chapter 2: preventive maintenance - amazon web …...cd444-28m 2 - 2 - 1 may 2019 (rev a) chapter 2...

CD444-28M 2 - 1 - 1May 2019 (Rev A)

Chapter 2 Tow Tractor Model MA-28Section 1 Maintenance Manual

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

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

1.2.1 Pre-Operation Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1-3Section 2: Preventive Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-2-1

2.1 Periodic Maintenance/Service Schedule and Checklist - - - - - - - - - - - - - - - - - - -2-2-12.1.1 Daily or Every 10 hours Maintenance Checks- - - - - - - - - - - - - - - - - - - - - - -2-2-22.1.2 Weekly or Every 50 hours Maintenance Checks - - - - - - - - - - - - - - - - - - - - -2-2-22.1.3 Monthly/Quarterly or Every 200/250 Hours Maintenance Checks - - - - - - - - -2-2-32.1.4 Two (2) Months or Every 500 Hours Maintenance Checks- - - - - - - - - - - - - -2-2-42.1.5 Six (6) Months or Every 1000 Hours Maintenance Checks- - - - - - - - - - - - - -2-2-42.1.6 Yearly or 2000 Hours Maintenance Checks - - - - - - - - - - - - - - - - - - - - - - - -2-2-52.1.7 Every 2 Years or 4000 Hours Maintenance Checks - - - - - - - - - - - - - - - - - -2-2-5

Section 3: Maintenance Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-1

3.1 Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-13.2 Jacking Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-1

3.2.1 Free Standing Jack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-13.2.2 Fluid Level Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-23.2.3 Engine Oil Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-23.2.4 Engine Coolant Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-33.2.5 Transmission Oil Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-43.2.6 Drive Axle Gear Box Oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-43.2.7 Brake Fluid Level- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-53.2.8 Fuel Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-53.2.9 Windshield Fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-5

3.3 Service and Lubrication Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.4 Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-6

3.4.1 Service Brake Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.4.2 Park Brake Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.4.3 Steering Gear Box Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.4.4 Toe-In Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-73.4.5 Cab Door Adjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-73.4.6 Vertical Headlight Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-73.4.7 Horizontal Headlight Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-83.4.8 Shifter Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-8

3.5 Service and Lubrication Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-93.6 Service Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-10

3.6.1 Engine Oil and Filter Change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-103.6.2 Engine Air Filter Replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-113.6.3 Transmission Oil and Filter Change- - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-123.6.4 Axle Gear Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-133.6.5 Brake Assembly: Wheel Cylinder Bleed - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-133.6.6 Fuel Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-14

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

4.1 Engine and Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-14.2 Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-14.3 Rear Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-2

Propert

y of A

merica

n Airli

nes

2- 1 - 2 CD444-28MMay 2019 (Rev A)

‘ Tow Tractor Model MA-28 Chapter 2Maintenance Manual Section 1

4.4 Steering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-24.5 Brake System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-34.6 Electrical System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-4

4.6.1 Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-44.6.2 Lights (Twelve (12) Volt System)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-44.6.3 Wiper Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-54.6.4 Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-6

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

5.1 Electrical Schematics- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-5-35.2 Hydraulic Schematics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-5-7

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 1 - 3May 2019 (Rev A)


Section1:Introduction

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

1.1SafetyPrecaution

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

1.2PreparationforUse

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

1.2.1Pre-OperationChecks

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

1.2.1.1EngineandTransmission

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

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

3. Check transmission fluid level.

4. Check transmission cooling lines for proper connection.

1.2.1.2FuelSystem

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

2. Make certain fuel tank drain valve is closed.

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

1.2.1.3Axles

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

2. Add oil, if needed.

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

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

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

Propert

y of A

merica

n Airli

nes

2 - 1 - 4 CD444-28MMay 2019 (Rev A)

Tow Tractor Model MA-28 Chapter 2 Maintenance Manual Section 1

1

1.2.1.4Brakes

1. Check master cylinder fluid level.

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

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

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

1.2.1.5TireInflation

1. Check air pressure in tires.

2. Add air, if needed.

• Front: 60 psi (413.7 kPa)

• Rear: 65 psi (448.1 kPa)

1.2.1.6VehicleDrive

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

1.2.1.7Battery

Connect the battery cables, if disconnected.

CAUTION:

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

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 2 - 1May 2019 (Rev A)


Section2:PreventiveMaintenance

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

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

2.1PeriodicMaintenance/ServiceScheduleandChecklist

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

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

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

• The required maintenance schedules are as follows:

• Daily or every 10 hours of operation

• Weekly or every 50 hours of operation

• Every 100 hours of operation

• Monthly or every 250 hours of operation

• Every six months or 500 hours of operation

• Annually or every 1000 hours of operation

• Every two years or 2000 hours of operation

• Four years or 5000 hours of operation

CAUTION:

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

Check the Engine Operation Manual for Specific Engine Maintenance

Propert

y of A

merica

n Airli

nes

2 - 2 - 2 CD444-28MMay 2019 (Rev A)


2

2.1.1DailyorEvery10hoursMaintenanceChecks

2.1.2WeeklyorEvery50hoursMaintenanceChecks

Table2-2-1:DailyorEvery10hoursMaintenanceChecksandServiceProcedures

No. Item DailyCheck/Action

1Engine System

Check oil level and top engine oil up if necessary.

2 Check coolant level and top up if necessary with correct mixture.

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

4 Fuel System Check fuel level.

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

5Tires

Check the pressure of the pneumatic tires.

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

7

Controls

Check all instruments, controls, and warning lights.

8Check that all controls are in good working order. Report a faulty control and do not use until repaired.

9

Lights

Check the operation and aiming of the headlights.

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

11Check the operation of the cab marker lights, the heater, the wiper and cab light, if equipped.

12 Horn Sound the horn.

Table2-2-2:WeeklyorEvery50hoursMaintenanceChecks

No. Item Weekly/50HoursCheck

1Engine System

Check underneath for oil leaks and damage.

2 Battery Check the battery charge.

3

Axles

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

4 Check drive axle and reduction gear box oil level.

5 Check king pins and steer pin for looseness.

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

6Nuts and

Bolts

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

7Check cylinder head bolt torque and all nuts and bolts for tightness. If required, torque to specified torque with oiled threads.

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

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 2 - 3May 2019 (Rev A)


2.1.3Monthly/QuarterlyorEvery200/250HoursMaintenanceChecks

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

9

Fluids

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

10Check the level of the brake fluid in the master cylinder. If low, top off as neces-sary.

11 Check power steering fluid level.

12 Switches Check neutral safety switch adjustment.

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

No. Item Monthly/QuarterlyorEvery200/250HoursCheck

1

Engine System

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

2 Inspect radiator hoses and clean radiator exterior.

3

Check gasoline fuel filter element and renew as necessary (Depending upon the quality of the fuel used, it maybe necessary to renew the filter element more frequently).

4Check dry filter element and renew as necessary (Depending upon the quality of the fuel used, it maybe necessary to renew the filter element more fre-quently).

5

Brake System

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

6 Check service brake operation.

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

8 Lube the service brake pedal pivot.

9 Lube the parking brake lever pivots.

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

10

Axles

Change drive axle and reduction gear box oil.

11 Lube the drive shaft joints.

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

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

Table2-2-2:WeeklyorEvery50hoursMaintenanceChecks

No. Item Weekly/50HoursCheck

Propert

y of A

merica

n Airli

nes

2 - 2 - 4 CD444-28MMay 2019 (Rev A)


2

2.1.4Two(2)MonthsorEvery500HoursMaintenanceChecks

2.1.5Six(6)MonthsorEvery1000HoursMaintenanceChecks

13Operator Compart-ment/Cab

Lube the adjusting slides beneath the operator’s seat.

14 Lube the throttle linkage.

15 Check neutral safety switch adjustment.

16 Lube the cab door handles (if equipped).

17 Fluid Level Check power steering fluid level.

18 Fittings Lube all grease fittings.

19 Hood Lube the hood latches and hinges.

Table2-2-4:Two(2)MonthsorEvery500HoursMaintenanceChecks

No. Item TwoMonths/500HoursCheck

1 Engine System

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

2 Replace air filter element.

3 Axles Check ball joints and tie rod ends looseness.

4 Wheels Inspect front wheel bearings; clean and repack.

5Nuts and

BoltsCheck all nuts and bolts for tightness.

Table2-2-5:Six(6)MonthsorEvery1000HoursMaintenanceChecks

No. Item Six(6)Months/1000hoursCheck

1 Battery Check battery and cable connectors.

2Axles

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

3 Change drive axle and reduction gear box oil.

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

4Brake

SystemCheck cylinder compression.

5 Hoses and Fastenings

Inspect PCV hoses, tubes and fittings.

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

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

No. Item Monthly/QuarterlyorEvery200/250HoursCheck

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 2 - 5May 2019 (Rev A)


2.1.6Yearlyor2000HoursMaintenanceChecks

2.1.7Every2Yearsor4000HoursMaintenanceChecks

Table2-2-6:Yearlyor2000HoursMaintenanceChecks

Item Yearly/2000HoursCheck

Transmission Adjust automatic transmission band.

Table2-2-7:Every2Yearsor4000HoursMaintenanceChecks

Item Every2Years/4000HoursCheck

Coolant System Clean coolant filler cap. Replace cap if seal has deteriorated.

Propert

y of A

merica

n Airli

nes

2 - 2 - 6 CD444-28MMay 2019 (Rev A)


2

Serial Number:Manufacture Date:

Service Requirement in Hours Daily 50 100200/2

50Check/ensure all controls are in good working order

Check fuel level

Check engine oil level

Check engine coolant level

Check engine coolant system for leaks and cleanliness

Check hot and cold starting functions.

Check the pressure of the pneumatic tires

Check tire treads, remove any foreign objects

Check the operation and aiming of the headlights

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

Check operation of Cab marker lights, heater/air, front & rear wipers, defroster, fan, some light(s) & alarms/mircro switches (lift cab only)Check all instruments, controls, and warning lights

Sound the horn

Check coolant, oil, fuel, exhaust and vacuum hoses/pipes for leaks, damage, deterioration and correct routingCheck underneath for oil leaks and damage

Check neutral safety switch adjustment

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

Check the level of the brake fluid in the master cylinder. If low, top off as necessaryCheck battery charge

Check the drive axle U-bolts and tighten if required

Check the transmission fluid level (with engine running at normal operating temperature)Check cylinder head bolt torque and all nuts and bolts for tightness. If required, torque to specified torque with oiled threadsCheck drive axle and reduction gear box oil level

Check king pins and steer pin for looseness

Check all visible electrical wiring for security, correct routing and evidence of chafing or heat damageCheck power steering fluid level

Check park brake operation.

Check service brake operation

Check the fan and alternator belts; tighten, if necessary

Inspect radiator hoses and clean radiator exterior.

Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch (3.175 mm)Change drive axle and reduction gear box oil

Lube the adjusting slides beneath the operator’s seat

Lube the service brake pedal pivot

Lube the drive shaft joints

Lube the parking brake lever pivots

Lube the throttle linkage

Lube all grease fittings

Lube the hood latches and hinges

Lube the cab door handles (if equipped)

Check condition and adjust tension of drive belt(s)

Check gasoline fuel filter element and renew as necessary (Depending upon the quality of the fuel used, it maybe necessary to renew the filter element more frequently)Check dry filter element and renew as necessary (Depending upon the quality of the fuel used, it maybe necessary to renew the filter element more frequently)

TUG Model MA-28 (Ford Engine) Tow TractorDate:ID Number:

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 2 - 7May 2019 (Rev A)


Notes

Propert

y of A

merica

n Airli

nes

2 - 2 - 8 CD444-28MMay 2019 (Rev A)


2

Serial Number:Date:

Service Requirement in Hours 400 800 1000 2000 4000Renew air filter element

Check spark plugs: Clean, adjust and test or replace

Check all nuts and bolts for tightness

Inspect front wheel bearings; clean and repack

Check ball joints and tie rod ends looseness

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

Change engine oil and renew engine oil filter

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

Check cylinder compression

Inspect PCV valve

Clean PCV hoses, tubes and fittings

Check battery and cable connectors

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

Adjust automatic transmission band

Clean coolant filler cap. Renew cap if seal has deteriorated

TUG Model MA-28 (Ford Engine) Tow TractorDate:ID Number:

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 2 - 9May 2019 (Rev A)


Notes

Propert

y of A

merica

n Airli

nes

THIS PAGE INTENTIONALLY BLANK

2- 2 - 10 CD444-28MMay 2019 (Rev A)

Tow Tractor Model MA-28 Maintenance Manual

Chapter 2Section 2

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 3 - 1May 2019 (Rev A)


Section3:MaintenanceProcedures

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

3.1SafetyPrecautions

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

3.2JackingInstructions

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

3.2.1FreeStandingJack

1. Park the unit on level ground.

2. Chock the wheels and apply parking brake.

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

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

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

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

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

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

WARNING:

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

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

Propert

y of A

merica

n Airli

nes

2 - 3 - 2 CD444-28MMay 2019 (Rev A)


3

Figure2-3-1:JackingPoints

3.2.2FluidLevelChecks

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

3.2.3EngineOilLevel

Check the engine oil level daily or before operation.

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

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

3. Pull up the dipstick and wipe clean.

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

WARNING:

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

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

Jacking Points

Jacking Points

Jacking Points

Jacking Points

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 3 - 3May 2019 (Rev A)


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

3.2.3.1EngineOilCondition

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

1. Per form an engine oil and filter service.

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

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

3.2.4EngineCoolantLevel

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

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

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

CAUTION:

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

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

NOTE:

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

WARNING:

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

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

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

Propert

y of A

merica

n Airli

nes

2 - 3 - 4 CD444-28MMay 2019 (Rev A)


3

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

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

3.2.5TransmissionOilLevel

Check the transmission oil level daily or before operation.

1. Ensure the parking brake is set.

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

3. Start the engine.

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

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

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

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

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

3.2.6DriveAxleGearBoxOil

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

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

2. Chock the wheels and jack unit up.

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

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

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

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

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

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

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

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

erty o

f Ameri

can A

irline

s

CD444-28M 2 - 3 - 5May 2019 (Rev A)


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

6. Remove the plug from the oil fill port.

7. Check oil level at the filling bores.

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

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

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

11. Clean bore hole and oil filling plug.

12. Replace screw plug gaskets with new gaskets.

13. Screw oil filling plug back in place.

3.2.7BrakeFluidLevel

Check the brake fluid level daily or before operation.

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

2. Add brake fluid as needed.

3. Inspect the brake lines and fittings for leaks.

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

5. When necessary, bleed the brakes.

6. Wipe up any spilled fluid.

3.2.8FuelLevel

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

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

3.2.9WindshieldFluid

1. Ensure cell drain valve is closed.

2. Fill fuel tank with correct fuel.

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

WARNING:

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

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

Propert

y of A

merica

n Airli

nes

2 - 3 - 6 CD444-28MMay 2019 (Rev A)


3

3.3Adjustments

3.3.1ServiceBrakeAdjustment

1. Remove master cylinder

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

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

3.3.2ParkBrakeAdjustments

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

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

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

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

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

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

6. Engage parking brake and un-chock the wheels

3.3.3SteeringGearBoxAdjustment

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

2. Remove the drag link from the Pitman arm.

3. Loosen the lock nut on the adjusting screw.

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

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

6. Tighten lock nut on adjusting screw.

7. Reinstall drag link.

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

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

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 3 - 7May 2019 (Rev A)


3.3.4Toe-InAdjustment

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

3.3.4.1FrontSideofTires

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

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

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

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

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

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

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

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

9. Reconnect the rod.

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

3.3.4.2RearSideofTires

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

3.3.5CabDoorAdjustment

To adjust a cab door:

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

2. Hold door in desired position

3. Tighten bolts to secure.

3.3.6VerticalHeadlightAdjustment

1. Loosen the nut on the horizontal bolt.

2. Aim headlight in desired position.

3. Tighten the nut.

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

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

Propert

y of A

merica

n Airli

nes

2 - 3 - 8 CD444-28MMay 2019 (Rev A)


3

3.3.7HorizontalHeadlightAdjustment

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

2. Aim headlight in desired direction.

3. Tighten the nut.

3.3.8ShifterAdjustment

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

2. Move hand lever to forward and reverse position.

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

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 3 - 9May 2019 (Rev A)


NOTES

Propert

y of A

merica

n Airli

nes

2 - 3 - 10 CD444-28MMay 2019 (Rev A)


3

3.4ServiceandLubricationPoints

Figure2-3-2:ServiceandLubricationPoints

12

3

10

6

13

9

2

78

4

1

14

5

15

11

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 3 - 11May 2019 (Rev A)


Table2-3-2:ServiceandLubricationPoints

3.5ServiceProcedures

3.5.1EngineOilandFilterChange

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

1. Place the unit on level ground.

2. Apply the parking brake and chock the wheels.

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

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

No. Description SpecificationCapacity

(Approximate)

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

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

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

Multi-purpose lithium-base grease As Required

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

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

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

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

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

9Newage Drive AxleAxletech Drive Axle (Optional)

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

*5 qt. (4.7 L)

10Newage Reduction Gear BoxAxletech Reduction Gear Box

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

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

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

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

14 Hydro-Boost DOT3, Extra Heavy Duty As Required

15 Power Steering, Hydraulic Reservoir Dexron VI0.158 US gal

(.6 L)

16Operator Seat, Adjusting Slides (Not shown)

Multi-purpose lithium-base grease As Required

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

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

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

Propert

y of A

merica

n Airli

nes

2 - 3 - 12 CD444-28MMay 2019 (Rev A)


3

5. Clean the area around the oil filter head.

6. Locate the remote oil drain line.

7. Loosen and remove the engine oil drain plug.

8. Allow the oil to drain.

9. Install and tighten the drain plug.

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

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

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

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

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

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

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

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

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

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

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

21. Return the unit to service.

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

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

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

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

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

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

CAUTION:Shut off the engine immediately to avoid engine damage if oil pressure is not registeredwithin 15 seconds.

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 3 - 13May 2019 (Rev A)


3.5.2EngineAirFilterReplacement


2. Apply the park brake.

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

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

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

6. Remove the primary filter and safety filter.

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

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

9. Check the safety filter and replace when dirty.

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

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

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

3.5.3TransmissionOilandFilterChange


2. Apply the parking brake and chock the wheels.

3. Disconnect the battery from the vehicle.

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

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

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

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

8. Remove the warning tag from the control panel.

9. Remove the unit from the jack stands.

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

11. Park Vehicle on a level surface.

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

WARNING:



Propert

y of A

merica

n Airli

nes

2 - 3 - 14 CD444-28MMay 2019 (Rev A)


3

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

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

14. Check the fluid level with the dipstick.

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

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

3.5.4AxleGearBox


2. Apply the park brake.


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

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

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

7. Protect all bearings from contamination.

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

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

3.5.5BrakeAssembly:WheelCylinderBleed


2. Chock the wheels and apply park brake.

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

WARNING:

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

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

CAUTION:

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

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

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

WARNING:

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

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 3 - 15May 2019 (Rev A)


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


5. Disconnect the batter cables of the batteries.

6. Refer to either the Newage or Axletech service manual in Chapter 5 and perform detailed stepsas outlined.

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

8. Reconnect the battery cables to the batter.

9. Remove the unit from jack stands.

10. Remove warning tag.

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

12. Place unit back in to service.

3.5.6FuelFilter


2. Turn off the engine.

3. Apply the parking brake.


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

6. Check the fuel Filter

7. If the accumulation of dirt and water in the filter is excessive, remove the fuel tank.

8. Flush the Tank.

9. Blow out the line from the fuel pump to the tank.

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

Propert

y of A

merica

n Airli

nes


2- 3 - 16 CD444-28MMay 2019 (Rev A)


Chapter 2Section 3

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 4 - 1May 2019 (Rev A)


Section4:Troubleshooting

The following troubleshooting tables provide information for diagnosis and correcting problems with theMA-28 Tow Tractor. These tables should be used as quick reference guide to resolving minor commonerrors.

4.1EngineandTransmission

Table2-4-1:EngineandTransmissionTroubleshooting

4.2AlternatorTable2-4-2:AlternatorTroubleshooting

WARNING:



Problem Cause Correction

Loss of power

Reduction in pulling power. Check transmission per appendix.

Engine power is reduced. Check engine per appendix.

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

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

No. Problem Cause Correction

1 Noisy alternator

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

Alternator bearings worn or dam-aged.

Replace alternator.

2Alternator output consistently high

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

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

Propert

y of A

merica

n Airli

nes

2 - 4 - 2 CD444-28MMay 2019 (Rev A)


4

4.3RearAxleTable2-4-3:DriveAxleTroubleshooting

4.4SteeringTable2-4-4:SteeringTroubleshooting


Rear axle noise

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

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

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

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

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


1Manual steering

difficult

Steering gearbox not lubricated. Check lubrication.

Drag link joints not greased. Add grease to joints.

King pins not greased. Add grease to kin pin.

2Power steering

difficult

King pins not greased. Add grease to kin pin.

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

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

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

3Front wheel

appears to wobble

Lug nuts loose. Torque lugs to proper value.

King pin worn. Check studs and king pins.

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

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 4 - 3May 2019 (Rev A)


4.5BrakeSystemTable2-4-5:BrakeSystemTroubleshooting

4Steering wanders

or weaves

Wheel bearings worn or not lubri-cated.

Replace wheel bearings or lubricate as necessary.

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

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

Steering gearbox has too much backlash.

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

5Vehicle pulls to one

side

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

Wheel bearings seized. Check wheel bearings.

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

Check tire “match” and inflation.


1Excessive stopping

distance

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

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

Air in brake circuit. Bleed Brakes.

2Brakes drag or

uneven pullBrake pad dragging.

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

3Brake spongy or excessive travel

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

Air in brake circuit. Bleed brake system.

4 Hard pedal

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

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

Brake booster (where applicable) is damaged.

Check booster for pressure or leak-ing.

Seized brake pedal. Inspect brake pads and rotor.


Propert

y of A

merica

n Airli

nes

2 - 4 - 4 CD444-28MMay 2019 (Rev A)


4

4.6ElectricalSystem4.6.1Battery

Table2-4-6:BatteryTroubleshooting

4.6.2Lights(Twelve(12)VoltSystem)

Table2-4-7:LightsTroubleshooting


Battery will not stay charged

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

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

Wire is broken. Check for breaks in wiring.

Component is draining battery with ignition off.

Check for large current draw with vehi-cle off.


1Poor, intermittent, or

no headlight

Blown fuse or tripped circuit breaker.

Check fuse or circuit breaker.

Headlight burned out. Replace LED Bulb.

Switch damaged.

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

Wired incorrectly.Check wiring & ground connec-tions.


no stop lights



Taillight burned out. Check bulbs or lamps.

Brake pressure switch damaged. Check brake light switch.

Wired incorrectly.Check wiring and ground connec-tions.

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 4 - 5May 2019 (Rev A)


4.6.3WiperMotor

Table2-4-8:WiperMotorTroubleshooting


no back-up lights



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

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

Transmission software incorrect.

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


4Poor, intermittent, or no turn signal lights



Bad flasher relay. Check relay.

Turn signal light burned out. Check bulbs or lamps.

Wired incorrectly.Check wiring, connections, and grounds.

5Poor, intermittent, or no cab marker lights



Broken switch. Check relay or switch.

Wired incorrectly. Check wiring & connections.

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


Wiper motor works intermittently, or will

not work




Broken switch. Check wiper control switch.

Burned out motor. Check motor.


Propert

y of A

merica

n Airli

nes

2 - 4 - 6 CD444-28MMay 2019 (Rev A)


4

4.6.4Horn

Table2-4-9:HornTroubleshooting


1Horn work intermit-tently, or no sound



Bad horn relay. Check relay.

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

Burned out speaker. Check horn speaker.

2Horn sounds contin-

uously

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

Damaged horn button. Check for a stuck horn button.

Relay stuck closed. Check relay.

Propert

y of A

merica

n Airli

nes

CD444-28M 2 - 5 - 1May 2019 (Rev A)


Section5:SystemSchematics

This section provides electrical and hydraulic information for diagnosing and correcting problems with theMA-28 Tow Tractor.The following pages display schematics to assist in the location of electrical wiringand hydraulic routing.

Propert

y of A

merica

n Airli

nes


2- 5 - 2 CD444-28MMay 2019 (Rev A)


Chapter 2Section 5

Propert

y of A

merica

n Airli

nes


CD444-28M 2 - 5 -3May 2019 (Rev A)

5.1ElectricalSchematics

Figure2-5-1:MA-28StandardElectricalSchematicWRG-MA-STD-28-103_RevA(Page1of4)

REFERENCEPAGE 2

WH

TG

RN

15 3

CODEENGINE

SWTICH

31 14 2533

FORD POWER PRODUCTS 42 PIN INTERFACE CONNECTOR

(PN

K/BL

U) P

1-3

BLU

19

20

21

16

18

17

12

5

4

10

113

2

1

158

9

137

6

14

38

37

36

35

30

28

2924

23

3422

41

42

40

39

3326

27

3125

32

42 PIN IN-LINEFORD POWER PRODUCTS

MAIN HARNESS CONNECTOR

CB130A

3D

80

12 VOLTBATTERY

SWITCH

NEUTRALSAFETY

90

93

M

1

2

3

STARTER MOTORAND BENDIX

90

BLK

VALIDATION SWITCHFOOT THROTTLE &

7 6

9

8

10

BRN

/WH

T

BLK/

ORG

GRY

/RED

(GRY

/RED

) FT9

(LT

BLU

/BLK

)FT1

4

(BLK

/ORG

) FT2

5

BRN/WHT

LT BLU/BLK

GRY/RED

BLK/ORG

LT B

LU/B

LK

9011

7

G

(BRN

/WH

T) F

T31

B

CODEENGINE

LIGHT

6

(PN

K/LT

GRN

) P1-

6 RE

D

(PN

K/BL

K) P

1-5

ELECTRICPUMPFUEL

MOTOR

5

G

BLK

BLK

M

(WH

T/PU

R) P

1-18

18

RED

/TA

N

REFERENCEPAGE 2

REFERENCE FORD 2.5LDWG: 1782000

BATT+

LT B

LU/P

NK

RELAY

8586

87A30

87

LT BLU/PNK

WH

T/PN

K

LT G

RN/P

UR

RED

/LT

GRN

STARTERFORD




90

1

(RED

/LT

GRN

) P1-

1

ALTERNATOREDI

13 2

RED


SWITCHIGNITION

6

2

1

5

3 4

POWERSTUD

B

P19

P19

P19(D27)

MASTERRELAY

87

30

86

85

ENGINE

REFERENCEPAGE 3

REFERENCEPAGE 3

TCU-11

TCU-10

BLK

CHKTRANSLIGHT

BLK

(AMBER)

P1

G9

FT

TCU

-11

TCU

-8

TCU-11

TCU-10

(D22)

(D18)

REFERENCEPAGE 3

REFERENCEPAGE 3

4

2

1

Propert

y of A

merica

n Airli

nes

2 - 5 -4 CD444-28MMay 2019 (Rev A)

Tow Tractor Model MA-28 Chapter 2Maintenance Manual Section 5


REFERENCEPAGE 1

CB320A

CB220A90 90

HORNSWITCHHORN

HORNRELAY

85

86

102

103

104

102

RED WHT

RED

WHTBL

K

RED

RIGHT FRONTHEAD LT

WHT

LEFT FRONTHEAD LT

HEAD LTSWITCH

PSWITCH

BRAKE LTPRESSURE

BRAKE/TAIL LIGHTRIGHT REAR

WHT

BLK

RED

BRAKE/TAIL LIGHTLEFT REAR

84

54

53

71

106

107

78

77

101- +

SHIFTERLIGHT

89

100 10

2

G

87

30

REFERENCEPAGE 1

RED

95

REFERENCEPAGE 490

4

2

1

3

(OPTION)

30

30

30

83

P24

P24

P24

D5

D3

D5

D3

P1

P4

P1

P4

P1

P4

GAUGEHOURMETER

CP5

CP5

(D20)

(D1) (D2)

(D10)(D25)

CP5

1

2

3

1

1

2

2

3

3

1

1

2

2

4

3

7

Propert

y of A

merica

n Airli

nes


CD444-28M 2 - 5 -5May 2019 (Rev A)


REFERENCEREFERENCEPAGE 1

REFERENCEREFERENCEPAGE 1

BAC5

2928

FORD 42 PIN INTERFACE CONNECTOR

ENGINE CAN BUS FOR DIAGNOSTIC CONNECTOR

C-1

C-2

C-3

C4

12 10 1 7 11

BLK RE

D

WH

T/BL

K

WH

T/RE

D

YEL

TCM-2600 TRANSMISSION CONTROL TCU CONNECTOR

CA

N H

I +

CAN

LO

W -

SHIE

LD G

ND

4L70 TRANSMISSION CONNECTOR

OUTPUT SHAFT SPEED SENSOR

LAPTOP CALIBRATION CONNECTION

TWIS

TED

PA

IR

PNK/

LT.

GRN

(CH

KTRN

S)

TCU

-8

8

G9

TCU

-11

TCU-10

120 OHM RESISTOR (5%,2 W)

SP 22

SP 23

G9

(CA

N1L

)TC

U-1 (C

AN

1H)

TCU

-7

CAN

1L

CAN

1H

TRANSMISSION HARNESS TCM-4635

(CAN1H) TCU-7

(CAN1L) TCU-1

CAN

1H

CAN

1L

TWISTED PAIR

G9 R5

C

CANHI CANLOW

FH-3 FUSE 15 AMP

P1

TCU-11

TCU-10

FH-10 FUSE 15 AMP

TCU-11

TCU-11REFERENCEPAGE 1

TCU-8

(CA

N1H

) TC

U-7

(CA

N1L

) TC

U-1

REFERENCEPAGE 1

Propert

y of A

merica

n Airli

nes

2 - 5 -6 CD444-28MMay 2019 (Rev A)



CB420A

RED

FRONTWIPERMOTOR

FRONTWIPER

SWITCH

66

RED

ORG

62L

62

HL MC

B

CABHEATERMOTOR

HL M

M

M63C

65

HEATERSWITCH

68

SWITCH

DOMELIGHT

DOMELIGHT

FLASHING BEACON LIGHT

FLASHER

LIGHT

REFERENCEPAGE 2 90

D7D7

IOPTIONAL CAB WIRING

(D17)

68

Propert

y of A

merica

n Airli

nes


CD444-28M 2 - 5 -7May 2019 (Rev A)

5.2HydraulicSchematics

MA-28HydraulicSchematicHYD-MA-28

2

1

ENGINE

1300 PSI

PT

L

R

3

4

1 1

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

4

ENG-MA-27-PS-1

STEER CYLINDER 1

3 660-1-3028 CHARLYNN POWER STEERING VALVE 1

RESERVOIR

TM1-2-8032

Propert

y of A

merica

n Airli

nes



2 - 5 -8 CD444-28M May 2019 (Rev A)

Propert

y of A

merica

n Airli

nes

chapter 2: preventive maintenance - amazon web …...cd444-28m 2 - 2 - 1 may 2019 (rev a) chapter 2...

Documents