property of american airlines maintenance...model htaw and htaz towing tractor 14 december 7, 2010...

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Maintenance

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Model HTAW and HTAZ Towing Tractor

December 7, 201010

Section 2, Periodic Maintenance

HT Diesel Tractors

Description Quantity

U.S. Metric

Engine Oil (Citgard 500 15W-40) 7.0 QT 6.6 L

Transmission Fluid, Hydraulic Fluid, Power Steering Fluid:Dexron® III, or IV, Mercon® AFT, or equivalent

11 3/4 QT 11.1 L

Oil Hypoid SAE 80W-90 9.0 QT 8.5 L

Brake Bleeder

Grease, Litholene H EP-2 AR AR

Brake Fluid (DOT 3) 0.25 GL .945 L

Anti-Freeze 4.0 GL 15.1 L

Diesel Fuel 16.0 GL 60.5 L

Locktite 660 for Steer Bushing 0.25 EA

Loctite 271 Threadlocker 250 M 0.20 OZ 60 ML

Table 1, Lubrication and Fluid Types

®Dexron is a registered trademark of General Motors Corporation. Mercon is a registered trademarkof Form Motor Company.

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Operation and Maintenance Manual Section 2, Periodic Maintenance

December 7, 2010 11

Table 2, HT Cummins Maintenance Interval Sheet

4 = Visual or Operational Check Item X = Service Item

Inspection IntervalDaily orat Refuel

250 Hrs or 3months

500 Hrs or 6Months

1000 Hrs orAnnually

2000 Hrs orEvery 2 Years

Inspection and Service ItemsAir Filter Element W/Restriction Indicator : As Required 4 XBattery 4Brake and Hydraulic Fluid Levels 4Brake System Service & Parking 4Engine Coolant Level 4Engine Oil Level 4Fuel/Water Separator XHeater Operation (When needed, if installed) 4Lights, Gauges, Horn 4Tire Pressure Check 4Transmission Oil Level 4Steering 4Windshield Wipers 4Air Intake System 4Engine Oil Chang XEngine Oil Filter Change XCharge Air Piping (if Turbocharged) 4Crankcase Ventilation Lines 4Check all Fluids (Brakes, Trans, Hydraulic, etc.) 4Exhaust System 4Engine Anti Freeze Concentration XGrease Steer Axle and Drive Line XOil Filler Cap 4Park Brake 4Radiator Hoses 4Brake Pads 4Electrical System 4Fuel Filter Element XFuel Pump and Fuel Lines 4General Equipment Inspection 4Grease Pillow Blocks (if they have grease fittings) XSteering 4Fan Belt Tensioner XF&R Axle Bearings Inspection/Service XTransmission Oil Change XTransmission Filter Screen XDrive Axle Oil Change XEngine Cooling System Drain and Flush XValve Lash Clearance First X XVibration Damper 4Last Updated on 1/13/10 By Bob Becker

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December 7, 201012

Table 3, HT Cummins Daily Inspection InstructionsComplete these items at the start of each service day or at each refueling.

InspectionItem

Service Required

Air Filter ElementInspection

If equipped with restriction indicator, verify that the red indicatorflag is not raised. Otherwise, inspect the filter element and cleanor replace if it is clogged.

Battery The cable should be tight and free of excessive corrosion.

Brake System Check brake firmness with engine at in idle and the transmissionselector at N (neutral) position by depressing the pedal andholding for 10 seconds. If the pedal does not remain firm, reportto maintenance personnel.

Park Brake With tractor on level ground and engine at idle and park brakeset, tractor must not move in 1st or forward nor reverse.

Brake and HydraulicFluid Levels

Before the tractor is started, remove master cylinder andhydraulic reservoir covers. The fluid must be within 1/4 IN or 6MM from the top of the cylinder or reservoir.

Engine Coolant Level Check coolant level when engine is cold or 45 minutes afterengine has been turned off. Add coolant as necessary withoutoverfilling. Look under the tractor for evidence of coolant leaks.Report any problems to maintenance.

Engine Oil Level Check the oil level with engine cold or 15 minutes after enginehas been turned off.

Fuel/Water Separator Drain the water and sediment from the separator. Drain the filtersump of water until clear fuel is visible.

Heater On tractors with heaters: When heater may be needed, checkshut-off valve and heater operation. At all times, check for leaks.

Lights / Gauges / Horn Start the tractor, pull the switches, ensure all lights, gauges,along with the horn are in good operating condition. Check allgauges for indications out of normal ranges.

Steering System Turn the wheel stop to stop. The front wheels must respond tosteering wheel with no binding or free play.

Tire Pressure / LugNuts

Pneumatic tires: Check for proper inflation. The correct pressuresare on the tire sidewalls. All tires: Remove any foreign objectsfrom the tread. Check for loose lug nuts.

Transmission Oil Level Check transmission fluid level at normal operating temperaturewith engine at idle, hand brake set and selector in N (neutral).Add Dexron transmission fluid as indicated.

Windshield Wipers Operate wipers. Replace worn or defective blades.Last Updated on 4/22/08 By Bob Becker

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December 7, 2010 13

Table 4, HT Cummins Daily Inspection Log

ConditionAcceptable

ConditionUnacceptable

Fill Amount orReplaced Part No.

Air Filter ElementInspection

Battery

Brake System

Park Brake

Brake and Hydraulic FluidLevels

Engine Coolant Level

Engine Oil Level

Heater

Lights / Gauges / Horn

Steering System

Tire Pressure

Specified on tire

Transmission Oil Level

Windshield Wipers

Operator

DateLast Updated on 5/25/10 By Bob Becker

Tire Pressures

In most cases, inflate tires to the pressure specified on the tire sidewall. The exception is when tires designedand rated for highway operation are used for low speed operation. This allows higher load ratings and higherpressures. This applies only to the tires listed below:

Max PressureBrand Tire

Harlan PartNumber PSI KPA

Goodride LT215/80R16, All Season, Radial, Rear 02030-0031 51 351

Geo Trac LT215/85R16, 10 ply, Rear 02030-0314 90 621

Hankook Dynapro AS LT215/75R15 02030-0360 60 414

Super Tripper LT215/85R16 90 621

Wrangler HT LT215/75R15 75 517

Source: Tire and Rim Association Handbook

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December 7, 201014

Table 5, HT Cummins 250 Hour Inspection Instructions

Air Filter Element If changing oil at 250 hours, clean and check air filterelement. Replace if necessary.

Air Intake System Clean or replace dirty air filters. Tighten or replace parts asnecessary to make sure the air intake system does not leak.Maximum intake air restriction is 762 mm H20 [30 in H20]

Anti Freeze Check Concentration with an anti-freeze hydrometer.Minimum concentration is 50%. Use higher concentration asrequired for local climate.

Charge Air Piping (if Turbocharged) Inspect the intake piping for cracked hoses, loose clamps, orpunctures that can allow dirt and debris to enter the engine.

Check all Fluids (Brakes, Trans,Hydraulic, etc.)

Fill as required to proper levels

Engine Oil Change The oil change interval for turbocharged engines is every 3months or 250 hours. Use 15W-40 multiviscosity oil.

Engine Oil Filter Change Replace the oil filter

Exhaust System Inspect exhaust system for leaks, broken clamps anddefective hangers. Replace defective parts as necessary.

Lug Nuts Front Lug Nuts: 100 Lb-FT / 135 NM

Rear Lug Nuts: 200 Lb-FT / 270 NM

Park Brake Disconnect drive shaft and remove park brake drum. Replacebrake shoes if worn.

Power Brake Back-up Pressure With engine off, pump the brake pedal hard until the pedalfeel indicates power brakes are no longer available. Theback-up pressure should last for a least two power brakeapplications. Maintain brake pedal pressure and start theengine. The pedal should sink under pressure as the back-upcylinder repressurizes, then it should return to normal.

Power Brake Noise Hissing noise during moderate to heavy brake application(Above 40 lbs. or 18 Kg) is normal. Noise with less thannormal brake pedal indicates air or foreign matter in hydraulicfluid.

Oil Filler Cap Inspect for sludge build-up. Clean or replace as required.

Radiator Hoses Inspect for wear and cracks. Replace as necessary.

Valve Lash Adjustment Initial valve lash adjustment is to be performed at 250 hoursor 3 months. Subsequent adjustments are to be performedevery 2000 hours or 2 years, whichever comes first.

Last Updated on 1/13/10 By Bob Becker

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December 7, 2010 15

Table 6, HT Cummins 250 Hr. Inspection Log

System ConditionAcceptable



Air Filter Element

Air Intake System

Anti Freeze Concentration

Charge Air Piping(if Turbocharged)

Check all Fluids (Brakes,Trans, Hydraulic, etc.)

Engine Oil Change

Engine Oil Filter Change

Exhaust System

Grease Steer Axle and DriveLine

Lug Nuts

Park Brake

Power Brake Back-upPressure

Power Brake Noise

Oil Filler Cap

Radiator Hoses

Valve Lash Adjustment

Operator


Warning

If the engine is hot, never open the radiator capwithout checking to see if the radiator hoses arepressurized.

Without pressure, a 50/50 coolant mixture boils at

240 F (115 C) at sea level, declining 1.5 F (1 C) foreach 1,000 feet (300 meters) of elevation. Pressureincreases the boiling temperature.

Releasing the pressure while the coolant is hot cancause very rapid boiling and severe scalds.

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December 7, 201016

Table 7, HT Cummins 500 Hr. Inspection Instructions

Inspection Item Service Required

250 Hour Inspection Complete 250 hour maintenance requirements

Air Filter Element Clean and check. Replace if necessary.

Battery Clean and reset terminals.

Brakes Inspect the calipers for excessive play and leaks. Repairas needed. Grease brake pedal pillow blocks if they havegrease fittings.

Electrical System Check wiring for loose connections, frayed insulation, andexposed conductors.

Fuel Filter Element Remove and Replace

General Equipment Steam clean the tractor engine and undercarriage. Checktractor for loose bolts, nuts and capscrews. Check brake,fuel and vacuum lines for chafing. Check all belts for wearand proper tension.

Grease Steer Axle and DriveLine

Grease all grease fittings Grease brake pedal pillow blocksif they have grease fittings.

Steering Inspect steering linkage, steering gear box and wheelbearings. Repair, adjust or replace parts as necessary.

Tires Check tires for wear and replace as needed. If tire wearindicates further maintenance action, action is required.


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December 7, 2010 17


System ConditionAcceptable



Air Filter Element

Battery

Brakes

Electrical System

Fuel Filter Element

General Equipment

Grease Steer Axle andDrive Line

Steering

Tires

Operator


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December 7, 201018

Table 9, HT Cummins 1000 Hr. Inspection Instructions

INSPECTION ITEM SERVICE REQUIRED


Cooling SystemPressure test the system, including radiator cap. Check hoses fordeterioration.

Fan Belt Tensioner

Measure the belt tension half way between the pulleys.

Fan Belt Deflection

New Belts 73 – 85 lbs 324-378 N

Used Belts 49 - 61 lbs 216 – 270 N

Drive Assembly Drain and refill transfer case and differential.

Transmission Filter Drain transmission pan and clean filter.

Transmission FluidCheck the transmission fluid for discoloration and burnt odor.Drain converter pan and replace.

Wheel BearingsClean and repack with medium weight, high temperature wheelbearing grease that has a melting point of 250 degrees or higher.


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December 7, 2010 19


System Condition Acceptable ConditionUnacceptable


Cooling System

Drive Assembly

Transmission Filter

Transmission Fluid

Wheel Bearings

Operator


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December 7, 201020

Table 11, HT Cummins 2000 Hr, Inspection Instructions

INSPECTION ITEM SERVICE REQUIRED


Cooling SystemDrain and flush the cooling System. Check for worn or damaged hoses,clamps, and radiator. Refill cooling system with 50% (or greater if localclimatic conditions require) antifreeze/water mixture.

Brake Pads STEP 1.

a. Jack up the tractor and place jack stands under theframe.

b. Remove the wheel nuts and remove wheelassemblies from tractor.

STEP 2. To replace disc brake pads:

a. Remove the caliper through-bolts.

b. Remove caliper from the brake backing plate or mountbracket. Avoid hanging the caliper from the hose attachedto the caliper.

STEP 3.

a. Retract the pads and the pistons by prying between eachpad and the rotor with a large screw driver. Use caution toavoid scratching the rotor. The pistons must be fully intothe caliper hosing to permit installation of the new thickerpads. If the rotor is scored or undercut, it should bereplaced or resurfaced.

b. Check the piston seal for signs of leaks. If all items are ok,install new pads. One side has a spring clip to hold it tothe piston.

c. Reinstall caliper onto the mounting plate. Reinstall thethrough-bolts into caliper housing and tighten both boltssecurely.

d. If the pistons were removed. bleed the system.

Valve LashAdjustment

Complete Overhead Set procedure as specified in CumminsOperation and Maintenance Manual.


Warning

If the engine is hot, never open the radiator cap withoutchecking to see if the radiator hoses are pressurized.

Without pressure, a 50/50 coolant mixture boils at 240 F

(115 C) at sea level, declining 1.5 F (1 C) for each 1,000 feet(300 meters) of elevation. Pressure increases the boilingtemperature.

Releasing the pressure while the coolant is hot can cause veryrapid boiling and severe scalds.

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December 7, 2010 21

Table 12, HT Cummins 2000 Hr Inspection Log

System Condition Acceptable ConditionUnacceptable


Front Brake Pads

Front Brake Rotors

Rear Brake Pads

Rear Brake Rotors

Valve LashAdjustmentLast Updated on 4/22/08 By Bob Becker

Brake Wear Standards

ItemStandard

DimensionMinimum Thickness

Inches or MM Inch MM Inch MM

Heavy Duty Steer Axle Rotor, 02023-1083 .25 6.35 .230 5.84

Drive Axle Rotor, 02025-0205 1.125 28.575 1.070 27.178

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December 7, 201022

Shipping and Storage

Preparation for Shipping

If the tractor is being shipped by air, no crating or special preservation is required. If it is beingshipped by flat-bed truck, a cover must be used to protect the tractor from rocks, sand, dirt, andadverse weather conditions. Perform these procedures before loading the tractor.

1. Check all of the lubricant and fluid levels. See Table 3, HT Cummins Daily InspectionInstructions, for details.

2. Check the tractor for damage and missing components. Repair all damage and replace allmissing parts.

3. Prepare a shipping document. Include the date the tractor was prepared for shipping and theserial number of the tractor. Put a copy of the document in the cab or put a copy in a weather-resistant envelope and securely attach it to the steering column of units without cabs.

If the tractor is shipped with any deficiencies, they must be noted on the shipping document.

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December 7, 2010 23

Preparation for Storage

When preparing the tractor for storage, be sure that the tractor is protected from local climaticconditions. These storage procedures are guidelines for normal weather conditions, make appropriateadjustments to meet local requirements.

The preparation for storage is determined the length of time the tractor will be in storage and thelocation of the tractor during storage. Short term storage is from one to six months. Long termstorage is over six months or indefinite storage. A tractor stored indoors will not require as muchexternal protection as a vehicle stored outdoors under cover or outdoors in the open.

Short Term Storage.To prepare a tractor for storage from one to six months, perform the following procedures:

a. Check the tractor for damage and missing components. Repair or replace all damageditems and replace all missing parts.

b. Check all of the lubricant and fluid levels. See Table 3, HT Cummins Daily InspectionInstructions for details. Be sure that the anti-freeze will protect the cooling system andengine to the lowest temperature expected during storage.

c. Be sure that all caps, lids, and dipsticks are installed and tightened.d. Drain ail of the water from the air tanks of all tractors that are so equipped.e. Remove the fire extinguishers and exterior mirrors from all tractors that are so equipped.

Wrap the mirrors and all attaching parts in paper and seal the wrapping with tape. Storethe fire extinguishers and mirrors on the floor of the cab. e. Check all controls andaccessories to be sure that they are turned off. Leave the key in the ignition.

f. Disconnect the battery cables from the battery. Wrap the cable terminals with maskingtape, Coat the battery terminals with a preservative to prevent corrosion.

g. Check the pressure of all tires. Be sure that they are inflated to specifications.h. Clean the interior surfaces, the engine compartment, and the exterior surfaces. Remove

sand and road salt from the chassis. Allow the tractor to air dry.i. Close all windows and air vents.j. Complete a storage document and put a copy in the cab. The document should contain

this information:

A description and the serial number of the tractor.

The date the tractor was prepared for storage.

The date the tractor was placed in storage.

The organization and the personnel that prepared the tractor for storage.

The special preparations that were performed for local conditions.

All defects that were not corrected before the tractor was put into storage

Make any preparations needed to protect the tractor from local condition.

If the tractor is stored outside, cover it with a tarp or other protective material to keepdirect sunlight out of the operator's compartment.

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December 7, 201024

Long Term Storage.To prepare a tractor for storage for six months or longer, perform the following procedures:

1. Complete all Short Term Storage Procedures as outlined above.

2. Wrap or cover all of the exterior lights, the radiator grill, and the air vents with moisture-resistant paper and secure the paper with tape.

3. Remove the battery from the engine compartment. Store it in accordance with local fireregulations.

4. Spray all exterior surfaces and the chassis with a preservative compound.

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Operation and Maintenance Manual Section 3, Mechanical Trouble Shooting

December 7, 2010 25

Section 3, Mechanical Trouble Shooting

Axle Leakage

Axle Vent

1. Inspect the axle vent toensure the vent is notclogged over and inspectfor proper operation.

Figure 3

2. Check the oil level toensure the axle is notoverfilled, remove the topfront plug. The oil levelshould be level with thebottom of the fill hole.

Figure 4

2

1

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December 7, 201026

Hub Leakage

1. Inspect and replace sleeves ifrequired.

2. Clean and inspect the sleeves, half ofitem 9 in Figure 7, on the axle arms.Replace if you find any wear ordamage.

Figure 5, Axle Sleeve

3. Clean and repack the inner bearings,items 15 and 16 in Figure 7, withgrease.

Figure 6, Packing Wheel Bearings

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December 7, 2010 27

Figure 7

4. Install the inner bearings, Items 15 and 16 in Figure 7, into the hub and rotor assembly.

5. Install the inner seal, second half of item 9 in Figure 7.

6. Repeat this operation on the second hub.

7. Attach the brake caliper backing plate (4), part number #02025-0094, using 6 bolts, (13) partnumber #02011-24C620 and lock washers (14), to the axle arm.

8. Use a drop of thread locking compound on each bolt.

9. Tighten the bolts in a criss-cross pattern to 35ft. /lbs.

10. Apply grease to lubricate the area where the inner seal (15) contacts the axle arm.

11. Lift the hub and rotor assembly and slide the assembly onto the axle arm. Do not force thehub because it is easy to damage the seal, which may cause the seal to leak. If the inside

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December 7, 201028

wheel bearing catches on the axle arm, gently strike the outer face of the hub slides on to thearm.

12. Install grease packed outer bearing part number #02025-0029 onto the axle arm and into thecup in the hub.

13. Apply grease to the insideof the hub,

14. Insert the outer grease seal(24), part number02025-0050, with the keylining up with the key wayin the axle arm.

15. Follow this with one of thebearing adjusting nuts (25),part number 02025-0051.

Figure 8

Adjusting the Outer Wheel Bearings

1. Tighten the inner nut while spinning the hub to center the wheel bearing.

2. Loosen the nut (25) part number #02025-0051, and then tighten it to zero clearance.

3. Install the lock washer (26), part number 02025-0052, onto the axle arm, with the key linesup with the keyway in the axle arm.

4. Install the hub second nut (26),

5. Tighten the outer nut and bend one lock washer tabs over of the inner nut and one over theouter nut.

6. Repeat this procedure on the other hub.

7. Apply gasket sealer to the mating surfaces of the hub and the axle shaft, part number 02025-0120.

8. Wash the bolts, part number #02025-0073, in alcohol and let dry.

9. Apply one drop of thread locking compound to each bolt and install in all the holes. Four ofthe holes will require alignment dowels, part number #02025-0054.

10. Using a criss-cross pattern torque each bolt to 70lbs/ft.

11. Repeat this procedure for the other axle shaft.

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December 7, 2010 29

Drop Box Leakage

Input SealThe most common problem is oil runningdown the front of the drop box noticeable onthe freeze plug. Remove the rear of the drive-line and remove the input flange and changethe seal. When installing the flange ensure theflange has been coated with a small amount ofgrease. To avoid seal failures make sure thereis a good finish on the output flange. The partnumber for the seal is #02029-0010.

Figure 9

1. Raise the rear of the tractor and place on suitable jack stands.

2. Disconnect the rear of the driveline.

3. Remove the drop box rear cover.

4. Remove the cotter pin and output gear. There will be a small amount of gear grease lost.

5. Remove the lock wire from the drop box mounting bolts.

6. Remove the drop box and clean all parts and reassemble.

Call the Factory for further assistance 1-00-255-4262

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December 7, 201030

Brake System TroubleshootingIf the first item does not solve the problem proceed to the next trouble shooting Instruction until theproblem is corrected.

Brakes Will Not Release

Pillow BlocksInspect the pillow block for properoperation and lubrication. Replace ifneeded.

Part Number #02026-0095

Figure 10

Check ValveWhenever a new master is installed, itmust have the check valves removed thatoperate the disc brake calipers. If thevalves are installed it will cause pressureto build until the tractor will not move.

Figure 11

Push Rod AdjustmentThis adjustment is critical if the push rod is maladjusted. It will allow brake line pressure to build tothe point the tractor will not move.

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December 7, 2010 31

Brake Fluid ContaminationOnly approved brake fluids arepermitted. Anytime the mastercylinder cap seal swells it is anindication that the system has beencompromised. If this has occurred thesystem should be drained, all sealsinspected and replaced if needed, newbrake fluid needs to be installed(approved) and the system completelybled.

Figure 12

Note: Commercial Use - DOT 3 Brake fluid; Military Use - MIL-B-46176A

Over Filling of the MasterCylinderThis will be visible during maintenance orinspections due to the deterioration ofpaint on the frame directly under themaster cylinder.

Figure 13

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December 7, 201032

Pulsating Brake Pedal

The rotors or the brake drums areuntrue and they need to be removedand turned. Do not exceed theminimum specifications. Replace ifrequired.

Figure 14

Hard Brake Pedal

This is an indication of a HydroVac orHydroBoost failure.

On HydroVac systems, Make sure the vacuumbooster hose is connected and has no leaks.

Figure 15

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December 7, 2010 33

On Hydro-Boost systems, inspect thehydraulic fluid supply for contamination.

Figure 16

Spongy Brake Pedal

This is an indication that there is air in thesystem.

1. Inspect for cracked or broken lines,broken hoses and fittings.

2. After insuring the system is completelysealed, bleed per specifications.

3. See the Bleeding Procedure.

Figure 17

Figure 18

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December 7, 201034

Brake Pedal Goes to the Floor

This is an indication that the system has a leak.

1. Add brake fluid as required, pressurizethe system and locate the leak.

2. Inspect all fittings, hoses and linesinsuring all bleeder screws are tight andundamaged.

3. Inspect the rear of the master cylinder forsigns of leakage.

Figure 19

Master Cylinder FailureIt is common that when a master cylinder fails,brake fluid passes past the piston seals and leaksout the rear of the master cylinder.

1. Replace master cylinder.

2. Bleed the brakes as required.

Figure 20

Manual Bleeding

CAUTION

Damage may occur during manual bleeding if the piston is bottomedout inside the master cylinder. Use extreme caution when manuallybleeding. Call the factory for further assistance 1-800-255-4262Pro

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December 7, 2010 35

Transmission

Checking Transmission Fluid

With the engine warm and the shifter selector in park or neutral, check the transmission fluid. Thefluid level should be within the acceptable level on the dipstick.

Shifter and Cable

1. Raise the rear of thetractor until the tires donot touch the ground andput safety jack standsunder the rear plate.

2. Turn the driveline byhand and inspect it fordamage.

3. Start the tractor, andmove the selector todrive, and verify that thedriveline turns.

4. If the driveline does notturn, disconnect theshifter linkage from thetransmission andmanually shift into gear.

5. If the driveline turns,adjust the shifter asrequired and inspect allparts as required.

Figure 21

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December 7, 201036

Tractor will not Move

If the driveline does not turn, seeTrouble Shooting and Repairs relatedto the Rear Axle.

Possible needed replacement parts:

P-R-N-D-3-2-1 shifter #02045-0046

P-R-N-D-3-2-1 shifter cable#02045-0161

FNR shifter #02045-0076

FNR shifter cable #02000005595

Figure 22

Call the factory for further assistance: 1-800-255-4262

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Operation and Maintenance Manual Section 4, Electrical Troubleshooting

December 7, 2010 37

Section 4, Electrical Troubleshooting

Figure 23, Circuit Breaker Pane

Circuit Breaker PanelThe circuit breaker replaces the fuse panel used before 2009 and later when specified by customers.All the breakers are fast open when short circuits occur. The 10, 20, and 30 ampere breakers aremanual reset types and their buttons protrude when open to give a visual indication. The 40-AmpureStarter Relay breaker will reset within 3 – 5 seconds after an overload and remain set if the overloadwas momentary. A persistent short circuit will immediately reopen the circuit breaker and afterseveral cycles, permanently open it.

If an overload appears to be momentary, you can reset the manual-reset circuit breakers once. If itopens again, the overload is not momentary and must be repaired before you reset the circuit breakeragain.

Tractor Will Not Crank

Note: If the first item does not solve the problem proceed to the next trouble shootingInstruction until the problem is corrected.

1. Turn the ignition switch to the off position.

2. Turn the ignition switch to the start position. This resets the anti restart.

3. If the tractor now starts, this is normal.

4. With the ignition switch on and the engine off, turn on the headlights.

5. Check for proper operation and battery condition. If the lights are dim or do not come on at all,check the battery cable terminals and clean them if indicated.

6. If the tractor has a battery disconnect switch, make sure it is on.

Gaugesor EPS

Turn Sigor Radio

Option

B+HornLightsCab

Turn Sigor Radio

HeaterStarterRelay

Batt

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December 7, 201038

7. Connect a battery charger onto the battery and try to start. Set the park brake, apply the brakes,then move the shift selectors through the shift positions and try to start the tractor. If the tractorstarts, adjust the neutral switch.

Note: If the Starter Relay looks like Figure 26 Old Style Starter Relay, skip Steps 9 and 10.

8. Measure voltage between the #26 and 15-Sec Relayterminals of the Starter Relay. There must be a12VDC for 15 seconds after you turn the IgnitionSwitch to start. If there is not, test for +12 VDC at#26.

9. If +12 VDC is at #26, test for ground at the 15-SecRelay terminal for 15 seconds after you turn theIgnition Switch to Start. If there is no or low voltage,go to Step 10.

a. If there is no ground, the 15-Second Relaymay be bad or disconnected.

b. If there is ground as required, test for+12VDC between the Batt and #33terminals.

If there is +12 VCD, the Starter Relaymay be bad. Use a screw driver tomomentarily short the Batt and #33terminals together.

If the engine cranks, replace the StarterRelay. Figure 24, Starter Relay

10. While trying to crank the engine, measure thevoltage drop between the Batt and Starter Relayterminals of 40-Amp circuit breaker in the CircuitBreaker panel. There should be near zero volts drop.

If there is more than a fraction of a volt, replacethis circuit breaker.

Figure 25, Circuit Breaker Panel

#26 15-SecRelay

Batt

#33

Batt

StarterRelay

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December 7, 2010 39

Old Style Starter Solenoid Switching Testing

If the Starter Relay looks like the one in Figure 24, Starter Relay, skip this step.

1. With the use of a jumper wire, aminimum wire gauge of 12, jump fromone side of the starter solenoid to theother as shown in Figure 26. This shouldbe accomplished by touching the wires tothe starter relay posts.

2. If the tractor cranks, further testing isrequired, see next step.

3. If it does not crank, replace the starter.

Figure 26 Old Style Starter Relay

1. Using a voltmeter, check for 12 Volts atwire terminal #26 located on the starterrelay. When the key switch is in the startposition, there should be 12 volts.

2. If there is no voltage indicated, removethe starter relay, sand, grind or brush allpaint and/or rust from the frame andreinstall the relay. Insuring a goodground test again.

3. If the unit still does not crank, replace therelay

Figure 27

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December 7, 201040

Figure 28, Circuit Breaker Pane

Circuit Breaker PanelThe circuit breaker replaces the fuse panel used before 2009 and later when specified by customers.All the breakers are fast open when short circuits occur. The 10, 20, and 30 ampere breakers aremanual reset types and their buttons protrude when open to give a visual indication. The 40-AmpureStarter Relay breaker will reset within 3 – 5 seconds after an overload and remain set if the overloadwas momentary. A persistent short circuit will immediately reopen the circuit breaker and afterseveral cycles, permanently open it.

If an overload appears to be momentary, you can reset the manual-reset circuit breakers once. If itopens again, the overload is not momentary and must be repaired before you reset the circuit breakeragain.

Tractor Will Not Crank


11. Turn the ignition switch to the off position.

12. Turn the ignition switch to the start position. This resets the anti restart.

13. If the tractor now starts, this is normal.

14. With the ignition switch on and the engine off, turn on the headlights.

15. Check for proper operation and battery condition. If the lights are dim or do not come on at all,check the battery cable terminals and clean them if indicated.

16. If the tractor has a battery disconnect switch, make sure it is on.

17. Connect a battery charger onto the battery and try to start. Set the park brake, apply the brakes,then move the shift selectors through the shift positions and try to start the tractor. If the tractorstarts, adjust the neutral switch.

Note: If the Starter Relay looks like Figure 26 Old Style Starter Relay, skip Steps 9 and 10.

Gaugesor EPS

Turn Sigor Radio

Option

Turn Sigor Radio

HeaterStarterRelay

Batt

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December 7, 2010 41

18. Measure voltage between the #26 and 15-Sec Relayterminals of the Starter Relay. There must be a12VDC for 15 seconds after you turn the IgnitionSwitch to start. If there is not, test for +12 VDC at#26.

19. If +12 VDC is at #26, test for ground at the 15-SecRelay terminal for 15 seconds after you turn theIgnition Switch to Start. If there is no or low voltage,go to Step 10.

c. If there is no ground, the 15-Second Relaymay be bad or disconnected.

d. If there is ground as required, test for+12VDC between the Batt and #33terminals.

If there is +12 VCD, the Starter Relaymay be bad. Use a screw driver tomomentarily short the Batt and #33terminals together.

If the engine cranks, replace the StarterRelay. Figure 29, Starter Relay

20. While trying to crank the engine, measure thevoltage drop between the Batt and Starter Relayterminals of 40-Amp circuit breaker in the CircuitBreaker panel. There should be near zero volts drop.

If there is more than a fraction of a volt, replacethis circuit breaker.


#26 15-SecRelay

Batt

#33

Batt

StarterRelay

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December 7, 201042

Old Style Starter Solenoid Switching Testing

If the Starter Relay looks like the one in Figure 24, Starter Relay, skip this step.

4. With the use of a jumper wire, aminimum wire gauge of 12, jump fromone side of the starter solenoid to theother as shown in Figure 26. This shouldbe accomplished by touching the wires tothe starter relay posts.

5. If the tractor cranks, further testing isrequired, see next step.

6. If it does not crank, replace the starter.

Figure 31 Old Style Starter Relay

4. Using a voltmeter, check for 12 Volts atwire terminal #26 located on the starterrelay. When the key switch is in the startposition, there should be 12 volts.

5. If there is no voltage indicated, removethe starter relay, sand, grind or brush allpaint and/or rust from the frame andreinstall the relay. Insuring a goodground test again.

6. If the unit still does not crank, replace therelay

Figure 32

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December 7, 2010 43

Tractor Will Not Start


1. Check for fuel in the fuel tank.The fuel pickup tube sets 1"above the bottom of the tank.Add fuel if needed.

2. If the tractor has the Oil-HeatShutdown option, check theGauges Circuit Breaker. Resetit if it’s open.


3. Check the Fuel-WaterSeparator. Drain it if needed.

4. Check all fuel lines and hosesfor obstructions.

5. Check the fuel filters.

6. Check for a 12 VDC input tothe fuel injection pumpsolenoid. If the tractor has theOil-Heat Shutdown option,make sure you press and holdthe Oil Pressure Bypass Button

(Figure 35) for this step.

a. If 12 VDC is present at theinjector pump solenoid, referthe Cummins manual totroubleshoot the fuel lift pump,fuel injector pump, fuelinjectors and injectorplumbing.

b. If there is no 12 VDC ispresent at the injector pump,go to No 12 VDC to FuelInjection Pump.

Figure 34, Injector Pump Solenoid Connections

6

2

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December 7, 201044

No 12 VDC to Fuel InjectionPump

7. If the tractor does not have anOil Pressure Bypass Switch-Button, go the Step 8. If it does,check for 12 VDC on the inputand output terminals of the OilPressure Bypass Switch whileyou press and hold the switch.

a. If there is a 12 VDC inputto, and no output from theOil Pressure BypassSwitch, replace the switch.

b. If there is 12 VDC outfrom the switch,troubleshoot the wiringbetween the switch and thefuel injector pump.

Figure 35, Oil Pressure Bypass Button

8. Check for 12 VDC at the IGNterminal while the IgnitionSwitch is on.

a. If there is no 12 VDC atthe IGN terminal, replacethe switch.

b. If there is 12 VDC at theIGN terminal and thetractor has the Oil-HeatShutdown option, go theStep 9.

c. If there is 12 VDC at theIGN terminal and thetractor does not have theOil-Heat Shutdown option,troubleshoot the wiringbetween the switch and thefuel injector pump.

Figure 36

8

7

6

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December 7, 2010 45

9. Check for 12 VDC at the Cterminal on Oil-Heat ShutdownOil Pressure Switch.

Figure 37, Oil-Heat Shutdown Oil Pressure Switch

a. If 12 VDC is not on the Cterminal, troubleshoot thewiring between the switch andthe Oil-Heat Shutdown circuitbreaker.

b. If 12 VDC is on the Cterminal, check for 12 VDC onthe NO terminal.

c. If 12 VDC is on the Cterminal, but not on the NOterminal, verify that the oilpressure is normal.

If the oil pressure isnormal, replace the switch.

If the oil pressure is toolow to activate the switch,repair the engine.

d. If 12 VDC is on the NOterminal, go to Step 10.

Figure 38, Oil-Heat Shutdown Oil Pressure Switch

9

1

b

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December 7, 201046

10. Check for 12 VDC at theShutdown Relay Pin 87a.

a. If there is 12 VDC at Pin 87a,check for 12 VDC at theShutdown Relay Pin 30.

If there is 12 VDC at Pin30, troubleshoot the wiringbetween Pin 30 and theFuel Injector pump.

If there is not 12 VDC atPin 30, check for 12 VDCbetween pins 85 and 86.

If there is 12 VDCbetween pins 85 and86, the relay isenergized, indicatingthat either the WaterTemperature Switch isclosed or the wire to itis shorted to ground.

If there is not 12 VDCbetween pins 85 and86, the relay contactsare stuck together.Replace the relay.

Figure 39

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December 7, 2010 47

Ignition Patch Harness Testing

Figure 40

1. Turn off the tractor and test Ohms resistance for #31 wire between the start solenoid (Figure40, 1) its connection with the ignition patch harness (Figure 40, 2). There should be 0.00 to0.01 Ohms resistance, if greater resistance is indicated replace or fix the broken wire.

2. Change the meter to VoltsDC and turn on the IgnitionSwitch. Check the #20 wireat the ignition patch harnessconnection. It should have12 VDC.

Figure 41

1

2

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December 7, 201048

3. Inspect the cannon plug fora poor connection repair orreplace if required

Figure 42

Note: We recommend a tester consisting of an ignition patch harness and an ignitionmodule.

4. Disconnect the existing ignition patch harness, connect #31 and #20 wires into the testharness.

5. Try to start the tractor. If the tractor starts, remove the tester ignition module and plug in thetractor ignition module.

6. Try to start. Replace the ignition patch harness or ignition module as required. If the tractorstill won't start, call the Plant for further assistance. 1-800-255-4262

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December 7, 2010 49

Neutral Switch Check and Adjustment

To check the Neutral Switch:

1. Disconnect plug “a”.

2. Connect an Ohm meter between pins a-1 and a-4.

3. Move the shift lever through its positions.

F-N-R shifters should close the connection (near 0 Ohms) only in Neutral.

P-R-N-D-3-2-1 shifters should close the connection in Neutral.

If the connection between a-1 and a-4 remains closed throughout the shift range or if thethere is no connection in any shifter position, replace the switch.

If the switch closes in the wrong position, adjust the switch.

To adjust the Neutral Start Switch:

1. Put the shift lever in neutral.

2. Loosen the mounting bolts “b”shown in 2 places in Figure 43.

3. Rotate the switch body until theconnection between a-1 and a-4closes.

4. Insert a 5/32 IN or 4 MM pin into thehole “c”. to lock the switch in thisposition.

5. Tighten mounting bolts to hold theswitch in place.

6. Remove the pin and connect theneutral switch plug.

7. Verify that the engine will start ineither Neutral or Park.

Figure 43

a

b

a-1

a-4

b

c

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December 7, 201050

8. If no power at #26, check wire number#19 at the neutral switch connection. Itcan be identified as the purple wire withorange stripe exiting from the neutralstart switch. With the key switch in thestart position, there should be 12volts atthis terminal.

Figure 44, Starter Relay

9. If you do not have 12 volts at theterminal, replace the neutral switch.

Figure 45

10. Remove the ignition switch from thedash, test wire #19 with the key in thestart position, wire #19 should have12volts.

11. If it does not, replace the ignition switch.

12. If the tractor still won’t crank, call theFactory for further assistance.1-800-255-4262

Figure 46

#26 15-SecRelay

Batt

#33

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December 7, 2010 51

Back-Up Light InoperativeNote: If the first item does not solve the problem proceed to the next trouble shooting

Instruction until the problem is corrected.

Bulb1. Remove the lens cover,

2. Remove and inspect the bulb.

3. Replace the bulb if required.

The bulb part number is 00700943224

Figure 47

Note: If the tractor has the Circuit Breaker Panel shown in Figure 23, skip this step.

Fuse1. Set the key to the on position.

2. Using a volt meter to test for 12 volts atthe top and bottom of fuse number #3.

3. If not, clean or replace the fuse to ensurethere is no corrosion inside the terminalof the fuse block.

4. Apply a small amount of electricalcontact grease, onto the fuse and reinstallthe fuse.

The fuse part number is 02060-0033-15. Figure 48

Note: The following causes the most common failures:

Instrument lights falling out of their sockets and lying on top of a gauge.

Shorting after driving over rough ground.

Push - Pull switch failures.

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December 7, 201052

Backup Light Assembly1. Remove the lens cover.

2. Remove the suspect bulb.

3. Turn on the key but do not start theengine.

4. Place the shift selector in reverse oractivate the optional push pull switch.

5. Use volt meter to check for 12 volts atthe back up light socket.

6. If you are getting 12 volts at the lightsocket, replace the bulb. Part numberfor the bulb #00700943224

7. If not, remove the back-up lightassembly check for 12 volts at wirenumber #7 terminal.

Figure 49

8. If yes, replace the backup lightassembly. Part number for the backuplight assembly #02060-0005

Figure 50

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December 7, 2010 53

Push Pull Switch1. With the key in the on position using a

12-volt test meter check for 12 volts atwire terminal number #6 located onthe back up light switch.

2. If yes, with the 12-volt test metercheck wire terminal #7 located on theback up light switch.

3. If you are not getting any power,replace the light switch.

4. If there is still no power, see Fuse.Part number for the tail light switch#02060-0026.

Figure 51

Neutral / Backup Switch1. With the key in the run position, but

the tractor not running, place theshifter selector in reverse. Ensure thepark brake is applied. Use a 12-volttest meter, check for 12 volts atterminal wire number #7 on theneutral switch.

2. If not, see Cannon Plug.

3. If yes, check wire terminal number 7Alocated on the neutral switch for 12volts. If you are not getting the 12volts, replace the neutral switch. Partnumber for the neutral switch #02045-0037

Figure 52

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December 7, 201054

Cannon Plug1. With the use of a 12-volt test meter to

ensure there is 12 volts at the terminalwire number #6 located at the stop lightswitch.

2. If you are getting 12 volts, test theswitch.

3. If not, inspect the cannon plug on thefirewall to ensure proper connections.Inspect all pins to ensure a secure fit. Aminimal amount of contact greaseshould be used in the cannon plug.

Figure 53

Broken WireTo test for a broken wire or bad connection:

1. Disconnect the circuit under test toisolate it. It will prevent getting any falsereadings and protect the meter fromoverload.

2. Set the meter for a low Ohms ( ) range.If the meter offers an audio signal for 0

, select it.

3. Check the meter by measuring directlyfrom lead to lead. This is the zeroreference.

4. Measure the resistance between the twopoints under test. A reading near 0indicated a good connection. A flashingreading or all 9s indicates no connection.Anything in between indicated a poorconnection.

Figure 54

5. Repair as required. Call the Factory for further assistance 1-800-255-4262

2

3, 4

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December 7, 2010 55

Brake-Lights Inoperative

Warning

This procedure applies only when the brakingoperation is normal and the only problem is thebrake lights. If the brakes are less effective thannormal, go to Brake System Troubleshooting

Electrical System

1. Make sure the key switch is on.

If the tractor has a fuse block, go to Step 3.

2. Make sure the Lights circuit breaker is notopen.

If the tractor has a circuit breaker panel, skipSteps 3 and 4.


Fuse

3. Test for 12 volts at the top and bottom offuse number #3.

4. If not, clean or replace the fuse to ensurethere is no corrosion inside the terminal ofthe fuse block. Apply a small amount ofelectrical contact grease, onto the fuse andreinstall the fuse.

Part Number for the Fuse is 02060-0033-15.

Figure 56, Fusel Block

2

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December 7, 201056

Bulb

5. Remove the stop light lens cover. Removethe bulb and inspect for broken filament.

6. If yes, replace bulb. Part number for the bulb#02000005645

Figure 57

Relay

7. If the tractor has a Brake Light relay, putyour finger on the relay and have someonestep on the brake pedal. Verify that you canfeel the relay energize when the brakes areapplied.

If there is no Brake Light relay, the brake lightswitch output powers the brake lights directly.

8. If applying the brakes neither lights the brakelights nor energizes the relay, go to Switch.

9. If the relay energizes but the brake lightsdon’t light, check for 12 VDC at the relayoutput, Pin-87, Wire #27.

10. If there is not 12 VDC output from the relay,replace the relay.

Figure 58, Brake Light Relay

11. If 12 VDC appears at the relay output, go toStep 16.

Note: If the tractor has the Brake Light Relayshown in Figure 58, Brake LightRelay, then Wires #6 and #27 are asshown in Figure 59, Brake LightRelay Wiring.

Figure 59, Brake Light Relay Wiring

9

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December 7, 2010 57

Switch

12. Remove the wires from the brake lightswitch.

Note: On tractors that do not have abrake light relay, Wires #6 and#27 are connected directly to thebrake light switch.

Figure 60, Brake Light Control Switch

13. Connect an Ohm meter across the switchterminals and step on the brake pedal.

14. If stepping on the brake pedal does not closethe brake light switch, replace the switch.

The part number for the switch is 02060-0034.

15. Check for 12 VDC at Wire #6. If there is not12 VDC on Wire #6, go to Cannon Plug.

Figure 61, Testing the Brake Light Switch

6

27

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December 7, 201058

16. If the bulb is good, use a 12volt-test meter totest the tail light socket. Test for 12VDC thensomeone steps on the brake pedal or whenWires #6 and #27 at the stop light switch areconnected together with a jumper wire.

Figure 62

Cannon Plug

17. Inspect all pins to ensure a secure fit. Aminimal amount of contact grease should beused in the cannon plug.

18. Use a 12-volt test meter to test for 12 volts atthe terminal wire number #6 located at thestop light switch.

19. If 12 VDC is at Wire #6 at the brake lightswitch, go to Switch.

20. If not, inspect the cannon plug on the firewallto ensure proper connections.

21. Inspect all pins to ensure a secure fit. Aminimal amount of contact grease should beused in the cannon plug.

Figure 63

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December 7, 2010 59

Tail Light Assembly

1. Remove the tail light assemblyfrom the truck, disconnect wirenumber #27 with the use of a 12volt test meter. You will need toensure that you have 12 volts at theharness.

2. If yes, replace tail light assembly.Part number for the tail lightassembly #02060-0007

3. If not, see broken wire.

Figure 64

Broken Wire1. With the use of an OHM meter, check for continuity between wire numbers #27 located at

the stop light switch and the connection of the rear harness.

2. If the first item does not solve the problem proceed to the next trouble shooting Instructionuntil the problem is corrected.

3. With the key in the on position use a 12-volt test meter to ensure there is 12 volts at the topand bottom of fuse number #1.

4. If not, and the tractor has a fuseblock, clean or replace the fuse toensure there is no corrosion insidethe terminal of the fuse block.Apply a small amount of electricalcontact grease, onto the fuse andreinstall the fuse. The fuse partnumber is 02060-0033-10.

Figure 65

The following causes the most common failures are:

1. Instrument lights falling out of their sockets and lying on top of a gauge, shorting every timethe unit hits a bump.

2. Push - Pull switch failures.

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December 7, 201060

Hour Meter Pressure Switch

1. (Normally open switch) use a 12 volttest meter to ensure there is 12 volts atthe number #18 wire located on thehour meter pressure switch.

2. If not, see Cannon Plug Inspection

Figure 66

Cannon Plug Inspection

1. Check continuity of number #16 wirefrom the fuse block to the hour meterpressure switch.

2. If not, inspect the cannon plug on thefirewall to ensure proper connections.

3. Inspect for bent or recessed pins. Aminimal amount of contact greaseshould be used in the cannon plug.

Figure 67

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December 7, 2010 61

Broken Wire

4. Inspect for broken connections by usinga OHM-meter to check continuity. Thisshould be done by disconnectingcircuits to ensure they are isolated. Itwill also ensure you are not getting anyfalse readings.

5. Repair as required.

6. Start the unit.Figure 68

7. Check for proper operation of the hourmeter pressure switch. Replace switchif needed. Part Number #02060-0030

8. Use a 12-volt test meter to test terminalend number #22 located on the back ofthe fuel gauge insuring there are 12volts.

Figure 69, Oil Pressure Switch

9. If not, see Cannon Plug Inspection

10. If not in Cannon Plug see BROKENWIRE

11. If not in Broken Wire check all gaugesfor 12 volts. Then See Broken Wire.Gauge Ground:

12. Use of a ground wire from the groundterminal of the gauge to an adequateframe grounding point.

Figure 70

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December 7, 201062

13. Check to ensure the gauge ground isconnected at the hour meter wirenumber #17 runs through the cannonplug and grounded onto the engine.

14. Test for continuity of wire number #17at the cannon plug.

15. If still inoperable call the Factory forfurther assistance, 1-800-255-4262

Figure 71

Head-Lights Won't Work.


1. Turn on the key switch.

2. If the tractor has a circuit breakerpanel, check the Lights circuit breaker.


3. If the tractor has a fuse panel, use a 12-volt test meter to ensure there is 12volts at the top and bottom of fusenumber #3.

Figure 73

2

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December 7, 2010 63

4. If not, then you need to clean orreplace the fuse to ensure that there isno corrosion inside the terminal of thefuse block.

5. Apply a small amount of electricalcontact grease to the fuse and reinstall.

6. Use a volt meter to test for 12 volts atwire terminal #9 (Left Headlight) andnumber #10 (Right Headlight) locatedat the headlight wire connection.

7. Repeat this step through terminals #9and #10 and the headlamp.

Figure 74

8. If yes, check the ground described inItem 3.

9. If not, replace the headlight

Figure 75

10. Use a 12-volt test meter to ensure aproper ground on headlight. Insert theprobe inside the terminal connectionand use the headlight-mounting base asthe ground. It should read 12 volts.

Figure 76

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December 7, 201064

11. Test for 12 volts on wire terminalnumber #5 on the headlight switch.

Figure 77

12. If there is not, locate and repair thebroken connection. Test for 12 volts onwire terminal number #9 and number#10 on the headlight switch

Figure 78

13. If not, replace the headlight switch.

14. Inspect the cannon plug on firewall forbent or recessed pins and a properconnection.

15. If the headlights still don’t work, callthe Factory for further assistance. 1-800-255-4262.

Figure 79

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December 7, 2010 65

Tractor Starts, Then Dies.


1. With a voltmeter, check the #20 wire atthe ignition patch harness. It will have12 volts when the key is in the runposition.

2. Inspect the cannon plug on firewall forbent or recessed pins and a properconnection.

Figure 80

Caution

Use only gentle force when reconnecting. The pins are easy to bend.

3. Check the ignition switch with the key inthe run position. There should be 12voltson the ignition terminal. Replace theswitch if required.

4. If the problem persists, call the factoryfor further assistance. 1-800-255-4262

Figure 81Prope

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December 7, 201066

Section 5, General Overhaul Practices

Removal Procedures

Warning!

Maintenance personnel should never performoverhaul operations on the vehicle without theimmediate presence or assistance of another personwho is capable of rendering aid.

1. Before removing any item, See the troubleshooting guide to prove that the problem is thesuspected component. The information contained in these charts will help isolate problems toa specific component.

2. Before removing any component, be sure that the system is not energized or pressurized.Disconnect the battery ground cable and be sure that all controls are in the "OFF" positionbefore beginning any overhaul operation.

3. Be sure that adequate clearance exists for removal of component. Disassemble adjacentcomponents and structure as necessary to provide adequate removal clearance.

4. Before removing exterior parts, clean mud, tar, grease or ether foreign materials from them.This will assist in the inspection and disassembly processes. Exterior surfaces can be cleanedusing a vapor pressure, spray-rinse cleaner.

5. Use a chain hoist, jack, or other suitable tool to lift the heavier components, position andattach the lifting device to the component to remove ail strain from the mounting hardwarebefore the hardware is removed.

6. To make installation easier, apply identifying tags to the mating ends of components as theyare removed or disconnected. Identify parts of similar configuration to be sure that they arereturned to their proper locations.

7. Make a note or diagram of the original position of components before removing. Duringreinstallation, be sure the original position is restored.

8. Treat all components, even if defective, as valuable items because of possible reclamation orsalvage value.

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Operation and Maintenance Manual Section 5, General Overhaul Practices

December 7, 2010 67

Disassembly Instructions

1. To avoid contamination of the internal parts of the components, keep the work area as cleanas possible.

2. Replace all gaskets, packing, and seals that are removed in the course of overhaul operationswith new ones whenever possible. These items are usually damaged or destroyed during theprocess of disassembly. Replace all lock wires, spring washers, cotter pins, and like itemsduring reassembly.

3. Do not use a metal tool to pry, pick or scrape off gaskets, packing or seals. Using metal toolswill scratch the sealing surfaces adjacent to these items. Instead, use a pointed wooden dowelto remove packing from their grooves. Use wood or plastic scrapers on gasket surfaces.

4. Before disassembling any component, study the exploded-view illustration. Pay closeattention to the relationship of internal parts. Being familiar with construction will speed updisassembly and help avoid improper reassembly.

5. To prevent moisture and foreign material from entering open housings and lines, installprotective plugs or covers as soon as possible after disassembly. Wrap parts in clean paper ordip parts in preservation oil.

6. Remove only parts requiring repair or replacement. Do not disassemble a component anyfurther than necessary to complete needed repairs.

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December 7, 201068

Cleaning Instructions

Caution

Never dip or soak electrical components, packing, rubber, plastic, orTeflon parts in a cleaning solvent. Clean these parts with a clean, lint-free cloth only. Cleaning solvents can react with these materials andcause severe damage to or destruction of these parts.

1. Use cleaning solvent in well-ventilated areas or in spray booths. Do not use gasoline forcleaning parts.

2. After soaking parts in cleaning solvent, wash away deposits by flushing or spraying withadditional solvent. Use a soft-bristled, nonmetallic brush dipped in solvent when necessary.

3. Dry all parts except bearings using filtered, compressed air after cleaning.

4. Unless specifically noted in the OVERHAUL PROCEDURES section, do not use metalscrapers, wire brushes, abrasive wheels, or compounds when cleaning parts.

5. Put ball or roller bearings in a basket that is suspended in a container of cleaning solventovernight. Use a soft bristle brush dipped in cleaning solvent to remove caked grease andchips. To prevent damaging balls and races, do not rotate the bearing before solid particlesare removed. After cleaning, immediately spin bearings in a light lubricating oil to removethe solvent. Allow the excess oil to drip off.

6. Check all oil passages and cavities for cleanliness and freedom from foreign material. Run athin, flexible wire through oil passages to make certain they are not clogged. Clean dirty orclogged passages with a pressure spray gun and dry cleaning solvent.

7. Clean electrical parts, such as relays, switches, terminals, etc., with a cloth moistened in drycleaning solvent.

8. Clean exterior surfaces of the battery with a weak solution of baking soda and water. Applythe solution with a soft bristle brush to remove corrosive build up on the battery cableterminals.

9. Wash painted surfaces of the vehicle with warm, soapy water. Rinse with clean water and drywith a clean cloth or allow to air dry.

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Operation and Maintenance Manual Section 5, General Overhaul Practices

December 7, 2010 69

Inspection Procedures

1. Check all surfaces that come in contact with gaskets, packing or seals for nicks, burrs, andscratches that can damage the new parts during reassembly.

2. Check bearings for rusted or pitted balls, races and separators. Check balls and races forbrinelling1, abrasions and discoloration. Excluding defects which may cause bearing bindingor misalignment, nicks or gouges outside the race load areas are not cause for rejection.Reject bearings only for cuts or grooves that run parallel to ball or roller rotation, fatigue pits(not minor machine marks or scratches), or cracks that are detected during magnetic particleinspection.

3. Check all hoses for broken or frayed fabric, damaged fitting threads, and breaks or leakscaused by sharp bends or rubbing against other parts of the vehicle. Be sure that the clampsdo not crimp the hoses.

4. Check all wires and wiring harnesses for damaged insulation, cuts, and breaks. Checkterminals and connectors for loose connections, corrosion, and broken parts.

5. Check all cap screws, nuts, fittings and tapped holes for distortion and for stripped orcorroded threads.

6. Check painted surfaces for cracked, peeling or chipped paint.

7. Check exterior parts and chassis for cracks.

1 is a surface fatigue caused by overloading or repeated impact. It is a sign of impending

bearing failure, possibly caused by contamination or over-tightened bearings.

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December 7, 201070

Repair and Replacement Procedures1. Remove nicks, burrs or scratches from surfaces that come in contact with gaskets, packing or

seals with a fine file or emery cloth. Do not change the shape or form of any part.

2. Hoses with broken or frayed fabric, damaged fitting threads or leaks must be replacedimmediately. Replace all cracked or burnt electrical parts and all wires that have severalbroken strands. Minor cuts in the wiring harness covers can be repaired with electrical tapeso long as the internal wires are not damaged.

3. Replace all damaged caps crews, nuts, and fittings. Minor damage to tapped holes can berepaired with the same sized tap. Do not change the size or thread type. Replace all self-locking fasteners during reassembly procedures.

4. Cracked, peeling or chipped paint can be removed using standard body part procedures.

Reassembly Instruction1. Remove all protective coatings from new parts.

2. Lubricate bearings with the same type of lubricant that is normally used or as directed in theOVERHAUL PROCEDURES section.

3. Reassemble preformed packing as follows:

a. Lubricate the packing with mineral oil or the specified lubricant.

b. Dovetail the groove. Then stretch the packing and put it into position.

c. Rotate the part on a flat surface and apply pressure downward to seat thepacking.

4. Lubricate the lips of oil seals with same type of lubricant normally used in the component oras specifically directed in the OVERHAUL PROCEDURES section.

5. Install oil seals, with lip facing in, by applying an even force to the outer edge of seal.

6. Coat both sides of gaskets with gasket sealing compound. Be sure all old gaskets and sealantare removed from parts before installing new gaskets.

7. Rethread caps crews of a part by hand until snug then tighten in a crisscross pattern to finaltorque. Install all caps crews, nuts and fasteners dry unless specifically directed to do so inthe OVERHAUL PROCEDURES section.

Installation Instructions1. Be sure components are placed in the same position that they were in when removed.

2. Check all identifying tags for the correct connection of all lines and hoses.

3. Check the level of lubricant or fluid. Add or drain as required.

4. Perform a test run on the vehicle and inspect the repaired component(s) for properadjustment, leaks, vibration, noise or misalignment. Correct any problems immediately.

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property of american airlines maintenance...model htaw and htaz towing tractor 14 december 7, 2010...

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