chapter 3: overhaul - aagsemanuals.s3.amazonaws.com · cd444-28m 3 - 1 - 3 may 2019 (rev a) chapter...

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

Chapter 3 Tow Tractor Model MA-28Section 1 Maintenance Manual

Chapter3:OverhaulSection 1: Overview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-1-3

1.1 Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-1-31.2 General Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-1-3

Section 2: Removal and Installation Procedures - - - - - - - - - - - - - - - - - - - - - - - - -3-2-1

2.1 Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-12.2 Front Bumper Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-1

2.2.1 Front Bumper Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-12.2.2 Front Bumper Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-1

2.3 Fender Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-12.3.1 Front Fender Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-12.3.2 Front Fender Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-22.3.3 Rear Fender Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-22.3.4 Rear Fender Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-2

2.4 Engine/Transmission Removal & Installation - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-32.4.1 Engine/Transmission Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-32.4.2 Engine/Transmission Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-4

2.5 Alternator Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-52.5.1 Alternator Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-52.5.2 Alternator Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-5

2.6 Battery Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-52.6.1 Battery Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-52.6.2 Battery Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-6

2.7 Fuel Tank Removal/Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-62.7.1 Fuel Tank Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-62.7.2 Fuel Tank Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-6

2.8 Drive Shaft Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-72.8.1 Drive Shaft Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-72.8.2 Drive Shaft Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-7

2.9 Axles, Shocks, Mounting Assemblies Removal/Installation - - - - - - - - - - - - - - - -3-2-72.9.1 Drive Axle Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-72.9.2 Drive Axle Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-82.9.3 Steer Axle Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-92.9.4 Steer Axle Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-92.9.5 Steer Axle Leaf Springs and Spring Strap Arms Removal - - - - - - - - - - - - -3-2-102.9.6 Steer Axle Leaf Springs and Spring Strap Arms Installation - - - - - - - - - - - -3-2-102.9.7 Steering Linkage Rod (Drag Link) Removal - - - - - - - - - - - - - - - - - - - - - - -3-2-102.9.8 Steering Linkage Rod (Drag Link) Installation - - - - - - - - - - - - - - - - - - - - - -3-2-112.9.9 Sector/Column and Steering Wheel Removal - - - - - - - - - - - - - - - - - - - - - -3-2-112.9.10 Sector/Column and Steering Wheel Installation - - - - - - - - - - - - - - - - - - -3-2-12

2.10 Brake System Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-122.10.1 Parking Brake, Linkage, Lever Removal- - - - - - - - - - - - - - - - - - - - - - - - -3-2-122.10.2 Parking Brake, Linkage, Lever Installation - - - - - - - - - - - - - - - - - - - - - - -3-2-132.10.3 Brake Pedal Removal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-132.10.4 Brake Pedal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-132.10.5 Brake Booster Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-132.10.6 Brake Booster Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-14

2.11 Tires and Wheels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-14

Propert

y of A

merica

n Airli

nes

Chapter 3- 1 - 2 CD444-28MMay 2019 (Rev A)

‘ Tow Tractor Model MA-28 Chapter 3Maintenance Manual Section 1

2.11.1 Tire and Wheel Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-142.11.2 Tire and Wheel Removal/Installation on Tractors with Standard Wheels - -3-2-14

2.12 Shifter Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-142.12.1 Shifter Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-142.12.2 Shifter Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-15

2.13 Accelerator Pedal and Throttle Control Cable Removal/Installation (If Equipped) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-152.14 Throttle Control Cable Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - -3-2-152.15 Tail Pipe/ Muffler/Exhaust Pipe Removal/Installation- - - - - - - - - - - - - - - - - - -3-2-16

2.15.1 Tail Pipe/ Muffler/Exhaust Pipe Removal - - - - - - - - - - - - - - - - - - - - - - - -3-2-162.15.2 Tail Pipe/ Muffler/Exhaust Pipe Installation - - - - - - - - - - - - - - - - - - - - - - -3-2-16

2.16 Cab Assembly Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-162.16.1 Cab Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-162.16.2 Cab Assembly Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-17

2.17 Seat Assembly Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-172.17.1 Seat Assembly Removal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-172.17.2 Seat Assembly Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-17

2.18 Door Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-172.18.1 Door Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-172.18.2 Door Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-17

2.19 Gauge Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-172.19.1 Gauge Removal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-172.19.2 Gauge Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-182.19.3 Temperature Sending Unit and Gauge Removal/Installation - - - - - - - - - -3-2-182.19.4 Oil Pressure Sending Unit and Gauge Removal/Installation - - - - - - - - - - -3-2-18

2.20 Switch Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-192.20.1 Ignition Switch Removal/Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-192.20.2 Headlight Switch Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-192.20.3 Auxiliary Switch Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-192.20.4 Brake Warning Light Removal/Installation - - - - - - - - - - - - - - - - - - - - - - -3-2-192.20.5 Glow Plug Button Removal/Installation- - - - - - - - - - - - - - - - - - - - - - - - - -3-2-20

2.21 Light Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-202.21.1 Headlight Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-202.21.2 Stop Light Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-202.21.3 Signal Light Removal/Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-202.21.4 Back-Up Light Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-2-20

Section 3: Overhaul Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-3-1

3.1 Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-3-13.2 Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-3-1

3.2.1 Engine Fault Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-3-13.3 Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-3-1

3.3.1 Transmission Fault Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-3-13.4 Axles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-3-1

Propert

y of A

merica

n Airli

nes

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


Section1:Overview

1.1SafetyPrecautions

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.

1.2GeneralOverview

The Model MA-28 Tow Tractor has many components which must be maintained by a flexible program ofpreventive maintenance, repair, and overhaul. Proper servicing, maintenance, adherence to manufactur-ers’ recommendations, and accurate record keeping are important in establishing overhaul periods. Over-haul is normally conducted on a periodic basis or during unscheduled down time.

Textron GSE provides the following to aid with keeping the unit at optimal performance:

• Periodic maintenance recommendations. See Section 2: "Preventive Maintenance".

• Troubleshooting tables specific to this equipment, to assist the operator and maintenance person-nel in quickly isolating and correcting most common malfunctions. See Section 4: "Troubleshoot-ing".

• Removal and installation instructions for the removal and installation of the engine and transmission as an assembly. See 2.4 "Engine/Transmission Removal & Installation"

If it is suspected that an overhaul of a system is required, the section or sections that cover the MA-28major component(s) should be read thoroughly and understood prior to beginning work.

If there is still additional information required that is not found in the overhaul section, contact the follow-ing:

Parts Department

Phone USA: 1-800-989-8499 ext. 1

Email: [email protected]

Equipment Sales

U.S. Phone: (770)-422-7230

Sweden: +46 (410) 140 50

Cheltenham: +44(0)1242 531201 Email: [email protected]

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

Propert

y of A

merica

n Airli

nes

THIS PAGE INTENTIONALLY BLANK

3- 1 - 4 CD444-28MMay 2019 (Rev A)

Tow TractorModel MA-28 Maintenance Manual

Chapter 3Section 1

Propert

y of A

merica

n Airli

nes

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


Section2:RemovalandInstallationProcedures

This section provides removal and installation procedures of vehicle components. The following instruc-tions outline the steps and precautions to take when removing items for replacement or repair.

2.1SafetyPrecautions

All operators and mechanics/technicians should adhere to the information located in the Safety sections,and to the Warnings, Cautions, and Notes throughout this manual.

2.2FrontBumperRemoval/Installation

2.2.1FrontBumperRemoval

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

2. Remove all but two of the bolts connecting the bumper to the frame, leaving the top bolt on eachside installed.

3. With bumper now connected by only one (1) bolt on each side, remove the NUT ONLY from boltwhile holding bumper in place.

4. Hold each side of the bumper at the headlight cutout.

5. Remove remaining bolts by lifting bumper up and forward.

2.2.2FrontBumperInstallation

1. With one person on each side, lift the bumper into position using a suitable hoist

2. While holding bumper in place, insert a bolt on each side (on the top bolt hole of the front surfaceof the bumper and the frame).

3. Install a nut on both bolts and tighten.

4. Install the remaining bolts in front bumper, connecting bumper to frame.

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

2.3FenderRemoval/Installation

2.3.1FrontFenderRemoval

1. Disconnect the headlight wire (wire #106 right headlight; #107 left light) from underneath the fenderat the disconnect socket.

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

WARNING: BUMPER IS TOO HEAVY TO LIFT BY HAND. USE A CRANE OR LIFT RATED FOR ATLEAST 1,000 LBS (453.6 KG) TO LIFT AND SUPPORT THE BUMPER. ALSO, TWOPEOPLE SHOULD BE USED TO STEADY THE BUMPER AS IT IS REMOVED.

NOTE: Make sure the bumper side angles are located beneath the front edge of the running board.

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

Propert

y of A

merica

n Airli

nes

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

Tow Tractor Model MA-28 Chapter 3 Maintenance Manual Section 2

2

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

3. Remove the bolt connecting the running board to the frame side bracket.

4. Remove the two (2) bolts connecting the aft end of the running board to the rear fender.

5. Lift front fender/running board from the tractor.

2.3.2FrontFenderInstallation

1. Place front fender/running board on the tractor and position it so that the fender/ running board isresting on the bumper side angle and on the rear fender flange.

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

3. Install the bolt connecting the running board to the frame side bracket.

4. Reconnect headlight wire.

5. Replace and connect battery if applicable.

2.3.3RearFenderRemoval

1. Disconnect stoplight wires at the disconnect plugs.

1. Position forklift tines or other suitable lift against under-surface of fender directly above rear tire.

2. Remove the two (2) outboard bolts connecting the seat assembly to the two shock mounts of therear fender seat supports.

3. Block up the disconnected side of the seat frame so a minimum of 2 inches (51 mm) vertical clear-ance is provided between seat frame and seat supports of the rear fender.

4. Remove the bolts connecting the forward edge of the fender to the running board.

5. Remove the bolts connecting the aft edge of the fender to the frame.

6. Ensure that adequate clearance is provided, and extract the rear fender from position by backingup forklift.

7. Disconnect forward aft seat supports (with shock mounts installed) by removing the four (4) bolts(two per support) connecting them to the inside surface of the fender.

2.3.4RearFenderInstallation

1. Install the forward (angle shaped) and rear (flat plate) seat supports (with seat shock mountsinstalled) to the inside surface of the fender with four (4) bolts.

2. Position forklift on the outboard side of fender and lift fender with forklift tines centered on fenderunder-surface.

WARNING: REAR FENDERS ARE VERY HEAVY. USE OF A SUITABLE LIFT IS REQUIRED TOPREVENT PERSONAL INJURY OR DAMAGE TO EQUIPMENT.

CAUTION: Make certain all fasteners have been removed from fender prior to lifting it.

CAUTION: To prevent damage to the seat frame, before positioning fender on tractor, ensure thatseat is blocked up to allow sufficient clearance between seat supports and seat framewhen the fender is positioned.

Propert

y of A

merica

n Airli

nes

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


3. Carefully position fender to the tractor using forklift to prevent hitting tire and seat frame.

4. Connect aft edge of fender to the frame and front edge of fender to running board.

5. Remove forklift.

2.4Engine/TransmissionRemoval&Installation

2.4.1Engine/TransmissionRemoval

1. Disconnect the battery cables from the battery.

2. Remove the front bumper plate following procedure of the specific section.

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

4. Drain the radiator and remove the radiator and shroud following the procedure of the specific sec-tion.

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

6. Remove the exhaust pipe from the engine and muffler as described in the specific section.

7. Disconnect the engine (or transmission) to frame ground cable from the engine by removing one(1) bolt.

8. Disconnect wire connected to the temperature sending unit.

9. Disconnect the cable connected to the starter.

10. Disconnect the transmission hoses/lines at the transmission.

11. Disconnect the wires attached to the alternator.

12. Disconnect the two (2) headlight wires from the connections under the front fenders and removeretaining clips.

13. If horn is mounted on frame, disconnect wire from horn and remove horn.

14. Disconnect the battery ground cable attached to the engine near the steering sector.

15. Remove the oil filter and 90º adapter (if adapter is present).

16. Disconnect wire from the oil pressure sending unit.

17. Disconnect wire from the oil pressure/timer switch, if so equipped.

18. Close the fuel line shut-off valve located under the floor plate near the forward portion of the fuelcell, on tractors so equipped.

19. Disconnect the metal fuel line from the rubber line connector line near the fuel pump and plug theline.

20. Following the 2.8 "Drive Shaft Removal/Installation" procedure, disconnect the drive shaft from thetransmission/parking brake drum installation.

21. Disconnect the parking brake linkage straps from the parking brake lever by removing the attach-ment bolt.

22. Remove the parking brake lever from parking brake transmission mount (if parking brake installedon transmission)

23. Disconnect wires from the positive (+) terminal of the coil and wire from the negative side of the coiland distributor connector.

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

Propert

y of A

merica

n Airli

nes

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


2

24. Disconnect the vacuum hose from the vacuum modulator valve on the transmission.

25. Disconnect the vacuum hose from the vacuum power brake booster.

26. Remove the connecting rod from the transmission and bell crank by removing the two (2) clevispins (upper and lower) on tractors so equipped.

27. Ensure the shifter is in neutral and disconnect the shifter cable assembly from the transmission.

28. Attach a chain hoist to the engine/transmission.

29. Remove the two (2) rear engine mounting bolts and the bolt connecting the front engine mount tothe frame, on tractors so equipped.

30. Remove two (2) nuts from the engine mounts and the two (2) nuts from the transmission mount.

31. Carefully move all wires back over the fire wall.

32. Check all areas for engine/transmission removal clearance.

33. Remove the assembly by hoisting assembly up and forward.

2.4.2Engine/TransmissionInstallation

1. Lower the engine/transmission into the tractor with a chain hoist so that the engine is resting on theengine mounts.

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

3. Install the two (2) nuts on the engine mounts and two (2) nuts on the transmission mount.

4. Remove the chain hoist from the engine.

5. Install connecting rod to transmission and bell-crank using two (2) clevis pins (upper and lower) ontractors so equipped. Adjust rod if needed.

6. Make sure the shifter is in neutral and connect the shifter cable assembly to the transmission.

7. Connect the vacuum hose to the vacuum power brake booster.

8. Connect the vacuum hose to the vacuum modulator valve on the transmission.

9. Connect wires to the positive (+) terminal of the coil and wire to the negative side of the coil and dis-tributor connector.

10. Install parking brake lever on transmission parking brake bracket (if parking brake lever installed ontransmission)

11. Connect the parking brake linkage straps to the parking brake lever using an attachment bolt,washers and nut.

12. Following the 2.8 "Drive Shaft Removal/Installation" procedure, install the front portion of the driveshaft.

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

14. Connect wire to the oil pressure sending unit.

15. Connect wire to the oil pressure/timer switch, if so equipped.

16. Install the oil filter (if removed).

17. Following the procedure of the specific section, install the steering sector and column and steeringwheel if removed.

NOTE: Do not change adjustment on connecting rod or on tractors so equipped

Propert

y of A

merica

n Airli

nes

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


18. Connect the battery ground cable to its attachment to the engine near the steering sector.

19. Connect the two (2) headlight wires to the lights by plugging in the wires to the connectors undereach front fender.

20. Install the wires to the alternator.

21. Connect coolant hoses.

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

23. Install the electrical cable to the starter.

24. Connect wire to the fast idle switch on the carburetor.

25. Connect wire to the temperature sending unit.

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

27. Install the exhaust pipe to the engine and muffler.

28. Install the radiator and shroud.

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

30. Install the front bumper plate.

31. Connect battery cables to the battery.

32. Add engine oil and/or transmission fluid and engine coolant as required.

2.5AlternatorRemoval/Installation

2.5.1AlternatorRemoval

1. Disconnect the battery ground cable from the battery.

2. Disconnect all electrical wires from the alternator.

3. Loosen the alternator mounting bolt on the adjustment arm and the mounting bolt on the front endof the alternator, and disengage the alternator belt.

4. Remove the alternator by removing the mounting bolt on the adjustment arm and the front mount-ing bolt attaching the alternator to the alternator engine mount.

2.5.2AlternatorInstallation

1. Install the alternator to the alternator engine mount and to the adjustment arm, tightening the two(2) mounting bolts only finger tight.

2. Engage the alternator belt, adjust the belt tension to 70-110 lb (94.9-149.1 Nm) by applying pres-sure (leverage) to the alternator front housing, and tighten the two (2) mounting bolts.

3. See the wiring schematics in Section 5.1 "Electrical Schematics" for wiring installation.

4. Connect the battery ground cable to the battery.

2.6BatteryRemoval/Installation

2.6.1BatteryRemoval

1. Open battery box cover by unscrewing the battery box cover bolt until it disengages the batterybox.

2. Remove battery case cover and disconnect battery cables from battery.

Propert

y of A

merica

n Airli

nes

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


2

3. Leave battery inside the plastic battery case and remove battery case from tractor using handleson each side of case.

4. Remove battery from battery case.

2.6.2BatteryInstallation

1. Carefully place battery inside plastic battery case. Do not drop battery.

2. Place battery case inside battery box with the terminals of the battery inboard to the tractor.

3. Connect positive (+) battery cable.

4. Connect the negative (-) battery cable.

5. Replace the top to plastic battery case.

6. Secure the battery box cover with the cover bolt.

2.7FuelTankRemoval/Installation

2.7.1FuelTankRemoval

1. Remove the seat assembly per 2.17 "Seat Assembly Removal/Installation".

2. Drain fuel from fuel tank into appropriate container.

3. Disconnect fuel line(s) at fuel tank.

4. Remove the fuel filler cap and the fuel compartment cover and rubber cushions inside compart-ment.

5. Remove fuel tank from compartment taking care not to bend or break fittings.

2.7.2FuelTankInstallation

1. Remove rubber matting in bottom of tank.

2. Place the fuel tank in the compartment so that the fuel line fittings match the holes in the compart-ment.

3. Reposition rubber cushions.

4. Connect fuel line(s).

5. Make certain fuel drain valve is closed.

CAUTION:

The positive (+) battery cable enters the battery box shaft and the negative (-) batterycable enters the battery box forward. Cables are also coded “positive (+)” and ”negative(-)”. The electrical system is negative ground. Ensure cable installations to the batteryare correct to prevent damage to the alternator.

WARNING:

USE EXTREME CARE IN REMOVAL AND INSTALLATION OPERATIONS ON THEFUEL TANK TO PREVENT FIRE HAZARDS OR EXPLOSIONS. NO SMOKING, OPENFLAME, OR USE OF ELECTRICAL EQUIPMENT SHOULD BE PERMITTED DURINGSUCH OPERATIONS.

NOTE:When installing new fuel tanks in early serial tractors, it may be necessary to cut out openingsin the compartment walls to match the relocated fittings. In addition, a cutout in the compart-ment cover may be needed for visual access to the fuel gauge.

Propert

y of A

merica

n Airli

nes

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


6. Reinstall compartment cover.

7. Reinstall seat see 2.17 "Seat Assembly Removal/Installation".

2.8DriveShaftRemoval/Installation

2.8.1DriveShaftRemoval

1. Chock the wheels.

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

Figure3-2-1:DriveShaftwith4L70Transmission

3. Disconnect the front section of the drive shaft by slipping the yoke out of the tail shaft of the trans-mission See Figure 3-2-1.

2.8.2DriveShaftInstallation

1. Position the front section of the drive shaft on the transmission/parking brake drum installation, sothat all four (4) bolt holes are properly aligned and carefully insert the yoke into the tail shaft of thetransmission. See Figure 3-2-1.

2. Attach the wheels, release the parking brake and shift the transmission to neutral.

3. Rotate the drive shaft until all four (4) bolt holes of the drive shaft coupling plate are aligned withthose of the drive axle reduction gear input shaft flange.

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

2.9Axles,Shocks,MountingAssembliesRemoval/Installation

2.9.1DriveAxleRemoval

1. Position a heavy duty chain hoist at the rear end of the tractor so that when the drive axle (withwheels installed) is disconnected from the tractor, the axle may be rolled out from under the trac-tor to the rear.

Propert

y of A

merica

n Airli

nes

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


2

2. Attach the hoist to the left and right sides of the rear portion of the frame.

3. Tighten and lock the hoist, but DO NOT lift the rear wheels off the ground.

4. Chock both front wheels.

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

6. Place a block under the drive reduction gear housing to prevent the axle from rotating when theaxle is disconnected from the tractor.

7. Disconnect the drive shaft from the reduction gear input shaft flange by removing four (4) bolts.

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

9. To remove the four (4) rubber drive axle shocks from the four (4) axle mounting assemblies, drivethe shocks out the bottom of the mounting assemblies by using a rubber mallet on the top side ofthe shocks.

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

11. Hoist the rear of the tractor approximately 16" (41 cm) and lock the hoist in position, thereby provid-ing clearance for drive axle roll out.

12. Remove the block under the axle reduction gear housing and roll the axle out from under the trac-tor.

13. Lower the tractor frame rear end onto blocks approximately 14" (36 cm) in height (or approved jackstands) until drive axle installation.

2.9.2DriveAxleInstallation

1. Install each drive axle mounting assembly to the frame using two (2) bolts to attach the verticalsurface of the mounts to the outboard side of the frame and using two (2) bolts to attach theinboard horizontal surface of the mounts to the lower portion of the frame.

2. Install four (4) rubber shocks (two on each side) into the drive axle mounting assemblies by drivingthe shocks into their mounting holes from the underside of the mounts.

3. Hoist the tractor approximately 16" (41 cm) and lock the hoist in position with the

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

5. On tractors equipped with a removable mounting bar, make certain the end of the bar with greaterhole spacing is forward.

6. Using the chain hoist, lower the tractor frame onto the axle and adjust the axle until the bolt holesfor attaching the axle mounting bars to the mounting assemblies are aligned.

7. Remove the block supporting the axle reduction gear housing.

8. Install four (4) bolts (two on each side) to attach the axle mounting bars to the mounting assem-blies.

9. Slide the rear section of the drive shaft into the front section of the drive shaft and connect the reardrive shaft to the drive axle reduction gear input shaft flange with four (4) bolts.

10. Remove the chain hoist.

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

12. Add brake fluid to master cylinder, purging brake system of air, following the procedure in brakeoverhaul section.

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

Propert

y of A

merica

n Airli

nes

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


13. Remove chocks from front wheel.

2.9.3SteerAxleRemoval

1. Engage the parking brake.

2. Disconnect battery.

3. Jack up tractor front end using the forward frame plate as a jacking point and secure on approvedjack stands.

4. Place retaining block under both sides of axle between springs and hubs.

5. Remove the two (2) front wheels by removing the five (5) lug nuts securing each wheel to the axlehub.

6. Disconnect the steering linkage rod (located on left side of the tractor) from the steer axle spindlearm by removing the cotter pin, nut and lock washer.

7. Tap the linkage rod bolt out of the spindle arm attach hole with a rubber head mallet.

8. Disconnect one side of the axle from the tractor by removing the two (2) U-bolts and attach plateconnecting the axle to the leaf spring and allow axle to rest on the retaining block.

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

10. Lower each end of axle to the ground by removing the blocks and remove axle from underneathtractor.

2.9.4SteerAxleInstallation

1. Position axle under tractor and place axle on retaining blocks located between leaf springs andaxle hubs.

2. Place the attach plate on the upper surface of the leaf spring so that the nut of the leaf springassembly bolt is in the center hole of the axle attach plate.

3. Position the axle boss against the underside of the leaf spring and install two (2) U- bolts by plac-ing the bolts under and around the axle and attaching the bolts to the attach plate on top of thespring.

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

5. Connect steering linkage rod to the steer axle spindle arm using a washer bolt, and cotter pin forbolt retention.

6. Remove axle retaining blocks, then remove jack.

7. Connect battery.

CAUTION: If leaf springs and steer axle are to be removed, remove as a unit and refer to the 2.9.3"Steer Axle Removal"

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

CAUTION: LINKAGE ROD BOLT AND THE INSTALLATION HOLE IS TAPERED. FAILURE TOINSERT BOLT FROM CORRECT SIDE WILL DAMAGE BOLT/ATTACHMENT HOLE.

Propert

y of A

merica

n Airli

nes

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


2

2.9.5SteerAxleLeafSpringsandSpringStrapArmsRemoval

1. Engage the parking brake.

2. Loosen (do not remove) the two (2) U-bolts on the right side of the axle which connect the axle tothe spring so that the bolt ends are flush with the nuts.

3. Move to left side of tractor and completely remove the two (2) U-bolts and attach plate connectingthe axle to the leaf spring.

4. Position a jack on the front left part of the frame and jack the tractor until there is approximately 2inches of clearance between the axle boss and the spring.

5. Remove the cotter pins, spacer washers and nuts from the front and rear spring attachment bolts.

6. Remove the spring by extracting the front and rear attachment bolts.

7. To remove the two strap arms that connect the rear end of the spring to the tractor, make a sketchof the bolt/spacer arrangement and remove the attachment bolt connecting the straps to the springshackle bracket.

2.9.6SteerAxleLeafSpringsandSpringStrapArmsInstallation

1. With the tractor still jacked on the left side and the axle left side disconnected as described above,install the two (2) strap arms that connect the rear end of the spring to the tractor by inserting theattachment bolt from the inboard side and positioning the spacer washers in their original arrange-ment. Use the strap attachment sketch from the previous step for reference.

2. Secure the strap arms with bolt and bolt-locking pin.

3. Using the front and rear spring attachment sketches mentioned in the removal procedure above,install the leaf spring with the attachment bolts inserted from inboard side and position the spacerwashers in their original arrangement.

4. Lower the left side of the frame with the jack until the spring is resting in position on the axle boss.

5. Place the axle attach plate on top of the spring surface so that the leaf spring assembly bolt nut isin the attach plate center hole.

6. Install the two (2) U-bolts by placing the bolts under and around the axle and attaching the bolts tothe attach plate on top of the spring.

7. Tighten the two (2) U-bolts on the right side of the axle and remove the jack.

2.9.7SteeringLinkageRod(DragLink)Removal

1. Disconnect the steering linkage rod from the steer axle spindle arm by removing the cotter pin, nutand lock washer.

2. Drive the linkage rod bolt out of the spindle arm attachment hole with a rubber mallet.

CAUTION: If steer axle and leaf springs are to be removed, remove axle and springs as a unit. Usethis section to remove axle and springs together and disregard axle removal fromsprings.

NOTE:The springs are shimmed for correct spacing and alignment at the factory. Check eachspring attachment for spacer washer reference if installing new springs.

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

Propert

y of A

merica

n Airli

nes

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


3. Disconnect the steering linkage rod from the steering sector pitman arm by removing the cotterpin, nut and lock washer.

4. Tap the linkage rod bolt out of the pitman arm attachment hole with a rubber mallet.

2.9.8SteeringLinkageRod(DragLink)Installation

1. Install the bolt of the linkage rod “short end” into the top of the spindle arm attachment hole, tap-ping the bolt into place.

2. Secure the installation with a lock washer, nut and cotter pin.

3. Turn the steering wheel for proper bolt alignment as necessary, and install the bolt of the linkagerod “long end” into the steering sector Pitman arm from the inboard side so that the threaded endof the bolt faces outboard.

4. Tap the bolt with a rubber mallet until it is seated in place.

5. Secure the installation with a lock washer, nut and cotter pin.

2.9.9Sector/ColumnandSteeringWheelRemoval

1. Remove the rubber disc from the dust cover on tractors so equipped by inserting a screwdriverunder the cover edge and prying it out.

2. Remove the dust cover.

3. Remove the horn components.

4. Remove the steering wheel retaining nut and remove the steering wheel.

5. Remove the remaining horn components, severing the wire where required.

6. Remove the steering column retaining strap by removing the two (2) bolts securing the strap to thetractor console.

7. Disconnect the steering sector Pitman arm from the steering linkage rod by removing the cotterpin, nut and lock washer and tapping the linkage rod bolt out of the Pitman arm with a rubber headmallet.

8. Remove the bolt and spacer connecting the aft end of the steering sector to the frame.

9. Remove the two (2) bolts connecting the steering sector mounting bracket to the frame, therebyhaving the sector and column disconnected from the tractor.

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

11. Disconnect the mounting bracket from the steering sector by removing the retainer nut andextracting the Pitman arm from the sector shaft using a puller tool.

CAUTION: LINKAGE ROD BOLTS AND THEIR INSTALLATION HOLES ARE TAPERED. FAILURE TOINSERT BOLTS FROM CORRECT SIDES WILL DAMAGE BOLTS/ATTACHMENT HOLES.

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

Propert

y of A

merica

n Airli

nes

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


2

2.9.10Sector/ColumnandSteeringWheelInstallation

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

2. With the tractor in the jacked position as described in step 10 of the removal procedure, place thesteering column and sector into the installed position by inserting the column up through the floorplate from underneath the tractor.

3. Attach the forward mounting bracket to the frame using two (2) bolts. Hand tighten only.

4. Attach the aft end of the steering sector to the aft bracket using a bolt and spacer. Hand tightenonly.

5. Attach the retaining strap around the steering column with two (2) bolts. Hand tighten only.

6. Align steering sector filler hole with hole in frame.

7. Secure steering column with retainer strap.

8. Ensure that stop light switch bracket is secured when strap is secured.

9. Secure front mounting bracket to frame.

10. If a space is present between spacer and sector, shim till space is filled.

11. Secure rear bolt.

12. Install and connect the wires to the horn components in the steering column.

13. Install the steering wheel to the column and secure the steering wheel with the retaining nut.

14. Install the remaining horn components.

15. Turn the front wheels until they are pointed in a straight forward position.

16. Without disturbing the steering shaft centered position, place the pitman arm on the sector shaftwith the arm pointing straight down and secure the arm with the retainer nut.

17. Connect the steering linkage rod to the Pitman arm and secure the connection with a lock washer,nut and cotter pin.

18. Lower the tractor and remove the jack.

2.10BrakeSystemRemoval/Installation

2.10.1ParkingBrake,Linkage,LeverRemoval

Perform the following steps to remove the parking brake, linkage and lever.

1. Chock the wheels.

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

3. Remove the driveshaft from the vehicle (only necessary if replacing the parking brake disc).

4. Remove the clevis pins securing the parking brake rod to the park brake lever and the parkingbrake caliper and remove the rod from the vehicle.

5. Remove the two (2) bolts securing the parking brake caliper to the rear axle assembly.

6. Disassemble the caliper and remove the pads from the body.

7. If the disc is to be replaced then remove the axle input flange nut.

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

Propert

y of A

merica

n Airli

nes

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


8. Pull the input flange and disc off of the input shaft as one piece.

9. Remove parking brake lever.

• Remove the mounting angles from the floor plate by removing the four (4) mounting bolts andnuts.

• Disconnect the parking brake lever from its mounting bracket by removing the two (2) attach-ment bolts.

2.10.2ParkingBrake,Linkage,LeverInstallation

1. Install the parking brake lever to the mounting angles with two (2) attachment bolts, nuts and spac-ers.

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

3. Inspect the parking brake disc. Repair or replace the disc if necessary.

4. Install the parking brake disc and input flange on the input shaft of the rear axle/drop box. Installand torque the retaining nut to 200-275 ft-lbs (271.2-372.9 Nm).

5. Install new pads and hardware when necessary while reassembling the caliper assembly.

6. Install the caliper assembly onto the rear axle using the original hardware.

7. Install the parking brake rod using the original clevis pins and new cotter pins to secure them.

8. When adjustment is necessary, follow 3.3.2 "Park Brake Adjustments", otherwise return the trac-tor to service.

2.10.3BrakePedalRemoval

1. Remove the cotter pin and washer from the push rod retainer lug on the pedal.

2. Remove the nut, bolt, and two (2) spacers which connect the upper end of the brake pedal to theconsole.

3. Disengage the push rod from the retainer lug on the pedal.

2.10.4BrakePedalInstallation

1. Place the brake pedal in the installed position and connect the push rod to the push rod lug on thepedal.

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

3. Install a washer and cotter pin to the push rod lug to retain the push rod.

2.10.5BrakeBoosterRemoval

1. Remove the master cylinder following the procedure of the specific section.

2. Disconnect the booster push rod from retainer lug on the brake pedal by removing the cotter pinand washer.

NOTE: The disc may then be removed from the flange.

NOTE: Some applications use grade 8 hardware with lock nuts in place of clevis pins.

Propert

y of A

merica

n Airli

nes

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


2

3. Disconnect the hydraulic hoses/lines.

4. Remove the brake booster from the engine side of the fire wall by removing the four (4) attachmentnuts on the driver side of the fire wall.

2.10.6BrakeBoosterInstallation

1. Install the brake booster to the engine side of the fire wall so that the vacuum hose fitting is posi-tioned up and inboard. Secure the booster to the fire wall with four (4) attachment nuts.

2. Connect the booster push rod to the retainer lug on the brake pedal and secure with a washer andcotter pin.

3. Prior to installing the master cylinder, measure the distance between the surface face of the vac-uum brake booster to the tip of the push rod. This length should be 0.9" ±0.06" (22.9±1.5 mm).Adjust the length as required to be within tolerance by turning the screw on the end of the push rodin or out.

4. Install the master cylinder and brake line following the procedure of the specific section.

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

2.11TiresandWheels

2.11.1TireandWheelRemoval/Installation

1. Jack the rear wheel off the ground using normal jacking procedures see 3.2 "Jacking Instructions".

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

3. Remove the tire for repair or replacement as required, using standard tire tools.

4. Install the new or repaired tire onto the wheel.

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

2.11.2TireandWheelRemoval/InstallationonTractorswithStandardWheels

1. Jack the front wheel off the ground using normal jacking procedures see 3.2 "Jacking Instructions".

2. Remove the five (5) lug nuts which secure the wheel to the steer axle hub and remove the wheel.

3. Remove the tire for repair or replacement as required, using standard tire tools.

4. Install the new or repaired tire on to the wheel.

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

2.12ShifterRemoval/Installation

2.12.1ShifterRemoval

1. Make sure the ignition switch is in the “off” position.

2. Disconnect battery.

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

4. Disconnect the shifter cable assembly from the shifter by removing the nut that holds the trunnionto the shifter lever plate.

CAUTION: Do not remove the hub nut for wheel removal. Hub nut is removed for axle or brakerepair only.

Propert

y of A

merica

n Airli

nes

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


5. Disconnect the five (5) shifter wires.

6. Remove the shifter by removing the two (2) Allen head cap screws located under the steering col-umn bracket, which secure the shifter to the bracket.

2.12.2ShifterInstallation

1. Place the (new) shifter in the installed position and secure it to the steering column bracket withthe two Allen head cap screws installed from the underside of the bracket.

2. Install the trunnion (which is on the upper end of the shifter connecting rod or the shifter cableassembly) in the second hole on the aft edge of the shifter lever plate and secure with nut.

3. Move lever to forward (F), neutral (N), and reverse (R) position, and check the shift control leveron the transmission by manual feel to see if it is correct in each position.

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

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

6. Connect battery.

2.13AcceleratorPedalandThrottleControlCableRemoval/Installation(IfEquipped)

1. Remove the two (2) bolts attaching the hinged mounting plate of the pedal to the floor plate.

2. Disconnect the pedal throttle control arm from the underside of the pedal by removing two (2) nuts.

3. Install the new accelerator pedal to the throttle control arm with two (2) attachment nuts.

4. Secure the hinged mounting plate of the pedal to the floor plate with two (2) mounting bolts.

2.14ThrottleControlCableRemoval/Installation

1. Remove the throttle linkage cable from the mounting angle at the bottom of the fire wall by remov-ing the attaching bolt.

2. Disengage the snap-out ball connection of the cable from the throttle linkage connector arm of theaccelerator pedal.

3. Disconnect the engine end of the throttle linkage cable by removing the bolt and retainer clip secur-ing the cable to the cable mount on the engine.

4. Disengage the snap-out ball connection of the cable from the throttle linkage assembly on theinjector pump.

5. Snap in the ball connector to the injector pump throttle linkage fitting.

6. Install the pedal end of the cable to the mounting angle at the bottom of the fire wall by bolting thecable to the angle.

7. Snap the cable ball connector onto the fitting of the linkage connector arm of the accelerator pedal.Check for full stroke and free travel.

NOTE:If adjustment is needed, adjust as noted in 3.3.8 "Shifter Adjustment". No adjustment is neces-sary when shifter cable assembly is used.

Propert

y of A

merica

n Airli

nes

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


2

2.15TailPipe/Muffler/ExhaustPipeRemoval/Installation

2.15.1TailPipe/Muffler/ExhaustPipeRemoval

1. Remove the U-bolt securing the tail pipe to the tail pipe retainer strap at the rear end of the tractorframe.

2. Remove the U-bolt securing the tail pipe to the muffler and extract the tail pipe from the muffler.

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

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

5. Remove the U-bolt securing the muffler/exhaust pipe connection.

6. From underneath the tractor, disengage the muffler from the exhaust pipe by pushing up and twist-ing the muffler.

7. Remove the exhaust pipe by disconnecting the two (2) bolts (gasoline engine or the three (3) nutsand bolts on the diesel engine) attaching the pipe to the exhaust manifold.

2.15.2TailPipe/Muffler/ExhaustPipeInstallation

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

2. Loosely install the exhaust pipe to the exhaust manifold, but DO NOT TIGHTEN the two (2) attach-ment bolts.

3. Position the muffler so that the exhaust outlet is over the drive axle and the intake end is facing theexhaust pipe.

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

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

6. Attach the tail pipe to the muffler and secure the connection with a U-bolt.

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

2.16CabAssemblyRemoval/Installation

2.16.1CabAssemblyRemoval

1. Disconnect the battery.

2. Disconnect the wires going into the cab.

3. Remove cab by removing eight (8) bolts.

NOTE: On persistent connections, it may be necessary to loosen the muffler/ exhaust pipe connec-tion using a chisel to expand the muffler intake pipe.

NOTE:The eight (8) bolts are located as follows:(2) bolts each on the right and left sides, and two (2)bolts each of the right and left back corners.

Propert

y of A

merica

n Airli

nes

CD444-28M 3 - 2 - 17May 2019 (Rev A)


2.16.2CabAssemblyInstallation

1. Install cab and secure by using the eight (8) bolts removed in step (c) above.

2. Connect the wires.

3. Connect the battery.

2.17SeatAssemblyRemoval/Installation

2.17.1SeatAssemblyRemoval

1. Remove the four (4) outboard bolts and lock washers that connect the seat frame to the four (4)shock mounts.

2. Lift seat assembly from tractor.

2.17.2SeatAssemblyInstallation

1. Place seat assembly in position with the rear end of the seat frame resting over the aft seat sup-ports.

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

3. Before installing the two rear bolts, lift rear of seat.

4. Check to make sure the front shock mounts are not being twisted.

5. If twisted, lower the rear of the seat and loosen the front bolts more.

6. Lift rear end of seat assembly, install bolts and lock washers in the two aft shock mounts.

7. Tighten bolts.

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

2.18DoorRemoval/Installation

2.18.1DoorRemoval

1. Remove door stop by removing securing nut.

2. Remove door by lifting door straight up and out of hinges.

2.18.2DoorInstallation

1. Install the door by lowering the door so that the pegs of the hinge go into the hinge.

2. Replace door stop and secure with a nut.

2.19GaugeRemoval/Installation

2.19.1GaugeRemoval

1. Disconnect the battery cables from the battery.

2. Disconnect wires from the gauge.

3. Remove the two (2) nuts securing the gauge to the retainer mount and slide the gauge out thedriver’s side of the instrument panel.

NOTE:Do not remove the four (4) inboard bolts, unless shock mount removal replacement is to beaccomplished.

Propert

y of A

merica

n Airli

nes

3 - 2 - 18 CD444-28MMay 2019 (Rev A)


2

2.19.2GaugeInstallation

1. Place the new gauge into the installed position and secure the unit to the retainer mount.

2. See the wiring schematics in Chapter 1 Section 2 Maintenance Manual for wiring installation.

3. Connect the battery cables to the battery.

2.19.3TemperatureSendingUnitandGaugeRemoval/Installation

2.19.3.1TemperatureSendingUnitRemoval/Installation

1. Drain engine coolant from radiator.

2. To remove the sending unit, disconnect wire from the unit terminal and unscrew the unit from itsmounting.

3. Install the new sending unit (use thread sealer) by screwing into its mounting hole on the enginehousing and connect wire to the unit terminal.

4. Refill with proper engine coolant/water mixture.

2.19.3.2WaterTemperatureGaugeRemoval/Installation

1. Disconnect the gauge light and housing from the back of the gauge.

2. Disconnect wire from the right side terminal post and wire from the left side terminal post of thegauge.

3. Remove the two (2) nuts securing the gauge to the gauge retainer mount and slide the gauge outfrom the driver's side of the instrument panel.

4. Place the new gauge into the installed position and secure the gauge retainer mount with two (2)retaining nuts.

5. Install wire to the right side and wire to the left side bolt/terminals of the gauge.

6. Connect the gauge light and housing to the back of the gauge.

2.19.4OilPressureSendingUnitandGaugeRemoval/Installation

2.19.4.1OilPressureSendingUnitRemoval/Installation

1. To remove the sending unit, disconnect wire from the unit terminal and unscrew the unit from itsmounting.

2. Install the new sending unit (use thread sealer) by screwing it into its mounting hole on the enginehousing and connecting the wire to the unit terminal.

2.19.4.2OilPressureGaugeRemoval/Installation

1. Disconnect the gauge light and housing from the back side of the gauge.

2. Disconnect wire from the right side terminal post and wire from left side terminal post of the gauge.

3. Remove the two (2) nuts securing the gauge to the gauge retainer mount and slide the gauge outfrom the driver’s side of the instrument panel.

4. Place the new gauge into the installed position and secure the gauge to the gauge retainer mountwith two (2) retaining nuts.

5. Install wire to the right side and wire to the left side bolt/terminals of the gauge using two (2) retain-ing nuts.

6. Connect the gauge light and housing to the back side.

Propert

y of A

merica

n Airli

nes

CD444-28M 3 - 2 - 19May 2019 (Rev A)


2.20SwitchRemoval/Installation

2.20.1IgnitionSwitchRemoval/Installation

1. Disconnect the battery cables.

2. Disconnect the wires from the terminal posts.

3. Remove the switch by removing the mounting nut on the operator’s side of the instrument panel.

4. Place the new master switch into position with the “OFF” position of the switch (marked on the sideof lever) pointing up.

5. Secure the switch with the mounting nut.

6. Refer to wiring schematics in 5.1 "Electrical Schematics" for wiring installation.


2.20.2HeadlightSwitchRemoval/Installation


2. Disconnect the wires from the headlight switch.

3. Remove the switch by removing the retainer nut.

4. Install the new light switch with the “ON” position of the switch pointing up and secure the switchwith the retainer nut.



2.20.3AuxiliarySwitchRemoval/Installation


2. Disconnect the wires from the auxiliary switch.

3. Remove the switch by removing the retainer nut.

4. Install the new switch with the “ON” position of the switch pointing up and secure the switch withthe retainer nut.

5. Refer to wiring schematics in 5.1 "Electrical Schematics"for wiring installation.


2.20.4BrakeWarningLightRemoval/Installation


2. Disconnect the wires from the brake warning light.

3. Remove the lens.

4. Remove the socket by removing the retainer nut.

5. Install the new socket and secure the socket with the retainer nut.

6. Install the lens.



Propert

y of A

merica

n Airli

nes

3 - 2 - 20 CD444-28MMay 2019 (Rev A)


2

2.20.5GlowPlugButtonRemoval/Installation


2. Disconnect the wires from the glow plug.

3. Remove the glow plug by removing the retainer nut.

4. Install the new glow plug with the retainer nut.

5. Refer to wiring schematics in C5.1 "Electrical Schematics" for wiring installation.


2.21LightRemoval/Installation

2.21.1HeadlightRemoval/Installation


2. Disconnect the wire at the disconnect plug.

3. Remove the nut and lock washer that secure the light to the frame rail.

4. Install the new headlight to the frame rail with a nut and lock washer.

5. Connect the wire at the disconnect plug.


2.21.2StopLightRemoval/Installation


2. Disconnect wires from stop light assembly.

3. Remove stop light assembly by removing the light from the gasket.

4. Install the new stoplight and secure by inserting the light into the gasket.



2.21.3SignalLightRemoval/Installation


2. Disconnect the wires from the turn signal light assembly.

3. Remove turn signal light assembly by removing the light from the gasket.

4. Install the new turn signal light assembly by inserting the light into the gasket.

5. Refer to wiring schematics in 5.1 "Electrical Schematics"for wiring installation.


2.21.4Back-UpLightRemoval/Installation1. Disconnect the battery.

2. Disconnect the wires from the backup light assembly.

3. Remove the backup light assembly by removing the light from the gasket.

4. Install the new backup light assembly by inserting the light into the gasket.

5. Refer to wiring schematics in5.1 "Electrical Schematics"for wiring installation.


Propert

y of A

merica

n Airli

nes

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


Section3:OverhaulProcedures

3.1SafetyPrecautionsAll operators and mechanics/technicians should adhere to the information located in the Safety sections,and to the Warnings, Cautions, and Notes throughout this manual.

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.

3.2Engine

For engine maintenance and overhaul procedures, refer to the Ford engine manual located in Chapter 5of the manual.

3.2.1EngineFaultCodes

The engine fault codes can be found in Chapter 5 of the manual.

3.3Transmission

A transmission overhaul is not included in this publication, however overhaul documentation for the Gen-eral Motors transmission can be obtained directly from General Motors.

3.3.1TransmissionFaultCodes

The transmission warning light illuminates when there is a transmission fault. The transmission fault codescan be found in chapter 5 of the manual.

3.4Axles

Axles require an overhaul if/when then individual gears or components cannot be replaced in order for theaxle to perform adequately.

An axle overhaul is not included in this publication, however overhaul documentation for the Axletech orNewage axle can be obtained directly from the manufacturer.

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

Propert

y of A

merica

n Airli

nes

THIS PAGE INTENTIONALLY BLANK

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

Tow Tractor Model MA-28 Maintenance Manual

Chapter 3Section 3

Propert

y of A

merica

n Airli

nes

chapter 3: overhaul - aagsemanuals.s3.amazonaws.com · cd444-28m 3 - 1 - 3 may 2019 (rev a) chapter...

Documents