MODEL T-137 CURTIS Property of American Airlines Maintenance · 2018-12-03 · T-137 CURTIS...

MODEL T-137 CURTIS

CHARLATTE AMERICA, INC. 600 MOUNTAIN LANE – P.O. BOX 968

BLUEFIELD, VA 24605 TELEPHONE: (276) 326-1510

FAX: (276) 326-1602 SPARE PARTS FAX: (276) 326-3898 e-mail: [email protected]

www.CharlatteAmerica.com www.MyCharlatte.com

U.S. AIRWAYS - REVISION “D” - 7/9/14 THIS GUIDE IS TO BE USED ONLY WITH THE MODEL T-137. OTHER MODELS IN THIS SERIES MAY HAVE OPERATING FEATURES UNLIKE THE MODEL T-137.

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CHARLATTE OF AMERICA, INC. T-137 CURTIS ELECTRIC TRACTOR

Chapter 2 Contents June 14

CHAPTER 2 MAINTENANCE

TABLE OF CONTENTS CHAPTER/SECTION PAGE I. SERVICING ......................................................................... 2-1

A. General Maintenance Instructions .......................................................................................... 1-1 B. Preparation For Initial Use ....................................................................................................... 1-3 C. Maintenance Check List ........................................................................................................... 1-5 D. Preventive Maintenance Schedule .......................................................................................... 1-6

1. Daily ..................................................................................................................................... 1-6 2. Monthly Or Every 50-75 Hours .......................................................................................... 1-8 3. Every Three Months Or Every 150 Hours ....................................................................... 1-10 4. Yearly Or Every 500 Hours .............................................................................................. 1-12

E. Lubrication Chart .................................................................................................................... 1-13 F. Lubrication Alphabetical Table .............................................................................................. 1-17 G. Lubricants, Fluids, And Capacities ....................................................................................... 1-18

II. ADJUSTMENT INSTRUCTIONS ......................................... 2-2 A. Front Brakes .............................................................................................................................. 2-1

B. Rear Brakes ............................................................................................................................... 2-1 C. Brake Pedal ................................................................................................................................ 2-5

D. Parking Brake ............................................................................................................................ 2-6

E. Brake Light Switch .................................................................................................................... 2-8

F. Foot Brake Switch ..................................................................................................................... 2-8

G. Toe-In ......................................................................................................................................... 2-9

H. Steering Pump ......................................................................................................................... 2-11

I. Accelerator Pedal .................................................................................................................... 2-11

J. Steer Stops .............................................................................................................................. 2-11

K. Seat Switch .............................................................................................................................. 2-12

L. AC Motor Controller ................................................................................................................ 2-12

M. Brake Bleeding ........................................................................................................................ 2-13

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T-137 CURTIS ELECTRIC TRACTOR CHARLATTE OF AMERICA, INC.


CHAPTER/SECTION PAGE N. Discharging/Recharging Hydraulic Pressure From Accumulator ..................................... 2-14 O. Service Mode / Service LOS ................................................................................................... 2-14 P. Setting Power Steering ........................................................................................................... 2-16

III. COMPONENT REMOVAL / INSTALLATION ...................... 2-3

A. Battery ........................................................................................................................................ 3-1 B. Tires & Wheels .......................................................................................................................... 3-3 C. Front Brakes .............................................................................................................................. 3-6 D. Rear Brakes ............................................................................................................................... 3-9 E. Parking Brake Assembly ........................................................................................................ 3-11 F. Master Cylinder/Brake Pedal ................................................................................................. 3-12 G. Front Axle ................................................................................................................................ 3-14 H. Steering Linkage ..................................................................................................................... 3-23 I. Rear Axle Assembly ................................................................................................................ 3-26 J. Pump/Motor ............................................................................................................................. 3-30 K. Operator Column / Operators Dash Controls ...................................................................... 3-31 L. Steering Valve ......................................................................................................................... 3-34 M. Hydraulic Hoses ...................................................................................................................... 3-36 N. Converter ................................................................................................................................. 3-37 O. AC Controller ........................................................................................................................... 3-38 P. Accelerator Pedal Switch ....................................................................................................... 3-40 Q. Parking Brake Switch ............................................................................................................. 3-42 R. Seat Switch .............................................................................................................................. 3-44 S. Accumulator System .............................................................................................................. 3-46 T. AC Traction Motor ................................................................................................................... 3-47

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CHAPTER/SECTION PAGE IV. TROUBLE SHOOTING ....................................................... 2-4

A. General Information .................................................................................................................. 4-1 B. Hydraulic System ...................................................................................................................... 4-2 C. Hydraulic Pump/Motor .............................................................................................................. 4-4 D. Steering ...................................................................................................................................... 4-8 E. Steering Cylinder ...................................................................................................................... 4-9 F. Brakes (Service) ...................................................................................................................... 4-10 G. Brake, Parking ......................................................................................................................... 4-13 H. Electrical / AC Controller ........................................................................................................ 4-14 1. General Diagnostics/Solutions .......................................................................................... 4-14 1. Charlatte Specific Fault Codes ......................................................................................... 4-17 2. General Fault Codes .......................................................................................................... 4-18 I. Rear Drive ................................................................................................................................ 4-25

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THIS PAGE INTENTIONALLY LEFT BLANK

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Chapter 2 Page 1-1 Sept. 13


I. SERVICING

A. General Maintenance Instructions

Long reliable service and the safety of those working with this unit can only be ensured by conscientious periodic maintenance of the machine.

Anyone performing maintenance on this machine should be trained to operate it and must be familiar

with this guide.

BEFORE MAINTENANCE OR SERVICING: 1. SHUTDOWN the unit on level ground (See Shutdown Procedure, Chapter 1, page 3-15). 2. Turn Master Switch to the “OFF” position. If work is to be done on the electrical system, the

battery should be disconnected. 3. Test all controls to be sure the unit will not operate. 4. Chock all four (4) wheels in both directions. During maintenance or servicing, if the motor is to be run, the unit must be jacked clear of the ground

and securely blocked. Both rear wheels must be free to rotate.

DO NOT perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity. The maintenance area should be as clean as possible.

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected by a qualified service technician.

CAUTION 1. THE MOTOR COULD BE DAMAGED BY ALLOWING IT TO REACH FULL SPEED WITH NO

LOAD.

2. REDUCE THE MOTOR SPEED SLOWLY. DO NOT ALLOW THE ACCELERATOR PEDAL TO GO INSTANTLY TO ZERO AS THE REGEN MAY STOP THE MOTOR INSTANTLY RESULTING IN DAMAGE.

WARNING IF WORK IS TO BE DONE ON THE AC MOTOR CONTROLLER, AC TRACTION MOTOR, OR THE DC-DC CONVERTER THAN THE AC CONTROLLER CAPACITORS WILL NEED TO BE DISCHARGED. THESE CAPACITORS WILL RETAIN A HIGH VOLTAGE CHARGE EVEN AFTER THE BATTERY HAS BEEN DISCONNECTED. WEAR HIGH VOLTAGE INSULATED RUBBER GLOVES AND A FACESHIELD DURING CAPACITOR DISCHARGING. MAKE SURE THAT THE CAPACITORS ARE COMPLETELY DISCHARGED BEFORE CONTINUING ANY PROCEDURE. REFER TO CHAPTER 5 FOR MORE DETAILS.

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CLEANLINESS cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

NOTICE DO NOT OPERATE ANY CONTROL UNLESS YOU ARE CERTAIN THAT NO ONE COULD BE INJURED BY THE MACHINES MOVEMENT. DISCONNECT BATTERY BEFORE WORKING INSIDE THE ELECTRICAL CONTROL BOX.

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B. Preparation For Initial Use

1. Wash down the unit and remove any foreign material from the operator’s compartment.

2. Inspect electrical cables, conduits, hydraulic hoses, brake hoses, and fittings for signs of wear or damage.

3. Check all terminals and connectors for tightness and security.

4. Check the operation of the converter by testing the headlights, taillights, horn, back up alarm, and any other safety accessories installed on the unit. Before the converter is replaced, refer to the troubleshooting section.

5. Visually inspect the condition and readability of all warning tags, labels, lights and reflectors. Replace any found missing or damaged.

6. Make a visual inspection of the tires, checking for damage and lack of proper inflation. Any damage observed on the three piece rims MUST be checked by a qualified repair person before the tractor is moved. This damage could be cracking in the paint, bends on the rim surface,or any other obvious distortion of the rim.

These same checks and inspections apply to solid tires.

7. Check the entire length of the unit for signs of fluid leakage.

8. Check master cylinder for proper fluid level. (The fluid reservoir is located under the floorboard in front of the brake pedal and is reached by turning the knob and lifting the lid.)

NOTICE THE FOLLOWING LIST OF MAINTENANCE CHECKS SHOULD BE PERFORMED BY A QUALIFIED MAINTENANCE TECHNICIAN BEFORE UNIT IS PUT INTO SERVICE. FOR MORE DETAILED INSTRUCTIONS ON MAINTENANCE PROCEDURES SEE PAGES 1-4 THROUGH 1-18.

ALL MAINTENANCE AND REPAIRS SHOULD BE PERFORMED BY A QUALIFIED MAINTENANCE TECHNICIAN.

NOTICE


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9. Visually inspect the battery for proper location, level of charge, and electrolyte level.

10. Check foot brake pedal for a firm smooth operation that ends travel well before contact with the floor.

11. Check that the parking brake lever requires an additional amount of force to make the final movement to the locked position.

12. With the master switch in the “ON” position, check the operation of the steering wheel. The operation should be smooth and consistent from lock to lock and back.

13. The rear axle incorporates a combination gearbox and axle housing; therefore, only one fluid level is to be checked. Check for leaks before filling. The outer axle hubs are a possible site for leakage that may be seen in the rear brake area.

15. Check the pump motor reservoir fluid level. Look for indications of leakage under the tractor before filling. The pump motor reservoir should be kept approximately half filled with the accumulator discharged.

16. Check the operation of the controller readout panel. Refer to Chapter 1, Page 3-12 for correct operation of the controller readout panel.

CAUTION DO NOT OVERFILL THE CELLS; SPILLED ACID WILL CAUSE TRAY CORROSION, FRAME GROUNDS, AND LOSS OF CAPACITY. TO A FULLY CHARGED BATTERY ADD ONLY DISTILLED, DE- MINERALIZED, OR APPROVED TAP WATER TO BRING THE LIQUID IN THE CELLS TO THE PROPER LEVEL. (CHECK THE INFORMATION FROM THE BATTERY SUPPLIER FOR THE PROPER FILL LEVEL.) NOTE: BATTERY WATER IS TO BE ADDED ONLY AFTER BATTERY HAS BEEN FULLY CHARGED.

EXTREME WATER CONSUMPTION (MORE THAN 2-3 GAL/WK) MAY INDICATE TOO MUCH CHARGING, TOO HIGH A FINISH RATE, OR A CHARGER MALFUNCTION.

THE PARKING BRAKE SHOULD ALSO BE CHECKED FOR PROPER OPERATION BY USING IT ON A SLOPE OR BRINGING THE TRACTOR TO A HALT FROM A LOW SPEED.

NOTICE

BEFORE CHECKING OR CHANGING THE FLUID IN THE PUMP MOTOR RESERVOIR, DISCHARGE THE ACCUMULATOR SYSTEM. (SEE PAGE 2-10 FOR MORE INFORMATION) WHEN THE ACCUMULATOR SYSTEM IS CHARGED, THEN THE FLUID IN THE PUMP MOTOR RESERVOIR WILL BE VERY LOW. ADDING FLUID WITH THE ACCUMULATOR CHARGED WILL CAUSE FLUID TO LEAK OUT OF THE RESERVOIR WHEN THE ACCUMULATOR DISCHARGES.

NOTICE

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C. Maintenance Check List (For Specific Instructions See Pages 1-4 Through 1-18.

ITEM OR LOCATION INSPECT ADJUST CHANGE LUBRICATE /

ADD FLUID

Daily Electrical cables, conduits, brake hoses, and

fittings. X

Warning tags, labels, and reflectors, and lights.

X

Tires and wheels X A/R Fluid leakage X Battery X Foot brake pedal X A/R Parking brake X A/R Steering X Controller readout panel X DC Converter X A/R

Monthly Or Evey 50-75 Hours (Includes Daily Check)

Battery (Cleaning and electrolyte) X A/R Wheel mounting nuts X X Hydraulic fluid X A/R Complete unit X

Every Three Months Or Every 150 Hours (Includes Daily And Monthly Check)

Grease points X X Accelerator pedal X A/R X Brake pedal X A/R X Parking brake X A/R X Hinges X X Cables and wiring X Electrical contacts X A/R Brakes (Front and Rear) X A/R Steering X X Master cylinder X Fluid Separator X X Pump/motor X A/R Rear Axle Assembly X A/R AC Traction Motor X A/R X

Yearly Or Every 500 hours (Includes Daily, Monthly, And Three Month Check)

Front wheel bearings X X Hydraulic fluid X Parking brake X A/R Rear Axle Assembly X X

A/R - Perform service as required.

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D. Preventive Maintenance Schedule

1. Daily

a. Wash down the unit and remove any foreign material from the operator’s compartment.

b. Inspect electrical cables, conduits, hydraulic hoses, brake hoses, and fittings for signs of wear or damage.

c. Visually inspect the condition and readability of all warning tags, labels, lights and reflectors. Replace any found missing or damaged.

d. Make a visual inspection of the tires and rims, checking for damage and lack of proper inflation (If inflation is needed, inflate tires to PSI indicated on tire). Check rim surface for cracking in paint, bends, or any other obvious distortion. Check tires for cuts, abrasions, and punctures.

TIRES/WHEELS FIGURE 2-1-1

e. Check the entire length of the unit for signs of fluid leakage.

f. Check foot brake pedal for a firm smooth operation that ends travel well before contact with the floor.

g. Check that the parking brake requires an additional amount of force to make the final movement to the locked position. (If adjustment is required see page 2-2)

NOTICE THE PARKING BRAKE SHOULD ALSO BE CHECKED FOR PROPER OPERATION BY APPLYING IT WHILE THE UNIT IS ON A SLOPE OR BRINGING THE UNIT TO A STOP FROM A SLOW SPEED.

CAUTION BATTERY SHOULD BE DISCONNECTED PRIOR TO PERFORMING ANY MAINTENANCE ON THE ELECTRICAL SYSTEM.

ALL MAINTENANCE AND REPAIRS SHOULD BE PERFORMED BY A QUALIFIED MAINTENANCE TECHNICIAN.

NOTICE

NOTICE THE UNIT SHOULD BE MAINTAINED ACCORDING TO THE SCHEDULES IN THIS SECTION. IF THE UNIT IS INVOLVED IN OPERATIONS THAT ARE UNUSUALLY SEVERE OR THE OPERATING AREA HAS A UNIQUE CLIMATE (HOT, WET, COLD, DUSTY, ETC.) A SPECIAL SCHEDULE MAY HAVE TO BE DEVELOPED.

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h. Check the operation of the steering wheel by rotating the steering wheel from left to right. The operation should be smooth and consistent from lock to lock and back.

i. Check the operation of the controller readout panel. Refer to Chapter 1, Page 3-4 for correct operation of the controller readout panel.

j. Check the 12 volt electrical converter by testing the operation of the horn and headlights.

DC CONVERTER FIGURE 2-1-2

NOTICE THE ONLY INDICATION OF A CONVERTER FAILURE IS A COMPLETE FAILURE OF THE 12 VOLT ELECTRICAL OPTIONS. BEFORE THIS UNIT IS REPLACED, REFER TO THE TROUBLESHOOTINGSECTION.


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2. Monthly Or Every 50-75 Hours (Includes Daily Maintenance)

a. Inspect the battery.

aa. Check the electrolyte level in all cells of the battery. If electrolyte level is low, see battery charging and maintenance instructions supplied with your battery.

bb. Check that all battery connections are tight and free of corrosion. cc. Clean the top of the battery. (See battery charging and maintenance instructions

supplied with your battery for proper cleaning instructions.) b. Check the wheel mounting nuts for proper torque. The nuts should be torqued to 100 ft. lbs.

CHECK WHEEL MOUNTING NUTS FIGURE 2-1-3

WARNING ALWAYS WEAR PROTECTIVE CLOTHING, GLOVES, AND EYEWEAR WHEN PERFORMING MAINTENANCE ON BATTERIES.

CAUTION DO NOT OVERFILL THE BATTERY CELLS; SPILLED ACID CAN CAUSE TRAY CORROSION, FRAME GROUNDS, AND LOSS OF CAPACITY.

TO A FULLY CHARGED BATTERY ADD ONLY DISTILLED, DEMINERALIZED, OR APPROVED TAP WATER TO BRING THE LIQUID IN THE CELLS TO THE PROPER LEVEL.

SEE ALSO BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS SUPPLIED WITH BATTERY FROM YOUR BATTERY SUPPLIER FOR THE PROPER FILL LEVEL.

EXTREME WATER CONSUMPTION (MORE THAN 2 - 3 GALLONS PER WEEK) MAY INDICATE TOO MUCH CHARGING, TOO HIGH A FINISH RATE, OR A CHARGER MALFUNCTION.

NOTICE

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c. Check the pump motor reservoir fluid level.

aa. Open rear access cover located behind the battery to allow access to the hydraulic pump/motor.

HYDRAULIC PUMP/MOTOR RESERVOIR FIGURE 2-1-4

bb. Clean any dirt or debris from around the fill cap. cc. Remove the fill cap. The hydraulic fluid level should be kept at a level that is

approximately 1/2 the capacity of the tank. dd. Replace the fill cap securely.

d. Make a complete walk around visual inspection of the complete unit, checking for signs of

damage, fluid leakage and loose or missing parts.

HYDRAULIC FLUID FILL CAP


NOTICE

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3. Every Three Months Or Every 150 Hours (Includes Daily And Monthly Maintenance)

a. Lubricate the unit at all points marked on the Lubrication Chart on page 1-13. b. Check the following area for corrosion, wear, and security. Lubricate with oil or a dry type of

lubricant.

aa. Accelerator pedal assembly. bb. Brake pedal assembly. cc. Entire parking brake assembly. dd. Battery cover hinges. ee. Battery plug latch (Keep oil off of the contact area of the plug). ff. Hitch.

c. Check all electrical cables and wiring for signs of heating, arcing, and moisture build up.

d. Check the electrical contactor tips. If the tips are burned or pitted, they should be replaced. d. Visually inspect the condition and operation of the front and rear brakes. Inspect all cables

and linkages for signs of wear or damage, have any potential problem repaired or replaced by a qualified maintenance technician.

aa. Minimum front brake pad thickness .078 inch (2 mm) bb. Minimum front rotor thickness .354 inch (9 mm)

e. Visually inspect the condition and operation of the steering linkages by hand movement of each component.

NOTICE DARKENING OF THE CONTACT TIPS DOES NOT INDICATE BURNING; THIS DARKENING IS NORMAL. BURNING IS JUDGED BY ACTUAL LOSS OF CONTACT MATERIAL OR DROPLETS OF MOLTEN CONTACT MATERIAL BEING DISPLAYED. THE CONTACT MAY BE USED UNTIL THE CONTACT MATERIAL IS ALMOST COMPLETELY WORN AWAY; HOWEVER, IT IS ADVISABLE TO REPLACE THE CONTACTS IF, IN THE OPINION OF THE MAINTENANCE TECHNICIAN, THE CONTACTS WILL NOT LAST UNTIL THE NEXT REGULAR INSPECTION.

NOTICE MAKE A COMPLETE INSPECTION OF THE CABLES USED TO OPERATE THE PARKING BRAKE. IF ANY PROBLEM IS INDICATED IN THIS AREA, REPLACE ANY AND ALL PARTS THAT ARE A POTENTIAL PROBLEM.

NOTICE REFER TO CHAPTER 5 FOR MORE DETAILED INFORMATION CONCERNING THE REAR BRAKES

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f. Check the master cylinder fluid level. The master cylinder is located under the cover behind the brake pedal. (For Fluid Specifications see page 1-18).

MASTER CYLINDER LOCATION FIGURE 2-1-5

aa. Open the master cylinder cover with the key. bb. Clean any dirt or debris from around the fill cap. cc. Remove the fill cap. dd. Fill the master cylinder as needed with clean brake fluid. ee. Replace the fill cap securely. ff. Close and latch the master cylinder cover

g. Inspect the commutator, brushes, and bearings in the pump/motor.

h. Check the oil level in the rear axle housing. Check for indications of leakage under the unit

and at each axle hub.

aa. Park the unit on solid level surface. bb. Apply the Emergency Park Brake. cc. Chock all four (4) wheels in both directions. dd. Clean any dirt or debris from around the level/fill plug and remove. ee. The oil should just barely flow out from the level/fill hole when full. ff. Should it be necessary to add oil, add oil slowly through the level/fill hole, just until it

begins to flow back out. Allow time for the fluid to travel throughout the axle when filling.

REAR AXLE HOUSING FILL/CHECK FIGURE 2-1-6

i. Inspect the winding field, washers, seals, and bearings in the AC traction motor. Replace if

necessary.

NOTICE THE COMMUTATOR SHOULD BE BROWN IN COLOR, SMOOTH WITHOUT EXTENSIVE GROOVES, AND WITHOUT SEVERE BURNING ALONG THE EDGES OF THE INDIVIDUAL BARS.

- FILL PORT

- LEVEL

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j. Clean any dirt or debris from the drive motor fan cover (grill). 4. Yearly Or Every 500 Hours (Includes Daily, Monthly, And Every Three Months

Maintenance)

a. Do a complete 3 month maintenance and service check. b. Repack the front wheel bearings. c. Change the steering fluid and replace the filter.

d. Check the parking brake adjustment. e. Drain the oil from in the rear axle housing and replace with new oil. Check for indications of

leakage under the unit and at each axle hub.

aa. Park the unit on solid level surface. bb. Apply the Emergency Park Brake. cc. Chock all four (4) wheels in both directions. dd. Place an approved container under the rear axle then clean any dirt or debris from

around the drain plug and remove. After the old oil has completely emptied from the axle, place the drain plug back into the rear axle.

gg. Remove the fill plug and add oil slowly through the fill hole, just until it begins to flow back out. Allow time for the fluid to travel throughout the axle when filling.

REAR AXLE HOUSING FILL FIGURE 2-1-7

- FILL PORT

- LEVEL

DRAIN

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E. Lubrication Chart See Lubrication Diagram for Specific Locations. See page 1-18 for Lubricant Specifications.

REF. NO. LOCATION AND DESCRIPTION

Grease Fittings (See Note 1) See Detail

1 Steering Cylinder – 2 Fittings (1 rod end and 1 base end) D 2 Spindle Pivot Pins (Kingpins) – 2 Fittings (1 each side) B 3 Steering Bellcrank – 1 Fitting D 4 Steering Tie Rod Ends – 2 Fittings (1 Per End - Bellcrank side) F & G 5 Rear Suspension Pivot Pins - 2 Fittings (1 each side) L 6 Front Suspension Mounting Pins – 2 Fittings (1 each side – Front) B 7 Brake Pedal Pivot Pin – 1 Fitting H

No Grease Fittings (See Note 2)

8 Operators Seat Sliding Tracks -- 9 Foot Brake Pedal Linkage H 10 Accelerator Pedal Pivot Pin & Linkage A 11 Operator Column Tilt Points A 12 Parking Brake Handle & Pulleys A & B 13 Steering Tie Rod Ends F & G 14 Front Brake Caliper Mounts E 15 Front Wheel Bearings B 16 Front Suspension Mounting Pins (Rear Pins) B 17 Shock Absorber Mounting Pins C 18 Battery Cover Hinges I 19 Rear Access Cover Hinges I 20 Controller Base --

Fluid levels

21 Brake Master Cylinder J 22 Hydraulic Fluid Reservoir (See Note 3) K 23 Rear Axle Assembly L NOTES:

1. Pump grease into fitting until old grease can be observed coming out of component. 2. Lubricate with oil or a dry type of lubricant. 3. The hydraulic fluid specification will change for different climates. Use the proper fluid.

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LUBRICATION CHART FIGURE 2-1-8A

DETAIL A

DETAIL B DETAIL C

10

12

11

9

6 12

16

12

2

14

17

17

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LUBRICATION CHART FIGURE 2-1-8B

DETAIL D

DETAIL E DETAIL G

DETAIL F

DETAIL H

3

1

1

4

14

13

4

13

7

9

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LUBRICATION CHART FIGURE 2-1-8C

DETAIL I

DETAIL J

DETAIL K

DETAIL L

19

21

5

23

5

22

18

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F. Lubrication Alphabetical Table

Component/System

Lubricant Type

Fittings Present

Accelerator Pedal Pivot Pin & Linkage Oil or Dry Type Lubricant Access Cover Pivot Points Oil or Dry Type Lubricant Axle Hubs Lithium-based Grease Brake Master Cylinder Brake Fluid DOT 3 Extra HD Brake Pedal Pivot Pin Lithium-based Grease X Operator Column Tilt Points Oil or Dry Type Lubricant Controller Base Type 120 Thermal Compound Fluid Separator Mineral Oil Based Lubricant Foot Brake Pedal Linkage Oil or Dry Type Lubricant Front Brake Caliper Mounts Silicon-based Grease Front Suspension Mounting Pins (Front Pins) Lithium-based Grease X Front Suspension Mounting Pins (Rear Pins) Oil or Dry Type Lubricant Front Wheel Bearings Lithium-based Grease Hydraulic Fluid Reservoir (See Note) DTE 13 ARTIC Operators Seat Sliding Tracks Oil or Dry Type Lubricant Parking Brake Handle & Pulleys Oil or Dry Type Lubricant Rear Axle / Reducer Hyploid Gear Oil, SAE 90 EP Rear Suspension Pivot Pins Lithium-based Grease X Shock Absorber Mounting Pins Oil or Dry Type Lubricant Spindle Pivot Pins (Kingpins) Lithium-based Grease X Steering Bellcrank Lithium-based Grease X Steering Cylinder Lithium-based Grease X Steering Tie Rod Ends (Bellcrank end) Lithium-based Grease X Steering Tie Rod Ends Oil or Dry Type Lubricant Note: Hydraulic fluid specification may have to be changed due to different climates.

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G. Lubricants, Fluids, And Capacities

LOCATION TYPE SUPPLIER CAPACITY NOTES

Hydraulic Reservoir DTE 13 ARTIC

Dextron Automatic Transmission Fluid

PENNZOIL

Dextron

1.3 Qts. 1

Rear Axle Housing 90 Weight Gear Oil As Required 2

Front Wheel Bearings Lithium EP2 NLGI #2 CERTIFIED As Required

Brake Master Cylinder Dot 3 Heavy Duty PENNZOIL As Required

Grease Fittings Lithium EP2 NLGI #2 CERTIFIED As Required 3

NOTES: 1. The hydraulic fluid level should be kept at a level that is approximately 1/2 the capacity of the tank with the accumulator fully discharged.

2. When filling the axle housing, allow enough time for lubricant to fill the various cavities and around

component parts in each assembly. Continue adding lubricant into each assembly until the required level is reached.

3. Pump grease into fitting until old grease can be observed coming out of component.


NOTICE

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Chapter 2 Page 2-1 June 14


II. ADJUSTMENT INSTRUCTIONS

A. Front Brakes

1. The front disc brakes require no adjustments. Only disc pad and rotor thickness measurements should be checked at three month intervals.

a. Pad thickness minimum .078 inch (2 mm)

b. Rotor thickness minimum .354 inch (9 mm)

B. Rear Brakes

1. The rear drum brakes typically require no adjustments. Drum diameter and pad thickness measurements should be checked at three month intervals.

a. Drum inside diameter maximum 10.078 inch (256 mm)

b. Pad thickness minimum .078 inch (9 mm)

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2. During rear brake check procedure, the rear brakes might require manual re-adjusting, so that the brake drum slightly rests on the brake pads while the vehicle is at rest. a. Inspection:

(a) During 3 month brake checks (every 150 hours), check the rear drum brake pads for wear. While the brake drum is removed, check for the presence of the self-adjusting spring. The self-adjusting spring will be located near the top of the parking brake lever.

REAR BRAKE DRUM REMOVAL FIGURE 2-2-1

NOTE: HUB DOES NOT NEED TO BE REMOVED FOR BRAKE ADJUSTMENT. HUB SHOWN REMOVED IN SOME PICTURES FOR CLARITY.

REAR BRAKES FIGURE 2-2-2

SELF-ADJUSTING SPRING BRAKE SETUP WITH DRUM

AND HUB REMOVED

MAIN ADJUSTMENT LEVER PARKING BRAKE

LEVER

REMOVE DRUM BRAKE SETUP WITH DRUM REMOVED

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b. Adjustment procedure: (a) Place a flathead screwdriver behind the top portion of the main adjusting lever. Using the screwdriver, move the adjusting lever until it clicks one time.

NOTE: THE MAIN ADJUSTING LEVER WILL BE LOCATED ON THE SIDE OF THE BRAKE CLOSEST TO THE FRONT OF THE VEHICLE.

REAR BRAKE ADJUSTMENT FIGURE 2-2-3

(b) After the adjustment lever has been moved one click, slide brake drum over hub to

check for slight resistance between brake pads and drum.

(c) If drum is still loose, remove drum and repeat steps (a) and (b) until slight brake pad resistance is apparent.

(d) If main adjustment lever is adjusted too many times, and drum fits too tightly onto

brake pads or cannot be reinstalled, then the adjusting levers must be reset.

BRAKE PAD MAIN ADJUSTMENT

LEVER

FRONT OF UNIT

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c. Reset adjusting levers:

(a) Place a flathead screwdriver between the main adjustment lever and the adjustment latch and separate the two by pivoting the screwdriver downward until there is no contact between them. The adjustment latch spring will then reset the levers to their original position. Repeat previous adjustment steps (a) and (b) until proper drum to brake pad resistance is obtained.

REAR BRAKE RESET FIGURE 2-2-4

ADJUSTMENT LATCH

BRAKE PAD

FRONT OF UNIT

WARNING

DO NOT PLACE SCREWDRIVER UNDER ADJUSTMENT LATCH AND LIFT UP TO RESET BRAKE. PERMANENT DAMAGE TO BRAKES WILL OCCUR IF LATCH IS BENT.

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C. Brake Pedal

1. The brake pedal may require adjustment if braking of the unit becomes difficult or the brake pedal is reaching the floor of the unit before the unit comes to a stop. Before adjusting the brake pedal, check the front and rear brakes, and the fluid in the master cylinder to ensure that these are not the source of the problem.

2. Adjustment procedure:

a Initial adjustment can be made at point “A” by rotating the adjustment screw located on the brake pedal.

BRAKE PEDAL ADJUSTMENT FIGURE 2-2-5

b. Additional adjustment can be made at point “B” by turning the adjustment nut located on

the push rod of the master cylinder to adjust the length of brake pedal travel. c. The brake pedal should reach the end of its travel before touching the floor.

ADJUSTMENT POINT “A”

ADJUSTMENT POINT “B”

TIGHTENING THE ADJUSTMENT NUT AT POINT B TOO TIGHTLY WILL CREATE PRESSURE IN THE BRAKE LINES WITHOUT PEDAL BEING PRESSED.

CAUTION

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D. Parking Brake

1. The parking brake assembly consists of the rear brake drums connected to the park brake handle by a series of linkages and a pulley.

2. Adjustment procedures:

a. Jack rear wheels clear of the ground and securely block. Both rear wheels must be free to rotate.

b. Chock the front wheel securely to prevent the unit from moving during adjustments. c. Remove heat shrink tubing from brake handle. (Heat shrink tubing is installed from the

factory to prevent unauthorized adjustment). d. With parking brake handle in the raised position, turn handle clockwise until rear wheels

can be rotated freely by hand (Figure 2-2-2).

PARKING BRAKE ADJUSTMENT FIGURE 2-2-6

e. With one maintenance technician rotating rear wheels and handle in the raised position,

rotate handle counter clockwise until rear wheels cannot be rotated by hand (Figure 2-2-3).


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f. Lower handle and start machine. (See Starting Procedure, Chapter 1, page 3-10). g. Place direction control lever in either “FORWARD” or “REVERSE” position and depress

accelerator pedal. Rear wheels should be rotating. h. Release the accelerator pedal and raise the handle to apply the parking brake. Rear

wheels should stop rotating. If rear wheels continue rotating, lower handle and rotate counter clockwise one (1) turn and reapply (Figure 2-2-4). Continue until the required amount of force is achieved to stop rear wheel rotation.


i. Turn power switch to the “OFF” position and place directional control lever in the

“NEUTRAL” position. j. Remove all chocks and blocking devices. k. Check parking brake operation by applying it while the unit is on a slope or applying it

while the unit is traveling at a slow speed. If additional adjustment is needed to stop the vehicle, lower the handle and rotate counterclockwise one turn and reapply. Continue adjustment until the park brake is capable of stopping the vehicle.

l. Additional adjustment is possible at the adjustment “A” or adjustment “B” but these should only be used if sufficient adjustment cannot be made at the park brake handle (Figure 2-2-5).

ADDITIONAL PARKING BRAKE ADJUSTMENT FIGURE 2-2-9

m. Remove the clevis pin from the clevis at point “A” and turn clockwise to remove slack in the system (Figure 2-2-9).

n. Remove the clevis pin from the clevises at points “B” and turn clockwise to remove slack in the system (Figure 2-2-9). (If adjustment is made at adjustment points “B”, than an equal adjustment should be made on the both brakes to equalize the brake load.)

ADJUSTMENT POINT “A”

ADJUSTMENT POINTS “B”

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E. Brake Light Switch

1. The brake light switch is mounted into the front of the master cylinder and requires no adjustment.

F. Footbrake Switch

1. The footbrake switch is located on the brake pedal pivot assembly (Figure 2-2-10). This switch communicates to the controller is the brake pedal is depressed or released, which the controller then makes adjustments to the vehicle performance accordingly. The switch can be adjusted to operate as the pedal is depressed by sliding the switch in the adjustment slots shown. The switch should remain in contact with the pedal for the first 3/8” (1 cm) of pedal movement.

FOOTBRAKE SWITCH ADJUSTMENT FIGURE 2-2-10

ADJUSTMENT SLOTS

3/8” FOOTBRAKE SWITCH

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G. Toe-In

1. The toe-in should be set to 0.0 in.; this can be set as follows.

a. Drive the tractor in a straight line for a short distance. b. Hold the steering wheel in the same position. c. Check the toe-in by taking measurements at points A-A and B-B on the brake rotor.

C=D

TOE-IN ADJUSTMENT MEASUREMENTS FIGURE 2-2-11

d. Adjust by loosening clamps C and then turning tie rod D until the correct measurements are reached.

TOE-IN ADJUSTMENT – TIE ROD

FIGURE 2-2-12

THE MEASUREMENTS MUST BE TAKEN AT POINTS A-A AND B-B WHICH ARE LOCATED THE SAME DISTANCE ABOVE THE GROUND. IF TAKEN AT OTHER POSITIONS ERRORS WILL RESULT DUE TO KING PIN INCLINATION.

NOTICE

IF ADJUSTMENT IS REQUIRED, MAKE A COMPLETE INSPECTION OF ALL OF THE STEERING COMPONENTS.

WARNING

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TOE-IN ADJUSTMENT – BELLCRANK E FIGURE 2-2-13

e. Once the correct adjustment is reached, tighten clamp C.

f. It may be necessary to adjust the steering wheel alignment by removing the nut cover, the nut, and the steering wheel. Reverse the process after the wheel has been rotated to proper spoke alignment and reinstalled on the shaft.

BELLCRANK E SHOULD APPEAR IN LINE WITH THE CENTER LINE OF THE TRACTOR. IF WORK IS TO BE DONE ON THE STEERING LINKAGE THEN ALIGNMENT MARKS SHOULD BE MADE ON THE BELLCRANK PIVOT TUBE AND THE AXLE, INDICATING WHEN THE BELLCRANK IS ALIGNED WITH THE CENTER LINE OF THE TRACTOR.

NOTICE

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H. Steering Pump

1. The steering pump has no external adjustments. Should steering become difficult, the problem can be in one of four places; the pump/motor, the rotary valve, the cylinder, or the axle pivots.

I. Accelerator Pedal

1. The accelerator pedal has no required adjustments.

J. Steer Stops

1. Each front spindle has an adjustable stop, consisting of a threaded plate, a bolt, and a jam nut. The stops should be set with an angle of 22 between the axle beam and the surface of the hub.

STEER STOP ADJUSTMENT

FIGURE 2-2-14

REFER TO CHAPTER 2 SECTION II PAGE 4-8 FOR MORE TROUBLESHOOTING INFORMATION

NOTICE

A PEDAL THAT STICKS CAN CAUSE THE STEERING PUMP TO RUN CONTINUOUSLY

CAUTION

A SHEETMETAL TEMPLATE CUT TO 22° MAY BE USED TO SET THE STEER STOPS.

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K. Seat Switch

1. The seat switch is mounted on a mounting bracket mounted on the pivot plate of the operator’s seat. Adjustment is accomplished by loosening the two (2) mounting screws of the switch and moving the switch up or down on the mounting bracket.

SEAT SWITCH ADJUSTMENT

FIGURE 2-2-15

L. AC Motor Controller

1. A section of this manual is dedicated to the AC Motor Controller. All adjustment, operation, and troubleshooting can be found in Chapter 5.


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M. Brake Bleeding

1. The brake system must be free of air to operate properly. Air can enter the when parts are disconnected for servicing or replacement, or when the fluid level in the master cylinder is allowed to get low. Air in the system will give the brake pedal a spongy feeling upon application.

2. Manual bleeding procedures:

a. Chock all four wheels in both directions, to prevent the unit from moving. b. Clean dirt and debris from the bleeder screw at each wheel. c. Start with the wheel farthest from the master cylinder (right rear). d. Attach a small rubber hose to the bleeder screw and place the other end in a clear

container of brake fluid. e. Fill the master cylinder with brake fluid (check often during bleeding procedure). Have an

assistant slowly pump up the brake pedal and hold pressure. f. Open the bleed screw about ¼ turn, press the brake pedal to the floor, close the bleed

screw and slowly release the pedal. Continue until no more air bubbles are forced from the cylinder on application of the brake pedal.

g. Repeat the procedure on all remaining wheel cylinders and calipers.

2. A power bleeder can also be used to bleed the brakes. To use this tool a special cap for the master cylinder is required:

a. The power bleeder must be filled with a COMPATIBLE brake fluid. b. The master cylinder should be filled with a COMPATIBLE brake fluid. c. The special cap is installed on the master cylinder. d. Connect the tube from the power bleeder to the special master cylinder cap.

e. Starting at the most distant wheel, open the bleed screw.

f. Allow brake fluid to flow from the pressure bleeder through the master cylinder, through the lines, and out the open bleed screw until there is no sign of any air bubbles.

g. Close the bleed screw and repeat this operation at each wheel.

THE OBJECT IS NOT TO SUPPLY PRESSURES SIMILAR TO THOSE USED TO APPLY THE BRAKES. BECAUSE THE RESERVOIR IS BEING PRESSURIZED, CAUTION MUST BE USED TO PREVENT DAMAGE TO THE SEALS BETWEEN THE MASTER CYLINDER BODY AND THE RESERVOIR. USE A PRESSURE OF 30 PSI (2 BAR).

CAUTION

BY PLACING A PIECE OF CLEAR TUBING OVER THE END OF THE BLEED SCREW AND USING A CLEAN CONTAINER TO CATCH THE EXCESS FLUID, LOSS CAN BE MINIMIZED. (BRAKE FLUID WILL DISSOLVE SOME MATERIALS USED FOR CONTAINERS AND IS VERY IRRITATING TO SKIN.)

CAUTION

DUE TO THE HIGH PLACES WHERE AIR CAN BE TRAPPED IN THIS SYSTEM, STEPS E, F AND G MAY NEED TO BE REPEATED. A SLIGHT PUSH WITH THE HAND ON THE BRAKE PEDAL EASES THE BLEEDING PROCESS.

CAUTION

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N. Discharging/Recharging Hydraulic Pressure From Accumulator

1. Discharging hydraulic pressure from accumulator:

a. Shutdown the unit and apply the parking brake. b. Disconnect the battery from the unit to remove all power from the tractor. c. Turn the steering wheel back and forth from stop to stop until there is no power steering

evident and it is difficult to move the steering wheel. It is now possible for service to be performed on the hydraulic system.

d. If it is necessary to bleed the nitrogen precharge, then refer to the accumulator section in Chapter 5.

2. Recharging hydraulic pressure from accumulator:

a. If no maintenance procedures have been performed that would release the gas pressure of the accumulator, then hydraulic pressure will be recharged in the accumulator by the pump/motor when the unit is next powered on.

b. If there is need for recharging the nitrogen precharge in the accumulator, refer to the accumulator section in Chapter 5.

O. Service Mode / Service LOS

1. After 400 hours of operation time, the unit will go into service mode, and SERVICE will appear on the display. Conduct standard preventative maintenance, then follow service reset procedure to return unit from “service mode” to regular operation mode.

SERVICE MESSAGE FIGURE 2-2-16

POWER STEERING SYSTEMS EQUIPPED WITH AN ACCUMULATOR ARE UNDER HIGH PRESSURE. DISCHARGE ACCUMULATOR BEFORE SERVICING SYSTEM.

WARNING

SERVICE

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2. Service reset procedure: a. Connect handheld programmer to unit.

b. Select the following from the programmer drop-down menu:

PROGRAM CHARLATTE TIMERS AND COUNTERS SERVICE TIMER RESET SERVICE TIMER

c. Set RESET SERVICE TIMER to “ON”.

3. If there has been a noticeable decrease in unit speed and performance, Service LOS (limited operating system) may be activated on unit.

a. To deactivate Service LOS, select the following from the

handheld programmer drop-down menu: PROGRAM CHARLATTE TIMERS & COUNTERS SERVICE TIMER

SERVICE LOS ENABLE

b. Set SERVICE LOS ENABLE to “OFF”

UNITS ARE TYPICALLY ONLY PROGRAMMED WITH SERVICE LOS ENABLE SET TO “ON” AT CUSTOMER’S REQUEST. IF SERVICE LOS ENABLE IS SET TO “ON” AND CUSTOMER WISHES TO KEEP THIS SETTING, FOLLOWING SERVICE RESET PROCEDURE (STEP #2) WILL RETURN UNIT TO PROPER OPERATING FORMAT.

NOTICE

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P. Setting Power Steering

At some point during operation of unit, an instance might occur when the power steering system will need to be adjusted. This will be evident by the power steering of the vehicle not functioning, and the steering going “hard”. It might also be evident by a FAULT 51 (Pressure Accumulator Fault) on the display, in which the vehicle will revert to LOS (limited operating system). The pump of the unit might also produce a loud “slurping” sound to go along with failed power steering. Whatever the case may be, it is important to first break the issue down to the problem the unit is experiencing. After identifying the problem, steps can be taken for proper power steering adjustment. The following explains possible power steering issues that might occur within a unit, followed by an explanation of how to correct said issues.

1. If unit is experiencing power steering drop-out (power steering goes “hard”): a. If unit is experiencing power steering drop-out alone, first check that hydraulic oil in tank

is at sufficient levels. Square hydraulic tanks will have a fill line, while circular tanks will need oil refilled to approximately 1/2” from the top of the tank.

CAUTION IT IS IMPORTANT TO DRAIN THE ACCUMULATOR BEFORE MOVING FORWARD. IF ACCUMULATOR IS NOT DRAINED, HYDRAULIC OIL WILL SPRAY FROM HYDARULIC LINES IF LINES ARE REMOVED FROM UNIT. DRAIN ACCUMULATOR BY TURNING UNIT “OFF” AND MOVING STEERING WHEEL BACK AND FORTH UNTIL NO POWER STEERING IS EVIDENT. FOR MORE INFORMATION ON DRAINING THE ACCUMULATOR, SEE PAGE 2-10.

IT IS IMPORTANT TO TEST FUNCTIONALITY OF POWER STEERING AFTER EACH STEP TO SEE IF POWER STEERING HAS BEEN RESTORED. IF POWER STEERING RETURNS AFTER A STEP, NO FURTHER STEPS ARE REQUIRED.

NOTICE

IF OIL GETS DOWN TO “SUCTION” LEVEL, THE PUMP WILL EMIT A NOISE AND OIL WILL BECOME “FROTHY”. IF THIS IS THE CASE, THERE IS CAVITATION IN THE HYDRAULIC OIL TANK. FOR STEPS TO CORRECT THIS, SEE STEP #3.

NOTICE

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b. The hydraulic pressure switch controls the pressure within the power steering system. To correct power steering malfunction, the hydraulic pressure switch might need adjustment. This switch is attached to the hydraulic pump/motor. (a) The red screw represents the Range, or high pressure point. When the pressure in

the system reaches this point, the system will stop pumping. Raise or lower the Range pressure level by turning the red screw in the appropriate direction. Range level is represented by a red meter on top of switch.

HYDRAULIC PRESSURE SWITCH FIGURE 2-2-17

ORIGINAL/RECOMMENDED SETTING FOR RANGE ON PRESSURE SWITCH IS 1300 PSI. FOLLOW AFOREMENTIONED STEPS IF A DIFFERENT PRESSURE IS NEEDED.

NOTICE

TURN RANGE SCREW

RANGE LEVEL METER

RANGE LEVEL METER

RANGE LEVEL IN PSI

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(b) The green screw represents the Differential. This represents the difference between the Range and the pressure point at which the system will start pumping. The optimum pressure at which the system should start pumping should be approximately 800 psi. To achieve this pressure, the Differential should be set to 500 psi, because the differential represents the difference between the shut off pressure point (Range setting) and the starting pressure point. Example:

Turn green screw in appropriate direction to bring Differential level to 500 psi.

HYDRAULIC PRESSURE SWITCH

FIGURE 2-2-18

DIFFERENTIAL SHOULD ALWAYS BE SET AT APPROXIMATELY 500 PSI, EVEN IF RANGE SETTING HAS CHANGED. PUMP STARTING PRESSURES BELOW 700 PSI CAN CAUSE DIFFICULTING IN STEERING, AND ANY PUMP STARTING PRESSURE ABOVE 800 PSI CAN CAUSE THE PUMP MOTOR TO SWITCH “ON” AND “OFF” MORE OFTEN, WHICH WILL QUICKLY DAMAGE MOTOR BRUSHES. FOR THESE REASONS, THE OPTIMUM DIFFERENTIAL SETTING IS APPROXIMATELY 500 PSI.

ONCE RANGE SETTING IS ADJUSTED, DIFFERENTIAL SETTING MUST BE ADJUSTED ASWELL IN ORDER TO KEEP PUMP STARTING PRESSURE AT 800 PSI. IF RANGE SETTING CHANGES AND DIFFERNTIAL IS LEFT THE SAME, STARTING PRESSURE WILL EITHER BE ABOVE OR BELOW 800 PSI, CAUSING ISSUES WITHIN THE STEERING SYSTEM.

NOTICE

TURN DIFFERENTIAL SCREW

DIFFERENTIAL LEVEL METER

DIFERENTIALLEVEL IN PSI


1300 psi (Pump shuts off at this pressure, Range setting) – 800 psi (Pump starts at this pressure) = 500 psi (Differential setting)

CAUTION

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(c) Although the Range pressure is shown by the Range level meter on top of the pressure switch, a pressure gauge should be attached to the system in order to get a more exact pressure reading. The pressure gauge test port is located behind the switch, and can be accessed by removing the test port cover and attaching a pressure gauge.

PRESSURE GAUGE TEST PORT FIGURE 2-2-19

c. Check that suction strainer in hydraulic tank is not clogged.

d. If power steering is unable to be corrected, hydraulic pressure switch might need replacement.

REMOVE PRESSURE GAUGE TEST PORT COVER

AT NO TIME SHOULD THERE BE A GAP IN POWER STEERING WHERE THE STEERING ON THE UNIT GOES HARD, FOLLOWED BY THE PUMP KICKING ON IN A MATTER OF SECONDS. THE STEERING SHOULD ALWAYS BE CONSTANT AND SMOOTH. TO INSURE CONSTANT POWER STEERING, ADJUST BOTH RANGE AND DIFFERENTIAL SETTING, OR ONLY DIFFERENTIAL SETTING ACCORDINGLY, STILL FOLLOWING ADJUSTMENT GUIDELINES EXPRESSED EARLIER.

NOTICE

THE PRESSURE GAUGE TEST PORT DOES NOT SUPPORT NPT PRESSURE GAUGES. AN ADAPTOR KIT FOR NPT PRESSURE GAUGES CAN BE PURCHASED FROM CHARLATTE AMERICA USING CHARLATTE PART NUMBERS: H00707, H00708

NOTICE

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2. If unit is experiencing power steering drop-out and FAULT 51 (pressure accumulator fault):

a. If unit is experiencing a FAULT 51 on display, unit will lose most of its power and drop

into LOS (limited operating system). First, the unit must be turned “OFF”, then back “ON” to remove the fault code from the display.

b. Make sure all the power steering check procedures from Step #1 are completed at this time.

c. If at this point the power steering system still does not work, the pressure relief on the side of the hydraulic pump should be checked.

(a) The pressure relief might be causing the pump to run continuously. If the pressure

relief is set too low, the pressure in the system will never reach 1300 psi (pump shut off pressure) thus the pump will continually run, causing a FAULT 51 in the system. If this is the case, adjustment of the pressure relief is needed.

(b) Loosen the nut surrounding the pressure relief adjustment rod. Using an allen wrench, adjust the pressure relief adjustment rod. To increase the amount of pressure relief, turn the adjustment rod inward. To decrease the amount of pressure relief, turn the adjustment rod outward.

PRESSURE RELIEF ADJUSTMENT FIGURE 2-2-20

THE PUMP MOTOR FOR THE UNIT IS TURNED “OFF” AND “ON” BY A PUMP CONTACTOR ON A 30 SECOND TIMER. IF WITHIN 30 SECONDS THE PRESSURE IN THE SYSTEM DOESN’T REACH THE RANGE SETTING ON THE PRESSURE SWITCH (APPROXIMATELY 1300 PSI), THE CONTACTOR WILL OPEN UP AND A FAULT 51 WILL OCCUR ON UNIT.

NOTICE

TURN ADJUSTMENT ROD: INWARD TO INCREASE PRESSURE RELIEF OUTWARD TO DECREASE PRESSURE RELIEF

LOOSEN NUT

PUMP WILL BECOME NOISY WHEN OIL GOES OVER/THROUGH PRESSURE RELIEF.

NOTICE

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d. Check that suction strainer in hydraulic tank is not clogged.

e. If power steering is unable to be corrected, hydraulic pressure switch might need replacement.

f. If power steering is still unable to be corrected, hydraulic pump might need to be replaced.

3. If unit is experiencing power steering drop-out and loud pump noise:

a. It is possible that the power steering system will sometimes experience cavitation (the formation of a gas bubble) within the hydraulic oil tank. This will be evident by a loud sound coming from the accumulator while unit is “ON” and a frothy consistency of the oil in the hydraulic tank. If this is the case, the power steering system requires further attention.

b. As stated earlier, ensure the correct amount of oil is present in the hydraulic tank. Square

hydraulic tanks will have a fill line, while circular tanks will need oil refilled to approximately 1/2” from the top of the tank. If accumulator sound disappears after oil refill, no further adjustment is required. If accumulator sound persists, continue on to step c.

THE ACCUMULATOR ON A UNIT CAN NOT BE TURNED “OFF”, DUE TO THE FACT THAT THE ACCUMULATOR ITSELF IS NOT CONTROLLED BY THE CURTIS MOTOR CONTROLLER. THE CURTIS MOTOR CONTROLLER ONLY CONTROLS A PUMP CONTACTOR THAT RUNS THE PUMP MOTOR.

NOTICE

CAUTION IF A UNIT IS EXPERIENCING POWER STEERING ISSUES, DO NOT SIMPLY TURN ACCUMULATOR ENABLE “OFF” IN ELECTRICAL SETTINGS USING CURTIS CONTROLLER HANDHELD. THIS WILL FORCE PUMP CONTACTOR TO TURN “ON” WHILE DRIVING AND WILL CAUSE DAMAGE TO THE CONTACTOR, AND POSSIBLY EVEN START A FIRE.

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c. In order to dispose of cavitation within the power steering system, the hydraulic pressure switch must be adjusted. This switch is attached to the hydraulic pump/motor.


d. The red screw represents the Range, or high pressure point. When the pressure in the system reaches this point, the system will stop pumping. Lower the Range pressure level by turning the red screw in the appropriate direction. Range level is represented by a red meter on top of switch. Decrease Range level until the noise in the system disappears.


ORIGINAL/RECOMMENDED SETTING FOR RANGE ON PRESSURE SWITCH IS 1300 PSI.

FOLLOW AFOREMENTIONED STEPS IF A DIFFERENT PRESSURE IS NEEDED.

NOTICE

TURN RANGE SCREW

RANGE LEVEL METER

RANGE LEVEL METER

RANGE LEVEL IN PSI

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e. The green screw represents the Differential. This represents the difference between the Range and the pressure point at which the system will start pumping. The optimum pressure at which the system should start pumping should be approximately 800 psi. To achieve this pressure, the Differential should be set to 500 psi, because the differential represents the difference between the shut off pressure point (Range setting) and the starting pressure point.

Example: Turn green screw in appropriate direction to bring Differential level to 800 psi.


IF RANGE SETTING IS ADJUSTED, DIFFERENTIAL SETTING MUST BE ADJUSTED ASWELL IN ORDER TO KEEP PUMP STARTING PRESSURE AT 800 PSI. IF RANGE SETTING CHANGES AND DIFFERNTIAL IS LEFT THE SAME, STARTING PRESSURE WILL EITHER BE ABOVE/BELOW 800 PSI, CAUSING ISSUES WITHIN THE STEERING SYSTEM.

NOTICE

DIFERENTIALLEVEL IN PSI


TURN DIFFERENTIAL SCREW


1300 psi (Pump shuts off at this pressure, Range setting) – 800 psi (Pump starts at this pressure) = 500 psi (Differential setting)

DIFFERENTIAL SHOULD ALWAYS BE SET AT APPROXIMATELY 500 PSI, EVEN IF RANGE SETTING HAS CHANGED. PUMP STARTING PRESSURES BELOW 700 PSI CAN CAUSE DIFFICULTING IN STEERING, AND ANY PUMP STARTING PRESSURE ABOVE 800 PSI CAN CAUSE THE PUMP MOTOR TO SWITCH “ON” AND “OFF” MORE OFTEN, WHICH WILL QUICKLY DAMAGE MOTOR BRUSHES. FOR THESE REASONS, THE OPTIMUM DIFFERENTIAL SETTING IS APPROXIMATELY 500 PSI.

CAUTION

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f. If none of the above methods solve the power steering issues, the oil in the hydraulic tank might be too viscous to pump properly through the system. Consult Chapter 2 Section 1 for proper oil to place in hydraulic tank.

g. Check that the suction strainer in the hydraulic tank is not clogged.

h. If power steering is unable to be corrected, hydraulic pressure switch might need replacement.

i. If power steering is still unable to be corrected, steering valve might need replacement.

j. If power steering is unable to be corrected after all other procedures have been followed,

accumulator might need replacement.

4. If power steering system switches “ON/OFF” rapidly:

a. If power steering system switches “ON/OFF” rapidly, first make sure the hydraulic

pressure switch is not faulty, and that it doesn’t need replacement.

b. Check the accumulator in the power steering system to see if it is faulty. Two possible issues could arise to cause the accumulator to become defective. These issues, and the steps needed to correct said issues, are as follows:

(a) The accumulator might be filled with hydraulic oil. Sometimes, a hole can form in

diaphragm or bladder of pump allowing hydraulic oil to fill entire accumulator cavity. If hydraulic oil is able to fill entire accumulator cavity, the accumulator no longer functions as an accumulator and instead becomes another hydraulic reservoir. If this is the case, accumulator must be replaced.

(b) The nitrogen pre-charge in the accumulator might have been drained. If this is the case, nitrogen in accumulator must be refilled. (i) Remove end cap of accumulator. This will be the end of the accumulator that is

NOT attached to a hydraulic line.

UNIT WILL HAVE EITHER A DIAPHRAGM STYLE ACCUMULATOR OR A BLADDER STYLE ACCUMULATOR. FOR MORE INFORMATION ON ACCUMULATOR STYLES AND OPERATION, REFER TO CHAPTER 1 SECTION 3.

NOTICE

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(ii) Connect a nitrogen tank to the end of the accumulator.

(iii) Using nitrogen tank attachment kit, refill nitrogen in accumulator. Charlatte recommends a nitrogen pressure between 550 psi and 600 psi.

A KIT FOR ATTACHING NITROGEN TANK TO ACCUMULATOR CAN BE PURCHASED FROM CHARLATTE AMERICA UNDER PART NUMBER: H00706

NOTICE

NITROGEN TANK ATTACHMENT KIT CANNOT BE USED IF THERE IS NO PRESSURE REGULATING VALVE PRESENT ON NITROGEN TANK.

WARNING

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Chapter 2 Page 3-1 Oct. 13


III. COMPONENT REMOVAL AND INSTALLATION

A. Battery

BATTERY

FIGURE 2-3-1

WARNING BATTERIES CONTAIN STRONG SULFURIC ACID THAT COULD CAUSE SEVERE BURNS IF SPILLED OR SPLASHED ON BODY PARTS OR IN THE EYES. PROTECTIVE CLOTHING, GLOVES, AND EYEWARE MUST BE WORN WHEN HANDLING AND WORKING ON BATTERIES.

NOTE: IF SULFURIC ACID IS SPLASHED OR SPILLED ON BODY PARTS OR EYES, WASH OR FLUSH COMPLETE AREA WITH COLD WATER FOR AT LEAST 10 MINUTES AND SEEK MEDICAL ATTENTION IF BURNING OR IRRITATION PERSISTS. ANY ACID SPILLED OR SPLASHED TO THE FACE OR EYES SHOULD BE FLUSHED AT ONCE WITH COLD WATER OR EYE WASH, AND THE VICTIM SHOULD SEEK MEDICAL ATTENTION.

DUE TO THE EXTREME WEIGHT OF LEAD ACID BATTERIES, ALWAYS KEEP BODY PARTS FROM UNDER BATTERY.

BATTERIES PRODUCE EXPLOSIVE GASES THAT COULD BE IGNITED CAUSING BURNS OR EXPLOSIONS. BATTERIES SHOULD BE WELL VENTED AND NOT EXPOSED TO OPEN FLAME, WELDING, SPARKS, OR ELECTRICAL ARCS.

WARNING BATTERIES ARE EQUIPPED WITH PLASTIC STRAP COVERS FOR SHORT CIRCUIT PROTECTION. DURING MAINTENANCE PROCEDURES ON BATTERIES, DO NOT ALLOW TOOLS OR SHARP METAL OBJECTS TO FALL ON THESE COVERS. THIS TYPE OF ACCIDENT COULD CAUSE BREAKAGE OR PUNCTURE OF COVERS AND LEAD TO A SHORT CIRCUIT OF BATTERY.

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1. To remove the battery:

a. Disconnect the electrical plug connecting the battery to the unit. b. Attach a hoist or other lifting device to the battery. (Lifting device should be capable of

lifting a minimum standard battery weight of approximately 5000 lbs.). A lifting bar for this purpose is the preferred method.

c. Lift the battery high enough to clear the unit. d. Place the battery in a predetermined location.

2. To replace the battery:

a. Make sure that the battery well and surrounding area is clear. b. Attach a hoist or other lifting device to the battery. (Lifting device should be capable of

lifting a minimum standard battery weight of approximately 5000 lbs.). A lifting bar for this purpose is the preferred method.

c. Lift the battery high enough to clear the unit and rotate to the proper alignment over the compartment and well.

d. Make sure no cables are under any part of the battery. e. Lower the battery into the unit, keeping hands and body parts clear of battery. f. Attach the electrical plug connecting the battery to the unit.

WARNING BATTERIES THAT HAVE BEEN REMOVED FROM A UNIT AND NOT IN USE SHOULD BE STORED AWAY FROM HIGH TRAFFIC AREAS AND IN A WELL VENTED LOCATION.

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B. Tires And Wheels

1. The tires on this unit are available as pneumatic or solid and use heavy duty three piece rims.

a. To remove the tire:

aa. Chock wheels that are not to be removed in both directions to prevent the unit from moving and apply parking brake.

bb. Loosen the lug nuts approximately ¼ turn while the unit is on the ground. cc. Jack the unit up until the tire/wheel is clear of the ground and insert a blocking device

under the frame that will support the weight of the unit. dd. Remove the lug nuts. ee. Remove the tire/wheel assembly.

b. To dismount the pneumatic tire:

TIRE/WHEEL ASSEMBLY

FIGURE 2-3-2

aa. Remove the valve core to deflate the tire. (Make sure tire is completely deflated).

WARNING DO NOT USE PRY BARS, HAMMERS, OR ANY OTHER SIMILAR DEVICES TO DISMOUNT THESE TIRES FROM THE MULTI-PIECE RIMS. RIM OR TIRE DAMAGE COULD OCCUR.

WARNING NEVER STRIKE THESE RIMS WITH A HAMMER OR OTHER DEVICE THAT MAY CAUSE DAMAGE. ONLY PROPERLY TRAINED MAINTENANCE TECHNICIANS WITH THE CORRECT TIRE MOUNTING EQUIPMENT SHOULD MOUNT OR DISASSEMBLE THESE TIRES AND RIMS.

WARNING BE CAREFUL THAT ICE OR OTHER DEBRIS INSIDE THE TIRE HAS NOT PREVENTED COMPLETE DEFLATION OF THE TIRE.

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bb. Remove the tire from the rim only with a tire mounting and dismounting machine, as

found at a local tire dealer. cc. Push the tire bead away from the seat on the lock ring side of the rim. USE PROPER

TIRE TOOLS-NOT A CROWBAR OR A HAMMER. dd. Push the tapered bead ring in far enough to permit the removal of the lock ring. ee. Remove the lock ring and tapered bead ring from the wheel. ff. Break the other tire bead and remove the tire.

c. To mount the pneumatic tire: aa. Clean all dirt and debris from rim and inspect for signs of any damage. bb. Replace tubeless valve stem. cc. Inspect the tire for any damage and clean all dirt and debris from bead and inside

tire. dd. Lubricate tire bead prior to mounting. ee. Install the tire on the rim only with a tire mounting and dismounting machine, as

found at a local tire dealer. ff. Place the tire on the rim and push it onto the rim as far as possible.

NOTICE WHEN LUBRICATING TIRE BEAD, ALWAYS USE TIRE MOUNTING LUBRICANTS SUCH AS MICHELIN TIGRE GREASE OR MURPHY’S TIRE MOUNTING COMPOUND.

WARNING PROPER TIRE MOUNTING IS IMPORTANT. FAILURE TO FOLLOW SPECIFIED MOUNTING PROCEDURES CAN CAUSE SEVERE PERSONAL INJURY AND TIRE DESTRUCTION. USE CAGE FOR INITIAL INFLATION.

ASSURE THAT ALL RIM COMPONENTS, LOCK RING, TAPERED BEAD RING, AND RIM BASE, ALL MATCH. USE OF MISMATCHED PARTS CAN RESULT IN VERY HAZARDOUS SITUATIONS.

TIRES SHOULD BE MOUNTED ON RIMS AND WHEELS THAT ARE IN GOOD CLEAN CONDITION. BENT, CHIPPED, OR RUSTED WHEELS CAN CAUSE TIRE DAMAGE AND PRODUCE VERY HAZARDOUS SITUATIONS.

NOTICE IF THE WHEEL IS BEING DISMANTLED IN A HORIZONTAL POSITION, THE WHEEL SHOULD BE SUPPORTED SO THE SIDEWALL OF THE TIRE IS NOT TOUCHING THE SURFACE OF THE WORK AREA.

NOTICE ALWAYS USE A NEW TUBE, FLAP, AND VALVE CORE WHEN REPLACING TIRES.

NOTICE SOME TIRES ARE DIRECTIONAL AND SHOULD BE MOUNTED SO THAT THEY ROTATE IN THE PROPER DIRECTION.

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gg. Place the tapered flange on the rim, pushing it down into the tire. hh. Install the locking ring and make sure the tapered ring and the locking ring are

mating properly before inflation. ii. Place the tire / wheel assembly into a safety cage. jj. Inflate the tire to 100 PSI (6.9 BAR) kk. Make a visual inspection of the locking ring to make sure that the entire ring is

engaged. ll. Install tire/wheel on unit and securely tighten lug nuts to 150 ft. lbs. mm. Remove blocking device and jack from under unit and retighten lug nuts.

d. To mount the solid tire:

aa. Solid tires require the same rims as pneumatic tires; however, the assembly and disassembly are done in a different manner. bb. Assembly and disassembly require a press and special ring to compress the tire the

required amount necessary to apply the locking ring. cc. The supplier of this equipment should furnish the information necessary to safely work with solid tires. Consult with the tire manufacturer to learn of any special methods or requirements for this work.

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C. Front Brakes

1. Brake pads only removal procedure:

a. Raise and properly support the front of the tractor. b. Remove the front wheels. c. Remove cotter pin C and slide out key D. This will permit the removal of the brake pads.

FRONT BRAKE PAD REMOVAL FIGURE 2-3-3

WARNING INSPECT THE CALIPERS, ROTORS, LINES, AND NEW PADS TO ASSURE GOOD CONDITION AND PARTS COMPATIBILITY.

NOTICE WHEN REMOVING THE CALIPER, IT MAY BE NECESSARY TO LOOSEN THE BLEED SCREW AND SPREAD THE PADS TO PERMIT TRAVEL PAST ANY RUST OR GROOVING ON THE OUTSIDE EDGE OF THE ROTOR. THIS PROCEDURE WILL CAUSE SOME FLUID LOSS THAT MAY REQUIRE FLUID ADDITION TO THE MASTER CYLINDER AFTER BRAKE WORK HAS BEEN COMPLETED.

WARNING BRAKE PADS MAY CONTAIN ASBESTOS. TAKE ALL NECESSARY PRECAUTIONS TO ENSURE THAT DUST FROM BRAKE PADS IS NOT INHALED.

NOTICE THE CALIPERS USED ON THIS TRACTOR CAN BE DISASSEMBLED TO TWO LEVELS.

A. REMOVAL OF THE BRAKE PADS ONLY.THIS PERMITS PAD REPLACEMENT WITHOUT CALIPER REMOVAL. B. REMOVAL OF THE ENTIRE CALIPER WHICH INCLUDES THE PISTON, PAD HOLDER, PADS, AND CALIPER FRAME. THIS SHOULD BE REQUIRED ONLY WHEN THE PISTON AREA IS TO BE REBUILT OR REPLACED.

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2. Brake pads only installation procedure:

a. Check the hub bearings for play. b. Check the rotor for runout. c. Check the rotor thickness. Minimum thickness is .354 INCH (9 MM). d. Slide the new pads into position.

e. Slide key D into place, and insert cotter pin C. f. Install pad springs E.

3. Entire caliper removal procedure:

a. Raise and properly support the front of the tractor. b. Remove the front wheels. c. Remove bolts A (do not lose the guiding pins, boots, O rings, or seals as the caliper is removed by sliding it off of the rotor).

FRONT BRAKE CALIPER REMOVAL

FIGURE 2-3-4

NOTICE IN ORDER TO INSTALL THE NEW THICKER PADS IT WILL BE NECESSARY TO OPEN THE BLEED SCREW SLIGHTLY AND FORCE THE PISTON BACK. THIS OPERATION WILL DRAIN FLUID THROUGH THE BLEED SCREW.

WARNING AFTER ANY WORK IS PERFORMED ON THE BRAKING SYSTEM, THE BRAKES SHOULD BE BLED, THE FLUID LEVEL IN THE MASTER CYLINDER CHECKED, AND A TEST DRIVE MADE.


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4. Entire caliper installation procedure:

a. Check the hub bearings for play. b. Check the rotor for runout. c. Check the rotor thickness (.354 in. min) d. Slide the entire caliper assembly over the rotor. e. Replace bolts A and torque to 100 ft.lbs. (13.5 kgf·m)

WARNING DO NOT ALLOW REMOVED CALIPER TO HANG BY THE BRAKE LINE. SUPPORT THE CALIPER OR TIE IT TO THE TRACTOR STRUCTURE.

NOTICE MAKE SURE ALL OF THE SEALS, O RINGS, GUIDING PINS, AND BOLTS ARE INSTALLED PER FIGURE 2-3-4.

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D. Rear Brakes

The brakes are drum type and incorporate a cable operated parking brake that uses the same shoes as the service brakes. Access to the braking components is accomplished as follows.

1. Rear brake removal procedure: a. Raise and support the tractor. b. Remove the rear wheels. (See Tire/Wheel Assembly Removal Procedure, page 3-3) c. Remove the two allen head bolts that retain the brake drum to the hub (Figure 2-3-5). d. Remove the drum by applying pressure to opposite sides of the drum. This is best done

with the use of the two allen screws in the brake drum (Figure 2-3-5). They permit the pressure to be applied in a straight line to prevent binding.

REAR BRAKE DRUM REMOVAL FIGURE 2-3-5

e. Once the drum is removed, a complete inspection of the drum is made. Look for cracking and severe grooving, and make sure the drum is round. The drum can be turned if no cracks are found and if enough material is present. The maximum interior turned diameter is 10.078 in. (256 mm).

BRAKE DRUM

ALLEN HEAD BOLTS

NOTICE IF THE DRUMS HAVE BEEN IN SERVICE FOR A LONG TIME SEVERAL LIGHT TAPS ON THE FLAT AREA BETWEEN THE LUG BOLTS MAY MAKE REMOVAL EASIER. ENSURE THAT THE PARKING BRAKE IS NOT APPLIED WHEN ATTEMPTING TO REMOVE THE DRUM.

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f. Disconnect the parking brake cable by lifting the end upward and out of the slot. g. Remove spring A by inserting a flat ended round punch into the center opening of the

spring, then pushing to release the retaining clip B (Figure 2-3-6).

REAR BRAKE REMOVAL

FIGURE 2-3-6

h. Remove the top transverse spring C (Figure 2-3-6). i. Remove the bottom transverse spring D (Figure 2-3-6). j. Pull the two shoe extensions from the slave cylinder E (Figure 2-3-6). k. The brake shoes can now be removed. The self-adjuster and the parking brake arm will

come off with the shoes (Figure 2-3-6). l. The adjuster and parking brake arm can be separated from the shoes by removing the

retaining clips on the back of the shoes.

2. Rear brake installation procedure:

a. Installation of the rear brakes is accomplished by reversing the order of the above steps. b. Bleed the braking system, and test the operation of the parking brake before placing unit

back into service. (See Brake Bleeding Procedure, page 2-9 and Park Brake Adjustment Procedure, page 2-2)

WARNING THE PUNCH MUST FIT INTO THE SPRING. IT MAY BE NECESSARY TO ANGLE THE SPRING WITH THE PUNCH TO PERMIT THE RELEASE OF THE CLIP.


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E. Parking Brake Assembly

1. The parking brake assembly is made up of several components as shown in figure 2-3-7. The replacement of cables, handle, pulleys, and pulley bushings are each routine mechanical operations.

The park brake adjustment is detailed in the preceding section Chapter 2, Section II, Page 2-1. The rear brake assembly is detailed in the preceding section Chapter 2, Section III, Pages 3-9.

PARKING BRAKE FIGURE 2-3-7

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F. Master Cylinder/Brake Pedal

1. Master cylinder/brake pedal removal procedure:

a. Disconnect and cap the two brake lines from the master cylinder.

MASTER CYLINDER FIGURE 2-3-8

b. Remove the two (2) mounting bolts and pull the master cylinder from its mount. c. Remove the return spring.

REMOVAL OF RETURN SPRING FIGURE 2-3-9

BRAKE LINES

MOUNTING BOLT

RETURN SPRING

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d. Remove the bolt “A” securing the brake pedal pivot pin and remove the pivot pin.

BRAKE PEDAL REMOVAL FIGURE 2-3-10

e. The brake pedal weldment can now be removed. The brake pin “B” will come out with the

pedal. f. The bushings in the pedal can now be replaced.

2. Master cylinder/brake pedal installation procedure:

a. Installation of the brake pedal is accomplished by reversing the order of the above steps c through f.

b. Thoroughly clean master cylinder mounting location. c. Place master cylinder in proper location and install mounting bolts. (Tighten mounting

bolts securely). d. Connect both brake lines to master cylinder and tighten securely. e. Bleed air from brake system. (See Brake Bleeding Procedure, page 2-9). f. Adjust brake pedal if necessary. (See Brake Pedal Adjustment Procedure, page 2-1)

BRAKE PEDAL WELDMENT

BRAKE PEDAL PIVOT PIN

PIVOT PIN BOLT “A”

BRAKE PIN “B”

WARNING AFTER COMPLETION OF ANY WORK PERFORMED ON THE BRAKING SYSTEM, THE BRAKES SHOULD BE BLED, THE FLUID LEVEL IN THE MASTER CYLINDER CHECKED, AND A TEST DRIVE MADE.

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G. Front Axle

1. Front axle removal procedure (Figure 2-3-10):

a. Jack the frame of the unit up and place jack stands or approved blocking devices under the frame.

b. Remove tire/wheel assemblies from front axle. (See Tire/Wheel Assembly Removal procedure, page 3-3)

c. Wipe clean and disconnect brake lines from front disc brake assemblies. Cap and plug the disconnected brake lines.

DISCONNECT FRONT BRAKE LINES FIGURE 2-3-11

d. Wipe clean and disconnect hydraulic lines from steering cylinder. Tag, cap and plug hydraulic lines and cylinder ports.

DISCONNECT HYDRAULIC LINES FROM STEERING CYLINDER FIGURE 2-3-12

CAUTION WIPE CONNECTIONS CLEAN PRIOR TO OPENING BRAKE AND HYDRAULIC SYSTEM.

CAP OR PLUG ALL OPEN PORTS.

NOTICE USE BACK-UP WRENCHES ON ALL MATING PARTS.

DISCONNECT BRAKE LINE

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e. Remove the two shock absorbers from each side of the axle.

REMOVE SHOCK ABSORBERS FIGURE 2-3-13

f. Use a transmission jack to support the front axle. g. Remove the four mounting pins connecting the front suspension leaf springs to the

chassis frame.

DISCONNECT FRONT SUSPENSION FROM CHASSIS FIGURE 2-3-14

h. Lower the jack and slide the axle assembly from under the tractor.

REMOVE SHOCK ABSORBERS MOUNTING PINS

WARNING THE SPRINGS AND AXLE MAY MOVE WHEN THE SHACKLE PINS ARE REMOVED; BE CAUTIOUS AND AWARE OF THIS POSSIBILITY.

REMOVE SUSPENSION MOUNTING PINS

REMOVE SUSPENSION MOUNTING PINS

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2. Front axle disassembly procedure:

a. The front axle is made up of several assemblies. Repairs will normally be made to only one assembly at a time.

The assemblies are divided as follows. 1. Hub 2. Spindle

SPINDLE & HUB ASSEMBLIES

FIGURE 2-3-15

3. Hub disassembly procedure:





d. Remove the brake caliper by removing the two (2) mounting bolts connecting it to the hub assembly.


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e. Remove the hub cap by removing the 4 bolts from the cap end. This will allow access to the spindle nut and washer.

HUB DISASSEMBLY

FIGURE 2-3-17 f. Remove the cotter pin, spindle nut and washer. g. The hub should now be removable by pulling the hub directly away from the spindle. h. After careful inspection of the roller bearings and bearing outer races that remain in the

hub, determine if the bearings require replacement. Always replace the inner race and bearing along with the outer race as a unit.

i. Remove any outer races that are to be replaced.

j.

k. Before reassembly check the condition of the inner hub seal.

CAUTION IF ANY PART OF EITHER BEARING ASSEMBLY IS DAMAGED MAKE SURE THAT ALL THE GREASE IN THE HUB IS REMOVED BECAUSE EMBEDDED DEBRIS MAY DESTROY THE NEW PARTS.

WARNING NEVER USE COMPRESSED AIR TO CLEAN OR SPIN A BEARING AS SEVERE PERSONAL INJURY MAY RESULT FROM FLYING DEBRIS OR THE BEARING LOCKING WHILE SPINNING ON A FINGER.

WARNING ALWAYS WEAR EYE PROTECTION WHEN TAPPING ON ANY BEARING RACE. USE ONLY APPROVED DRIVES OR PUNCHES WHEN DRIVING AN OUTER RACE FROM THE HUB BECAUSE THE RACE MATERIAL IS VERY BRITTLE AND MAY SHATTER

HUB

HUB CAP

HUB CAP BOLTS

SPINDLER WASHER & NUT

OUTER RACE & BEARING

INNER RACE & BEARING

HUB SEAL

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4. Hub reassembly procedure:

HUB RESASSEMBLY

FIGURE 2-3-18

a. Replace any outer races that have been removed. b. Repack the old bearings or pack the new bearings. c. Install the inner race. d. Reinstall or replace the inner seal. e. Slide the hub over the spindle, centering it as much as possible to protect the seal. f. Slide the outer bearing race onto the spindle and push it into the hub. g. Place the washer onto the spindle. h. Install the spindle nut and tighten until the hub has some resistance to rotation, then

reverse the nut until the first notch lines up with the cotter pin hole. i. Install the cotter pin. j. Rotate the hub several times to make sure the bearings are seated. If the hub becomes

loose, it indicates the inner bearing may not have been seated all the way on the spindle. Retighten the spindle nut and reinstall the cotter pin.

k. Install the hub cap using silicone sealer as a gasket. l. Reinstall the brake caliper.

m. Torque the caliper mounting bolts to 100 Ft. Lbs. (13.5 kgf·m) n. Reinstall tire/wheel assemblies on front axle. (Refer to Tire/Wheel Assembly installation

procedure, page 3-3) o. Bleed air from brake system. (Refer to Brake Bleeding procedure, page 2-9).

WARNING MAKE SURE ALL OF THE CALIPER MOUNTING PARTS ARE INSTALLED CORRECTLY. ALWAYS CHECK THE PADS FOR IRREGULAR WEAR DUE TO HUB MOVEMENT IF THE BEARINGS WERE BAD. ALWAYS BLEED THE BRAKES AFTER ANY WORK IS DONE ON THE BRAKING SYSTEM. A TEST DRIVE SHOULD BE MADE AFTER ANY BRAKE OR SUSPENSION REPAIRS

HUB

HUB CAP

HUB CAP BOLTS

SPINDLER WASHER & NUT

OUTER RACE & BEARING

INNER RACE & BEARING

HUB SEAL

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5. Spindle disassembly procedure:





d. Disconnect the steering linkages from spindle on each side of the axle.

DISCONNECT STEERING LINKAGE FIGURE 2-3-20

DISCONNECT LINKAGE


NOTICE THE MECHANIC MAY CHOOSE TO REMOVE THE BRAKE CALIPER FROM THE SPINDLE OR REMOVE THE BRAKE LINE FROM THE CALIPER. IF THE CALIPER IS REMOVED, IT MUST BE SUPPORTED TO PROTECT THE BRAKE LINE.

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e. Remove the cotter pin and castle pin from the bottom of the king pin.

SPINDLE DISASSEMBLY FIGURE 2-3-21

f. Remove the spindle pivot pin (king pin) from the axle weldment. Slide the spindle

outward to remove it. The lower bearing and adjusting washer may fall out as the spindle clears the axle beam.

g. Make a careful inspection of the king pin, particularly the area where the bearing fits.

h. Remove the upper seal. This will permit the removal of the upper inner race and roller

bearing. i. Inspect the upper and lower outer races. j. Remove any outer races that are damaged.

CAUTION IF ANY PART OF EITHER BEARING ASSEMBLY IS DAMAGED, MAKE SURE THAT ALL THE GREASE IN THE HUB IS REMOVED AS EMBEDDED DEBRIS MAY DESTROY THE NEW PARTS.

WARNING NEVER USE COMPRESSED AIR TO CLEAN OR SPIN A BEARING AS SEVERE PERSONAL INJURY MAY RESULT FROM FLYING DEBRIS OR THE BEARING LOCKING WHILE SPINNING ON A FINGER.

CAUTION ALWAYS WEAR EYE PROTECTION WHEN TAPPING ON ANY BEARING RACE. USE ONLY APPROVED DRIVES OR PUNCHES WHEN DRIVING AN OUTER RACE FROM THE HUB BECAUSE THE RACE MATERIAL IS VERY BRITTLE AND MAY SHATTER

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6. Spindle assembly procedure:

SPINDLE ASSEMBLY FIGURE 2-3-22

a. Repack the old bearings or pack the new bearings with approved lubricant. (Refer to

Lubrication Specifications, page 1-18). b. Install any new outer races that are required. c. Insert the upper inner race and the upper seal. Place the upper spacer in the seal.

INSTALL UPPER SPACER

FIGURE 2-3-23

d. Install and hold the lower inner race and bearing as the spindle assembly is moved into position.

NOTICE THE UPPER SPACER CARRIES THE LOAD PLACED ON THE SPINDLE. IF IT IS NOT INSTALLED,THE BEARING WILL NOT BE LOADED AND THE TOP OF THE SPINDLE WILL RUB THE AXLE BEAM

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e. Drop the king pin through the axle beam and the spindle assembly. Make sure the milled flat on the pin head is in the proper position on the axle beam to prevent rotation.

f. Insert the bottom sleeve over the king pin and into the axle beam. g. Install the washer and castle nut onto the bottom of the king pin. h. Tighten until resistance is felt when rotating the spindle. Then reverse the nut until the

first slot lines up with the cotter pin hole. Install the cotter pin. i. Thoroughly grease the spindle pivot pin. (Refer to Lubrication Chart, page 1-18) j. Reconnect the brake lines to the brake caliper or reinstall the brake caliper, if it was

removed. Torque the caliper mounting bolts to 100 Ft. Lbs. (13.5 kgf·m) k. Reconnect the steering linkages. l. Reinstall tire/wheel assemblies on front axle. (Refer to Tire/Wheel Assembly installation

procedure, page 3-3). m. Bleed air from brake system. (Refer to Brake Bleeding procedure, page 2-9).

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H. Steering Linkage

The steering linkage is made up of three parts: the hydraulic cylinder, the tie rods, and the bellcrank.

STEERING LINKAGE

FIGURE 2-3-24

1. Steering cylinder removal procedure:


b. Wipe clean and disconnect hydraulic lines from steering cylinder. Tag, cap and plug hydraulic lines and cylinder ports.

DISCONNECT HYDRAULIC LINES FROM STEERING CYLINDER FIGURE 2-3-25

c. Remove the self-locking nuts on the pins at each end of the cylinder. d. Lift the cylinder off of the pins. e. Always inspect the pins for damage or wear. f. Cylinder repair should be done by a hydraulics repair facility.

2. Steering cylinder installation procedure:

a. Reverse the steps above to replace the cylinder.


WARNING

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3. Steering tie rod removal procedure:


STEERING TIE ROD FIGURE 2-3-26

b. Remove the cotter pin and nut from the outer ball joint. c. Using a ball joint tool, remove the outer joint. d. Remove the Allen bolt and washer and slide the rod end off. e. Both end fitting are secured by a clamp.

4. Steering tie rod installation procedure:

a. Reverse the steps above to replace the tie rods.

NOTICE THE TIE RODS HAVE A DIFFERENT METHOD OF ATTACHMENT ON EACH END; ON THE OUTSIDE END A CONVENTIONAL TIE ROD END IS USED, AND ON THE INSIDE A SPHERICAL ROD END IS USED.

NOTICE WHEN REPLACING THE TWO END FITTINGS, NOTE THAT THEY HAVE RIGHT AND LEFT THREADS TO MAKE ADJUSTMENT EASY.

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5. Steering bellcrank removal procedure:

STEERING BELLCRANK FIGURE 2-3-27


b. Remove the tie rods from the bellcrank. c. Remove the plug from the bellcrank. Then remover the slotted nut from the bellcrank

pivot pin. d. The washer, the conical bearings, the seal, and the bellcrank will now slide off of the pin. e. The replaceable parts are the top and bottom conical bearings and the seals. f. Knock out the old bearings and press in the new bearings. g. Inspect the pin for wear. If the old bearings were allowed to wear completely out, the pin

may be damaged and require replacement. This work will require cutting and welding that should be done with the axle assembly removed.

6. Steering bellcrank installation procedure:

a. Reverse the steps above to install the bellcrank.

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I. Rear Axle Assembly

1. Rear axle removal procedure:

a. Chock front wheels in both directions to prevent unit from moving. b. Disconnect the battery from the tractor. c. Jack the frame of the unit up and place jack stands or approved blocking devices under

the frame. d. Remove tire/wheel assemblies from front axle. (See Tire/Wheel Assembly Removal

procedure, page 3-3) e. Remove tension in the park brake assembly by placing the parking brake handle in the

raised position then turning handle clockwise (Figure 2-3-28).

REMOVING PARKING BRAKE TENSION FIGURE 2-3-28

f. Disconnect the two park brake cables from the parking brake bellcrank located in the center area of the unit. Pull these cables back through the holes in the chassis (Figure 2-3-29).

PARK BRAKE CABLES & BELLCRANK

FIGURE 2-3-29

WARNING WORK IN THIS AREA HAS THE POSSIBILITY OF ELECTRIC SHOCK OR BURNS FROM A SHORT CIRCUIT CONDITION. DISCONNECT THE BATTERY BEFORE THIS WORK. REMOVAL OF ALL METALLIC JEWELRY IS RECOMMENDED.

WARNING WHEN THE UNIT IS RAISED AND BLOCKED, ALWAYS USE APPROVED BLOCKING DEVICES THAT WILL SUPPORT THE UNITS WEIGHT.

DISCONNECT PARK BRAKE CABLES

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g. Wipe clean and disconnect the brake lines at each brake drum on rear axle. Cap and

plug disconnected brake lines (Figure 2-3-30).

DISCONNECT BRAKE LINES FROM REAR BRAKES FIGURE 2-3-30

h. Disconnect the brake lines from the mounted locations on the rear axle by removing the cable clamps used to hold the brake lines (Figure 2-3-31).

DISCONNECT BRAKE LINES FROM REAR AXLE

FIGURE 2-3-31

CAUTION WIPE CONNECTION CLEAN PRIOR TO OPENING BRAKE SYSTEM.

CAP OR PLUG ALL OPEN PORTS.

NOTICE USE BACK-UP WRENCHES ON ALL MATING PARTS.

DISCONNECT BRAKE LINE ON EACH SIDE

CABLE CLAMP

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i. Disconnect the brake lines from the brake tee located on the driver’s side of the rear axle. Remove the brake lines from the unit. Disconnect the brake tee from the rear axle by removing the mounting nut shown (Figure 2-3-32).

DISCONNECT BRAKE LINES BRAKE TEE AND REMOVE TEE

FIGURE 2-3-32 j. Remove the traction motor leads cover, located next to the steering pump/motor, to allow

access to the traction motor leads. Disconnect and tag the motor leads and fold these wires back out of the way (Figure 2-3-33). Locate the speed sensor wiring, and cut the wiring in order to allow the motor to be dropped out.

REMOVE COVER TO ACCESS AC MOTOR AND DISCONNECT WIRING FIGURE 2-3-33

REMOVE MOUNTING NUT TO REMOVE BRAKE TEE

DISCONNECT BRAKE LINES FROM TEE

DISCONNECT BRAKE LINES FROM TEE

MOTOR LEADS

SPEED SENSOR WIRING

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k. Use a transmission jack to support the rear axle. l. Remove the sixteen (16) mounting nuts for the axle U-bolts that attach the rear axle to

the leaf springs (Figure 2-3-34).

REMOVE MOUNTING NUTS TO THE AXLE U-BOLTS

FIGURE 2-3-34

m. Lower the transmission jack and roll axle out toward the rear of the unit. n. To disassemble the AC traction motor from the rear axle, refer to AC Traction motor

removal procedure, page 3-47.

2. Rear axle installation procedure: a. Installation of the rear axle is accomplished by reversing the order of the above steps a

through o. b. The speed sensor wiring will need to be spliced back together per the Wiring Diagram. c. Upon completion of rear axle installation, bleed air from brake system (See Brake

Bleeding procedure, page 2-9) and adjust operation of the parking brake (See Parking Brake Adjustment procedure, page 2-3).

3. Differential disassembly procedure:

The differential, all reduction gears, axle tubes, axles, brakes, and parking brake are all combined in the same assembly. Although the assembly is quite simple, the shimming of the differential requires precise measurements or a great deal of trial and error

WARNING DO NOT LIFT UNIT FRAME FROM JACK STANDS WHEN SUPPORTING REAR AXLE WITH TRANSMISSION JACK.

WARNING GREAT CAUTION MUST BE TAKEN BECAUSE THE MOTOR/AXLE ASSEMBLY IS HEAVY AND VERY LIKELY TO TIP DUE TO THE MOUNTING POSITION OF THE MOTOR

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J. Pump/Motor

1. Hydraulic pump/motor removal procedure:

a. Disconnect the battery plugs, to remove power from the unit. b. Open the rear access cover located behind the battery to allow access to the hydraulic

pump/motor. c. Disconnect and tag the electrical pump motor leads.

PUMP/MOTOR FIGURE 2-3-35

d. Wipe clean and disconnect hydraulic hoses from the pump. Tag and cap hoses after

removal. e. Disconnect the pressure switch at the hydraulic tee. f. Loosen and remove the four (4) nuts and lockwashers the holds the pump/motor in

place. g. Remove pump/motor from unit as complete assembly.

2. Hydraulic pump/motor installation procedure:

a. Installation of the hydraulic pump/motor is accomplished by reversing the order of the above steps.

b. After installation is completed, air must be bled from hydraulic system.


WARNING


DISCONNECT HYDRAULIC LINES

DISCONNECT PRESSURE SWITCH

DISCONNECT MOTOR LEADS

MOUNTING NUTS

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K. Operator Column / Operators Dash Controls

1. Operator column disassembly procedure:

a. The column can be disassembled to many different levels dependent on the maintenance requirement.

b. Remove the steering wheel by removing the steering wheel cap, which allows access to the nut underneath. Remove the nut and the steering wheel.

REMOVE STEERING WHEEL NUT FIGURE 2-3-36

c. The top of the operator’s dash can be removed by removing the mounting screws from each side of the top dash. Carefully lift the dash panel up over the steering column. This will allow access to the operators dash controls, switches, and the heater contactor.

REMOVE TOP DASH PANEL FIGURE 2-3-37


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d. The display unit can be removed at this time. To remove the display unit.

aa. Disconnect and tag the electrical connector to the display unit. bb. Remove the two (2) screws from the gauge U-bracket. cc. Remove the U-bracket and the gauge. dd. When reinstalling the display gauge, apply a small amount of Nye Nyogel 760G

to the electrical pins of the gauge.

e. Remove the tilt adjustment lever by rotating the lever counterclockwise until the lever is threaded off of the adjustment pin. The upper side dash panels can then be removed.

REMOVE TILT ADJUSTMENT LEVER FIGURE 2-3-38

f. To remove the upper side dash panels, remove the mounting screws located in front and

behind the column. The dash panels can then be pulled apart. This will allow better access to the start button, emergency stop switch, and the steering column u-joint.

REMOVE SIDE PANELS (TOP DASH PANEL NOT SHOW FOR CLARITY)

FIGURE 2-3-39

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g. To allow access to the lower side dash panels, the wiring cover will first need to be removed. Remove the two (2) screws mounting the wiring cover to the headlight cover and the steering column. Remove the cover.

REMOVE WIRING COVER FIGURE 2-3-40

h. To remove the lower side dash panels, remove the four (4) mounting screws located on the right and left of the column. The dash panels can then be pulled apart. This will allow better access to the steering valve column. Additionally this will allow full access to all column wiring and the headlight relay.

REMOVE LOWER DASH PANELS FIGURE 2-3-41

2. Operator column assembly procedure:

a. Assembly of the column is accomplished by reversing the order of the above steps. b. When reassembling dash panels, the left side panel always overlaps the right side panel. c. Care must be taken when reassembling the column that no wiring is pinched between

dash panels. d. If reinstalling the display gauge, apply a small amount of Nye Nyogel 760G to the

electrical pins of the gauge.

REMOVE MOUNTING SCREWS

REMOVE MOUNTING SCREWS

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L. Steering Valve

1. Steering valve removal procedure: a. Disassemble the operator column. (See operator column disassembly procedure, page

3-31) b. Jack the frame of the unit up and place jack stands or approved blocking devices under

the frame. c. Remove the four (4) bolts mounting the underside cover to the chassis. This will allow

access to the hydraulic lines located under the front of the unit.

REMOVE UNDERSIDE COVER FIGURE 2-3-42

d. Wipe clean and disconnect hydraulic lines connected to steering valve. (Tag and plug

hydraulic lines after disconnecting).

DISCONNECT HOSES FROM STEERING VALVE FIGURE 2-3-43

REMOVE MOUNTING BOLTS

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e. Remove the four (4) mounting bolts connecting the steering valve to the column. Lower the steering valve out from under the vehicle.

REMOVE MOUNTING BOLTS FOR STEERING VALVE FIGURE 2-3-44

2. Steering valve installation procedure:

a. Installation of the steering valve is accomplished by reversing the order of the above steps.

b. Following installation of the steering valve, reassemble the COBO console (See COBO console assembly procedure, page 3-31)


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M. Hydraulic Hoses

The hoses on this tractor use 24 end fittings and see a normal operating pressure of 1800 PSI (124 BAR)

Below is a schematic that shows the connections of the hoses and other hydraulic components.

HYDRAULIC HOSING FIGURE 2-3-45

WARNING WHEN REPLACING A HOSE, MAKE SURE THE EXACT REPLACEMENT IS USED.


WARNING

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N. Converter

The converter is located in the electrical control box at the left rear of the tractor. Access to this area is accomplished by removing the access cover.

1. Converter removal procedure: a. Disconnect and tag the wiring leading to the converter. b. Remove the four (4) screws mounting the converter to the end wall of the electrical

control box. c. Remove the converter, taking caution not to damage the wiring in the control box area.

DC-DC CONVERTER LOCATION FIGURE 2-3-46

2. Converter installation procedure:

a. Installation of the converter is accomplished by reversing the order of the above steps.



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O. AC Controller

1. AC Controller panel removal procedure: a. Disconnect the battery from the tractor. b. Open the rear cover of the tractor and remove the controller cover to allow access to the

AC controller panel. c. Disconnect and tag the three (3) motor leads to the AC controller. Move the wiring aside.

DISCONNECT MOTOR LEADS FIGURE 2-3-47


“M3” “M2” “M1”


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d. Disconnect and tag the wiring connector shown. Move the wiring aside.

DISCONNECT CONNECTIONS TO CONTROLLER FIGURE 2-3-48

e. Disconnect and tag the wiring and bus bar to the negative bus terminal. Move the wiring

aside, and push the bus bar to one side. f. Disconnect the bus bar from the positive bus terminal, and push the bus bar to one side. g. Remove the four (4) mounting screws located around the edge of the controller base and

carefully lift the controller out.

2. AC Controller installation procedure: a. Apply a small amount (approximately 0.001”) of a heat transfer compound on the bottom

surface of the controller prior to mounting.

aa. A serrated surface (resembling a saw-toothed edge) may be used to apply the thermal compound. The teeth projections are approximately 0.001”

bb. Recommended compounds: AOS Thermal Spray, G6451 or Dow Corning Heatsink Compound.

b. Install the control panel and tighten the four mounting screws to 35 lb. ft. (47 N·m). c. Reconnect all wiring and bus bars and tighten to 10 lb. ft. (14 N·m)

d. Reconnect the battery.

WIRING CONNECTOR

CAUTION IT IS EXTREMELY CRITICAL THAT THE 3 PHASE LEADS (MOTOR LEADS) BE STRAIGHT AND PARALLEL TO EACH OTHER.

NEGATIVE BUS TERMINAL

POSITIVE BUS TERMINAL

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P. Accelerator Pedal/Switch The accelerator pedal is a simple pivot device with an electronic module mounted to the pedal bracket.

1. Accelerator pedal/switch removal procedure: a. Remove any covers from the front of the tractor to allow access to the accelerator switch

wiring.

REMOVE COVERS TO ACCESS ACCELERATOR WIRING FIGURE 2-3-49

b. Trace the cable leading from the accelerator pedal to the wiring loom located at the front

of the vehicle. Remove any loom/tape required to access the wiring connections. c. Disconnect and tag the wiring connections from the accelerator pedal cable to the wiring

harness.

DISCONNECT WIRING FROM ACCELERATOR PEDAL SWITCH FIGURE 2-3-50


WIRING HARNESS

WIRING CONNECTIONS

ACCELERATOR PEDAL

WIRING COVERS

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d. Remove the two mounting screws connecting the accelerator pedal to the pedal bracket.

REMOVE MOUNTING BOLT FIGURE 2-3-51

2. Accelerator pedal/switch installation procedure:

a. Installation of the accelerator pedal/switch is accomplished by reversing the order of the above steps.

REMOVE MOUNTING BOLTS PEDAL

MOUNT

CAUTION USE A SELF LOCKING NUT WHEN REINSTALLING. TAKE CARE NOT TO OVERTIGHTEN AND CRUSH THE METAL SPRING HOUSING.

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Q. Parking Brake Switch

The parking brake switch is located between the operators and passengers seats behind the parking brake handle.

1. Parking brake switch removal procedure:

a. Disconnect the wiring from the rear of the parking brake switch.

DISCONNECT WIRING TO THE SWITCH FIGURE 2-3-52

b. Remove the two (2) screws mounting the parking brake switch and cover to the park

brake handle.

REMOVE MOUNTING SCREWS FIGURE 2-3-53


MOUNTING SCREW

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2. Park brake switch installation procedure:

a. Installation of the park brake switch is accomplished by reversing the order of the above steps.

b. When installing the switch, ensure that the whisker is placed over the glide pin in the park brake handle. This allows the switch to be triggered when the park brake is applied.

PARK BRAKE RELEASED PARK BRAKE APPLIED

INSTALLATION OF PARK BRAKE SWITCH FIGURE 2-3-54

WHISKER

GLIDE PIN

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R. Seat Switch

The seat switch is located behind the driver’s seat on the seat mount.

1. Seat switch removal procedure:

a. Using the adjustment lever on each seat, push the passenger and driver’s seat forward to allow access to the seat switch and wiring cover.

WIRING COVER REMOVAL FIGURE 2-3-55

b. Remove the two (2) bolts mounting the wiring cover to the chassis. Remove the wiring

cover from behind the seat. c. Disconnect and tag the wiring from the seat switch to the wiring harness.

DISCONNECT WIRING TO SEAT SWITCH FIGURE 2-3-56


WIRING COVER

SEAT SWITCH

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d. Remove the two (2) mounting screws connecting the seat switch to the mounting bracket.

SEAT SWITCH REMOVAL

FIGURE 2-3-57

2. Seat switch installation procedure:

a. Installation of the seat switch is accomplished by reversing the order of the above steps. b. After installing the switch on the mounting bracket, ensure that the switch will engage and

disengage properly when an operator is in the seat.

NO OPERATOR OPERATOR IN SEAT IN SEAT

SEAT SWITCH OPERATION

FIGURE 2-3-58

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S. Accumulator System

1. Discharge hydraulic pressure from the accumulator system. 2. The accumulator system is made up of several components as shown below. Each

component can be replaced through routine mechanical operations. For more information on the accumulator, refer to Chapter 5.

HYDRAULIC ASSEMBLY WITH ACCUMULATOR

FIGURE 2-3-59


WARNING

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T. AC Traction Motor

1. Traction Motor removal procedure: a. Remove the rear axle/motor combination from the unit. See Rear Axle Removal

procedure, page 3-26. b. Locate a sling under the center of the motor and attach it to a crane or engine lift. This

will support the motor when it is disconnected from the rear axle. c. Remove the five (5) bolts that connect the traction motor to the rear axle. Pull the traction

motor away from the rear axle differential taking care not to damage the splined shaft of the motor or rear axle.

TRACTION MOTOR REMOVAL FIGURE 2-3-60

2. Traction motor installation procedure:

a. Before reinstalling the traction motor, coat the input shaft splines with Molydal, Gripcott

N.F. High Temperature paste, and apply a silicon RTV to the mounting surface of the axle to prevent oil leakage. Align the new AC traction motor to the rear axle mounting pattern with the electrical connections pointing up and install the mounting bolts removed previously.

b. After the traction motor is reinstalled on the rear axle, reinstall the rear axle into the unit. See Rear Axle installation procedure, page 3-29.



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3. Traction motor speed sensor check: a. Raise and properly support the rear of the tractor. Place chocks under the front wheels

to prevent movement. b. Open the rear cover of the tractors and remove the electrical panel cover to access the

controller diagnostic plug.

CONTROLLER DIAGNOSTIC PLUG FIGURE 2-3-61

c. Connect either the diagnostic handheld or a laptop (which has the controller diagnostic

software to the controller diagnostic plug). Turn the vehicle on and connect the diagnostic handheld or laptop software to the vehicle.

d. Locate the speed sensor monitoring settings with the diagnostic handheld/laptop. This will located under the menu at Monitor>Motor>MotorSpeedA and MotorSpeedB.

MOTOR MONITOR FIGURE 2-3-62

e. While monitoring the display on the diagnostic handheld/laptop, have another technician

turn the motor connected to the rear axle by turning one of the rear wheels by hand. (This will be very hard due to the axle reduction.)

f. The display on the diagnostic handheld/laptop should register a RPM number as the wheel is turned. If the display registers a RPM number, then the speed sensor bearing is operating correctly. If the display does not register a RPM number, then additional troubleshooting will be required as detailed in stops g-r. Disconnect the diagnostic handheld/laptop from the vehicle diagnostic plug.

DIAGNOSTIC PLUG

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g. If additional troubleshooting is required, disconnect the battery to remove power from the vehicle before continuing.

h. Remove the motor cover shown to allow access to the drive motor speed sensor wiring.

REMOVE MOTOR COVER FIGURE 2-3-63

i. Locate the speed sensor wiring lead coming from the speed sensor. This is identifiable

as wiring which comes out from the end shield of the motor. Disconnect the vehicle wiring harness from the motor’s speed sensor.

SPEED SENSOR WIRING FIGURE 2-3-64

j. A 12 volt DC source will be required to check the speed sensor manually. This can be

supplied by a small 12 volt battery charger or a 12 volt battery. If a battery is used, an inline fuse should be used to protect the electrician in the case of a short during the connection process.

k. The test can be run by either connecting through the plug via the pins, or by cutting the wires at the plug and connecting to the wiring. Wires should be connected as follows:

12 V Source – Positive Red Sensor Wire 12 V Source – Negative Black Sensor Wire

Voltmeter – Positive Red Sensor Wire Voltmeter – Negative Blue Sensor Wire

l. With these connections in place, have another technician turn the motor connected to the

rear axle by turning one of the rear wheels by hand. (This will be very hard due to the axle reduction.)

m. With the motor turning slowly, the VOM should show voltage fluctuations between approximately 0 and 11 volts.

SPEED SENSOR WIRING

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n. Now move the VOM negative lead to the white wire and repeat the test. Thus, the wiring should be as follows:

12 V Source – Positive Red Sensor Wire 12 V Source – Negative Black Sensor Wire

Voltmeter – Positive Red Sensor Wire Voltmeter – Negative White Sensor Wire

o. The meter should once again move between approximately 0 and 11 volts. p. A properly operating speed sensor should provide a constant voltage value at a constant

speed. As the speed of the motor increases or decreases then the voltage will change accordingly.

q. If the voltage does not register during the turning of the motor, or the voltage fluctuates despite a constant speed, then the speed sensor will need to be replaced.

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4. Traction motor speed sensor removal procedure:

a. Test the speed sensor as listed previously to determine if the speed sensor needs to be replaced. (See page 3-48 for testing procedure.)

b. Disconnect the battery to remove power from the unit before continuing. c. Remove the drive motor from the vehicle to allow easier removal of the bearing. (See

page 3-50 from drive motor removal procedure.) d. The speed sensor bearing is located within the end shield of the traction motor and is

held in place by two snap rings. Accessing the bearing will require the removal of the end cap, fan, and rotor.

DRIVE MOTOR BREAKDOWN

FIGURE 2-3-65

END SHIELD

SPEED SENSOR BEARING

END CAP

FAN

CAUTION WHEN REPLACING THE SPEED SENSOR BEARING, THE FAN WILL NEED TO BE REPLACED AS WELL DUE TO THE FAN BEING A PRESS FIT DESIGN. CHARLATTE ALSO HIGHLY RECOMMENDS REPLACING THE SNAP RINGS AT THE SAME TIME AS THESE ITEMS ARE EASILY DAMAGED AND WORN DURING THE REMOVAL PROCEDURE.

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e. Remove the end cap from the drive motor to allow access to the fan and rear end shield. This will require the removal of four mounting bolts.

END CAP REMOVAL FIGURE 2-3-66

f. Remove the two screws holding the speed sensor wiring connector to the side of the motor frame. Pull the speed sensor wiring free from the clips on the motor frame.

CONNECTOR MOUNT & WIRING CLIPS FIGURE 2-3-67

WIRING CLIPS

MOUNTING SCREWS

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g. Using a brake puller, remove the fan from the shaft of the rotor. If the fan is flexing too much to allow the brake puller to remove it, then the fan can be pried off with a long screwdriver and hammer. Dispose of the fan as a new fan will need to be installed each time the speed sensor bearing is replaced.

FAN REMOVAL FIGURE 2-3-68

h. Using an allen wrench, remove the 4 bolts holding the rear end shield in place.

END SHIELD BOLT REMOVAL FIGURE 2-3-69

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i. The entire rotor of the motor should now be pulled out from the motor. This may require initially prying around the end shield to start. The rotor should remove from the motor easily after that. This will allow access to the speed sensor bearing within the end shield.

ROTOR REMOVAL FIGURE 2-3-70

j. Using a pair of 90 degree snap ring pliers, remove the large snap ring from behind the speed sensor bearing. This will allow the rear end shield to be removed from the shaft of the rotor. (Note: Wiring shown clipped for clarity only.)

END SHIELD REMOVAL FIGURE 2-3-71

CAUTION DO NOT ATTEMPT TO REMOVE THE END SHIELD FROM THE ROTOR AT THIS TIME. THE SNAP RINGS WHICH HOLD THE BEARING IN PLACE WILL NOT ALLOW END SHIELD TO BE REMOVED FROM THE ROTOR. ATTEMPTING TO REMOVE THE ROTOR WITH THE BEARING IN PLACE WILL RESULT IN DAMAGING THE END SHIELD AND POSSIBLY THE ROTOR.

END SHIELD


SNAP RING (SHOWN REMOVED)

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k. Using a pair of snap ring pliers, remove the other smaller snap ring from in front of the bearing. This will allow the bearing to be removed from the shaft of the rotor.

BEARING SNAP RING REMOVAL

FIGURE 2-3-72

l. Using a brake puller, remove the bearing from the shaft.

BEARING REMOVAL

FIGURE 2-3-73


SNAP RING

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5. Traction motor speed sensor installation procedure:

a. Identify the bearing and drive shaft ends of the rotor. The drive shaft end will be the one reinserted into the motor.

ROTOR FIGURE 2-3-74

b. Place the new speed sensor bearing and O-ring on the bearing end of the rotor and

press into the location behind the groove for the small snap ring. Place the small snap ring into place to hold the bearing into place on the rotor.

ROTOR FIGURE 2-3-75

BEARING END

DRIVE END

BEARING

SNAP RING

CAUTION WHEN REPLACING THE SPEED SENSOR BEARING, THE FAN WILL NEED TO BE REPLACED AS WELL DUE TO THE FAN BEING A PRESS FIT DESIGN. CHARLATTE ALSO HIGHLY RECOMMENDS REPLACING THE SNAP RINGS AT THE SAME TIME AS THESE ITEMS ARE EASILY DAMAGED AND WORN DURING THE REMOVAL PROCEDURE.

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c. Place the end shield over the bearing and ensure that the wiring of the speed sensor lines up with the inside and outside notches in the end shield for the wiring to pass through.

END SHIELD NOTCH FIGURE 2-3-76

d. Put the large snap ring into position behind the bearing to hold the bearing within the end

shield. e. Replace the rotor and end shield back into the drive motor frame. Ensure that the speed

sensor wiring is coming out on the same side as the plug area on the motor frame. Place the speed sensor wiring into the clips on the motor frame. Replace the two mounting screws to mount the speed sensor wiring connector to the motor frame.

CONNECTOR MOUNT & WIRING CLIPS FIGURE 2-3-77

INSIDE NOTCH

OUTSIDE NOTCH

WIRING CLIPS

MOUNTING SCREWS

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f. Replace the four allen end screws to install the end shield to the drive motor frame.

WIRING CLIPS FIGURE 2-3-78

g. Place the fan on to the rotor shaft and press back into position on the motor frame as

shown.

FAN INSTALLATION FIGURE 2-3-79

h. Replace the end cap on the motor and replace the four mounting bolts removed earlier. i. Replace the traction motor into the vehicle. (See page 3-47 for installation procedure.) j. Reconnect the vehicle wiring harness to the speed sensor plug. k. Reconnect the battery plug and test the speed sensor for proper functioning per the

previous section. l. If speed sensor is operating correctly, lower the vehicle and test the vehicle for proper

operation.

WIRING CLIPS

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IV. TROUBLE SHOOTING

A. General Information

The following section lists possible problems that may be encountered when operating or servicing the Model T-137 AC Electric Tow Tractor and can aid in locating and correcting these problems.

1. It is IMPORTANT to be familiar with and know the normal operation of this unit before

attempting to bring it back to proper operation. This is especially true with the electrical portion of the unit. Due to the numerous interlocks present, the possibility of non-operation is present.

2. Whenever a potential problem is uncovered during operation or maintenance, the unit should

be removed from service and the problem corrected by a qualified maintenance technician. 3. See the AC Motor Controller Section of Chapter 5 before attempting to troubleshoot the

electronics on the unit. 4. Do not expose the AC Motor Controller of the machine to high temperatures or water.

WARNING WHEN TROUBLE SHOOTING THE UNIT:

ALWAYS CHOCK ALL FOUR (4) TIRES IN EACH DIRECTION OR RAISE THE UNIT CLEAR OF THE GROUND SO THAT TIRES ARE FREE TO ROTATE. DISCONNECT THE BATTERIES EXCEPT WHEN VOLTAGE CHECKS ARE BEING MADE. USE INSULATED GLOVES AND TOOLS WHEN WORKING INSIDE THE ELECTRICAL CONTROLLER. DO NOT MOVE ANY CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE COULD BE HURT BY THE MACHINE’S MOVEMENT. DO NOT PERFORM MAINTENANCE OR TROUBLE SHOOT THE MACHINE IN A CONJESTED AREA

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B. Hydraulic System (General)

Trouble, Symptom Or Condition

Probable Cause

Test, Check Or Remedy

Dirty Oil

1. Components not properly

cleaned after servicing. 2. Hose connections not

properly covered, plugged, or capped during servicing of machine.

1. Disassemble components

and clean parts. 2. Clean hose connections.

Foaming Oil

1. Return tank line not below

fluid level. 2. Oil contaminated with

incompatible material. 3. Suction leak to pump aerating

oil.

1. Check hydraulic fluid level. 2. Drain oil and replace with

clean oil. 3. Replace or tighten fittings or

lines. Moisture in Oil

1. Soluble oil solution splashing

into poorly gasketed tank or fill cap left off.

2. Moisture in oil storage

containers or used replacement oil.

3. Extreme temperature

differential in certain geographical locations.

1. Drain oil and refill with clean

oil. Check fill cap to see if it is properly closed.

2. Replace or clean oil storage

containers. 3. Replace with recommended

oil for correct temperature range.

Foreign Matter Sources In The Circuit

1. Sealing Compound (pipe

dope, teflon tape) in circuit. 2. Burrs inside piping

components. 3. Lines left unprotected and

dirty during parts replacement.

4. Replacement parts not

properly protected during storage.

1. Clean or replace seals. 2. Disassemble piping and

remove any burrs. 3. Drain and replace oil. 4. Clean parts thoroughly

before installation.


WARNING

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Probable Cause


Overheating of System

1. Fluid viscosity too high. 2. Excessive slippage or internal

leakage past pump or cylinders.

3. Improper air circulation

around reservoir.

1. Check fluid specs. 2. Fluid viscosity too low. 3. Check to see if the area

around the reservoir is clear.

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C. Hydraulic Pump/Motor

Trouble, Symptom Or

Condition

Probable Cause

Test, Check Or Remedy Pump Makes Excessive Noise

1. Vacuum leak in suction line. 2. Vacuum leak in pump shaft

seal. 3. Poor alignment with drive

motor. 4. Incorrect fluid in system. 5. Seal deterioration (hard or

loss of elasticity). 6. Seal deterioration (loss of

radial squeeze due to flat spots or wear on O.D. or I.D.).

1. Check for leaks in fittings or

damaged suction line. 2. Repair or replace pump. 3. Align pump and pump motor. 4. Check fluid specs. 5. Replace seal. 6. Replace seal.

Seal Leak

1. Torn or worn seal. 2. Gland bearing worn. 3. Seal deterioration (soft or

gummy). 4. Seal deterioration (hard or

loss of elasticity). 5. Seal deterioration (loss of radial

squeeze due to flat spots or wear on O.D. or I.D.).

6. Aeration of fluid in tank. 7. Worn or damaged gears and

housing. 8. Worn or faulty bearing. 9. Plugged or restricted suction

line or strainer. 10. Oil viscosity too high or

operating temperature too low.

1. Replace seal. 2. Replace gland and seals. 3. Replace seal. 4. Replace seal. 5. Replace seal. 6. Correct air leak. 7. Replace gears and housing. 8. Replace faulty bearing. 9. Clean or replace suction line

or strainer. 10. Replace with recommended

oil


WARNING

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Probable Cause


Seal Leak (Continued)

11. Air leak in suction line or fittings.

12. Loose or worn pump parts 13. Air leak at pump shaft seal. 14. Oil level too low. 15. Air bubbles in intake oil. 16. Pump housing bolts loose or

not properly torqued.

11. Replace line or fittings if badly worn.

12. Replace worn pump parts. 13. Replace seal. 14. Check oil level. 15. Check oil level and tighten

any loose fittings. 16. Tighten and re-torque bolts.

Pump Failure to Deliver Oil

1. Low oil level in tank. 2. Air leak in suction line and

preventing priming. 3. Pump shaft turning too

slowly. 4. Oil viscosity too high. 5. Incorrect shaft rotation. 6. Pump shaft or parts broken. 7. Dirt or contamination in

pump.

1. Check oil level. 2. Tighten or replace suction

line. 3. Gears are worn and need

replacing. 4. Replace with recommended

oil. 5. Check pump motor wiring. 6. Replace shaft or broken

parts. 7. Clean pump.

Oil Leakage Around Pump

1. Shaft seal worn. 2. Hydraulic line connection

leaking. 3. Pump housing bolts loose or

improperly torqued.

1. Replace seal. 2. Tighten or replace fittings. 3. Tighten and re-torque bolts.

Excessive Pump Wear

1. Abrasive dirt or contamination in hydraulic oil being circulated through the system.

2. Pump misalignment. 3. Oil viscosity too low. 4. System pressure exceeding

pump rating.

1. Clean tank and refill with clean oil.

2. Realign pump. 3. Replace with recommended oil. 4. Check system pressure.

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Probable Cause


Pump Parts Inside The Housing Are Broken

1. Seizure due to lack of oil. 2. Excessive system pressure

above maximum pump rating. 3. Excessive torquing to

housing bolts. 4. Contamination being drawn in

from tank.

1. Check oil level. 2. Check system pressure. 3. Re-torque housing bolts. 4. Clean tank and replace with

clean oil. Pump Motor Won’t Start

1. Usually control trouble.

1a. Check pressure switch

settings. Adjust if necessary. 1b. Check source of power

supply. 1c. Check overloads, fuses,

controls, etc. Pump Motor Makes Excessive Vibrations

1. Rubbing between rotating

and stationary parts. 2. Armature out of balance. 3. Resonance.

1. Locate and repair cause of

rub. 2. Check rotor balance and

repair as required. 3. Tune system.

Motor Over-Heating

1. Overload. Compare actual

amps to the nameplate rating.

2. Improper ventilation. 3. Armature rubbing on stator. 4. Field over-voltage. 5. Open armature windings. 6. Full voltage on field at stand

still. 7. Ground. 8. Improper connections.

1. Check for excessive friction in

motor or pump. 2. Check to see that the area

around the motor is clear. 3. Check for bad bearings. 4. Check voltage. 5. Check field commutator for

burned bars. 6. Reduce voltage to 60% with

field economy circuit in control.

7. Locate and repair. 8. Check all connections per

Wiring Diagram in Chapter 4.

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Probable Cause


Growling or Whining

1. Bad bearing.

1. Replace bearing. Purge and

replace grease. Bearing Over-Heating

1. Too much grease in bearing. 2. Insufficient grease in bearing. 3. Dirt or contaminants in

bearing.

1. Remove grease until cavity is

about ¾ full. 2. Add grease until cavity is

about ¾ full. 3. Clean bearing and bearing

cavity. Repack with correct grease.

Pump Motor Makes Excessive Noise

1. Foreign material in air gap or

ventilation openings.

1. Remove armature and foreign

material, replace armature. Check the integrity of the insulation and ventilation openings.

Pump Motor Runs Constantly

1. Pressure switch settings. 2. Accumulator problem. 3. Controller settings.

1. Check pressure switch

settings. Adjust if necessary. 2. Check pressure in

accumulator. Re-pressurize or repair as necessary.

3. Check controller settings with

computer or handheld unit.

Pump Motor Runs Every Time Steering Wheel Is Moved

1. Pressure switch settings. 2. Accumulator problem.

1. Check pressure switch

settings. Adjust if necessary. 2. Check pressure in

accumulator. Re-pressurize or repair as necessary.

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D. Steering


Probable Cause


Machine Pulls To One Side While Traveling

1. Unequal air pressure in tires. 2. Toe-in out of adjustment. 3. Front wheel bearings worn or

out of adjustment.

1. Check and adjust air

pressure. 2. Check steering tie rod for

damage and adjust toe-in. 3. Replace or adjust bearings as

required. Steering Very Difficult

1. Low oil level in tank. 2. System pressure too low. 3. Pump motor is not operating. 4. Pump not operating or

delivering correct oil pressure.

1. Check oil level. 2. Check system pressure. 3. See Pump Motor Trouble

Shooting. 4. See Hydraulic Pump Trouble

Shooting.

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E. Steering Cylinder


Probable Cause


Cylinder Drifts

1. Piston seal leak. 2. Other circuit leaks.

1. Replace seals. 2. Correct leaks.

Cylinder Fails To Move The Load When Actuated

1. Pressure too low. 2. Piston seal leak. 3. Piston rod broken at piston

end. 4. Contamination in hydraulic

system resulting in scored cylinder bore.

1. Check pressure at cylinder to

meet circuit requirements. 2. Replace seals. 3. Disassemble and replace

piston rod. 4. Disassemble and replace

necessary parts.

Erratic Or Chatter In Operation

1. Excessive friction due to

misalignment. 2. Counterbalance valve

needing adjustment.

1. Correct cylinder to load

alignment. 2. Adjust counterbalance valve.

Excessive Or Rapid Piston Wear

1. Excessive high back pressure

due to over adjustment.

1. Correct pressure adjustment.

Cylinder Body Seal Leak

1. Excessive pressure. 2. Seal is pinched or extruded. 3. Seal deterioration (soft or

gummy).

1. Reduce pressure to rated

limits. 2. Replace cylinder body seal. 3. Check compatibility of seal

material with operating fluid. Replace oil.

Piston Is Leaking

1. Contamination has scored

the piston or rod.

1. Replace rod or piston.

Piston Freezes To The Tube

1. Scoring in the piston.

1. Replace piston.

Packing And Gasket Leaks Develop

1. Excessive heat.

1. Replace packing and gasket.


WARNING

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Chapter 2 Page 4-10

Apr. 13

F. Brakes (Service)


Probable Cause


Brakes Slow To Apply

1. Defective front brake caliper. 2. Defective rear brake cylinder. 3. Brake lines or fittings leaking

or damaged. 4. Pedal linkage out of

adjustment. 5. Defective master cylinder. 6. Low brake fluid level or air in

system.

1. Replace or repair caliper. 2. Replace or repair cylinder. 3. Check for leaks and repair. 4. Adjust linkage. 5. Repair or replace master

cylinder. 6. Check fluid level and bleed

brakes if required. Brakes Won’t Release

1. Pedal linkage out of

adjustment or binding. 2. Defective brake pads or

shoes. 3. Defective master cylinder. 4. Defective brake caliper.

1. Check for proper adjustment

or binding. 2. Check pads or shoes. 3. Replace master cylinder. 4. Repair or replace brake

caliper. Insufficient Brakes


adjustment. 2. Brake line mashed. 3. Worn brake pads or shoes. 4. Defective master cylinder. 5. Low brake fluid level or air in

system.

1. Adjust linkage. 2. Check lines and replace. 3. Replace pads or shoes. 4. Repair or replace master

cylinder. 5. Check fluid level and bleed

brakes if required. Brakes Will Not Release Completely

1. Defective front caliper. 2. Defective rear brake cylinder. 3. Air in brake system. 4. Defective master cylinder.

1. Repair or replace brake

caliper. 2. Repair or replace brake

cylinder. 3. Bleed brakes. 4. Repair or replace master

cylinder.

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Chapter 2 Page 4-11

Apr. 13


Probable Cause


Excessive Braking

1. Defective front caliper.

2. Defective rear brake cylinder.

3. Defective master cylinder.

4. Pedal linkage out of adjustment.

1. Repair or replace brake

caliper.

2. Repair or replace brake cylinder.

3. Repair or replace master cylinder.

4. Adjust linkage

No Brakes


adjustment.

2. Brake line mashed or broken.

3. Worn brake pads or shoes.

4. Defective master cylinder.

1. Adjust linkage.

2. Check lines and replace.

3. Replace pads or shoes.

4. Repair or replace master cylinder.

Excessive Pedal Travel Or Pedal Goes to Floor Consistently

1. Air in brake lines.

2. Low fluid level.

3. Rear brake shoes out of adjustment or worn.

4. Front brake pads worn.

5. Loose or improper alignment of pedal to master cylinder linkage.

6. Pedal linkage out of adjustment.

1. Bleed brakes

2. Check fluid level.

3. Adjust or replace brake shoes.

4. Replace pads.

5. Repair or replace as required.

6. Adjust linkage.

Brake Pedal Feels Spongy When Applied

1. Low fluid level.

2. Rear brake shoes out of adjustment or worn.

3. Front wheel bearings out of adjustment.

4. Disc brake caliper attachment loose.

5. Worn or damaged rear self-adjusters.

1. Check fluid level.

2. Adjust or replace brake shoes.

3. Adjust bearings.

4. Tighten or replace as

required.


Noise At Wheels When Brakes Are Applied (Squeaks Or Chatter).

1. Worn or scored brake drums

and lining or rotors and pads.

2. Missing or damaged brake pad insulators.

3. Burrs or rust on rotor or drum.

1. Inspect, repair or replace as

required.


3. Clean or de-burr as required.

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Chapter 2 Page 4-12

Apr. 13


Probable Cause


Noise At Wheels When Brakes Are Applied (Squeaks Or Chatter). (Continued)

4. Dirty, greased or glazed pads

or shoes.

4. Clean or replace as required.

Brakes Pull To One Side

1. Unequal air pressure in tires. 2. Grease or fluid on pads or

shoes. 3. Loose or missing disc brake

caliper attaching bolts. 4. Restricted brake lines or

hoses. 5. Worn or damaged rear self-

adjusters.

1. Check and adjust air

pressure. 2. Clean or replace as required. 3. Replace missing bolts and

tighten to proper torque. 4. Repair Or Replace As

Required. 5. Repair or replace as required.

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Chapter 2 Page 4-13

Apr. 13

G. Brake, Parking


Probable Cause


Brake Slow To Apply

1. Defective brake caliper. 2. Cable or linkage out of

adjustment. 3. Cable or linkage damaged or

binding. 4. Worn or scored rear brake

drums and lining or rotors and pads.

1. Replace or repair caliper. 2. Adjust cable or linkage. 3. Repair or replace cable or

linkage. 4. Replace or repair as

necessary.

Brake Won’t Release

1. Defective rear brake cylinder. 2. Cable or linkage damaged or

binding.

1. Replace or repair brake

cylinder. 2. Repair or replace cable or

linkage. Insufficient Brakes

1. Cable or linkage out of


binding. 3. Rear brake shoes out of

adjustment or worn. 4. Defective rear brake cylinder.

1. Adjust cable or linkage. 2. Repair or replace cable or

linkage. 3. Adjust or replace brake

shoes. 4. Replace or repair brake

cylinder. Brake Will Not Release Completely



binding. 3. Defective rear brake cylinder.

1. Adjust cable or linkage. 2. Repair or replace cable or

linkage. 3. Replace or repair brake

cylinder. Excessive Braking


adjustment. 2. Defective rear brake cylinder.

1. Adjust cable or linkage. 2. Replace or repair brake

cylinder. Parking Brake Lever Hard To Apply

1. Brake handle out of

adjustment. 2. Frozen or damaged brake

cable.

1. Adjust or repair as required. 2. Repair or replace as required.

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Chapter 2 Page 4-14

Apr. 13

H. Electrical / AC Controller

1. General Diagnostics/Solutions

A. Unit will not turn on B. Unit will turn on but will not run and no display C. Unit will turn on, display is working but will not run and no errors D. Unit shows an error on the screen E. Unit works correctly but either lights, horn, alarms, gps, trailer attachments or security

system not working

A. Unit will not turn on

If the unit will not turn on when the master switch is in the “on” position please check the following:- Battery is present and the battery cable is plugged into the tractor cable.

If the unit has the manual disconnect charging system make sure vehicle cable is plugged into the charging receptacle. If charger cable is still attached to the vehicle, unplug the unit.

Check the e-stop on the rear controls is not pushed in (twist release type)

Check continuity between the battery positive and the main battery positive post in the electrical box. Repeat continuity check with battery negative and the main battery negative post in the electrical box. If either show open, change cables.

Check that battery voltage is above 70V DC. If voltage below 70V DC, charge vehicle.

If present, make sure the charge interlock switch is in the correct position.

Check the dash harness is connected to the main harness via the two circular amp connectors located at the base of the steering column.

Check that there are no burnt pins in the circular amp connectors located at the base of the steering column

Check the master switch wiring is correctly connected to the contact blocks behind the master switch and that the contact blocks are closing when the master switch is in the “on” position.

If present, check the charging contactor has a good coil and is working correctly. Check for 80V DC on the coil. Manually make sure the moving tips can be moved freely. Please note the battery should be unplugged when doing this check.

NOTICE THE ELECTRONIC MOTOR CONTROL INSTALLED ON THIS UNIT CAN PREVENT OPERATION IF A FAULT CONDITION OCCURS.

NOTICE REFER TO CHAPTER 5 FOR DETAILED INFORMATION ON TROUBLESHOOTING THE AC CONTROLLER.


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Chapter 2 Page 4-15

Apr. 13

B. Unit will turn on but will not run and there is no display

Check in the rear electrical box to see if either of the LEDs on top of the controller are illuminated.

If they are on:- o Check the connector on the side of the controller for backed out pins or plug not fully inserted. o Check the connection to the display

If they are not on:- o Check to make sure e-stop in the rear inching controls is not pushed in. (Switch is the twist-

release type). o Check to make sure the connector on the side of the controller is plugged in correctly o Check pin 1 on the controller plug to see if 80V DC present with master switch in the “on”

position.

If no 80V is present, check the following: o Fuse 1 on the side mounted strip o E-stop contact block and wiring o Dash column connectors for bad pins o Master switch to see if the contact block with wires #118 and #120 is closing.

If voltage reads below 70V, recharge battery

If the 80V is present, make sure pin 1 is correctly installed in the connector and then re-insert the plug into controller until it locks into position. If still no LED’s are illuminated, replace pin 1 in the Curtis 35 pin plug and check on the controller side to make sure the male pin has not been damaged in some way. If all looks correct then the controller has failed and needs to be replaced.

C. Unit will turn on the display but there is no drive and no errors shown

Plug the diagnostic tool into the controller (either handheld or PC) and check the driver inputs are correct. This is found under monitor>inputs. o Handbrake should be open (scroll down list until you see handbrake sw) o Deadman should be closed (this is actually the seat switch) o Direction selected should be closed (the switches are shown as forward sw and reverse sw). If

both direction switches are closed this will stop drive but should give a fault. o FS1 should close when you press the accelerator pedal. o Throttle pot should increase in a linear fashion as you press the accelerator pedal down.

Should start around 0.21V and reach 5V when fully depressed. o Brake switch should be open

If all driver inputs are correct, check the throttle command in the monitor inputs screen. When you try to drive the unit this command should increase from 0% to 100% (full speed). o If the command doesn’t move from 0% then the controller is not sending any current to the

motor. Recheck driver inputs and faults. If still nothing incorrect shows up, contact Charlatte’s technical support at 276-326-1510.

o If the command does go from 0% to 100% but the unit does not move then check in the monitor>controller>current (rms) screen. If this shows current going to 550a but unit not moving change any two motor leads (swap u and v, or u and w, or v and w cables over on the controller studs) to see if the motor and controller were out of phase.

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Chapter 2 Page 4-16

Apr. 13

D. Unit shows an error on the screen

Check to see what fault is present either by looking at the diagnostics section on the calibrator, looking at the description on the 6 LED display or by the flash code from the controller LEDs. To get the two digit flash code, count the yellow flashes after one red flash for first digit then count the yellow flashes after two red flashes for the second digit. See the fault codes

E. Unit works correctly but either lights, horn, alarm, gps, trailer attachments or security system not working

If only one component not operating check that bulb, switch and wiring (use the wiring diagram in the vehicle manual to assist)

If all lights not operating but horn and buzzers are then check fuse 3 and fuse 4

If all 12v system not working o Check 80v feed into converter. If no 80v going to converter check fuse f1 and check wiring

(see wiring diagram for assistance). If 80v is present check for 12-14v output from converter. If no 12v-14v present check the fuse in converter (if present) and check for a short between the output wires as this shuts down the converter. If fuse good and no short replace converter.

o If 12v present on converter output check fuse 2, the keyswitch contact block, and wire connections (see wiring diagram for assistance).

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Chapter 2 Page 4-17

Apr. 13

2. Charlatte Specific Fault Codes CODE PROGRAMMER LCD DISPLAY /

EFFECT OF FAULT POSSIBLE CAUSE SET/CLEAR CONDITIONS

-- HPD – High Pedal Disable Vehicle will not run

1. Throttle pedal was pressed down before direction was selected.

1. Release throttle pedal, select direction.

52 SRO – Static Return to Off Vehicle will not run

1. Direction lever was not in neutral position when main switch cut on.

1. Move direction lever back to neutral position, then select direction.

53 HANDBRAKE Vehicle will not run

1. Handbrake is set. 1. Release handbrake.

54 DEADMAN Vehicle will not run

1. Seat switch not activated. 2. Throttle was pressed when main switch was turned on.

1. Check that seat switch is activated by operator in seat. 2. Release throttle. Recycle main switch.

56 VCL HPD – High Pedal Disable Vehicle will not run

1. Throttle pedal was pressed down before direction was selected.

1. Release throttle pedal, select direction.

57 60 SECONDS (Does not display) Vehicle will not run

1. Unit has been stopped with direction lever in selected position for more than 60 seconds.

1. Move direction lever back to neutral, then select direction to drive.

58 PRESSURE ACCUMULATOR FAULT Vehicle enters limited (creep) mode

1. Hydraulic pressure switch is closed for more than 30 seconds – pump runs continually.

1. Take unit for immediate maintenance to check pressure switch, accumulator, or hydraulic pump for possible leaks/failures.

CODE PROGRAMMER LCD DISPLAY / EFFECT OF FAULT

POSSIBLE CAUSE SET/CLEAR CONDITIONS

51 PRESSURE ACCUMULATOR FAULT Vehicle enters limited (creep) mode

1. Hydraulic pressure switch is closed for more than 30 seconds – pump runs continually.

1. Take unit for immediate maintenance to check pressure switch, accumulator, or hydraulic pump for possible leaks/failures.

52 NO MOTOR SELECTED Vehicle will not run

1. No motor selected in controller.

1. Program controller.

NOTICE IF NEW SOFTWARE IS IN USE ON UNIT, ONLY TWO FAULT CODES WILL BE POSSIBLE. THESE CODES ARE AS FOLLOWS:

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Chapter 2 Page 4-18

Apr. 13

3. General Fault Codes

NOTICE REFER TO CHAPTER 5 FOR DETAILED INFORMATION ON TROUBLESHOOTING THE AC CONTROLLER.

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Chapter 2 Page 4-19

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3. General Fault Codes (Continued)

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Chapter 2 Page 4-24

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Chapter 2 Page 4-25

Apr. 13

I. Rear Drive


Probable Cause


Traction Motor Won’t Run

1. Usually controller trouble. 2. Speed sensor trouble. 3. Phases incorrect.

1a. Check source of power

supply. 1b. Check overloads, fuses,

controls, etc. 2. Check speed sensor for

proper functioning. Replace if necessary.

3. Check that phase leads are

connected correctly to controller.

Excessive Noise Or Vibration

1. Differential oil level low. 2. Rear brake problem. 3. Differential problem. 4. Axle shaft broken or bad

bearing. 5. Speed sensor trouble. 6. Phases incorrect.

1. Check oil level and refill as

required. Check for leaks. 2. See Brakes (Service)

(Trouble Shooting). 3. Check differential, repair or

replace as required. 4. Check axle shafts and

bearings. Repair or replace as required.

5. Check speed sensor for

proper functioning. Replace if necessary.

6. Check that phase leads are

connected correctly to controller.

Hub Area Or Differential Over Heating

1. Differential oil level low. 2. Bad bearing.

1. Check oil level and refill as

required. Check for leaks. 2. Check bearings and replace

as required.

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Chapter 2 Page 4-26

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MODEL T-137 CURTIS Property of American Airlines Maintenance · 2018-12-03 · T-137 CURTIS...

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Transcript of MODEL T-137 CURTIS Property of American Airlines Maintenance · 2018-12-03 · T-137 CURTIS...