Chapter 2: Preventive Maintenance - Amazon Web Services€¦ · 2 - 1 - 4 CD444-44M June 2019 (Rev...

CD444-44M 2 - 1 - 1June 2019 (Rev A)

Chapter 2 Tow Tractor Model MA-44Section 1 Maintenance Manual

Chapter2:PreventiveMaintenanceSection 1: Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1-3

1.1 Safety Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1-31.2 Preparation for Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1-3

Section 2: Preventive Maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-2-1

2.1 Periodic Maintenance/Service Schedule and Checklist - - - - - - - - - - - - - - - - - - -2-2-1Section 3: Maintenance Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-1

3.1 Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-13.2 Jacking Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-13.3 Service and Lubrication Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.4 Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.5 Service Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-8

Section 4: Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-1

4.1 Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-14.2 Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-14.3 Rear Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-24.4 Steering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-24.5 Brake System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-34.6 Electrical System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-4

Section 5: System Schematics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-5-1

5.1 Electrical Schematics- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-5-35.2 Hydraulic Schematics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-5-9

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2- 1 - 2 CD444-44MJune 2019 (Rev A)

Tow Tractor Model MA-44 Maintenance Manual

Chapter 2Section 1

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CD444-44M 2 - 1 - 3June 2019 (Rev A)


Section1:Introduction

Preventive maintenance is regularly performed maintenance that will lessen the likelihood of equipmentfailure. Preventive maintenance is performed while the equipment is still operating properly, so that it doesnot break down unexpectedly. The following sections provide information on how to maintain the vehicle toensure optimal equipment performance.

1.1SafetyPrecaution

Read the Safety chapter at the beginning of this manual and refer to the Warnings, Cautions, and notesthroughout this manual before proceeding with any Maintenance.

1.2PreparationforUse

Set the parking brake by moving the park brake switch to ON position and perform Pre-Operation Checksprior to putting the unit into service.

1.2.1Pre-OperationCheck

The following items must be checked before putting the unit into service

1.2.1.1EngineandTransmission

1. Check engine oil level, add oil if needed see Section 2: "Layouts" for lubrication specification.

2. Check radiator coolant/water mixture level. If coolant is needed, make sure radiator drain valve isclosed, then add required coolant/water mixture.

3. Check transmission fluid level.

4. Check transmission cooling lines for proper connection.

1.2.1.2FuelSystem

1. Check all fuel line connections to make sure they are properly connected.

2. Make certain fuel tank drain valve is closed.

3. Fill fuel tank with correct fuel. Refer to the engine manual included in Chapter 5 (1.1 "Vendor Infor-mation") to determine the correct fuel specifications.

1.2.1.3Axles

1. Check oil level in the rear axle and gear reduction box.

2. Add oil, if needed.

CAUTION:Every operator and mechanic/technician involved with this equipment must read andabide by the Safety sections.

NOTE:This check is to determine if there is fluid in the transmission. If any fluid shows on the dipstick,do not add transmission fluid until it is checked with the engine running, after the engine hasreached normal operating temperature

NOTE:The rear axle and reduction gear box are internally connected See Section 2: "Layouts" forLubrication Specification.

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Tow Tractor Model MA-44 Chapter 2 Maintenance Manual Section 1

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1.2.1.4Brakes

1. Check master cylinder fluid level.

2. If low, check for leaks in brake lines.

3. Check service brake to make sure it is working properly.

4. Check park brake to make sure it is working properly.

1.2.1.5TireInflation

1. Check air pressure in tires.

2. Add air, if needed.

• Front: 60 psi (413.7 kPa)

• Rear: 65 psi (448.1 kPa)

1.2.1.6VehicleDrive

Check that the tractor drives properly in both forward and reverse directions.

1.2.1.7Battery

Connect the battery cables, if disconnected.

CAUTION:

THE RECOMMENDED TIRE PRESSURES LISTED ARE FOR THE 8.00 X 16.5 (DRIVEWHEELS) AND 6.9 X 9.0 (STEER WHEELS) TIRES THAT ARE STANDARD ON THE MAUNIT. OTHER OPTIONAL TIRES SHOULD BE INFLATED ACCORDING TO THE TIREMANUFACTURER SPECIFICATIONS.

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CD444-44M 2 - 2 - 1June 2019 (Rev A)


Section2:PreventiveMaintenance

Routine maintenance is essential if the vehicle is to be an efficient materials handling unit. Lack of mainte-nance will result in costly repairs and interruptions in daily operations.

It is recommended that in addition to mechanical irregularities one should check for the presence andquality of exterior reflector markings. To ensure continued safe operation, any noted deficiencies shouldbe corrected immediately.

2.1PeriodicMaintenance/ServiceScheduleandChecklist

The unit should be maintained in accordance with periodic schedules. Maintain the unit by performing theperiodic maintenance procedures as listed in this chapter.

During the periodic maintenance of the unit, follow the instructions for service/adjustment of the compo-nents and systems as described in this chapter, the manufacturers’ service instructions and manuals.

Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, performall previous maintenance checks that are due for scheduled maintenance.

• The required maintenance schedules are as follows:

• Daily or every 10 hours of operation

• Weekly or every 50 hours of operation

• Every 100 hours of operation

• Monthly or every 250 hours of operation

• Every six months or 500 hours of operation

• Annually or every 1000 hours of operation

• Every two years or 2000 hours of operation

• Four years or 5000 hours of operation

CAUTION:Only qualified personnel should service this tractor. Do not attempt to carry out repairsunless you are a qualified maintenance mechanic. Report a faulty tractor and do notuse until repaired.

CAUTION: Check the Engine Operation Manual for Specific Engine Maintenance

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2.1.1DailyorEvery10hoursMaintenanceChecks

2.1.2WeeklyorEvery50hoursMaintenanceChecks

Table2-2-1:DailyorEvery10hoursMaintenanceChecksandServiceProcedures

No. Item DailyCheck/Action

1

Engine System

Check Lubricating oil level and top oil up if necessary.

2 Check coolant level and top up if necessary

3 Check engine tightness (visual inspection for leaks).

4 Check and empty water tank in the pre-filter

5Check suction air filter/dry air filter (maintain in accordance with maintenance indicator).

6Exhaust System

Check exhaust system including exhaust after treatment components for leaks.

7 Fuel System Check fuel level.

DO NOT CHANGE PNEUMATIC TIRE FOR CUSHION TIRE OR VICE VERSA WITHOUT FIRSTCONSULTING TEXTRON GSE. TIRES OF A DIFFERENT TYPE OR MAKE, TREAD OR MATERIALCAN REDUCE THE LOAD CAPACITY OR AFFECT SAFETY.

8Tires

Check the pressure of the pneumatic tires.

9 Check the tire treads for damage. Remove any stone, etc.

10 ControlsCheck that all controls are in good working order. Report a faulty control and do not use until repaired.

11

Lights

Check the operation and aiming of the headlights.

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

13Check the operation of the cab marker lights, the heater, the wiper and cab light, if equipped.

14 Horn Sound the horn.

Table2-2-2:WeeklyorEvery50hoursMaintenanceChecks

No. Item Weekly/50HoursCheck

1 Engine System

Change engine oil.

2 Check underneath for oil leaks and damage.

TRANSMISSION FLUID MAY REACH HIGH TEMPERATURES AND THE CASE MAY BE UNDER PRESSURE. CARE MUST BE TAKEN WHEN REMOVING THE DIPSTICK TO AVOID BURNS.

3 TransmissionCheck the transmission fluid level (with engine running at normal operating tem-perature).

4Exhaust System

Check exhaust system for leaks and holes.

NOTE:Only the initial change is required at the 50-hour maintenance level, change monthly or every200 hours thereafter.

5 Battery Check the battery charge.

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CD444-44M 2 - 2 - 3June 2019 (Rev A)


2.1.3Monthly/QuarterlyorEvery200/250HoursMaintenanceChecks

6

Axles

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

7 Check drive axle and reduction gear box oil level

8 Check king pins and steer pin for looseness.

9Brake

SystemCheck the level of the brake fluid in the master cylinder. If low, top off as neces-sary.

10Steering System

Check power steering fluid level.

LUG NUTS MUST BE RETIGHTENED TO 125 FT-LB (169.5 NM) AFTER ANY CHANGE OF A WHEEL AND ANYTIME THE LUG NUTS HAVE BEEN LOOSENED FOR ANY REASON, AND AT THE INTER-VALS SPECIFIED IN THIS PERIODIC MAINTENANCE SECTION.

11

Nuts and Bolts

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

12Check cylinder head bolt torque and all nuts and bolts for tightness. If required, torque to specified torque with oiled threads.

13 Switches Check neutral safety switch adjustment.

Table2-2-3:Monthly/QuarterlyorEvery200/250HoursMaintenanceChecks

No. Item Monthly/QuarterlyorEvery200/250HoursCheck

1 Engine System

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

2 Inspect radiator hoses and clean radiator exterior.

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

3Axles

Change drive axle and reduction gear box oil.

4 Lube the drive shaft joints.

5

Brake System

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

6 Check service brake operation.

7Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch (3.175 mm).

8 Lube the service brake pedal pivot.

9 Lube the parking brake lever pivots.

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

Table2-2-2:WeeklyorEvery50hoursMaintenanceChecks

No. Item Weekly/50HoursCheck

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2.1.4Two(2)MonthsorEvery500HoursMaintenanceChecks

2.1.5Six(6)MonthsorEvery1000HoursMaintenanceChecks

10Operator Compart-ment/Cab

Lube the adjusting slides beneath the operator’s seat.

11 Lube the throttle linkage.

12 Lube the cab door handles (if equipped).

13 Check neutral safety switch adjustment.

14Steering System

Check power steering fluid level.

15 Hood Lube the hood latches and hinges.

16 Fittings Lube all grease fittings.

Table2-2-4:Two(2)MonthsorEvery500HoursMaintenanceChecks

No. Item TwoMonths/500HoursCheck

1Engine System

Replace lubricating oil. A lubricating oil application/change strategy adapted opti-mally to the individual engine application type can be created, for example, with the DEUTZ oil diagnosis. Refer to Deutz Manual (1.1 "Vendor Information") in Chapter 5.

2 Check V-belt.

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

4 Air Intake Check intake air pipes for damage.

5Cooling System

Check the cooling system (additive concentration).

6Fuel

SystemChange fuel cartridge for filter.

7 Axles Check ball joints and tie rod ends looseness.

8Hydraulic System

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

9 Wheels Inspect front wheel bearings; clean and repack.

Table2-2-5:Six(6)MonthsorEvery1000HoursMaintenanceChecks

No. Item Six(6)Months/1000hoursCheck

1

Engine System

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

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

3 Check V-rib belt and tensioning pulley.

4 Replace V-belts.

Table2-2-3:Monthly/QuarterlyorEvery200/250HoursMaintenanceChecks

No. Item Monthly/QuarterlyorEvery200/250HoursCheck

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2.1.6Yearlyor2000HoursMaintenanceChecks

2.1.7Every2Yearsor4000HoursMaintenanceChecks

5Air Intake

Check the intake manifold bolts and tighten, if necessary.

6 Replace dry air filter.

7

Fuel System

Fuel filter cartridge for filter size 0.9 L

8Replace filter insert for the fuel pre-filter. If the warning system responds (lamp/ horn), the water trap bowl must be emptied immediately.

9Hoses and Fastenings

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

10 Battery Check battery and cable connectors.

11Axles

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

12 Change drive axle and reduction gear box oil.

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

13Brake

SystemCheck cylinder compression.

14 Controls Check cold starting device.

Table2-2-6:Yearlyor2000HoursMaintenanceChecks

No. Item Yearly/2000HoursCheck

1 EngineCheck engine monitor, warning system. Maintenance only to be carried out by authorized service personnel.

2Transmission

Adjust automatic transmission band

3 Change transmission fluid and filter.

4 Fuel System Replace fuel pre-filter.

5Hydraulic System

Drain, flush, refill and bleed the hydraulic brake system.

Table2-2-7:Every2Yearsor4000HoursMaintenanceChecks

No. Item Every2Years/4000HoursCheck

1Engine System

Replace timing belt, extreme-duty, see adjacent table within Deutz Manual (1.1 "Vendor Information") in Chapter 5.

2Coolant System

Replace coolant.

Table2-2-5:Six(6)MonthsorEvery1000HoursMaintenanceChecks

No. Item Six(6)Months/1000hoursCheck

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2.1.8Every3Yearsor6000HoursMaintenanceChecks

2.1.9StatusDependent

Table2-2-8:Every3Yearsor6000HoursMaintenanceChecks

Item Every3Years/6000HoursCheck

General General Overhaul.

Table2-2-9:StatusDependent

Item StatusDependent

FuelSystem

Change diesel particle filter (the required exchange is displayed via an electronic dis-play).

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Serial Number:Manufacture Date:

Service Requirement in Hours Daily 50 100200/250

Check/ensure all controls are in good working order

Check fuel level

Check Lubricating oil level (If necessary top up)

Check engine coolant level

Check engine coolant system for leaks and cleanliness

Check engine tightness (visual inspection for leaks)

Check and empty water tank in the pre-filter.

Check the pressure of the pneumatic tires

Check tire treads, remove any foreign objects

Check the operation and aiming of the headlights

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

Check operation of Cab marker lights, heater/air, front & rear wipers, defroster, fan, some light(s) & alarms/mircro switches (lift cab only)Sound the horn

Check exhaust system including exhaust after treatment components for leaks.

Check coolant, oil, fuel, and vacuum hoses/pipes for leaks, damage, deterioration and correct routing.Check suction air filter/dry air filter (maintain in accordance with maintenance indicator).Check underneath for oil leaks and damage

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

Check cylinder head bolt torque and all nuts and bolts for tightness. If required, torque to specified torque with oiled threadsChange engine oil.

Check battery charge

Check the drive axle U-bolts and tighten if required

Check drive axle and reduction gear box oil level

Check the transmission fluid level (with engine running at normal operating temperature)Check the level of the brake fluid in the master cylinder. If low, top off as necessaryCheck power steering fluid level

Check exhaust system for leaks and holes

Check king pins and steer pin for looseness

Check all visible electrical wiring for security, correct routing and evidence of chafing or heat damageCheck neutral safety switch adjustment

Check park brake operation.

Check service brake operation

Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch (3.175 mm)Lube the service brake pedal pivot

Lube the parking brake lever pivots

Check the fan and alternator belts; tighten, if necessary

Inspect radiator hoses and clean radiator exterior.

Change drive axle and reduction gear box oil

Lube the drive shaft joints

Lube the adjusting slides beneath the operator’s seat

Lube the throttle linkage

Lube all grease fittings

Lube the hood latches and hinges

Lube the cab door handles (if equipped)

TUG Model MA-44 (Deutz Engine) Tow TractorDate:ID Number:

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2 - 2 - 8 CD444-44MJune 2019 (Rev A)


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Notes

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CD444-44M 2 - 2 - 9June 2019 (Rev A)


Serial Number:Date:

Service Requirement in Hours 500 1000 2000 4000 6000Status

Dependent

Check the cooling system (additive concentration)

Change fuel cartridge for filter

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

Check intake air pipes for damage

Check V-Belt

Inspect front wheel bearings; clean and repack

Check ball joints and tie rod ends looseness

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

Replace lubricating oil.

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

Check cylinder compression

Check the intake manifold bolts and tighten, if necessary.Check charge air cooler entry area (drain lube oil/condensate).Check battery and cable connectors

Check cold starting device.

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

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

Check V-rib belt and tensioning pulley.

Replace V-belts.

Fuel filter cartridge for filter size 0.9 L

Replace filter insert for the fuel pre-filter. If the warning system responds (lamp/ horn), the water trap bowl must be emptied immediately.Replace dry air filter.Adjust automatic transmission band

Change transmission fluid and filter.

Drain, flush, refill and bleed the hydraulic brake system.

Check engine monitor, warning system. Maintenance only to be carried out by authorised service personnel.Replace fuel pre-filter.

Replace Coolant

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

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

ID Number:

TUG Model MA-44 (Deutz Engine) Tow TractorDate:

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Notes

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CD444-44M 2 - 3 - 1June 2019 (Rev A)


Section3:MaintenanceProcedures

The following procedures outline the steps and precautions to take when servicing the unit for mainte-nance or repair.

3.1SafetyPrecautions

Read the Safety chapter at the beginning of this manual and refer to the Warnings, Cautions and Notesthroughout this manual before proceeding with any overhaul.

3.2JackingInstructions

The unit can be supported by either free standing jack stands or the unit’s hydraulic jacks.

3.2.1FreeStandingJack

1. Park the unit on level ground.

2. Chock the wheels and apply parking brake.

3. Place a warning tag on control panel stating “Unit Out of Service.”

4. Praise the unit using equipment with lifting capacity at least one and a half (1.5) times greater thanthe unit’s weight.

5. Place the jack stands under the unit at the appropriate location(s). See Figure

6. Disconnect battery cables from starting motor and from engine ground

WARNING: ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO PERFORMING ANYWORK ON THIS EQUIPMENT.

CAUTION:Every operator and mechanic/technician involved with this equipment must read andabide by the Safety sections.

WARNING:

TO AVOID INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT, ALWAYSUSE LIFTING EQUIPMENT, SAFETY JACKS AND CHAINS WITH A SAFEMINIMUM CAPACITY OF ONE AND A HALF (1.5)TIMES THE WEIGHT OFTHE VEHICLE BEING LIFTED.

TO AVOID INJURY TO PERSONNEL, NEVER WORK UNDER UNIT WHENUNIT IS SUPPORTED ONLY BY JACKS.

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Figure2-3-1:JackingPoints

3.2.2FluidLevelChecks

Perform all fluid level checks with the unit parked on a level surface. Ensure the unit’s parking brake isapplied and wheels are chocked.

3.2.3EngineOilLevel

Check the engine oil level daily or before operation.

1. When the engine is warm, turn off the unit and wait for 15 minutes before checking the oil level.

2. With the engine stopped and cooled, locate the engine oil dipstick. See Figure 2-3-4 Service andLubrication Points.

3. Pull up the dipstick and wipe clean.

4. Re- the dipstick, withdraw it and read the oil level.

WARNING:

ALWAYS SET THE PARK BRAKE ON PRIOR TO SHUTTING OFF THE UNITOR EXITING THE VEHICLE. OTHERWISE, THE UNIT CAN ROLL AWAY,CAUSING DEATH, SEVERE PERSONAL INJURY, AND/OR PROPERTY DAM-AGE.

NOTE: Maintain the oil level between the “L” and “H” dipstick ranges.

Jacking Points

Jacking Points

Jacking Points

Jacking Points

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5. When the oil level is below the dipstick “L” mark, add oil through the oil filler to the bring the levelup to the dipstick “H” mark.

3.2.3.1EngineOilCondition

When moisture is found on the oil fill cap and/or the engine oil has a milky appearance an engine oil andfilter service is required.

1. Per form an engine oil and filter service.

2. After the engine oil and filter service, drive the unit at operating temperature 215ºF (101.6ºC)under load for at least 30 minutes.

3. Ensure the unit is driven at operating temperature for a minimum of 30 minutes every 50 hoursthereafter.

3.2.4EngineCoolantLevel

1. When the engine is warm, turn off the unit and wait until the coolant temperature is below120°F(50°C) before checking the coolant level.

2. With the engine stopped and cooled, locate the coolant reservoir/expansion tank.

3. Ensure coolant level is between the “COLD” and “HOT” markings on the radiator or reservoir/expansion tank.

CAUTION:

Never operate the engine when the oil level is below the “L” (low) mark or above the“H” (high) mark. Damage to the engine or poor engine performance may occur.

Over-filling the engine crankcase can result in oil leaks or bearing damage. Check theoil level frequently while adding oil to avoid over-filling the crankcase.

NOTE:

Due to natural environmental conditions, condensation will deposit moisture inside theengine crankcase. This moisture will be vaporized when the motor oil reaches an operatingtemperature above 215ºF (101.6ºC). Operations with short driving distances may not providethe engine with enough time for the engine oil to exceed 215ºF (101.6ºC), resulting in anaccumulation of moisture in the engine oil, causing the engine oil to have a milky appear-ance. To prevent this, all engines should be brought to operating temperature, and drivenunder load, for a minimum of 30 minutes every 50 hours.

WARNING:

THE COOLING SYSTEM IS PRESSURIZED. ESCAPING STEAM ANDHOT COOLANT CAN CAUSE SEVERE BURNS. NEVER OPEN A RADIATORCAP WHEN COOLANT TEMPERATURE EXCEEDS 120°F (50°C).

USE A CLOTH OR WEAR SUITABLE GLOVES WHEN HANDLING A HOTRADIATOR PRESSURE CAP. ETHYLENE GLYCOL ANTIFREEZE IS TOXICAND WILL IRRITATE THE SKIN. WASH ANY PART OF THE BODY THATCOMES IN CONTACT WITH ANTIFREEZE SOLUTION AS SOON AS POSSI-BLE.

NOTE:Some minor coolant loss is normal due to thermal expansion. A very low coolant level indi-cates serious leakage in the system that must be located and corrected immediately.

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4. When the coolant level is below the “COLD” marking, prepare a coolant solution with the correctamounts of antifreeze, coolant additive and water.

5. Add coolant solution to restore the fluid to the proper level.

3.2.5TransmissionOilLevel

Check the transmission oil level daily or before operation.

1. Ensure the parking brake is set.

2. Place the transmission shift lever in the NUETRAL (N) position.

3. Start the engine.

4. With the service brake pedal depressed, cycle the transmission through all gears and allow trans-mission to reach 215ºF (101.6ºC).

5. Return the shift level to the NUETRAL (N) position.

6. Pull the transmission oil dipstick out of its tube and wipe it clean.

7. Re- the dipstick, withdraw it and read the oil level.

8. When the oil level is down to the dipstick “ADD” mark, add oil through the oil filler to bring the levelup to “FULL”.

3.2.6DriveAxleGearBoxOil

The oil level can be checked in the rear axle and gear reduction box to add oil, if needed.

1. Park the unit on level ground and set the parking brake.

2. Chock the wheels and jack unit up.

3. Place jack stands under the unit and release parking brake.

4. Place warning tags on the control pane stating: “UNIT IS OUT OF SERVICE”.

WARNING: ETHYLENE GLYCOL ANTIFREEZE IS TOXIC AND WILL IRRITATE THE SKIN.WASH ANY PART OF THE BODY THAT COMES IN CONTACT WITH ANTI-FREEZE SOLUTION AS SOON AS POSSIBLE.

CAUTION:DO NOT add cold coolant to a hot engine. Engine castings can be damaged. Allow theengine to cool to below 120°F (50°C) before adding coolant.

NOTE: The transmission oil level must be checked with the engine running at its normal operatingtemperature of 215ºF (101.6ºC).

NOTE: Maintain the oil level between the “ADD” and “FULL” dipstick ranges.

CAUTION:Over-filling the transmission can result in oil leaks or possible damage. Check the oillevel frequently while adding oil to avoid over-filling the transmission.

NOTE: Refer to the transmission documentation in Chapter 5 for transmission oil recommendations/specifications.Prop

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CD444-44M 2 - 3 - 5June 2019 (Rev A)


5. Ensure that oil has cooled down before checking it.

6. Remove the plug from the oil fill port.

7. Check oil level at the filling bores.

8. If oil level is below the filling bore, fill hub assembly with clean oil until the oil level reaches the fill-ing bore.

9. After a few minutes, check the oil level again at the filling bores.

10. Keep filling with oil until the oil level remains constant.

11. Clean bore hole and oil filling plug.

12. Replace screw plug gaskets with new gaskets.

13. Screw oil filling plug back in place.

3.2.7BrakeFluidLevel

Check the brake fluid level daily or before operation.

1. Locate the sight gauge on the side of the Brake Fluid tank to observe the fluid level. See 3.3 "Ser-vice and Lubrication Points"s.

2. Add brake fluid as needed.

3. Inspect the brake lines and fittings for leaks.

4. Repair any leaks found before returning the unit to service.

5. When necessary, bleed the brakes.

6. Wipe up any spilled fluid.

3.2.8FuelLevel

1. Check the fuel level in the fuel tank using the fuel level gauge on the control panel.

2. Fill the fuel tank as needed, through its filler pipe. See 3.3 "Service and Lubrication Points".

3.2.9WindshieldFluid

1. Check all fuel line connections to ensure they are properly connected, from the fuel tank to fuelpump to injector pump (diesel).

2. Ensure cell drain valve is closed.

3. Fill fuel tank with correct fuel.

NOTE: The fluid level needs to be level with or near the bore opening.

WARNING:

EXERCISE EXTREME CAUTION WHEN PERFORMING MAINTENANCE ONTHE HYDRAULIC BRAKE SYSTEM. FLUID ESCAPING UNDER HIGH PRES-SURE CAN CAUSE SERIOUS PERSONAL INJURY. A FACE SHIELD ANDPROTECTIVE CLOTHING MUST BE WORN.

STAY CLEAR OF ANY MOVING COMPONENTS. OTHERWISE, DEATH ORSERIOUS INJURY COULD RESULT.

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2 - 3 - 6 CD444-44MJune 2019 (Rev A)


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3.3Adjustments

3.3.1ServiceBrakeAdjustment

1. Remove master cylinder

2. Measure the distance between the inner face of the piston to the tip of the push rod.

3. Adjust the length as required to be within tolerance by turning the screw on the end of the push rodin or out.

3.3.2ParkBrakeAdjustments

The parking brake lever is connected by rod to the parking brake caliper on the input shaft of the rear axle.When the lever is in the “lock” position, the rod is pulled, actuating the caliper which squeezes the padsand holds the tractor from moving. Perform the following steps to adjust the parking brake:

1. Turn the knob on the lever to the right (clockwise) to tighten the brakes

2. Turn it to the left (counterclockwise) to slacken the brakes.

3. Rotate the knob on the parking brake handle counterclockwise so the adjustment arm is approxi-mately 1” (0.40cm) from the top of the adjustment range.

4. When necessary, adjust the parking brake rod by removing the clevis pins and adjusting the yokeson each end until the rod is just starting to engage the caliper when the park brake handle is in thereleased position.

5. Install new cotter pins to secure the clevis pins.

6. Engage parking brake and un-chock the wheels

3.3.3SteeringGearBoxAdjustment

1. Locate the adjustment screw opposite the Pitman arm spline on the right hand side of the steeringgear box.

2. Remove the drag link from the Pitman arm.

3. Loosen the lock nut on the adjusting screw.

4. Turn the adjusting screw clockwise or counterclockwise until the Pitman arm does not have anyfree play in it at the straight ahead position.

5. Turn the adjusting screw an additional eighth to a quarter of a turn in the same direction used toadjust it.

6. Tighten lock nut on adjusting screw.

7. Reinstall drag link.

NOTE: This length should be 0.9" (+ 0.06").

NOTE:The rod has adjustable yokes on each end which allow for more adjustment as the parkingbrake wears. This rod can be adjusted during normal maintenance procedures while the unit ison a lift.

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CD444-44M 2 - 3 - 7June 2019 (Rev A)


3.3.4Toe-InAdjustment

The toe-in adjustment must be performed on both the rear side and front sides of tires. A level stretch ofpavement is that is flat and smooth for at least twenty feet (20 ft. or 6.1 m), is required for this adjustment.

3.3.4.1FrontSideofTires

1. Drive slowly forward with the cross spoke of the steering wheel at center, and run the unit straightwithout touching the steering wheel.

2. Apply the parking brake to stop the unit at the end of the run.

3. Place the toe-in gauge in front of the front tires and between the outside edges of the tires.

4. Ensure that the gauge is placed halfway up the tire sidewall (aligned with center of wheel).

5. Observe the number the needle is pointing to on the gauge. If the needle points to the number 2,the toe-in does not need any adjustment. If not, then continue to next step.

6. Remove the cotter pin and castellated nut from the tie rod end at the steering knuckle.

7. Adjust tie rod length as needed to achieve the needle pointing to the number 2 (1/8" or 3.175 mm)toe-in measurement.

8. Reinstall rod end, nut and new cotter pin once the needle points to the number 2 (1/8" or 3.175mm) and the appropriate toe-in is achieved.

9. Reconnect the rod.

10. Set toe-in gauge to the number 0 (90°).

3.3.4.2RearSideofTires

In order to properly adjust the rear toe-in, perform the same steps as the front toe-in adjustment on therear side tires.

3.3.5CabDoorAdjustment

To adjust a cab door:

1. Loosen the bolts on the hinges [(2) per hinge].

2. Hold door in desired position

3. Tighten bolts to secure.

3.3.6VerticalHeadlightAdjustment

1. Loosen the nut on the horizontal bolt.

2. Aim headlight in desired position.

3. Tighten the nut.

NOTE: The needle should be pointing to number 2 (1/8" or 3.175 mm) on the toe-in side of the gauge.

NOTE: To decrease toe-in, turn the tie rod end clockwise and counter-clockwise to increase toe-in.

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2 - 3 - 8 CD444-44MJune 2019 (Rev A)


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3.3.7HorizontalHeadlightAdjustment

1. Loosen the nut on the vertical shaft that holds the entire headlight assembly to the rail.

2. Aim headlight in desired direction.

3. Tighten the nut.

3.3.8ShifterAdjustment

1. Place transmission in neutral and adjust the length of the cable to fit loosely in the transmission shiftcontrol lever.

2. Move hand lever to forward and reverse position.

3. Adjust the cable for best fit in all three positions.

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CD444-44M 2 - 3 - 9June 2019 (Rev A)


NOTES

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2 - 3 - 10 CD444-44MJune 2019 (Rev A)


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3.4ServiceandLubricationPoints

Figure2-3-2:ServiceandLubricationPoints

12

2

511

7

1

6

9

15

14

4

3

8

13

10

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CD444-44M 2 - 3 - 11June 2019 (Rev A)


3.5ServiceProcedures

3.5.1EngineOilandFilterChange

Change the engine oil just after the engine has been operated and it is still warm.

1. Place the unit on level ground.

2. Apply the parking brake and chock the wheels.

3. Place a warning tag on the control panel stating: “UNIT OUT OF SERVICE”

Table2-3-2:ServiceandLubricationPoints

No. Description SpecificationCapacity

(Approximate)

1 Radiator Coolant Delo ELC 50/50 3.7 qt. (3.5 L)

2 Steer Axle Hubs/Front Wheel Bearing Multi-purpose lithium-base grease As Required

3Steer Axle (Kings Pins, Links, and Tie Rod Ends)

Multi-purpose lithium-base grease As Required

4 Hinged Hood Multi-purpose lithium-base grease As Required

5 Automatic Transmission Dexron VI 5 qt. (4.7 L)

6 Drive Shaft Joints Multi-purpose lithium-base grease As Required

7 Brake Calipers Hypoid Gear oil, SAE 90 EP As Required

8Newage Drive AxleAxletech Drive Axle (Optional)

SAE 80W-90 2.6 US gal (10 L)

*5 qt. (4.7 L)

9Newage Reduction Gear BoxAxletech Reduction Gear Box

SAE 80W-90Included in New-age Drive Axle,*1.25 qt. (1.2 L)

10 Hitch Pin Multi-purpose lithium-base grease As Required

11 Brake Pedal Linkage Pivots Multi-purpose lithium-base grease As Required

12 Steering Gear Box (Manual Steering) Hypoid Gear oil, SAE 90 EP As Required

13 Hydro-Boost DOT3, Extra Heavy Duty As Required

14 Power Steering, Hydraulic Reservoir Dexron VI0.7 US gal

(2.64 L)

15 Engine Oil 15W40 CJ-4 or 5W-20 SJ 2.11 US gal (8 L)

16Operator Seat, Adjusting Slides (Not shown)

Multi-purpose lithium-base grease As Required

17 Windshield Reservoir (Not shown) Peak Windshield Wash 50/50 As Required

CAUTION:Oil could be very hot. Protect yourself when performing an oil change by wearing rub-ber gloves.

NOTE:Most contaminants are still suspended in the oil and will be carried out when the warm oildrains

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2 - 3 - 12 CD444-44MJune 2019 (Rev A)


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4. Place a catch pan below the engine oil drain plug.

5. Clean the area around the oil filter head.

6. Locate the remote oil drain line.

7. Loosen and remove the engine oil drain plug.

8. Allow the oil to drain.

9. Install and tighten the drain plug.

10. Place a catch pan under the engine oil filter.

11. Use an oil filter wrench to loosen the oil filter for removal.

12. Remove the filter and empty its oil into the catch pan.

13. Inspect the filter mounting base assembly for deposits or dirt.

14. Remove any deposits on the filter gasket sealing surface and wipe the filter gasket sealing sur-face clean.

15. Apply thin coat of clean engine oil to the new filter gasket.

16. Install the filter on the oil filter head, tightening it until the gasket contacts the filter head surface.

17. Fill the engine crankcase as necessary to bring the oil level to the “H” mark on the dipstick.

18. Check the crankcase level with dipstick and remove the warning tag once the crankcase is full.

19. Start the unit and check the engine oil filter for leakage.

20. When needed, tighten the filter element with a strap wrench to stop any leaks.

21. Return the unit to service.

NOTE: The remote oil drain line can be accessed from the front left wheel well.

NOTE:The remote oil filter is located on the hydraulic tank on the passenger right passenger sideenclosure.

NOTE: Always refer to the filter manufacturer’s directions.

CAUTION:Do not mix oils from different refiners or of different viscosities. To prevent over-fillingthe crank case, check the oil level frequently during filling. Oil leaks and bearing dam-age could otherwise result.

NOTE:Refer to the Deutz Maintenance Manual (1.1 "Vendor Information") provided in Chapter 5 forengine oil specifications.

NOTE: Engine oil pressure must be indicated on the gauge within 15 seconds after starting.

CAUTION:Shut off the engine immediately to avoid engine damage if oil pressure is not regis-tered within 15 seconds.

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CD444-44M 2 - 3 - 13June 2019 (Rev A)


3.5.2EngineAirFilterReplacement


2. Apply the park brake.

3. Place a warning tag on the control panel stating: “UNIT OUT OF SERVICE”.

4. Open the driver side enclosure to access the air filter assembly.

5. Release the cover latches and remove the service cover.

6. Remove the primary filter and safety filter.

7. Remove any accumulated dirt or debris from the filter housing.

8. Wipe the housing clean to ensure an air-tight seal to a new filter element.

9. Check the safety filter and replace when dirty.

10. Install the safety filter and the new primary filter.

11. Re-install the service cover and fasten the four (4) cover latches.

12. Remove the warning tag and return the unit to service.

3.5.3TransmissionOilandFilterChange


2. Apply the parking brake and chock the wheels.

3. Place a warning tag on the control panel stating, “Unit is Out of Service.”

4. Jack up the unit at jack points and place jack stands under the unit as required.

5. Place a catch pan under the transmission drain plug located in the lower front of the transmissioncase.

6. Refer to the General Motor’s technician’s guide in (1.1 "Vendor Information") and perform detailedsteps as outlined.

7. Remove the warning tag from the control panel.

8. Remove the unit from the jack stands.

9. Start the engine and operate the unit for 15 minutes or until transmission fluid reaches an operat-ing temperature of 180-200ºF (82-93ºC).

10. Park Vehicle on a level surface.

11. Cycle through the gears every 3 seconds to allow the fluid to circulate stop on neutral (N).

CAUTION:Ensure no debris or dirt enters the air filter housing while it is open. Dirt or debris lateringested into the engine can cause serious engine damage.

WARNING:

TO AVOID INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT, ALWAYSUSE LIFTING EQUIPMENT, SAFETY JACKS AND CHAINS WITH A SAFEMINIMUM CAPACITY OF ONE AND A HALF (1.5)TIMES THE WEIGHT OFTHE VEHICLE BEING LIFTED.

TO AVOID INJURY TO PERSONNEL, NEVER WORK UNDER UNIT WHENUNIT IS SUPPORTED ONLY BY JACKS.

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2 - 3 - 14 CD444-44MJune 2019 (Rev A)


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12. Apply parking brake and let engine idle for 3 minutes.

13. Check the fluid level with the dipstick.

14. Add fluid as required to maintain the level in the safe operating zone.

15. Check the system for leaks before returning the unit to service.

3.5.4AxleGearBox


2. Apply the park brake.


4. Place a container underneath to catch any escaping oil and drain.

5. Remove oil seals carefully to prevent damage if to be re-used, however to prolong the life of theaxle, it is best to replace these items.

6. If removing taper roller bearings for re-use keep them in matched set.

7. Protect all bearings from contamination.

8. Rinse all metal parts in solvent to remove dirt, grease, and oil.

9. Be careful to remove solvent from items before re-fitting.

3.5.5BrakeAssembly:WheelCylinderBleed


2. Chock the wheels and apply park brake.

3. Jack the unit up and place jack stands under the unit.

NOTE: The fluid must be within the hot cross-hatched area using the lowest level reading.

WARNING:

BEFORE CARRYING OUT ANY SERVICE WORK ALWAYS ENSURE THATTHE ENGINE IS SWITCHED OFF.

REMEMBER HOT OIL CAN CAUSE BURNS - WORK SAFELY - USE COM-MON SENSE.

CAUTION:

Before removal of the Axle for repair or overhaul carefully study the following proce-dures. Use Proper hand tools, slings and hoists for the job.

Keep all work areas, tools, and axle clean. All oil should be drained into a suitable con-tainer. Wipe up any spilled oil or fluids to prevent accidents. Wear correct safety equip-ment i. e. safety glasses and safety shoes to guard against personal injury.

All operations should be carried out by suitably qualified personnel and strictly inaccordance with the procedures detailed in the Newage or Axletech workshop manual.

WARNING:

IF USING CLEANING SOLVENTS THESE CAN BE TOXIC, FLAMMABLE, ASKIN IRRITANT OR GIVE OFF HARMFUL FUMES. AVOID PROLONGEDCONTACT, VAPOR INHALATION, OR SMOKING. FAILURE TO TAKE CARECAN RESULT IN INJURY OR DEATH.Prop

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2- 3 - 15 CD444-44MJune 2019 (Rev A)

Tow Tractor Model MA Maintenance Manual

Chapter 2Section 3


5. Disconnect the batter cables of the batteries.

6. Refer to either the Newage or Axletech service manual (1.1 "Vendor Information") in Chapter 5and perform detailed steps as outlined.

7. Check the brake fluid level in the hydraulic system reservoir; and add fluid as needed.

8. Reconnect the battery cables to the batter.

9. Remove the unit from jack stands.

10. Remove warning tag.

11. Drive unit under no load conditions to ensure brake system is operating properly.

12. Place unit back in to service.

3.5.6FuelFilter

3.5.6.1FuelFilterCartridgeReplacement


2. Switch off the engine.

3. Apply the parking brake.


5. Place a container under the fuel filter to catch any escaping fuel.

6. Remove clamps when twist protection mounted (optional).

7. Loosen and unscrew filter element by turning it counter clockwise using a 32mm hex drive on thebottom of the filter.

8. Clean any dirt of the sealing surfaces of the filter support with a lint-free, clean cloth.

9. Oil the gasket of the new DEUTZ original filter cartridge lightly.

10. Screw on new filter by hand until the gasket is touching and tighten with a torque of: 10-12 Nm.

11. Fasten Clamps of the twist protection (optional).

12. Vent the Fuel System.

3.5.6.2FuelPre-FilterInsertReplacement


2. Turn off the engine.

3. Apply the parking brake.


5. Shut off the fuel supply to the engine (with high-level tank).

6. Place a container under the fuel filter to catch any escaping fuel.

7. Disconnect Electrical Cable Connections.

WARNING: INSTALL THE POSITIVE BATTERY CABLE BEFORE THE NEGATIVE(GROUND) CABLE TO AVOID ELECTRICAL SPARKS AND BURNS.

CAUTION:The filter cartridge should never be pre-filled. There is a danger of dirt contamina-tion.

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2 - 3 - 16 CD444-44MJune 2019 (Rev A)


3

8. Loosen Drain Plug.

9. Drain fluid until pure diesel fuel runs out.

10. Remove and discard the filter element.

11. Clean any dirt of the sealing surfaces of the new filter cartridge and opposite side of filter head.

12. Wet the sealing surfaces of the filter cartridge slightly with fuel and screw back on the filter head,clockwise (17-18 Nm)

13. Mount drain plug.

14. Tighten Torque to 1.6 ±0.3 Nm.

15. Reconnect electrical cable connections.

16. Open the fuel shutoff tap and vent system, see venting the fuel system in chapter 4 of the Illus-trated Parts list.

CAUTION:Do not pour fuel directly into the center of the filter, as this will allow unfiltered fuel toenter the system. Unfiltered fuel can cause damage to the fuel system components.

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CD444-44M 2 - 4 - 1June 2019 (Rev A)


Section4:Troubleshooting

The following troubleshooting tables provide information for diagnosis and correcting problems with theMA-44 Tow Tractor.These tables should be used as quick reference guide to resolving minor commonerrors.

4.1EngineTable2-4-1:EngineTroubleShooting

4.2AlternatorTable2-4-2:AlternatorTroubleshooting

WARNING:

TO AVOID INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT, ALWAYSUSE LIFTING EQUIPMENT, SAFETY JACKS AND CHAINS WITH A SAFE MINI-MUM CAPACITY OF ONE AND A HALF (1.5)TIMES THE WEIGHT OF THE VEHI-CLE BEING LIFTED.

TO AVOID INJURY TO PERSONNEL, NEVER WORK UNDER UNIT WHEN UNITIS SUPPORTED ONLY BY JACKS.

Problem Cause Correction

Loss of power

Reduction in pulling power. Check transmission per appendix.

Engine power is reduced. Check engine per appendix.

Rear axle is damaged.Check rear axle for damage and proper oil level.

Brakes are dragging.Check for stuck service and park brake pads.

No. Problem Cause Correction

1 Noisy alternator

Loose alternator belt.Check mounting, pulleys, and belts for correct tension and tightness.

Alternator bearings worn or dam-aged.

Replace alternator.

2Alternator output consistently high

Incorrect wiring.Check wiring connections at alter-nator and battery.

High electrical system load.Check for high current draws in electrical system.

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2 - 4 - 2 CD444-44MJune 2019 (Rev A)


4

4.3RearAxleTable2-4-3:DriveAxleTroubleshooting

4.4SteeringTable2-4-4:SteeringTroubleshooting


Rear axle noise

Low oil.Check lubrication level. Top off as needed.

Dirty drop box oil.Check drop box magnetic plugs for metal chips.

Dirty axle oil.Check axle magnetic plugs for metal chips.

Damaged wheel bearings.Check bearings for damage and proper lubrication.

Damaged internal axle components.Tear down and inspect axle and drop box. Repair or replace damaged parts.


1Manual steering

difficult

Steering gearbox not lubricated. Check lubrication.

Drag link joints not greased. Add grease to joints.

King pins not greased. Add grease to kin pin.

2Power steering

difficult

King pins not greased. Add grease to kin pin.

Hydraulic system contaminated.Flush hydraulic system and replace fluid with clean fluid.

Damaged steer valve.Check valve, replace if damaged or faulty.

Worn/damaged steer cylinder.Replace steer cylinder or repair seals.

3Front wheel

appears to wobble

Lug nuts loose. Torque lugs to proper value.

King pin worn. Check studs and king pins.

Wheel bearing worn.Check bearings and hubs. Repair or replace as required.

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CD444-44M 2 - 4 - 3June 2019 (Rev A)


4.5BrakeSystemTable2-4-5:BrakeSystemTroubleshooting

4Steering wanders or weaves

Wheel bearings worn or not lubri-cated.

Replace wheel bearings or lubricate as necessary.

Toe-in mis-adjusted. Check toe-in and adjust.

Steering gearbox loose.Check steering gearbox mountings and tighten as necessary.

Steering gearbox has too much backlash.

Check steering gear box for back-lash adjustments or replace gear-box if gears are worn.

5Vehicle pulls to one

side

Brakes are dragging.Check brakes and replace calipers as necessary.

Wheel bearings seized. Check wheel bearings.

Tires are mis-matched, mis-inflated, or differently worn.

Check tire “match” and inflation.


1Excessive stopping

distance

Brake pads worn.Check brakes pads for glazing or excessive wear. Place as neces-sary

Brake fluid under-filled or bad.Check fluid level and refill if neces-sary. Flush and replace fluid if past PM cycle.

Air in brake circuit. Bleed Brakes.

2Brakes drag or

uneven pullBrake pad dragging.

Check pads and rotor for damage or incorrect parts. Check for seized pistons.

3Brake spongy or excessive travel

Brake system fluid leak.Check fluid lines, fittings, and mas-ter cylinder for leaks.

Air in brake circuit. Bleed brake system.

4 Hard pedal

Brake booster (where applicable) not getting adequate hydraulic flow.

Check hydraulic pressure relief valve is adjusted to 850 PSI (5.86e+6 kPa).

Brake booster (where applicable) is damaged.

Check booster for pressure or leak-ing.

Seized brake pedal. Inspect brake pads and rotor.


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2 - 4 - 4 CD444-44MJune 2019 (Rev A)


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4.6ElectricalSystem4.6.1Battery

Table2-4-6:BatteryTroubleshooting

4.6.2Lights(Twelve(12)VoltSystem)

Table2-4-7:LightsTroubleshooting


Battery will not stay charged

Battery is worn out.Check for low battery voltage (indicat-ing dead battery). Replace battery.

Alternator is not charging battery. Check alternator output & belts.

Wire is broken. Check for breaks in wiring.

Component is draining battery with ignition off.

Check for large current draw with vehi-cle off.


1Poor, intermittent, or

no headlight

Blown fuse or tripped circuit breaker.

Check fuse or circuit breaker.

Headlight burned out. Replace LED Bulb.

Switch damaged.

Check headlight switch (or pres-sure switch on transmission if headlights are wired through trans-mission).

Wired incorrectly.Check wiring & ground connec-tions.


no Stop lights



Taillight burned out. Check bulbs or lamps.

Brake pressure switch damaged. Check brake light switch.

Wired incorrectly.Check wiring and ground connec-tions.

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CD444-44M 2 - 4 - 5June 2019 (Rev A)


4.6.3WiperMotor

Table2-4-8:WiperMotorTroubleshooting


no back-up lights



Back-up light burned out. Check bulbs or lamps.

Mis-adjusted switch or bad relay.Check reverse switch under shifter or reverse relay.

Transmission software incorrect.

Check that TCM is grounding when vehicle is in reverse (if reverse wired through TCM and reverse relay. Check schematic to confirm).


4Poor, intermittent, or no turn signal lights



Bad flasher relay. Check relay.

Turn signal light burned out. Check bulbs or lamps.

Wired incorrectly.Check wiring, connections, and grounds.

5Poor, intermittent, or no cab marker lights



Broken switch. Check relay or switch.

Wired incorrectly. Check wiring & connections.

Cab marker lights burned out.Check sockets, bulbs, or lamps. Replace bulb/lamps as required.


Wiper motor works intermittently, or will

not work




Broken switch. Check wiper control switch.

Burned out motor. Check motor.


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2 - 4 - 6 CD444-44MJune 2019 (Rev A)


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4.6.4Horn

Table2-4-9:HornTroubleshooting

4.6.5ElectricEngineFan

Table2-4-10:ElectricFanTroubleshooting


1Horn work intermit-tently, or no sound



Bad horn relay. Check relay.

Wired incorrectly.Check wiring, horn button, and grounds for horn button and switch.

Burned out speaker. Check horn speaker.

2Horn sounds contin-

uously

Wiring short.Check for shorted wire between horn button and relay.

Damaged horn button. Check for a stuck horn button.

Relay stuck closed. Check relay.


Works intermittently, or won’t work


Check circuit breaker.

Incorrectly wired.Check wiring and ground connec-tions.

Bad or mis-wired temperature sen-sor.

Check temperature sensor.

Bad fan controller. Check fan control circuit board.

Burned out fan motor. Check fan motor.Propert

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CD444-44M Chapter 2 - 5 - 1June 2019 (Rev A)


Section5:SystemSchematics

This section provides electrical and hydraulic information for diagnosing and correcting problems with theMA-44 Tow Tractor.The following pages display schematics to assist in the location of electrical wiringand hydraulic routing.

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Chapter 2- 5 - 2 CD444-44MJune 2019 (Rev A)

Tow Tractor Model MA-44 Maintenance Manual

Chapter 2Section 5

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CD444-44M 2 - 5 -3June 2019 (Rev A)

5.1ElectricalSchematics

Figure2-5-1:MA-44StandardElectricalSchematicWRG-MA-STD-44_103_RevA(Page1of6)

M

1

2

3

2

12 VOLTBATTERY

1

43

STARTERRELAY R5

A35

D+

B+

W

ALTERNATORBOSCH

A45 A23

85

86

87

30

ST

BAT IGN

OFF

SWITCHIGNITION

F125A

K1 K3 K5 K35

BD1

BAT

ALT

ALT

ALT

1

1A

REF. SHT-4

REF. SHT-2

REF. SHT-4

G2

P3

2

1

3D

P6

41

2

A1

B1

A1

B1

P2

1

B+

G2

SWITCHSAFETY

NEUTRAL

WH

T

SW2

SW3

F230A

C1

D1

P2

2

K15

GRN

K68

STATERMOTOR

ANDBENDIX

GP

SWITCHDIAGNOSTIC

ENGINE

SW4

K19

GN

D

EDC17CV54 CONNECTOR

D1

ECM

+

ECM +

C1

DIODE1N5406

5252

BAT

50

ECM

-K35

ECM

-K15

ECM

-K68

ECM

-K19

ECM

-K1

POS

POS

BAT

1B

1

1A

1B

1

1A

1

1A

1B

K73

ECM

-K73

ECM

-K28

K28

2

PX17

3

ECM

-K73

ECM

-K28

1

P10

2

R1.3GLOWPLUG

R1.2

1 2

PX18

R1.4 R1.1

RELAY R6PRE HEAT

4 3

2P20

51

50

ECM

-A23

ECM

-A45

ECM

-A35

51

ECM

-A23

POS

50

1

POWERMAIN

RELAY R4

G2

3D

3D3D

G2

G2

BLK

REF. SHT-55252525252

TCU-10 TCU-10

ECM

-K3

ECM

-K5

PD2.2

ECM

-K35

ECM

-K15

ECM

-A45

ECM

-A35

52

RADIATOR

ELECTRIC FAN A2

A15

ECM

-A15

86

85 87

30

FAN RELAYRADIATOR

ENGINE

R7

CB240A

2P18

1 3

BLK

RED

WH

T

4

YEL

G1

G1

G3

ECM

-A15

P6

EP

2 2

G1

USEDNOT

1212

1B

1111

SHIFTER

A1

1

1A

1B

CB1150A

DUETZ ENGINEPRE HEAT

ECM

-A15

REF. SHT-4G1

+

-

SPL-30

SPL-29

GROUNDCHASSIS

50 50 50 50

BAT BAT

POS

ALT

POS

ALTALTALT

G2

BAT

ALT

GLOWPLUG

GLOWPLUG

GLOWPLUG

REF. SHT-4G2G2G2 G2G2

1B1B

1B1B

1B

PD2.1

BLK

51

51

B+

ECM

-K35

ECM-K35

2

1

P8

REF. SHT-51818

1818

18

ECM

+

SPL-2

SPL-1MAIN

ECM-A15

CIRCUIT BREAKER

ECM-K68

ECM-K68

ECM

-A15

G3

G3

TCU-10

TCU

-10

TCU

-10

TCU

-10

F1315A

E10

F10

P1

27

P1

26

Propert

y of A

merica

n Airli

nes

2 - 5 -4 CD444-44MJune 2019 (Rev A)

Tow Tractor Model MA-44 Chapter 2Maintenance Manual Section 5


RELAY R3FUEL PUMP

G7

K2 K4 K6

EDC17CV54 CONNECTOR

2 3

+

6 5 4 1

-

+

K46

WH

T

RED

GRNBLK

BLU

YEL

K63K62

ACCELERATOR PEDALSWITCH SW5

LOW COOLANT

K29 K87

+S -

K13 K48

LT2WARN LT

PRE-HEATENGINE

WARN LTCODE

ENGINE

LT3

K70 K65

FILTER SW6WATER IN FUEL

K64K57

F1120A

C4

D4

11

D4

P2

C4

MMOTORFUEL PUMP

ELECTRIC

G8

K90 K26

C7

35

K16

ECM

-K64

ECM

-K57

30 86

87A 8587

ECM

-K90

ECM

-K26

79

34

2P1

20P1

A8

-

+

G7

G7

P21

-+

-+

BLK

BLK

BLK

BLK

ECM

-48

AMBER AMBER

REF. SHT-1 1A 1A1A 1A

PD2.2

ECM

-K6

ECM

-K4

ECM

-K2

ECM

-K16

ECM

-K46

ECM

-K63

ECM

-K62

ECM

-K16

ECM

-K46

ECM

-K63

ECM

-K62

ECM

-K29

ECM

-13

ECM

-87

P19

3 1 2

ECM

-K29

ECM

-13

ECM

-87

ECM

-K29

ECM

-K29

ECM

-K29

ECM

-K29

ECM

-48

ECM

-K70

ECM

-K65

ECM

-K70

ECM

-K65

ECM

-K64

ECM

-K57

ECM

-K64

ECM

-K57

PD2.2

P14

1 2

A7

C8

EDC17CV54 CONNECTOR

A3

35

M5ECM

-K70

ECM

-K70

ECM

-K62

ECM

-K46

ECM

-K46

ECM

-K63

ECM

-K62

SPL-36

ECM-K62

SPL-37

SWITCHVALIDATION

POTENTIOMETERACCELERATOR

-S - S +

ECM

-K16

REF. SHT-4

G7

SPL-3

ECM

-K29

SPL-4

SPL-5

1A1A

K61

PD2.1

FUEL LOW PRESSURE

14 23

U P

A44

ENGINE OIL PRESSURE

14 23

U P

26

ECM

-A29

ECM

-A29

ECM

-K61

ECM

-K61

ECM

-K61

BOOST TEMP PRESSURE

14 23

Up&t

ECM

-A44

ECM

-A44

ECM

-A24

ECM

-A24

A43

ECM

-A43

ECM

-A24

ECM

-A40

ECM

-A43

ECM

-A40

282223

A24 A40

ECM

-A29

ECM

-A44

ECM

-A43

ECM

-A24

ECM

-A40

ECM

-A44

ECM

-A43

ECM

-A24

ECM

-A40

2 4

P12

2 4

1

P15

P12

ECM

-A29

ECM

-K61

ECM

-A24

EDC17CV54CONNECTOR

27

A29

REF. SHT-3

REF. SHT-3ECM-A40

ECM-A29

1P15

ECM-A24

17

PX17

Propert

y of A

merica

n Airli

nes


CD444-44M 2 - 5 -5June 2019 (Rev A)


24

Ut

2 1

ECM

-A40

ECM

-A27

ECM

-A27

Ut

2 1

ECM

-A28

AIR INLET TEMP COOLANT TEMP

ECM

-A29

ECM

-A28

29

A27 A28

ECM

-A27

ECM

-A28

ECM

-A27

ECM

-A28

REF. SHT-2

REF. SHT-2

PD2.1

PX17

21

ECM

-A33

CYL 1 INJECTOR

ECM

-A16

3562

ECM

-A33

ECM

-A16

ECM

-A33

ECM

-A16

ECM

-A33

ECM

-A16

A16A33

TWISTEDPAIR

21

ECM

-A46

CYL 2 INJECTOR

ECM

-A03

4140

A03A46

21

ECM

-A32

CYL 3 INJECTOR

ECM

-A02

38

A02A32

21

ECM

-A48

CYL 4 INJECTOR

ECM

-A18

3742

A18A48

ECM

-A46

ECM

-A03

ECM

-A32

ECM

-A02

ECM

-A48

ECM

-A18

ECM

-A46

ECM

-A03

ECM

-A32

ECM

-A02

ECM

-A48

ECM

-A18

ECM

-A03

ECM

-A32

ECM

-A02

ECM

-A48

ECM

-A18

ECM

-A46

TWISTEDPAIR

61

TWISTEDPAIR

TWISTEDPAIR

21

ECM

-A05

ACTUATOR MPROP

ECM

-A04

1920

A04A05

TWISTEDPAIR

TWISTEDPAIR

ECM

-A05

ECM

-A04

ECM

-A05

ECM

-A04

ECM

-A05

ECM

-A04

FUEL RAIL PRESSURE

1 2 3

UP

ECM

-A25

31

A25

ECM

-A26

25

A26

ECM

-A07

32

A07

ECM

-A25

ECM

-A26

ECM

-A07

ECM

-A25

ECM

-A26

ECM

-A07

ECM

-A25

ECM

-A26

ECM

-A07

21

ECM

-A52

CAMSHAFT SPEED

ECM

-A37

1413

A37A52

n U

ECM

-A52

ECM

-A37

ECM

-A52

ECM

-A37

ECM

-A52

ECM

-A37

9

SHIE

LD

A35

ECM

-A35

21

CRANKSHAFT SPEED

1521

A39A54

n U

ECM

-A54

ECM

-A39

1

A38

ECM

-A38

SHIE

LD

SHIE

LD

SHIE

LD

ECM

-A54

ECM

-A39

ECM

-A54

ECM

-A39

ECM

-A54

ECM

-A39

EDC17CV54 CONNECTOR EDC17CV54 CONNECTOR

ECM-A40

ECM-A29

PX17

48

A20

EXHAUST GAS RECIRCULATION

+-

21

ECM

-A20

ECM

-A19

3 4 5

A19

ECM

-K82

K82

ECM

-K85

K85

ECM

-K44

K44

TWISTEDPAIR

TWISTEDPAIR

47 51 46 50

ECM

-A20

ECM

-A19

ECM

-K82

ECM

-K85

ECM

-K44

ECM

-A20

ECM

-A19

ECM

-K85

ECM

-K44

ECM

-A20

ECM

-A19

ECM

-K85

ECM

-K44

ECM-K82

ECM-K85

ECM-K44

PD2.2

EDC17CV54CONNECTOR

GND SIG 5V

PX17G3

Propert

y of A

merica

n Airli

nes

2 - 5 -6 CD444-44MJune 2019 (Rev A)



K54 K76

FM

CAN

0 C

UST

OM

ER C

AN

H

H

CAN

1 D

IAG

NO

STIC

CA

N H

G

K75 K53

CAN

0 C

UST

OM

ER C

AN

L

CAN

1 D

IAG

NO

STIC

CA

N L

ECM

-K75

ECM

-K53

F415A

A2

B2

A

DIA

GN

OST

IC P

LUG

IGN

PW

R

4

B2

P2

1A

2

B

DIA

GN

OST

IC P

LUG

GRO

UN

DG

1

DIAGNOSTIC CONNECTOR& POWER WIRES FOR

ENGINE CAN BUS

E4

12

F1215A

F4

F4

P2

E4

EDC17CV54

REF. SHT-5

REF. SHT-5

E1

3

F315A

F1

F1

12P1

15

24

D5

F515

3086

87A85 87

D5 F5

F6 D6 E6

RELAYR2

VEHICLEHORN

F6

SWITCHSW7

HORNBUTTON

HORNAL1

VEHICLE

25P1

31

4

USEDNOT

D6

13

E6

G5

F1

P17

PAIRTWISTED

32

G1

G1

G9

TRANSMISSION CONTROLTCU CONNECTOR PLUG C1

REF. SHT-1

P11

12

BLK

32

10

RED

1

32

11

YEL

1 7

TCU

-1

TCU

-7

TCU-1

TCU-7

WH

T/RE

D

WH

T/BL

K

1

1A

15

1

1A

1

1A

1

1A

1

1

1

-

+ TRANSTEMP

WARNING

BLK

8

PNK/

LT G

RN

LT4

TCU-10 TCU-10 TCU-10

TCU

-10

TCU-10

TCU-1

TCU-7

CAN LCAN H

CUSTOMER

CAN LCAN H

DIAGNOSTIC

ECM

-K54

ECM

-K76

P5

1

REF. SHT-5

4

444

TCU-1

TCU-7

ECM

-K75

ECM

-K53

TWISTEDPAIR

4

G2

G2

4

CONNECTOR

11

TCU

-10

TCU

-10

TWISTEDPAIR

TWISTEDPAIR

P2

44

TWISTEDPAIR

TCU

-11

TCU

-8

TCU

-8

G9

G9

PAIRTWISTED

PD2.2

WIRE HARNESSTRANSMISSION

23

1A1A

BLK

TRANSMISSION OUTPUT SHAFTSPEED SENSOR PLUG C-2

OPTIONAL COM P C-3(NOT REQUIRED FOR USE)

REF. SHT-1

4

G1

G1 G1

G9

SPL-16SPL-10

EDC17CV54CONNECTOR

PD2.2

K88

ECM

-K88

1 1

11

1 1 REF. SHT-5

2

3

1 6

5

4

2

3

1 6

5

4

A B

PIN 2 - CAN BUS SIGNAL HIGH

PLUG "A" (P9B)

PIN 1 - IGNITION POWER

PIN 3 - CAN BUS SIGNAL LOWPIN 4 - CAN SHIELDPIN 3 - FUEL SENDING UNIT

DIGITAL DIGITAL DISPLAYGA3

(OPTIONAL)

SPL-6

SPL-8

ECM

-K54

PAIRTWISTED

REF. SHT-5

4

4

REF. SHT-1

REF. SHT-2

B2

ECM

-K54

SPL-7ECM-K54

TWISTEDPAIR

ECM-K76

SPL-9

ECM

-K76

SPL-11

23

23

44

REF. SHT-423

2323

REF. SHT-5G2

RESISTOR120 OHM

10 WRS 2

SPL-41 SPL-40

RESISTOR120 OHM

(10 W)R1SPL-7

SPL-9

Propert

y of A

merica

n Airli

nes


CD444-44M 2 - 5 -7June 2019 (Rev A)


FUEL LEVELGAUGE GA2

4

2

1

3P7

23 G2 4

SW9SWITCH

HEADLIGHT

SENDING

FUELTANK

UNIT

G2

G2

HOUR METERGAUGE GA1

4

21

3

1

4

-+ SHIFTER

BACK LTLT6

LIGHTRELAY R1

EXTERIORAND DASH

E2

6

F620A

F2

F2

P2

E2

A5

C5

3086

87A85 87

A5 C5

C6 A6 B6

C6 A6

3 21

USEDNOT

B6

10

P1

22 11P1

3P10

GN

DBL

U

5

11

11

11

C3

8

F825A

D3

D3

P2

SWITCHSW10

BRAKELIGHT

G10

C3

EDC17CV54 CONNECTORK71

ECM

-K71

P4

F515A

C2

D2

5

D2

P2

C2

30

G2

G2

4

30

REF. SHT-4

REF. SHT-4

1

1A

23G

9

30

10TURN SIGNALSWITCH SW11

+

(OPTION)

PILOT LT13

GRN

RED

GRY

BLK

BLU

P9

7

2

5

3

4

DIODE1N5406

TAIL/TURN LTLEFT REAR BRAKE

LT11

TAIL/TURN LTRIGHT REAR BRAKE

LT12

BLK

WHT

2

RED3

BLK

WHT

2

RED3

1

3

4

53

54

30

101

78

LT9TURN LT OPTION

LEFT FRONT

BLKWHT

P16D

12

LT10TURN LT OPTION

RIGHT FRONT

BLKWHT

P16F

12

P16

2

3

P22

7

1P16

1010

101

10

5P10

9P13

G

G5

G5

G5

G5

G5

G5

G2

REF. SHT-6

10

5

1

1A

-

+-

+-

+-

+-

YEL

P

18

1

1A

4

-

+BRAKEWARNING

LIGHTLT5

BLK

PSWITCHSW8

BRAKE SYSWARNING

BLK

33G

ND

4

4

1

1A

1

1A

1

1A

4

4REF. SHT-4

PD2.2

30

5

30

P16

81

P13

8585

85

REF. SHT-6

18

82

8383 82

86

82

86

RES1

REF. SHT-1 18

85

33

LT7HEADLIGHT

FRONTLEFT

BLK

P10A

1

+

-

P10A

2

WH

T

LT7HEADLIGHT

FRONTRIGHT

BLK

P10C

1

+

-

P10C

2

WH

T

10

SPL-18

10

30

SPL-17

SPL-13

1REF. SHT-4 11

11

1

G2

18

SPL-28

1818181818

SPL-32

REF. SHT-1

REF. SHT-4

G2

G2

G2

G2

G2

G2

G2

G2

P9

SPL-40

SPL-39

SPL-25

DIODE1N5406

85

BD2

BD3

+

-

+

-

HDLT

SPL-1HDLT

G5

G5

G5

G5

P16D

P16F

8080

4REF. SHT-4

4

P1

REF. SHT-1

52

52

5252

5252

5252 52 52

23

SPL-26

REF. SHT-4 23

2323

23

SPL-124444

4 4

4

4

SPL-19

10

G2

LIGHTING

OPTIONALCAB MARKER

USED FOR

P13

7101

G2

1

P1

P4

P4

1

REF. SHT-6

18

18

G10

G10 REF. SHT-6G10 G10

SPL-21

REF. SHT-6

REF. SHT-6

18

REF. SHT-6

REF. SHT-6

52

SPL-22

3

P22

4

LIGHTING

OPTIONAL CABBRAKE/TURN

USED FOR

P22

SPL-23

10

P22

LIGHTING

OPTIONAL CABAMBER TURN

USED FOR

SPL-24

11

P22

LIGHTING

OPTIONAL CABAMBER TURN

USED FOR

5

P13

LIGHTING

OPTIONAL REARAMBER TURN

USED FOR

6

P13

LIGHTING

OPTIONAL REARAMBER TURN

USED FOR

80A

80A

81A

81A

11P13

2323

SPL-2

SPL-1

G10

G

CP5

7

77

9CP5

3

4

CP5

83

82

101

56A

53

54

55A

SPL-42

RIG

HT

TURN

LEFT

TU

RN4

WAY

Propert

y of A

merica

n Airli

nes



2 - 5 -8 CD444-44M June 2019 (Rev A)


REF. SHT-5 1

1AREF. SHT-5

+ -+-

3

P2

RED

3

P3

12

LT17LIGHT

REVERSE

LT16LIGHT

REVERSE

RED

1P2

LEFT REARRIGHT REAR

5

BLK

SWITCHLIGHT

SW14

REVERSE

4P10

BLK

37

1P13

ALARMAL2

REVERSEREAR

12A

12

G10

GRY

/BLK

A3

7

F715A

B3

B3

A3P9

REF. SHT-5

XL

D3

DIODE1N5406FLASHER

TURN SIGNALSOLID STATE

(FL1)

8

P2

1P9

17

17B

BLK

G3

P10

12P13

G10

(OPTION)

86

6P9

17

YEL

17

17

17

YEL YEL

1

1A

A4

10

F1020A

B4

B4

P2

47

8P22

A4

SW17SWITCHWIPER

47

(0PTION)

6463

63

5

MM2

MOTOR

FRONTWIPER

+

-

P229

G4

(OPTION)

63

63

65

G4

-

+ CABDOMELIGHTLT18

SWITCHSW15

DOME LT

RED

HL

M FANVENTILATION

(OPTION)

CAB

M4

BLK

L M

MOTORHEATER

CAB

M M1

60

SW16SWITCH

CABFRONT

HEATER

HL M

B

(OPTION)

6260BL

K

(OPTION)

6161

21

LED LIGHTBEACON

FLASHING/

LT20

FLASHUNIT

BLK

YEL

BEACONPROGRAMING

WIRE

RED

E3

9

F920A

F3

F3

P2

C

+

-

ROTATING

G6 G6

G6

G6

83A

BLK

BLK

6

P22

59

5959

59

68

4747

SW12SWITCH

WORK LIGHTREAR HITCH

SW13SWITCH

WORK LIGHTFRONT HITCH

18

410P13

+

-

+

-LT14

WORK LIGHTREAR HITCH

LT15WORK LIGHT

FRONT HITCH

49 48

49

4848

WH

T

WH

T4

P10

1

P10B

BLK

BLK

2

P10B

5

P16

(OPTION) (OPTION)

G5

3

P27

G5

YEL

P22

12

REF. SHT-5

G3G3G3

G3

G3

86

8

E3

1A 1A 1A

SPL-14

SPL-15

68

62

H

BLK

3

18

SPL-2

WH

T

1P3

WH

T

GG

59

G3

18REF. SHT-5

P16

G10G10G10

6

P27

G10

REF. SHT-5 G10

G10

G10

SPL-25

47

47

47474747

37

1

P22

2

(OPTIONAL)REVERSE LTS

37

37

2

12

37

SPL-20

REF. SHT-5

REF. SHT-5

G3

86

CAB ROOF 12

12

RED

YEL

P23

ORG

Propert

y of A

merica

n Airli

nes


CD444-44M 2 - 5 -9June 2019 (Rev A)

5.2HydraulicSchematics

Figure2-5-7:MA-44HydraulicSchematicHYD-MA-44(Page1of2)

1

3

ENGINE

1000 PSI

4 GPM

PR

4

5

7

6

8

2

Propert

y of A

merica

n Airli

nes

2 - 5 -10 CD444-44MJune 2019 (Rev A)


Figure2-5-8:MA-44HydraulicSchematicHYD-MA-44(Page2of2)

ENGINE

1000 PSI

4 GPM

PR

P

T

L R

5

4

1

3

7

910

11

12

13

6

2

8

Propert

y of A

merica

n Airli

nes

Chapter 2: Preventive Maintenance - Amazon Web Services€¦ · 2 - 1 - 4 CD444-44M June 2019 (Rev...

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Transcript of Chapter 2: Preventive Maintenance - Amazon Web Services€¦ · 2 - 1 - 4 CD444-44M June 2019 (Rev...