. Installation

(a) Attach air filter assembly to right side panel by installing the four (4) bolts and nuts (ifapplicable).

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(b) Place side bolts (one aft end of end of the panel in position and install four (4) in eachcorner of panel), thus attaching the panel to the fire wall and the forward panel to theradiator shroud assembly.

(c) Connect air filter hose to air filter assembly and secure with a hose clamp (ifapplicable).

(d) Close hood and secure with the two (2) hood latches.

C. FRONT BUMPER

1. Removal

(a) Remove the four (4) bolts (2 per side) connecting the bumper to the front of therunning boards.

(b) Remove all but two of the bolts connecting the bumper to the frame, leaving the topbolt on each side installed.

WARNING: BUMPER IS TOO HEAVY TO LIFT BY HAND. USE ACRANE OR LIFT RATED FOR AT LEAST 1,000 LBS (453.6 KG) TOLIFT AND SUPPORT THE BUMPER. ALSO, TWO PEOPLE SHOULDBE USED TO STEADY THE BUMPER AS IT IS REMOVED.

(c) With the bumper now connected by only one (1) bolt on each side, remove the NUTONLY from bolt while holding the bumper in position. With one person on each side,hold each side of the bumper at the headlight cutout and remove the remaining boltsby lifting the bumper up and forward.

2. Installation

(a) With one person on each side, lift the bumper into position using a suitable hoist)making sure the bumper side angles are located beneath the front edge of the runningboard. While holding the bumper in this position, insert a bolt on each side in the topbolt hole of the front surface of the bumper and the frame.

(b) Install a nut on both bolts and tighten.

(c) Install the remaining bolts in front bumper, connecting bumper to frame.

(d) Install the four (4) bolts (2 per side) to connect bumper sides to running board.

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D. FRONT FENDER / RUNNING BOARD

1. Removal

NOTE: If the left side front fender/running board is to be removed,disconnect battery cables from battery and remove battery from thebattery box.

(a) Disconnect the headlight wire (wire #106 right headlight; #l07 left light) fromunderneath the fender at the disconnect socket.

(b) Remove the two (2) bolts connecting the front fender to the front bumper.

(c) Remove the bolt connecting the running board to the frame side bracket.

(d) Remove the two (2) bolts connecting the aft end of the running board to the rearfender.

(e) Lift front fender/running board from the tractor.

2. Installation

(a) Place front fender/running board on the tractor and position it so that the fender/running board is resting on the bumper side angle and on the rear fender flange.

(b) Align bolt holes at front and rear of running board and install four (4) bolts.

(c) Install the bolt connecting the running board to the frame side bracket.

(d) Reconnect headlight wire.

(e) Replace and connect battery if applicable.

Note

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E. RADIATOR AND RADIATOR SHROUD ASSEMBLY

1. Removal

(a) Raise the hood all the way back, letting it rest against the steering wheel (diesel unitsonly).

WARNING: USE EXTREME CARE IN REMOVING THE RADIATORCAP. THIS TRACTOR USES A PRESSURIZED COOLING SYSTEM,AND A SUDDEN RELEASE OF PRESSURE CAN CAUSE SERIOUSPERSONAL INJURY. LOOSEN CAP VERY SLOWLY USING A CLOTHSHOP TOWEL AND ALLOW STEAM TO ESCAPE.

(b) Remove radiator cap (see warning above) and drain coolant from radiator by turningradiator drain winged nut counterclockwise.

(c) Disconnect the two (2) transmission cooling lines from the lower portion of theradiator by disconnecting the line connecting nuts (turn counterclockwise) from theelbow fittings attached to the radiator.

(d) Disconnect the two (2) large upper and lower radiator hoses from the radiator byloosening the hose clamps.

(e) Disconnect the running/turn signal light wires at the quick disconnect plugs (ifapplicable).

(f) Remove the four (4) bolts (2 per side) attaching the forward ends of the enginecompartment side panels to the radiator shroud (diesel units only).

(g) Remove the four (4) bolts (two on each side) which attach the radiator shroudmounting brackets to the frame.

(h) Remove the radiator/radiator shroud assembly from tractor, being careful not todamage radiator by hitting it against the fan or other components.

(i) To remove the radiator from the radiator shroud, remove the four (4) bolts (one ineach corner of the radiator) attaching the radiator to the radiator mounts of theshroud.Prope

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2. Installation

(a) Position radiator in shroud by inserting radiator from the rear of the shroud with theradiator filler tube slanting to the rear.

NOTE: When properly positioned the radiator will be resting on theradiator mounts and the filler tube will be aligned with the hole in the topof the shroud.

(b) Insert and install four (4) radiator mounting bolts from the shroud FRONT, thus havingnuts on the radiator side of the installation.

(c) Place radiator/radiator shroud assembly into position on tractor, being careful not todamage radiator, and install assembly to the tractor frame with four (4) bolts (two oneach side).

(d) Connect the two (2) transmission cooling lines to the elbow fittings located on thelower portion of the radiator. (Turn connecting nuts clockwise).

(e) Connect the two (2) large upper and lower radiator hoses to the radiator and securewith hose clamps.

(f) Connect running light/signal light wires to the lights at the quick connect plugs.

(g) Attach the forward ends of the engine side panels to the radiator shroud by installingfour (4) bolts (two on each side) .

(h) Check radiator drain nut and make sure it is CLOSED. (Turn clockwise to close;counterclockwise to open.)

(i) Install coolant and replace filler cap.

(j) Close hood and secure it with the hood latches.

Note

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F. REAR FENDER

1. Removal

(a) Disconnect stoplight wires at the disconnect plugs.

WARNING: REAR FENDERS ARE VERY HEAVY. USE OF ASUITABLE LIFT IS REQUIRED TO PREVENT PERSONAL INJURYOR DAMAGE TO EQUIPMENT.

(b) Position forklift tines or other suitable lift against under-surface of fender directlyabove rear tire.

(c) Remove the two (2) OUTBOARD bolts connecting the seat assembly to the twoshock mounts of the rear fender seat supports. Block up the disconnected side of theseat frame so that a minimum of 2 inches (51 mm) vertical clearance is providedbetween the seat frame and the seat supports of the rear fender.

(d) Remove the bolts connecting the forward edge of the fender to the running board.

(e) Remove the bolts connecting the aft edge of the fender to the frame.

CAUTION: MAKE CERTAIN ALL FASTENERS HAVE BEENREMOVED FROM FENDER PRIOR TO LIFTING IT.

(f) Make sure that adequate clearance is provided, and extract the rear fender fromposition by backing up forklift.

(g) Disconnect forward and aft seat supports (with shock mounts installed) by removingthe four (4) bolts (two per support) connecting them to the inside surface of thefender.

2. Installation

(a) Install the forward (angle shaped) and rear (flat plate) seat supports (with seat shockmounts installed) to the inside surface of the fender with four (4) bolts.

(b) Position forklift on the outboard side of fender and lift fender with forklift tinescentered on fender under-surface.

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CAUTION: BEFORE POSITIONING FENDER ON TRACTOR,MAKE SURE THAT SEAT IS BLOCKED UP TO ALLOWSUFFICIENT CLEARANCE BETWEEN SEAT SUPPORTS AND SEATFRAME WHEN THE FENDER IS POSITIONED TO PREVENTDAMAGE TO THE SEAT FRAME.

(c) Carefully position fender to the tractor using forklift to prevent hitting tire and seatframe.

NOTE: Forward edge of rear fender is under aft edge of running boardwhen properly positioned.

(d) Connect aft edge of fender to the frame and front edge of fender to running board.

(e) Remove forklift.

G. SEAT CUSHIONS

1. Back Cushion

(a) Removal: Remove the four (4) bolts that secure the back cushion to the seatassembly.

(b) Installation: Place back cushion in the proper position and align the four (4) holes inthe seat assembly. Install the four (4) bolts, securing the back cushion to the seatassembly.

2. Bottom Cushion

(a) Removal: Lift forward edge of bottom cushion up, past the top edge of the seatassembly cushion toward the front of the tractor. Lift up and out.

(b) Installation: Installation of bottom cushion is the reversal of the removal of the bottomcushion.

Note

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H. SEAT ASSEMBLY

1. Removal

(a) Remove the four (4) OUTBOARD bolts and lock washers that connect the seatframe to the four (4) shock mounts.

NOTE: Do not remove the four (4) INBOARD bolts, which connect theshock mounts to the seat supports of the rear fenders, unless shockmount removal replacement is to be accomplished.

(b) Lift seat assembly from tractor.

2. Installation

(a) Place seat assembly in position with the rear end of the seat frame resting over theaft seat supports.

(b) Install, but DO NOT TIGHTEN, two (2) bolts and lock washers in the two forwardshock mounts.

NOTE: Before installing the two rear bolts, lift rear of seat, checking tomake sure the front shock mounts are not being twisted. If they aretwisted, lower the rear of the seat and loosen the front bolts more.

(c) Lift rear end of seat assembly, install bolts and lock washers in the two aft shockmounts. Tighten bolts.

(d) Tighten the two (2) front mount bolts.

I. BATTERY

1. Removal

(a) Open battery box cover by unscrewing the battery box cover bolt until it disengagesthe battery box.

(b) Remove battery case cover and disconnect battery cables from battery.

(c) Leave battery inside the plastic battery case and remove battery case from tractorusing handles on each side of case.

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(d) Remove battery from battery case.

2. Installation

(a) Carefully place battery inside plastic battery case. Do not drop battery.

(b) Place battery case inside battery box with the terminals of the battery inboard to thetractor.

CAUTION: POSITIVE (+) BATTERY CABLE ENTERS THEBATTERY BOX AFT AND THE NEGATIVE (-) BATTERY CABLEENTERS THE BATTERY BOX FORWARD. CABLES ARE ALSOCODED “POSITIVE (+)” AND ”NEGATIVE (-)”. THE ELECTRICALSYSTEM IS NEGATIVE GROUND. MAKE SURE CABLEINSTALLATIONS TO THE BATTERY ARE CORRECT TO PREVENTDAMAGE TO THE ALTERNATOR.

(c) Connect positive (+) battery cable.

(d) Connect the negative (-) battery cable.

(e) Replace the top to plastic battery case.

(f) Secure the battery box cover with the cover bolt.

J. FUEL CELL / COMPARTMENT ASSEMBLY

1. Removal

WARNING: USE EXTREME CARE IN REMOVAL ANDINSTALLATION OPERATIONS ON THE FUEL CELL/COMPARTMENT TO PREVENT FIRE HAZARDS OR EXPLOSIONS.NO SMOKING, OPEN FLAME, OR USE OF ELECTRICALEQUIPMENT SHOULD BE PERMITTED DURING SUCHOPERATIONS.

(a) Remove the seat assembly (per section above).

(b) Drain fuel from fuel cell into appropriate container.

(c) Disconnect fuel line(s) at fuel cell.

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(d) Remove the fuel filler cap and the fuel compartment cover and rubber cushions insidecompartment.

(e) Remove fuel cell from compartment taking care not to bend or break fittings.

2. Installation

(a) Remove rubber matting in bottom of cell.

(b) Place the fuel cell in the compartment so that the fuel line fittings match the holes inthe compartment.

NOTE: When installing new fuel cells in early serial tractors, it may benecessary to cut out openings in the compartment walls to match therelocated fittings. In addition, a cutout in the compartment cover may beneeded for visual access to the fuel gauge.

(c) Reposition rubber cushions.

(d) Connect fuel line(s).

(e) Make certain fuel drain valve is closed.

(f) Reinstall compartment cover.

(g) Reinstall seat (per section above).

K. TIRES AND WHEELS

1. Tire and Wheel Removal/Installation

CAUTION: DO NOT REMOVE THE HUB NUT FOR WHEELREMOVAL. HUB NUT IS REMOVED FOR AXLE OR BRAKEREPAIR ONLY.

(a) Jack the rear wheel off the ground using normal jacking procedures (i.e., chock othertires, engage parking brake, etc.).

(b) Remove the eight (8) lug nuts that secure the wheel to the drive axle hub and removethe wheel.

(c) Remove the tire for repair or replacement as required, using standard tire tools.

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(d) Install the new or repaired tire onto the wheel.

(e) Install the wheel to the hub with the eight (8) lug nuts and torque to 125 ft-lb(169.5 Nm).

2. Tire and Wheel Removal/Installation on Tractors Equipped with Split Wheels

(a) Jack the front wheel off the ground using normal jacking procedures (i.e., check othertires, engage parking brake, etc.).

(b) Deflate to the tire prior to removing the lug nuts!

WARNING: FAILURE TO DO SO MAY RESULT IN SEVERE INJURYOR DEATH.

(c) Remove the five (5) lug nuts which secure the wheel to the steer axle hub andremove the wheel.

WARNING: DO NOT ATTEMPT TO REMOVE THE TIRE BYDISASSEMBLING THE SPLIT WHEEL WITHOUT FIRSTCOMPLETELY DEFLATING TIRE.

(d) To remove the tire, deflate the tube completely. After the tube is deflated, remove theeight (8) attachment bolts, nuts and lock washers that attach the two wheel halvestogether.

(e) Repair or replace the tube and tire as required.

(f) To mount the new or repaired tire and tube, position the tube in the tire and place thetire on the wheel half, installing the tube valve stem in its hole.

(g) Connect the wheel halves together using the eight (8) attachment bolts, making surethe halves are not pinching the tube. Torque to 35 ft-lb (47.5 Nm).

(h) Inflate tire and mount the wheel to the steer axle hub with the five (5) lug nuts andtorque to 125 ft-lb (169.5 Nm).

3. Tire and Wheel Removal/Installation on Tractors with Standard Wheels

(a) Jack the front wheel off the ground using normal jacking procedures (i.e., chock othertires, engage parking brake, etc.).

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(b) Remove the five (5) lug nuts which secure the wheel to the steer axle hub andremove the wheel.

(c) Remove the tire for repair or replacement as required, using standard tire tools.

(d) Install the new or repaired tire on to the wheel.

(e) Install the wheel to the hub with the five (5) lug nuts and torque to 125 ft-lb(169.5 Nm).

L. DRIVE SHAFT

1. Removal

(a) Chock the wheels.

Figure 3-1. Drive Shaft Assembly With C6 Transmission

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(b) Disconnect the ear section of the drive shaft by removing the four (4) bolts and nutsattaching the drive shaft coupling plate to the drive axle reduction gear input shaftflange. (See Figure 3-1 and Figure 3-2).

(c) Disconnect the front section of the drive shaft by removing the four (4) bolts attachingthe u-joint saddles to the transmission/parking brake drum installation (Ford with C6).See Figure 3-1.Disconnect the front section of the driveshaft on units equipped with GM 4L70transmissions by slipping the yoke out of the tailshaft of the transmission.See Figure3-2)

2. Installation

(a) Position the front section of the drive shaft on the transmission/parking brake druminstallation, so that all four (4) bolt holes are properly aligned. Secure the front section

Figure 3-2. Drive Shaft Assembly With 4L70 Transmission

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(b) Attach the host to the left and right sides of the rear portion of the frame. Tightenand lock the hoist, but DO NOT lift the rear wheels off the ground.

(c) Chock both front wheels.

using four (4) bolts (Ford with C6). See Figure 3-1.For units equipped with the GM 4L70, carefully insert the yoke into the tailshaft ofthe transmission. See Figure 3-2.

(b) Attach the wheels, release the parking brake and shift the transmission to neutral.

(c) Rotate the drive shaft until all four (4) bolt holes of the drive shaft coupling plate arealigned with those of the drive axle reduction gear input shaft flange.

(d) Install the drive shaft using four (4) bolts and nuts. Torque to 35 ft-lb (47.5 Nm).

M. DRIVE AXLE, SHOCKS AND MOUNTING ASSEMBLIES

1. Removal

(a) Position a heavy duty chain hoist at the rear end of the tractor so that when the driveaxle (with wheels installed) is disconnected from the tractor, the axle may be rolledout from under the tractor to the rear.

Figure 3-3. Drive Axle Mounting Assemblies

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(d) Disconnect the brake line(s) from the “T” joint(s) at the center of the axle and drainbrake line(s).

(e) Place a block under the drive reduction gear housing to prevent the axle from rotatingwhen the axle is disconnected from the tractor.

(f) Disconnect the drive shaft from the reduction gear input shaft flange by removingfour (4) bolts.

(g) Disconnect the drive axle mounting bars from the mounting assemblies.(See Figure 3-3.)

(h) To remove the four (4) rubber drive axle shocks from the four (4) axle mountingassemblies, drive the shocks out the bottom of the mounting assemblies by using arubber mallet on the top side of the shocks.

(i) Disconnect the mounting assemblies (two on each side) as required from the frame.

(j) Hoist the rear of the tractor approximately 16" (406 mm) and lock the hoist in position,thereby providing clearance for drive axle roll out.

(k) Remove the block under the axle reduction gear housing and roll the axle out fromunder the tractor.

(l) Lower the tractor frame rear end onto blocks approximately 14" (356 mm) in height(or approved jack stands) until drive axle installation.

2. Installation

(a) Install each drive axle mounting assembly to the frame using two (2) bolts to attachthe vertical surface of the mounts to the outboard side of the frame and using two (2)bolts to attach the inboard horizontal surface of the mounts to the lower portion of theframe.

(b) Install four (4) rubber shocks (two on each side) into the drive axle mountingassemblies by driving the shocks into their mounting holes from the UNDERSIDE ofthe mounts.

NOTE: Coat the surfaces of the rubber shocks with a rubber lubricant(American Grease Stick Company RU-GLYDE, or equivalent) to aid inshock installation.

(c) Hoist the tractor approximately 16" (406 mm) and lock the hoist in position with the

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support blocks. Move the axle into position and block the axle reduction gear housing.

(d) On tractors equipped with a removable mounting bar, make certain the end of the barwith greater hole spacing is forward.

(e) Using the chain hoist, lower the tractor frame onto the axle and adjust the axle untilthe bolt holes for attaching the axle mounting bars to the mounting assemblies arealigned.

(f) Remove the block supporting the axle reduction gear housing.

(g) Install four (4) bolts (two on each side) to attach the axle mounting bars to themounting assemblies.

(h) Slide the rear section of the drive shaft into the front section of the drive shaft andconnect the rear drive shaft to the drive axle reduction gear input shaft flange withfour (4) bolts.

(i) Remove the chain hoist.

(j) Connect the brake line(s) to the “T” joint(s) on the axle.

(k) Add brake fluid to master cylinder, purging brake system of air, following theprocedure in brake overhaul section.

(l) Remove chocks from front wheels.

N. TRANSMISSION/TORQUE CONVERTER (GASOLINE AND DIESEL)

1. Transmission Removal

(a) Disconnect the battery cables from the battery.

(b) Disconnect the drive shaft from the transmission/parking brake drum installation perprocedure in specific section.

(c) Continue removal following the manufacturer’s procedure.

2. Transmission Installation

(a) Install the transmission/torque converter assembly following the manufacturer’s

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installation procedure.

(b) Install the drive shaft, following the procedure in the specific section.

(c) Connect the battery cables to the battery.

O. ENGINE / TRANSMISSION

1. Removal


(b) Remove the front bumper plate following procedure of the specific section.

(c) Remove the engine compartment side panels by removing the eight (8) panelattachment bolts (four (4) bolts on each panel. (If applicable.)

(d) Drain the radiator and remove the radiator and shroud following the procedure of thespecific section.

(e) Drain the oil from the engine (if required).

(f) Remove the exhaust pipe from the engine and muffler as described in the specificsection.

(g) Disconnect the engine (or transmission) to frame ground cable from the engine byremoving one (1) bolt.

(h) Disconnect wire connected to the temperature sending unit.

(i) Disconnect the cable connected to the starter.

(j) Disconnect throttle and modulator cables from engine and transmission (units with C6Transmission and Perkins, Deutz Tier 4i, Cummins and Kubota).

(k) Disconnect the transmission hoses/lines at the transmission.

(l) Disconnect the wires attached to the alternator.

(m) Disconnect the two (2) headlight wires from the connections under the front fendersand remove retaining clips.

(n) If horn is mounted on frame, disconnect wire from horn and remove horn.

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(o) Disconnect the battery ground cable attached to the engine near the steering sector.

(p) Remove the oil filter and 90º adaptor (if adaptor is present).

(q) Disconnect wire from the oil pressure sending unit.

(r) Disconnect wire from the oil pressure/timer switch, if so equipped.

(s) Close the fuel line shut-off valve located under the floor plate near the forwardportion of the fuel cell, on tractors so equipped.

(t) Disconnect the metal fuel line from the rubber line connector line near the fuel pumpand plug the line.

(u) Following the procedure of the specific section, disconnect the drive shaft from thetransmission/parking brake drum installation.

(v) Disconnect the parking brake linkage straps from the parking brake lever by removingthe attachment bolt.

(w) Remove the parking barke lever from parking brake transmision mount (if parkingbrake installed on transmission)

(x) Disconnect wires from the positive (+) terminal of the coil and wire from the negativeside of the coil and distributor connector.

(y) Disconnect the vacuum hose from the vacuum modulator valve on the transmission.

(z) Disconnect the vacuum hose from the vacuum power brake booster.

(aa) Remove the connecting rod from the transmission and bell crank by removing thetwo (2) clevis pins (upper and lower) on tractors so equipped. Do not changeadjustment on connecting rod, on tractors so equipped.

(bb) Make sure the shifter is in neutral and disconnect the shifter cable assembly from thetransmission.

(cc) Attach a chain hoist to the engine/transmission.

(dd) Remove the two (2) rear engine mounting bolts and the bolt connecting the frontengine mount to the frame, on tractors so equipped.

(ee) Remove two (2) nuts from the engine mounts and the two (2) nuts from thetransmission mount.

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NOTE: At this point, all engine/transmission interfaces to the frameshould have been disconnected or removed. Carefully move all wiresback over the fire wall and check all areas for engine/transmissionremoval clearance.

(ff) Remove the assembly by hoisting assembly up and forward.

2. Installation

(a) Lower the engine/transmission into the tractor with a chain hoist so that the engine isresting on the engine mounts.

(b) Install the two (2) rear engine mounting bolts and the bolt connecting the front enginemount to the frame, on tractors so equipped.

(c) Install the two (2) nuts on the engine mounts and two (2) nuts on the transmissionmount.

(d) Remove the chain hoist from the engine.

(e) Install connecting rod to transmission and bellcrank using two (2) clevis pins (upperand lower) on tractors so equipped. Adjust rod if needed.

(f) Make sure the shifter is in neutral and connect the shifter cable assembly to thetransmission.

(g) Connect the vacuum hose to the vacuum power brake booster.

(h) Connect the vacuum hose to the vacuum modulator valve on the transmission.

(i) Connect wires to the positive (+) terminal of the coil and wire to the negative side ofthe coil and distributor connector.

(j) Install parking brake lever on transmission parking brake bracket (if parking brakelever installed on transmission)

(k) Connect the parking brake linkage straps to the parking brake lever using anattachment bolt, washers and nut.

(l) Following the procedure of the specific section, install the front portion of the driveshaft.

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(m) Connect the metal fuel line to the rubber connector line near the fuel pump and openthe fuel shut-off valve under the floor plate, on tractors so equipped.

(n) Connect wire to the oil pressure sending unit.

(o) Connect wire to the oil pressure/timer switch, if so equipped.

(p) Install the oil filter (if removed).

(q) Following the procedure of the specific section, install the steering sector and columnand steering wheel if removed.

(r) Connect the battery ground cable to its attachment to the engine near the steeringsector.

(s) Connect the two (2) headlight wires to the lights by plugging in the wires to theconnectors under each front fender.

(t) Install the wires to the alternator.

(u) Connect coolant hoses.

(v) Connect vacuum line (C6 transmission).

(w) Install the throttle and modulator cables to the engine and transmission (units with C6transmission and Perkins, Deutz Tier 4i, Cummins and Kubota).

(x) Install the horn (if removed) and connect wire to the horn.

(y) Install the electrical cable to the starter.

(z) Connect wire to the fast idle switch on the carburetor.

(aa) Connect wire to the temperature sending unit.

(bb) Install the engine/transmission-to-frame ground cable to the right side of the engine byusing one (1) mounting bolt.

(cc) Install the exhaust pipe to the engine and muffler.

(dd) Install the radiator and shroud.

(ee) Install the engine side panels with eight (8) attachment bolts.

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(ff) Install the front bumper plate.

(gg) Connect battery cables to the battery.

(hh) Add engine oil and/or transmission fluid and engine coolant as required.

P. PERKINS DIESEL ENGINE / TRANSMISSION

1. Removal


(b) Remove the front bumper plate following the procedure of the specific section.

(c) Disconnect the air filter hose from the intake manifold, and plug end.

(d) Remove the engine compartment side panels by removing the eight (8) panelattachment bolts [four (4) bolts on each panel].

(e) Drain the radiator and remove the radiator and shroud following the procedure of thespecific section.

(f) Remove the exhaust pipe from the engine and muffler as described in the specificsection.

(g) Disconnect the engine to frame ground cable from the engine by removing one (l)bolt.

(h) Disconnect the wire from the oil pressure sending unit.

(i) Disconnect wire connected to the temperature sending unit.

(j) Disconnect the wires connected to the fuel shutdown solenoid on the injector pump.

(k) Disconnect wire from the oil pressure/timer switch.

(l) Disconnect the throttle linkage cable from the injector pump by removing the cablehold-down bolt on the throttle cable bracket and disengage the snap-out ballconnection from the linkage.

(m) Disconnect the coolant lines at the transmission.

(n) Disconnect the wires attached to the alternator.

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(o) Disconnect the wire from the glow plug.

(p) Disconnect the two (2) headlight wires from the connections under the front fendersand remove retaining clips.

(q) Disconnect the battery ground cable attachment to the engine near the steeringsector.

(r) Following the procedure of the specific section, remove the steering wheel, columnand steering attachment bolt (if needed for clearance).

(s) Disconnect the metal return fuel line from the rubber connector line.

(t) Disconnect the metal fuel line from the rubber connector line from the fuel pump andplug the line.

(u) Following the procedure of the specific section, disconnect the drive shaft from thereduction gear input shaft flange of the drive axle.

(v) Remove parking brake lever.

(w) Disconnect the vacuum hose from the vacuum power brake booster.

(x) Make sure the shifter is in neutral and remove the shifter cable assembly from thetransmission.

(y) Attach a chain hoist to the engine/transmission.

(z) Remove the four (4) front engine mounting bolts and the four (4) bolts connecting thecenter engine mount to the transmission support.

(aa) Remove the two (2) nuts from the transmission mount.

NOTE: At this point, all engine/transmission interfaces to the frameshould have been disconnected or removed. Carefully move all wiresback over the fire wall and check all areas for engine/transmissionremoval clearance.

(bb) Remove the assembly by hoisting assembly up and forward.

2. Installation

(a) Lower the engine/transmission into the tractor with a chain hoist so that the engine is

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resting on the engine mounts.

(b) Install the four (4) front engine mounting bolts and the four (4) bolts connecting thecenter engine mount to the transmission support.

(c) Remove the chain hoist from the engine.

(d) Make sure the shifter is in neutral and connect the shifter cable assembly to thetransmission.

(e) Connect the vacuum hose to the vacuum power brake booster.

(f) Install the parking brake lever.

(g) Following the procedure of the specific section, install the rear portion of the driveshaft.

(h) Connect the metal return fuel line to the rubber connector line.

(i) Connect the metal fuel line to the rubber connector line from the fuel pump.

(j) Connect the wires to the fuel shutdown solenoid on the injector pump.

(k) Connect wire to the oil pressure sending unit.

(l) Connect wire to the temperature sending unit.

(m) Connect wire to the oil pressure/timer switch, if so equipped.

(n) Following the procedure of the specific section, install the steering sector, column andsteering wheel.

(o) Connect the battery ground cable to its attachment to the engine near the steeringsector.

(p) Connect the two (2) headlight wires to the lights by plugging in the wires to theconnectors under each front fender.

(q) Install the wires to the alternator.

(r) Attach coolant lines to the transmission.

(s) Install the throttle linkage cable to the injector pump at the snap-out ball connectionand secure it to the cable mounting bracket with the retaining clip and bolt.

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(t) Connect the wire to the glow plug.

(u) Install the electrical cable to the starter.

(v) Install the engine-to-frame ground cable by using one (1) mounting bolt.

(w) Install the exhaust pipe to the engine and muffler.

(x) Install the radiator and shroud.

(y) Install the engine side panels with eight (8) attachment bolts.

(z) Remove plug and connect the air filter hose to the intake manifold.

(aa) Install the front bumper plate.

(bb) Connect battery cables to the battery.

(cc) Add engine oil and/or transmission fluid and engine coolant as required.

Q. SHIFTER

1. Removal

(a) Make sure the ignition switch is in the “off” position.

(b) Disconnect battery.

(c) Remove the shifter cover by removing the two (2) hex head bolts on the right side ofthe shifter.

(d) Disconnect the shifter cable assembly from the shifter by removing the nut that holdsthe trunnion to the shifter lever plate.

(e) Disconnect the five (5) shifter wires.

(f) Remove the shifter by removing the two (2) Allen head cap screws located under thesteering column bracket, which secure the shifter to the bracket.

2. Installation

(a) Place the (new) shifter in the installed position and secure it to the steering column

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bracket with the two Allen head cap screws installed from the underside of thebracket.

(b) Install the trunnion (which is on the upper end of the shifter connecting rod or theshifter cable assembly) in the second hole on the aft edge of the shifter lever plateand secure with nut.

(c) Move lever to forward, neutral, and reverse position, and check the shift control leveron the transmission by manual feel to see if it is correct in each position. Ifadjustment is needed, adjust as noted in step 3 below.

NOTE: No adjustment is necessary when shifter cable assembly is used.

(d) Connect the green wire to wire 118, the white wire to wire 117, the blue wire to wire#89, red wire to #11, and black to #12 with backup lights.

(e) Attach shifter cover to shifter with two (2) hex head bolts.

(f) Connect battery.

3. Adjustment

(a) Place transmission in neutral and adjust the length of the cable to fit loosely in thetransmission shift control lever.

(b) Move hand lever to forward and reverse position and adjust the cable for best fit in allthree positions.

R. ACCELERATOR PEDAL AND THROTTLE CONTROL CABLE (IF EQUIPPED)

1. Removal/Installation

(a) Remove the two (2) bolts attaching the hinged mounting plate of the pedal to the floorplate.

(b) Disconnect the pedal throttle control arm from the underside of the pedal by removingtwo (2) nuts.

(c) Install the new accelerator pedal to the throttle control arm with two (2) attachmentnuts.

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(d) Secure the hinged mounting plate of the pedal to the floor plate with two (2) mountingbolts.

2. Throttle Control Cable Removal/Installation

(a) Remove the throttle linkage cable from the mounting angle at the bottom of the firewall by removing the attaching bolt.

(b) Disengage the snap-out ball connection of the cable from the throttle linkageconnector arm of the accelerator pedal.

(c) Disconnect the engine end of the throttle linkage cable by removing the bolt andretainer clip securing the cable to the cable mount on the engine.

(d) Disengage the snap-out ball connection of the cable from the throttle linkage assemblyon the injector pump.

(e) Snap in the ball connector to the injector pump throttle linkage fitting.

(f) Install the pedal end of the cable to the mounting angle at the bottom of the fire wallby bolting the cable to the angle.

(g) Snap the cable ball connector onto the fitting of the linkage connector arm of theaccelerator pedal. Check for full stroke and free travel.

S. TAIL PIPE / MUFFLER / EXHAUST PIPE

1. Removal

(a) Remove the U-bolt securing the tail pipe to the tail pipe retainer strap at the rear endof the tractor frame.

(b) Remove the U-bolt securing the tail pipe to the muffler and extract the tail pipe fromthe muffler.

(c) Remove the exhaust manifold shroud from the exhaust manifold by removing the two(2) attachment bolts, thus providing additional clearance for exhaust pipe removal(Gasoline only).

(d) Loosen, but DO NOT REMOVE, the two (2) bolts (gasoline engine or the three (3)nuts and bolts on the diesel engine) connecting the exhaust pipe to the exhaust

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manifold.

(e) Remove the U-bolt securing the muffler/exhaust pipe connection.

(f) From underneath the tractor, disengage the muffler from the exhaust pipe by pushingup and twisting the muffler.

NOTE: On persistent connections, it may be necessary to loosen themuffler/ exhaust pipe connection using a chisel to expand the mufflerintake pipe.

(g) Remove the exhaust pipe by disconnecting the two (2) bolts (gasoline engine or thethree (3) nuts and bolts on the diesel engine) attaching the pipe to the exhaustmanifold.

2. Installation

(a) Slide the exhaust pipe retaining collar onto the exhaust pipe so that the inside(concave) surface of the collar will be toward the manifold.

(b) Loosely install the exhaust pipe to the exhaust manifold, but DO NOT TIGHTEN thetwo (2) attachment bolts (gasoline or the three (3) nuts and bolts on the diesel).

(c) Position the muffler so that the exhaust outlet is over the drive axle and the intake endis facing the exhaust pipe.

(d) Slide the muffler inlet pipe over the exhaust pipe and secure the connection with a U-bolt.

(e) Tighten the two (2) bolts (gasoline or the three (3) nuts and bolts on the diesel)connecting the exhaust pipe to the manifold.

(f) Attach the tail pipe to the muffler and secure the connection with a U-bolt.

(g) Secure the aft end of the tail pipe to the tail pipe retainer strap with a U-bolt.

T. STEER AXLE

NOTE: If leaf springs and steer axle are to be removed, remove as aunit and refer to the specific section.

Note

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1. Removal

(a) Engage the parking brake.

(b) Disconnect battery.

(c) Jack up tractor front end using the forward frame plate as a jacking point and secureon approved jack stands. Place retaining block under both sides of axle betweensprings and hubs.

NOTE: DO NOT lower axle down on blocks. Blocks are to retain eachside of axle as axle is detached from tractor.

(d) Remove the two (2) front wheels by removing the five (5) lug nuts securing eachwheel to the axle hub.

(e) Disconnect the steering linkage rod (located on left side of the tractor) from the steeraxle spindle arm by removing the cotter pin, nut and lock washer. Tap the linkage rodbolt out of the spindle arm attach hole with a rubber head mallet.

(f) Disconnect one side of the axle from the tractor by removing the two (2) U-bolts andattach plate connecting the axle to the leaf spring and allow axle to rest on theretaining block.

(g) Repeat step (f) on the other side of axle.

(h) Lower each end of axle to the ground by removing the blocks and remove axle fromunderneath tractor.

2. Installation

(a) Position axle under tractor and place axle on retaining blocks located between leafsprings and axle hubs.

(b) Place the attach plate on the upper surface of the leaf spring so that the nut of theleaf spring assembly bolt is in the center hole of the axle attach plate.

(c) Position the axle boss against the underside of the leaf spring and install two (2) U-bolts by placing the bolts under and around the axle and attaching the bolts to theattach plate on top of the spring.

(d) Repeat steps (b) and (c) on the other side of the axle.

(e) Connect steering linkage rod to the steer axle spindle arm using a washer bolt, and

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cotter pin for bolt retention.

CAUTION: LINKAGE ROD BOLT AND THE INSTALLATION HOLEIS TAPERED. FAILURE TO INSERT BOLT FROM CORRECT SIDEWILL DAMAGE BOLT/ATTACHMENT HOLE.

(f) Remove axle retaining blocks, then remove jack.

(g) Connect battery.

U. STEER AXLE LEAF SPRINGS AND SPRING STRAP ARMS

NOTE: If steer axle and leaf springs are to be removed, remove axleand springs as a unit. Use this section to remove axle and springstogether and disregard axle removal from springs.

1. Removal

(a) Engage the parking brake.

(b) Loosen (do not remove) the two (2) U-bolts on the RIGHT SIDE of the axle whichconnect the axle to the spring so that the bolt ends are flush with the nuts.

(c) Move to LEFT SIDE of tractor and completely remove the two (2) U-bolts andattach plate connecting the axle to the leaf spring.

(d) Position a jack on the front left part of the frame and jack the tractor until there isapproximately 2 inches of clearance between the axle boss and the spring.

NOTE: The springs are shimmed for correct spacing and alignment at thefactory. Check each spring attachment for spacer washer reference ifinstalling new springs.

(e) Remove the cotter pins, spacer washers and nuts from the front and rear springattachment bolts.

NOTE: Use a rubber mallet to aid in extracting the two (2) attachmentbolts.Note

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(f) Remove the spring by extracting the front and rear attachment bolts.

(g) To remove the two strap arms that connect the rear end of the spring to the tractor,make a sketch of the bolt/spacer arrangement and remove the attachment boltconnecting the straps to the spring shackle bracket.

2. Installation

(a) With the tractor still jacked on the LEFT SIDE and the axle left side disconnected asdescribed above, install the two (2) strap arms that connect the rear end of the springto the tractor by inserting the attachment bolt from the INBOARD side andpositioning the spacer washers in their original arrangement. Use the abovementioned strap attachment sketch for reference.

(b) Secure the strap arms with bolt and bolt-locking pin.

(c) Using the front and rear spring attachment sketches mentioned in the removalprocedure above, install the leaf spring with the attachment bolts inserted fromINBOARD side and position the spacer washers in their original arrangement.

(d) Lower the left side of the frame with the jack until the spring is resting in position onthe axle boss.

(e) Place the axle attach plate on top of the spring surface so that the leaf springassembly bolt nut is in the attach plate center hole.

(f) Install the two (2) U-bolts by placing the bolts under and around the axle andattaching the bolts to the attach plate on top of the spring.

(g) Tighten the two (2) U-bolts on the RIGHT SIDE of the axle and remove the jack.

V. STEERING LINKAGE ROD (DRAG LINK)

1. Removal

(a) Disconnect the steering linkage rod from the steer axle spindle arm by removing thecotter pin, nut and lock washer. Drive the linkage rod bolt out of the spindle armattachment hole with a rubber mallet.

(b) Disconnect the steering linkage rod from the steering sector pitman arm by removingthe cotter pin, nut and lock washer. Tap the linkage rod bolt out of the pitman armattachment hole with a rubber mallet.

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2. Installation

CAUTION: LINKAGE ROD BOLTS AND THEIR INSTALLATIONHOLES ARE TAPERED. FAILURE TO INSERT BOLTS FROMCORRECT SIDES WILL DAMAGE BOLTS/ATTACHMENT HOLES.

NOTE: To correctly position the steering linkage rod for installation,note that the rod has a bend in it, resulting in a “short end” and a “longend”. The bolt of the short end attaches to the steer axle spindle arm,while the bolt of the long end attaches to the steering sector Pitman arm.

(a) Install the bolt of the linkage rod “short end” into the top of the spindle armattachment hole, tapping the bolt into place. Secure the installation with a lockwasher, nut and cotter pin.

(b) Turn the steering wheel for proper bolt alignment as necessary, and install the bolt ofthe linkage rod “long end” into the steering sector Pitman arm from the inboard sideso that the threaded end of the bolt faces outboard. Tap the bolt with a rubber malletuntil it is seated in place. Secure the installation with a lock washer, nut and cotter pin.

W. SECTOR / COLUMN AND STEERING WHEEL

1. Removal

(a) Remove the rubber disc from the dust cover on tractors so equipped by inserting ascrewdriver under the cover edge and prying it out.

(b) Remove the dust cover.

(c) Remove the horn components.

(d) Remove the steering wheel retaining nut and remove the steering wheel.

(e) Remove the remaining horn components, severing the wire where required.

(f) Remove the steering column retaining strap by removing the two (2) bolts securingthe strap to the tractor console.

(g) Disconnect the steering sector Pitman arm from the steering linkage rod by removingthe cotter pin, nut and lock washer and tapping the linkage rod bolt out of the Pitmanarm with a rubber head mallet.

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(h) Remove the bolt and spacer connecting the aft end of the steering sector to theframe.

(i) Remove the two (2) bolts connecting the steering sector mounting bracket to theframe, thereby having the sector and column disconnected from the tractor.

(j) Using proper jacking procedures (parking brake engaged, etc.) jack up the left frontof the tractor and remove the steering sector and column out of the bottom of thetractor.

(k) Disconnect the mounting bracket from the steering sector by removing the retainernut and extracting the Pitman arm from the sector shaft using a puller tool.

2. Installation

NOTE: For ease in connecting the horn, lengthen the wire by splicing, ifrequired.

(a) Connect the forward mounting bracket to the forward portion of the steering sector,using two (2) bolts.

(b) With the tractor in the jacked position as described in step (j) of the removalprocedure, place the steering column and sector into the installed position by insertingthe column up through the floor plate from underneath the tractor.

(c) Attach the forward mounting bracket to the frame using two (2) bolts. Hand tightenonly.

(d) Attach the aft end of the steering sector to the aft bracket using a bolt and spacer.Hand tighten only.

(e) Attach the retaining strap around the steering column with two (2) bolts. Handtighten only.

(f) Align steering sector filler hole with hole in frame.

(g) Secure steering column with retainer strap. Be sure that stop light switch bracket issecured when strap is secured.

(h) Secure front mounting bracket to frame.

(i) If a space is present between spacer and sector, shim till space is filled. Secure rearbolt.

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(j) Install and connect the wires to the horn components in the steering column.

(k) Install the steering wheel to the column and secure the steering wheel with theretaining nut.

(l) Install the remaining horn components.

(m) Turn the front wheels until they are pointed in a straight forward position.

(o) Without disturbing the steering shaft centered position, place the pitman arm on thesector shaft with the arm pointing straight down and secure the arm with the retainernut.

(p) Connect the steering linkage rod to the Pitman arm and secure the connection with alock washer, nut and cotter pin.

(q) Lower the tractor and remove the jack.

X. MASTER CYLINDER

1. Removal

(a) Disconnect the brake lines from the master cylinder outlet ports -- two lines on splitmaster cylinders; a single line on single reservoir master cylinders.

(b) Remove the master cylinder from the vacuum brake booster by removing theattachment nuts.

(c) Remove the cylinder reservoir cover and gasket and pour out the brake fluid into anapproved waste container.

2. Installation

(a) Prior to installing the master cylinder in the tractor, bleed the master cylinder asfollows:

(1) Support the master cylinder in a vise and loosely install a plug in the outletports. Install the stoplight switch, if previously removed, and if equipped.

(2) Fill the reservoir with brake fluid and depress the cylinder piston several times

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until air bubbles cease to appear in the fluid.

(3) Tighten the plugs and attempt to depress the piston. The piston travel shouldbe greatly restricted after all air is expelled.

(b) Replace the reservoir cover and gasket assembly.

(c) Prior to installing the master cylinder, measure the distance between the surface faceof the vacuum brake booster to the tip of the push rod. This length should be0.9"±0.06" (22.9±1.5 mm). Adjust the length as required to be within tolerance byturning the screw on the end of the push rod in or out.

(d) Install the master cylinder to the vacuum brake booster with the attachment nuts.

(e) Remove the output port plug and install the brake line. For units with 4-wheel braking,the forward port is for the front wheel brakes. The aft port is for the rear wheelbrakes.

(f) Check pedal play distance required to bring push rod in contact with master cylinder.Distance should be between ¼" (6,4 mm) to ½"(12.7 mm). Correct out-of-tolerancecondition by adjusting push rod as described in (c) above.

(g) Connect the wires to the stoplight switch, if equipped.

CAUTION: BEFORE OPERATING THE TRACTOR, REMOVE THEMASTER CYLINDER RESERVOIR COVER AND GASKET. MAKESURE THE BRAKE PEDAL IS NOT DEPRESSED AND CHECK THEPISTON CLEARANCE IN THE FRONT (SMALL) PORT OF EACHRESERVOIR WITH A FEELER WIRE. IF THE PISTON HASEXCEEDED THE TRAVEL DISTANCE, THUS CLOSING THE PORT,THE BRAKES WILL LOCK. ADJUST THE BOOSTER PUSH RODLENGTH BY ADJUSTING THE NUT ON THE END OF THE ROD SOTHAT THE PORT IS UNOBSTRUCTED BY THE PISTON.

Y. BRAKE BOOSTER

1. Removal

(a) Remove the master cylinder following the procedure of the specific section.

(b) Disconnect the booster push rod from retainer lug on the brake pedal by removing thecotter pin and washer.

(c) Disconnect the vacuum hose from the fitting on the booster. (For units with Hydro-

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boost: Disconnect the hydraulic hoses/lines.)

(d) Remove the brake booster from the engine side of the fire wall by removing thefour (4) attachment nuts on the driver side of the fire wall.

2. Installation

(a) Install the brake booster to the engine side of the fire wall so that the vacuum hosefitting is positioned up and inboard. Secure the booster to the fire wall with four (4)attachment nuts.

(b) Connect the booster push rod to the retainer lug on the brake pedal and secure with awasher and cotter pin.

(c) Prior to installing the master cylinder, measure the distance between the surface faceof the vacuum brake booster to the tip of the push rod. This length should be0.9" ±0.06" (22.9±1.5 mm). Adjust the length as required to be within tolerance byturning the screw on the end of the push rod in or out.

(d) Install the master cylinder and brake line following the procedure of the specificsection.

(e) Connect the vacuum hose to the fitting on the booster. (For units with Hydro-boost:Connect the hydraulic hoses/lines.)

Z. BRAKE PEDAL

1. Removal

(a) Remove the cotter pin and washer from the push rod retainer lug on the pedal.

(b) Remove the nut, bolt, and two (2) spacers which connect the upper end of the brakepedal to the console.

(c) Disengage the push rod from the retainer lug on the pedal.

2. Installation

(a) Place the brake pedal in the installed position and connect the push rod to the push rodlug on the pedal.

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(b) Connect the upper end of the brake pedal to the console with the attachment bolt,with one (1) spacer on each side of the pedal bolt shaft between the pedal and theinside surface of the console mounting walls.

(c) Install a washer and cotter pin to the push rod lug to retain the push rod.

AA. PARKING BRAKE, LINKAGE AND LEVER (FORD WITH C6 TRANSMISSION)

1. Removal

(a) Chock the wheels and shift the transmission into drive gear.

(b) Disconnect the forward section of the drive shaft (See specific section).

(c) Apply the parking brake, remove the transmission output shaft flange attaching nut,then release the parking brake.

(d) Slide the drum with output flange attachment toward rear of tractor and remove fromend of transmission.

(e) Disconnect the two (2) linkage straps from the parking brake assembly by removingthe clevis and cotter pin.

(f) Disconnect the forward ends of the linkage. Remove straps from the parking brakelever by removing the clevis and cotter pin.

(g) Remove yoke and clevis assembly by removing the two (2) clevis and cotter pins.

(h) Remove bell crank assembly by removing the nut and washer from the stud in thetransmission housing.

(i) Remove the brake lining assemblies and cam shaft by removing the three (3)retaining springs.

(j) Remove brake lining plate and the brake drum shield by removing the four (4) bolts,nuts and washers.

(k) Remove drum from output flange by removing the four (4) attachment bolts and nuts.

(l) Disconnect the parking brake lever from the two (2) mounting angles by removing thetwo (2) attachment bolts, nuts and spacers.

(m) Remove the mounting angles from the floor plate by removing the four (4) mounting

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bolts and nuts.

NOTE: Steps (l) and (m) are for gasoline engine tractors with serialnumbers 0362 and up, and diesel engine tractors with serial numbers0362 through 2236.

(n) Disconnect the parking brake lever from its mounting bracket by removing the two (2)attachment bolts.

(o) Remove the parking brake lever mounting bracket by removing the two (2)attachment bolts.

NOTE: Steps (n) and (o) are only for diesel engine tractors with serialnumbers 2237 and up.

2. Installation

(a) Install the parking brake lever mounting angles to the top side of the floor plate usingfour (4) mounting bolts and nuts.

(b) Install the parking brake lever to the mounting angles with two (2) attachment bolts,nuts and spacers.

NOTE: Steps (a) and (b) are for gasoline engine tractors with serialnumbers 0362 and up, and diesel engine tractors with serial numbers0362 through 2236.

(c) Install the parking brake lever mounting bracket by installing the two (2) attachmentbolts.

(d) Install the parking brake lever to its mounting bracket by installing the two (2) bolts,nuts and spacers.

NOTE: Steps (c) and (d) are for diesel engine tractors with serialnumbers 2237 and up, only.

(e) Install drum to output flange by installing the four (4) attachment bolts and nuts.

(f) Install the brake lining plate and the brake drum shield by installing the four (4) bolts,nuts and washers.

(g) Install the brake lining assemblies and the cam shaft by installing the three (3) springs.

(h) Install the bell crank assembly by installing the nut and washer on the stud in the

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transmission housing.

(i) Replace yoke and clevis assembly by replacing the two (2) clevis and cotter pins.

(j) Connect the forward ends of the two (2) linkage straps to the parking brake lever byinstalling the clevis and cotter pins.

(k) Connect the aft ends of the two (2) linkage straps to the parking brake assembly byinstalling the clevis and cotter pins.

(l) Slide the drum with the output flange attached toward the front of the tractor andplace over the lining assemblies and the output shaft of the transmission.

(m) Apply the parking brake, secure the transmission output flange to the output shaft withthe attachment nut and then release parking brake.

(n) Connect the forward section of the drive shaft.

(o) Engage parking brakes and unchock the wheels.

BB. PARKING BRAKE, LINKAGE AND LEVER (FORD WITH GM 4L70 TRANSMISSION)

1. Removal

(a) Chock the wheels.

(b) Disconnect the rear section of the drive shaft (See specific section).

(c) Remove the driveshaft from the vehicle (only necessary if replacing the parkingbrake disc).

(d) Remove the clevis pins securing the parking brake rod to the park brake lever andthe parking brake caliper and remove the rod from the vehicle.

(e) Remove the two (2) bolts securing the parking brake caliper to the rear axleassembly.

(f) Disassemble the caliper and remove the pads from the body.

(g) If the disc is to be replaced then remove the axle input flange nut. Once removed,pull the input flange and disc off of the input shaft as one piece. The disc may thenbe removed from the flange.

(h) Remove parking brake lever.

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- Remove the mounting angles from the floor plate by removing the four (4)mounting bolts and nuts.

- Disconnect the parking brake lever from its mounting bracket by removingthe two (2) attachment bolts.

2. Installation

(a) Install the parking brake lever to the mounting angles with two (2) attachment bolts,nuts and spacers.

(b) Install the parking brake lever mounting angles to the top side of the floor plate usingfour (4) mounting bolts and nuts.

(c) Inspect the parking brake disc. Repair or replace the disc if necessary.

(d) Install the parking brake disc and input flange on the input shaft of the rear axle/dropbox. Install and torque the retaining nut to 200-275 ft-lbs (271.2-372.9 Nm).

(e) Install new pads and hardware if necessary while reassembling the caliper assembly.

(f Install the caliper assembly onto the rear axle using the original hardware.

(g) Install the parking brake rod using the original clevis pins and new cotter pins tosecure them.

NOTE: Some applications use grade 8 hardware with lock nuts in place ofclevis pins.

(h) If adjustment is necessary, follow the next few steps, otherwise return the tractor toservice.

(i) Rotate the adjustment knob on the parking brake handle counterclockwise so theadjustment arm is approximately 1” from the top of the adjustment range

(j) If necessary, adjust the parking brake rod by removing the clevis pins and adjustingthe yokes on each end until the rod is just starting to engage the caliper when thepark brake handle is in the released position. Once complete, install new cotter pinsto secure the clevis pins.

(k) Engage parking brakes and un-chock the wheels.

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CC. ALTERNATOR

1. Removal

(a) Disconnect the battery ground cable from the battery.

(b) Disconnect all electrical wires from the alternator.

(c) Loosen the alternator mounting bolt on the adjustment arm and the mounting bolt onthe front end of the alternator, and disengage the alternator belt.

(d) Remove the alternator by removing the mounting bolt on the adjustment arm and thefront mounting bolt attaching the alternator to the alternator engine mount.

2. Installation

(a) Install the alternator to the alternator engine mount and to the adjustment arm,tightening the two (2) mounting bolts only finger tight.

(b) Engage the alternator belt, adjust the belt tension to 70-110 lb (31.8-49.9 kg) byapplying pressure (leverage) to the alternator front housing, and tighten the two (2)mounting bolts.

(c) See the wiring schematics in Section 2 for wiring installation.

(d) Connect the battery ground cable to the battery.

DD. STARTER SOLENOID (DIESELUNITS ONLY)

1. Removal

(a) Disconnect the battery ground cable from the battery.

(b) Disconnect all electrical wires from the solenoid.

(c) Remove the solenoid from the fire wall by removing the two (2) attachment nuts.

2. Installation

(a) Install the solenoid to the fire wall with two (2) attachment nuts.

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(b) Connect the starter cable to the main terminal of the solenoid.

(c) Connect the battery ground cable to the battery.

EE. TEMPERATURE SENDING UNIT AND GAUGE

1. Temperature Sending Unit Removal/Installation

(a) Drain engine coolant from radiator.

(b) To remove the sending unit, disconnect wire from the unit terminal and unscrew theunit from its mounting.

(c) Install the new sending unit (use thread sealer) by screwing into its mounting hole onthe engine housing and connect wire to the unit terminal.

(d) Refill with proper engine coolant/water mixture.

2. Water Temperature Gauge Removal/Installation

(a) Disconnect the gauge light and housing from the back of the gauge.

(b) Disconnect wire from the right side terminal post and wire from the left side terminalpost of the gauge.

(c) Remove the two (2) nuts securing the gauge to the gauge retainer mount and slide thegauge out from the driver's side of the instrument panel.

(d) Place the new gauge into the installed position and secure the gauge retainer mountwith two (2) retaining nuts.

(e) Install wire to the right side and wire to the left side bolt/terminals of the gauge.

(f) Connect the gauge light and housing to the back of the gauge.

FF. OIL PRESSURE SENDING UNIT AND GAUGE

1. Oil Pressure Sending Unit Removal/Installation

(a) To remove the sending unit, disconnect wire from the unit terminal and unscrew theunit from its mounting.

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(b) Install the new sending unit (use thread sealer) by screwing it into its mounting hole onthe engine housing and connecting the wire to the unit terminal.

2. Oil Pressure Gauge Removal/Installation

(a) Disconnect the gauge light and housing from the back side of the gauge.

(b) Disconnect wire from the right side terminal post and wire from left side terminal postof the gauge.

(c) Remove the two (2) nuts securing the gauge to the gauge retainer mount and slidethe gauge out from the driver’s side of the instrument panel.

(d) Place the new gauge into the installed position and secure the gauge to the gaugeretainer mount with two (2) retaining nuts.

(e) Install wire to the right side and wire to the left side bolt/terminals of the gauge usingtwo (2) retaining nuts.

(f) Connect the gauge light and housing to the back side.

GG. GAUGES

1. Removal


(b) Disconnect wires from the gauge.

(c) Remove the two (2) nuts securing the gauge to the retainer mount and slide the gaugeout the driver’s side of the instrument panel.

2. Installation

(a) Place the new gauge into the installed position and secure the unit to the retainermount.

(b) See the wiring schematics in Chapter 1 Section 2 Maintenance Manual for wiringinstallation.

(c) Connect the battery cables to the battery.

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HH. SWITCHES

1. Ignition Switch Removal/Installation

(a) Disconnect the battery cables.

(b) Disconnect the wires from the terminal posts.

(c) Remove the switch by removing the mounting nut on the operator’s side of theinstrument panel.

(d) Place the new master switch into position with the “OFF” position of the switch(marked on the side of lever) pointing up.

(e) Secure the switch with the mounting nut.

(f) See the wiring schematics in Section 2 for wiring installation.

(g) Connect the battery.

2. Headlight Switch Removal/Installation

(a) Disconnect the battery.

(b) Disconnect the wires from the headlight switch.

(c) Remove the switch by removing the retainer nut.

(d) Install the new light switch with the “ON” position of the switch pointing up andsecure the switch with the retainer nut.

(e) See the wiring schematics in Chapter 1 Section 2 Maintenance Manual for wiringinstallation.

(f) Connect the battery.

3. Auxiliary Switch Removal/Installation


(b) Disconnect the wires from the auxiliary switch.

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(c) Remove the switch by removing the retainer nut.

(d) Install the new switch with the “ON” position of the switch pointing up and secure theswitch with the retainer nut.

(e) See the wiring schematics in Section 2 for wiring installation.


4. Brake Warning Light Removal/Installation


(b) Disconnect the wires from the brake warning light.

(c) Remove the lens.

(d) Remove the socket by removing the retainer nut.

(e) Install the new socket and secure the socket with the retainer nut.

(f) Install the lens.

(g) See the wiring schematics in Section 2 for wiring installation.

(h) Connect the battery.

5. Glow Plug Button Removal/Installation


(b) Disconnect the wires from the glow plug.

(c) Remove the glow plug by removing the retainer nut.

(d) Install the new glow plug with the retainer nut.

(e) See the wiring schematics in Chapter 1 Section 2 Maintenance Manual for wiringinstallation.


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II. HEADLIGHTS, STOP LIGHTS, AND TURN SIGNAL LIGHTS

1. Headlight Removal/Installation


(b) Disconnect the wire at the disconnect plug.

(c) Remove the nut and lock washer that secure the light to the frame rail.

(d) Install the new headlight to the frame rail with a nut and lock washer.

(e) Connect the wire at the disconnect plug.


2. Stop Light Removal/Installation


(b) Disconnect wires from stop light assembly.

(c) Remove stop light assembly by removing the light from the gasket.

(d) Install the new stoplight and secure by inserting the light into the gasket.



3. Signal Light Removal/Installation


(b) Disconnect the wires from the turn signal light assembly.

(c) Remove turn signal light assembly by removing the light from the gasket.

(d) Install the new turn signal light assembly by inserting the light into the gasket.

(e) See the wiring schematics in Chapter 1 Section 2 Maintenance Manual for wiring

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installation.


4. Back-Up Light Removal/Installation


(b) Disconnect the wires from the backup light assembly.

(c) Remove the backup light assembly by removing the light from the gasket.

(d) Install the new backup light assembly by inserting the light into the gasket.



JJ. CAB ASSEMBLY

1. Removal


(b) Disconnect the wires going into the cab.

(c) Remove cab by removing eight (8) bolts. The eight (8) bolts are located as follows:(2) bolts each on the right and left sides, and two (2) bolts each of the right and leftback corners.

2. Installation

(a) Install cab and secure by using the eight (8) bolts removed in step (c) above.

(b) Connect the wires.

(c) Connect the battery.

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KK. DOOR

1. Removal

(a) Remove door stop by removing securing nut.

(b) Remove door by lifting door straight up and out of hinges.

2. Installation

(a) Install the door by lowering the door so that the pegs of the hinge go into the hinge.

(b) Replace door stop and secure with a nut.

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SECTION 4: SHIPPING

A. PREPARATION

WARNING: HAZARD EXISTS WHEN REFUELING AND DEFUELINGTHE TRACTOR - NO SMOKING, NO OPEN FLAMES, NOELECTRICAL DEVICE OPERATIONS.

1. Battery

(a) Disconnect battery terminals from battery posts.(b) Leave battery in battery box.

2. RadiatorDrain engine coolant from radiator and engine block.

3. Fuel Cell

(a) Drain fuel from fuel tank into appropriate container.

(b) Disconnect fuel line at lowest readily accessible connection and drain fuel from fuelline.

(c) Reconnect fuel lines.

(d) Leave fuel cap on tank, but loosened.

4. Checks

(a) Make certain fuel line is connected.

(b) Make certain shut-off valve on radiator is closed.

(c) Make certain fuel cell drain valve is closed.

(d) Before shipping the unit, review the transportation data plate (if equipped) foradditional shipping information.

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B. PREPARATION FOR OPERATION

WARNING: MAKE CERTAIN ALL FUEL LINES ARE PROPERLYCONNECTED FROM TANK TO FUEL PUMP TO CARBURETOR(GASOLINE) OR INJECTOR PUMP (DIESEL).

1. Radiator

(a) Make certain that radiator shut-off valve is closed.

(b) Add required amount of coolant/water mixture to radiator

2. Fuel Cell

(a) Add fuel to fuel tank.

(b) Check all fuel lines for leaks.

3. BatteryConnect battery terminals to battery posts.

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SECTION 5: STORAGE

A. FOR ONE MONTH

l. Engine

(a) Gasoline

(1) Add fuel stabilizer, Ford Part Number E8AZ-19C544-A, or an equivalentadditive can be used for any length of storage. It is imperative in anyapplication where the fuel will not be consumed within thirty days. Ford FuelStabilizer comes in an 8 fl. oz. (0.24 L) bottle for consumer use and should beavailable through all EDI Distributors. The correct ratio is 2 oz. (0.06L)Stabilizer to 5 gallons (18.9 L) of gasoline. Without the use of an additive, theunused fuel in your fuel tank can and will go sour in a very short period oftime, causing varnish and contaminants to form. This causes problems in fueldelivery by clogging fuel injectors.

(2) While the engine is running, treat upper cylinders by spraying engine foggingagent (from your local aftermarket supplier) into the air intake for about twominutes. Open throttle for short burst of speed, shut off engine and allow it tocome to a stop while continuing to spray into air intake.

(3) Leave spark plugs in holes or seal spark plug holes with suitable threadedmetal plugs and cover all openings into engine with dust-proof caps or shields(suitable non-hygroscopic material).

(4) If engine is less transmission, spray flywheel and ring gear with mixture ofone part recommended engine oil, and one part Stoddard Solvent orequivalent.

(5) Check coolant protection. Store indoors in dry area.

(6) Attach a tag on steering wheel stating, "CAUTION: Oil and water havebeen removed from engine."

(b) Diesel

(1) Run the engine until it reaches normal operating temperature and then shutthe engine down.

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CAUTION: OIL WILL BE HOT.

(2) Drain oil from crank case and refill with required amount.

(3) Drain water from radiator and engine block (Deutz diesel units excluded).

(4) Attach a CAUTION tag on steering wheel stating, "CAUTION: Water hasbeen removed from engine."

2. TransmissionNo special attention needed.

3. Axle and Reduction Gear BoxNo special attention needed.

4. TiresThe tractor should be raised and axles chocked to prevent tire contact with ground. Thepressure should be reduced to 15 psi (103.4 kPa)

5. LubricationEnsure that all points are lubricated with specified grease, oil, etc.

6. Fluid LevelsAll fluid levels should be checked and topped off as necessary.

7. Wheel BearingsWheel bearings should be repacked.

8. BatteryDisconnect battery terminals.

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B. INDEFINITE PERIOD

1. Engine

(a) Gasoline

(1) Add fuel stabilizer, Ford Part Number E8AZ-19C544-A, or an equivalentadditive can be used for any length of storage. It is imperative in anyapplication where the fuel will not be consumed within thirty days. Ford FuelStabilizer comes in an 8 fl. oz. (0.24 L) bottle for consumer use and shouldbe available through all EDI Distributors. The correct ratio is 2 oz (0.06L).Stabilizer to 5 gallons (18.9 L) of gasoline. Without the use of an additive, theunused fuel in your fuel tank can and will go sour in a very short period oftime, causing varnish and contaminants to form. This causes problems in fueldelivery by clogging fuel injectors.

(2) Drain crankcase completely and refill with recommended engine oil, (SAE10) or equivalent.

(3) Run engine until completely out of fuel. Gasoline only: Restart and run onunleaded gasoline, mixed with stabilizer, for at least 10 minutes. While engineis still running and at completion of above run, treat upper cylinders byspraying fogging agent into the air intake for about two minutes. Openthrottle for short burst of speed, shut off engine and allow it to come to a stopwhile continuing to spray into air intake.

(4) Check coolant protection.

(5) Disconnect and remove battery.

(6) Clean exterior surface of engine.

(7) Leave spark plugs in holes or seal spark plug holes with suitable threadedmetal plugs.

(8) Seal all openings in engine and accessories with non-hygroscopic material.Mask off all areas to be used for electrical contacts.

(9) Make sure all surfaces are dry, then spray all taped openings, all engineaccessories including ignition wiring, and all exterior surfaces of engine withInsulation Compound.

(10) If engines are equipped with automotive-type clutch, block clutch in slightlydisengaged position so that lining and pressure plates are not in contact.

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(b) Diesel

(1) Run the engine until it reaches normal operating temperature and then shutthe engine down (excluding Deutz diesel units).

CAUTION: OIL WILL BE HOT.

(2) Drain oil from crank case and refill with required amount.

(3) Drain water from radiator and engine block.

(4) Attach a CAUTION tag on steering wheel stating, "CAUTION: Water hasbeen removed from engine."

2. Transmission

(a) Drain transmission fluid.

(b) Refill transmission.

NOTE: Prolonged storage may be detrimental to the seals in thetransmission.

3. Axle and Reduction Gear Box(a) Drain drive axle and reduction gear box by removing drain plug located on the

underside of the differential carrier housing. Reinstall plug after draining. The driveaxle and reduction gear box are connected internally and share the same oil.

(b) Attach a CAUTION tag on steering wheel stating: "CAUTION: Oil has beenremoved from axle and reduction gear box".

4. TiresThe tractor should be raised and axles chocked to prevent tire contact with the ground. Tirepressure should be reduced to 15 psi (103.4 kPa), and sprayed with a rubber preservative.

5. LubricationEnsure that all points are lubricated with specified grease, oil, etc.

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6. Fluid LevelsAll fluid levels should be checked and topped off as necessary.

7. Wheel BearingsWheel bearings should be repacked.

8. BatteryThe battery should be removed and stored separately. The battery must be stored in a cooldry place and must not be exposed to direct sunlight. A recommended storeroom temperatureof 32 °F (0 °C) to 90 °F (32 °C) should be maintained. If the battery is stored in the open, itmust be covered for protection against dirt and moisture. A slow charge should be given tothe battery every one to two months.

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CHAPTER 2: OVERHAUL

TABLE OF CONTENTSTS

SECTION 1: GENERAL ............................................................................................................. 2-1-1

SECTION 2: STEERING ........................................................................................................... 2-2-1

A. Procedure ............................................................................................................. 2-2-1

SECTION 3: DRIVE SHAFT UNIVERSAL JOINTS .................................................................. 2-3-1

A. Disassembly ......................................................................................................... 2-3-1B. Assembly .............................................................................................................. 2-3-1

SECTION 4: DRIVE AXLE ......................................................................................................... 2-4-1

SECTION 5: BLEEDING THE REAR DISC BRAKE SYSTEM............................................... 2-5-1

1. General ................................................................................................................. 2-5-12. Manual Bleeding ................................................................................................... 2-5-13. Pressure Bleeding ................................................................................................ 2-5-14. Check-Out ............................................................................................................ 2-5-2

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SECTION 1: GENERAL

If an overhaul of a component or system is suspected or required, the section or sections that cover thecomponent or system should be read in full and understood completely before attempting any part of anoverhaul of a component or system.

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SECTION 2: STEERING

A. PROCEDURE

If the tractor has been properly lubricated and maintained and has not experienced damage to thesteering system, the steering components will provide many hours of service without an overhaul.Should overhaul be required, or suspected as being required, follow the procedure below:

1. Jack up the front end of the tractor using normal jacking procedures ( i.e., chock rear tires,apply hand brake, and place blocks under tractor front bumper).

2. Inspect the steering linkage rod for damage. Also check for wear of the linkage rod ball bygrasping the rod and shaking it. If the linkage rod ball joints are loose, replace the rod.

3. Grasp the top and bottom of each tire and shake it in and out to determine any wobble orlooseness, while observing the hub and spindle area. If there is any wobble or looseness inthe hub, but the spindle is rigid, then the wheel bearings and seals should be adjusted bytightening the hub retainer nut. If excessive noise is experienced after adjustment, thebearings and seals should be replaced as follows:

(a) Remove the front wheels by removing the lug nuts on each wheel.

(b) Remove the hub plate attachment bolts, the hub plate, gasket, outer hub retainer nut,nut lock, and inner hub retainer nut.

(c) Grasp the hub and slide it off the axle shaft.

(d) Remove the inner and outer seals and bearings from the hub and wipe the hubinterior clean.

(e) Inspect hub interior surfaces (bearing races) for scoring. If the races are scored orworn, replace with new races.

(f) Install new bearings and seals into the hub, packing the bearings with lithium-basegrease, and replace the hub onto the axle shaft.

(g) Secure the hub with the retainer nuts and nut lock and replace the hub plate.

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4. Grasp the top and bottom of the wheel and check for spindle bolt and bushing wear by shakingthe wheel in and out while observing the hub and spindle area. If the hub is rigid, but thespindle has play in it at the axle connection, the spindle bolt and bushings should be replaced asfollows on each wheel:

(a) Remove the front wheels.

(b) Disconnect the spindle arm from the axle by removing the cotter pin and retainer nut.

(c) Remove the spindle bolt retainer clip, washer, and grease seal.

(d) Remove the spindle bolt and lock pin and pull the spindle bolt out the top of thespindle.

(e) Replace the two (2) bushings in the spindle bolt holes of the spindle.

(f) Clean and inspect the spindle bearing, replacing the bearing if worn, and repack thebearing.

(g) Position the spindle onto the axle end with the bearing positioned between the lowerflange of the spindle and the axle end.

(h) Install spacers between the upper flange of the spindle and the axle until a snuginstallation is obtained.

(i) Install the new spindle bolt and secure it in place within the axle using the spindlebolt lock pin.

(j) Install the grease seal, washer, and spindle bolt retainer clip.

(k) Install the spindle arm to the axle with the retainer nut and cotter pin.

(l) Install the wheel.

5. Grasp the sides of the wheel and shake it from side to side while observing the rod ends. Ifexcessive movement of slack is observed in the rod connection ends, replace the connectingrod ends as follows:

(a) Disconnect the rod ends from the spindle arms by removing the cotter pins andretainer nuts.

(b) Remove the connecting rod and remove the rod end retainer clamps.

(c) Screw the new rod ends approximately ¼" into each end of the rod.

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(d) Install the connecting rod to the spindle arms, securing the connecting rod ends to thespindle arms with the two (2) retainer nuts and cotter pins.

(e) With the wheels pointing straight forward, adjust the “toe-in” by turning theconnecting rod until the tire centerline-to-centerline distance across the back of thetires is 0" to 1/8" longer than the centerline-to-centerline distance across the front ofthe tires.

(f) After the toe-in adjustment has been accomplished, install the rod end clamps, thussecuring the connecting rod adjustment.

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SECTION 3: DRIVE SHAFT UNIVERSAL JOINTS

A. DISASSEMBLY

1. Remove the drive shaft from the tractor.

2. Place one section of the shaft in a vise being careful not to damage it.

3. Remove the snap rings that retain the bearings.

4. Press the bearing out of the flange by using a universal joint removal tool. If the bearingcannot be pressed all the way out of the flange, remove it with vise grip or channel lockpliers.

5. Reposition the tool to press on the spider in order to remove the bearing from the oppositeside of the flange.

6. Remove the flange from the spider.

7. Remove the bearings and spider from the other end of the drive shaft, following the aboveprocedure.

8. Clean all foreign matter from the flange and yoke of both drive shaft ends.

9. Wash all parts in cleaning fluid. Use of vapor degreaser is permissible in lieu of kerosene orother solvents. Check the lubricant passages in the journals for evidence of wear or excessiveheat.

10. Soak the needle bearing assemblies in a commercial cleaning fluid to soften particles ofhardened grease. Then, wash these parts in cleaning fluid, using a stiff brush if necessary, toremove all old lubricant. Check each bearing for missing rollers.

11. After the needle bearing assemblies are thoroughly clean, apply clean lubricant to the rollers.Rotate them on the trunnion of the journal to check wear. Fill the journal passages withlubricant and fill the bearings approximately 1/3 full of lubricant before reassembly.

B. ASSEMBLY

1. Start a new bearing into the yoke at the rear of the drive shaft.

2. Position the spider in the rear yoke and press the bearing below the surface.

3. Remove the tool and install a new snap ring.

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4. Start a new bearing into the opposite side of the yoke.

5. Install the tool and press on the bearing until the opposite bearing contacts the snap ring.

6. Remove the tool and install a new snap ring.

7. Reposition the drive shaft and install a new spider and two new bearings in the front yoke inthe same manner as the rear yoke.

8. Position the flange on the spider and install two (2) new bearings and snap rings.

9. Check the joint for freedom of movement. If a bind has resulted from misalignment duringthe foregoing procedure, tap the ears of the drive shaft sharply to relieve the bind. Do notinstall the drive shaft unless the universal joints are free of bind.

10. Lubricate the universal joints with long life lithium based grease.

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SECTION 4: DRIVE AXLE

If the tractor has been properly lubricated, maintained and operated, and has not experienced damage to thedrive axle, the drive axle will provide many hours of service without an overhaul. Should overhaul berequired, or suspected of being required, follow the procedure in AxleTech or Newage Vendor Manuals inChapter 4 this Manual.

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SECTION 5: BLEEDING THE REAR DISC BRAKE SYSTEM

1. GENERAL

(a) If the caliper was removed for overhaul, or if the brake hose or steel line wasdisconnected for any reason, it will be necessary to bleed all air from the calipers andconnecting lines.

(b) Prior to bleeding the system, it is important to check the master cylinder reservoir.Use hydraulic fluid, DOT 3, Extra Heavy Duty Brake Fluid to bring the level up towithin 1/8" (3mm) of the top.

(c) Brakes can be bled either manually or with pressure bleeding equipment.

CAUTION: FLUID THAT IS DRAINED, FLUSHED OR BLED OUT OF ATRACTOR’S BRAKE SYSTEM SHOULD BE DISCARDED. IT IS NOTSAFE FOR REUSE FOR ANY PURPOSE.

2. MANUAL BLEEDING

(a) Manual bleeding requires two people, one to pump the brake pedal and another tooperate the bleeder valves. Make sure that the master cylinder is full. After thebleeder valve is opened, depress the brake pedal one full stroke, close bleeder valve,then allow the pedal to return slowly to the released position. Allowing the pedal toreturn too quickly may draw air into the system. Continue operating the pedal in thismanner until one cylinder or caliper is bled. Refill the master cylinder and go on tothe next cylinder or caliper.

CAUTION: IN ORDER TO ENSURE THAT NO AIR CAN BESUCKED BACK INTO THE SYSTEM, THE BLEEDER VALVE MUSTBE CLOSED AT THE END OF EACH STROKE, BEFORE THEBRAKE PEDAL IS RELEASED.

(b) Since it is desirable to bleed the longest line first, the normal sequence for manualbleeding at the wheels is: Right Aft, Left Aft, Right Forward and Left Forward.

(c) Check the fluid level in the reservoir frequently during the bleeding procedure.

3. PRESSURE BLEEDING

(a) If the equipment is available, the pressure tank method of bleeding is faster, since the

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master cylinder does not have to be refilled several times. Pressure bleedingequipment must be of the diaphragm type. That is, it must have a rubber diaphragmbetween the air supply and the brake fluid to prevent air, moisture, oil and othercontaminants from entering the hydraulic system. Install the special bleeding adapterto the master cylinder. Make sure that the pressure tank is at least 1/3 full of fluid.Position the tank so that its hose will easily reach the adapter on master cylinder ofthe vehicle being serviced, then make the air pressure connection to tank (20 to 25psi) . Open the tank valve to bleed all air out of the hose before connecting it to theadapter. After making this connection, open the valve when ready to begin bleeding.

CAUTION: DO NOT LIFT, MOVE OR SHAKE THE TANK AFTER AIRPRESSURE IS APPLIED. THIS MAY CAUSE AIR TO BECOMETRAPPED IN THE FLUID.

(b) Bleed both rear calipers, then bleed both front calipers. This provides the mosteffective means for expelling all air from the brake system when pressure bleeding.

NOTE: The pressure bleeding process may be speeded up by lightly tappingthe brake pedal when the bleeder valve is opened. This createspulsations that tend to purge air from the system.

4. CHECK-OUT

(a) Check brake pedal for sponginess or hard pedal.

(b) Drive tractor slowly and make several slow speed stops.

(c) Check all brake fluid line fittings and caliper areas for fluid leakage.

(d) Correct any discrepancies before returning tractor to normal service.

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Property of American Airlines Maintenance · Orig CD402-Maint Chapter 1 MA Tow Tractor Table of...

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Transcript of Property of American Airlines Maintenance · Orig CD402-Maint Chapter 1 MA Tow Tractor Table of...