Property of American€¦ · Chapter 2 Tow Tractor Model MA-38 Section 1 Maintenance Manual Chapter 2: Preventive Maintenance Section 1: Introduction - - - - ... 2.1.6 Six (6) Months

CD444-38M 2 - 1 - 1July 2019 (Rev A)

Chapter 2 Tow Tractor Model MA-38Section 1 Maintenance Manual

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

1.1 Safety Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1-11.2 Preparation for Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1-1

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

2.1 Periodic Maintenance/Service Schedules 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 - - - - - - - - - - - - - - - - - - - - -2-2-32.1.3 Bi-Weekly or Every 100 Hours Maintenance Checks- - - - - - - - - - - - - - - - - -2-2-32.1.4 Monthly or Every 200 Hours Maintenance Checks - - - - - - - - - - - - - - - - - - -2-2-42.1.5 Two (2) Months or Every 500 Hours Maintenance Checks- - - - - - - - - - - - - -2-2-42.1.6 Six (6) Months or Every 1000 Hours Maintenance Checks- - - - - - - - - - - - - -2-2-52.1.7 Yearly or 2000 Hours Maintenance Checks - - - - - - - - - - - - - - - - - - - - - - - -2-2-52.1.8 Every 2 Years or 4000 Hours Maintenance Checks - - - - - - - - - - - - - - - - - -2-2-6

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-53.2.7 Brake Fluid Level- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.2.8 Fuel Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-63.2.9 Windshield Fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-6

3.3 Service and Lubrication Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-83.4 Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-9

3.4.1 Fan Belt Adjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-93.4.2 Service Brake Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-103.4.3 Park Brake Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-103.4.4 Steering Gear Box Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-113.4.5 Toe-In Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-113.4.6 Cab Door Adjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-113.4.7 Vertical Headlight Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-123.4.8 Horizontal Headlight Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-123.4.9 Shifter Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-12

3.5 Service Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-123.5.1 Engine Oil and Filter Change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-123.5.2 Engine Air Filter Replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-133.5.3 Transmission Oil and Filter Change- - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-143.5.4 Axle Gear Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-153.5.5 Brake Assembly: Wheel Cylinder Bleed - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-163.5.6 Fuel Filter Change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-3-16

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

4.1 Engine and Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-14.2 Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-4

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2- 1 - 2 CD444-38MJuly 2019 (Rev A)

‘ Tow Tractor Model MA-38 Chapter 2Maintenance Manual Section 1

4.3 Rear Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-54.4 Steering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-54.5 Brake System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-64.6 Electrical System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-7

4.6.1 Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-74.6.2 Lights (12 Volt System) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-74.6.3 Wiper Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-84.6.4 Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4-9

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

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

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CD444-38M 2 - 1 - 1July 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 pulling the park brake lever and perform Pre-Operation Checks prior to puttingthe 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 for oil level and contamination, add oil if needed see Section 2: "Layouts" for lubri-cation specification.

2. Check for water leaks.

3. Check radiator coolant level. If coolant is needed, make sure radiator drain valve is closed, thenadd required coolant.

4. Check transmission fluid level.

5. Check transmission cooling lines for proper connection.

6. Check for dust in air cleaner dust cup.

7. Check for damaged parts and loosened bolts and nuts.

8. Start engine and check for proper functions of meters and pilot lamps with no stains.

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

WARNING:

STOP THE ENGINE AT A FLAT AND WIDE SPACE WHEN CHECKING.

KEEP DUST OR FUEL AWAY FROM THE BATTERY, WIRING, MUFFLER ANDENGINE TO PREVENT A FIRE. CHECK AND CLEAR THEM BEFORE OPERATINGEVERYDAY. PAY ATTENTION TO THE HEAT OF THE EXHAUST PIPE OR EXHAUSTGAS SO THAT IT CAN NOT IGNITE TRASH.

BE SURE TO INSTALL SHIELDS AND SAFEGUARDS ATTACHED TO THE ENGINEWHEN OPERATING.

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

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Tow Tractor Model MA-38 Chapter 2 Maintenance Manual Section 1

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9. Check for unusual engine noise.

10. Check engine start-up condition.

11. Check slow-down and acceleration behavior.

1.2.1.2FuelSystem

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

2. Ensure the in-line fuel shut-off valve under the tank is open.

3. Make certain fuel tank drain valve is closed.

4. 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.

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 and adjusted 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.

NOTE:When ambient temperature is low, operate the machine after the engine has been completelywarmed up.

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

CAUTION:

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

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CD444-38M 2 - 2 - 1July 2019 (Rev A)


Section2:PreventiveMaintenance

2.1PeriodicMaintenance/ServiceSchedulesandChecklist

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.

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 maintenanceschedules 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 200 hours of operation

• Every two months or 500 hours of operation

• Every six months or every 1000 hours of operation

• Annually or 2000 hours of operation

• Two years or 4000 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.

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2 - 2 - 2 CD444-38MJuly 2019 (Rev A)


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2.1.1DailyorEvery10hoursMaintenanceChecks

Table2-2-1:DailyorEvery8hoursMaintenanceChecksandServiceProcedures

No. Item DailyCheck/8HourChecks

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

THE COOLING SYSTEM IS PRESSURIZED. ESCAPING STEAM AND HOT COOLANT CANCAUSE SEVERE BURNS. NEVER OPEN A RADIATOR CAP WHEN COOLANT TEMPERATUREEXCEEDS 200 °F (95 °C). USE A CLOTH OR WEAR SUITABLE GLOVES TO HANDLE A HOTRADIATOR PRESSURE CAP. ETHYLENE GLYCOL ANTIFREEZE IS TOXIC AND IRRITATES THESKIN. WASH ANY PART OF THE BODY THAT COMES IN CONTACT WITH ANTIFREEZE SOLU-TION AS SOON AS POSSIBLE.

1

Engine System

Check oil level and top oil up if necessary.

2 Check coolant level and top up if necessary

3 Check engine tightness (visual inspection for leaks).

4 Check and clean air filter element if necessary.

5 Check Fan Belt.

6 Fuel System Check fuel level.

DO NOT CHANGE PNEUMATIC TIRE FOR CUSHION TIRE OR VICE VERSA WITHOUT FIRSTCONSULTING TUG. TIRES OF A DIFFERENT TYPE OR MAKE, TREAD OR MATERIAL CANREDUCE THE LOAD CAPACITY OR AFFECT SAFETY.

7Tires

Check the pressure of the pneumatic tires.

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

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

10

Lights

Check the operation and aiming of the headlights.

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

12Check the operation of the cab marker lights, the heater, the wiper and cab light, if equipped.

13 Horn Sound the horn.

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CD444-38M 2 - 2 - 3July 2019 (Rev A)


2.1.2WeeklyorEvery50hoursMaintenanceChecks

2.1.3Bi-WeeklyorEvery100HoursMaintenanceChecks

Table2-2-3:Bi-WeeklyorEvery100HoursMaintenanceChecks

Table2-2-2:WeeklyorEvery50hoursMaintenanceChecks

No. Item Weekly/50HourChecks

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.

1

Engine System

Change engine oil.

2 Check underneath for oil leaks and damage.

3 Replace the oil filter cartridge.

4Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place.

NOTE: Only the initial change is required at 50-hours, check monthly or every 200 hours thereafter.

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

6

Axles

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

7 Check drive axle and reduction gear box oil level

8 Check king pins for looseness.

9 Nuts and Bolts

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

10 Check nuts and bolts for tightness. If required, torque to specified torque.

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

11Brake

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

12 Steering System

Check hydraulic fluid level.

13 Check steer pins for looseness

14 Fuel System Check fuel hoses for signs of wear or damage.

No. Item Bi-Weekly/100HourChecks

1EngineSystem

Adjust engine fan belt if necessary.

2 Clean and Adjust Spark Plugs if necessary.

3 Clean air filter element.

4Fuel

System Check and Change Fuel Filter if necessary.

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2 - 2 - 4 CD444-38MJuly 2019 (Rev A)


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2.1.4MonthlyorEvery200HoursMaintenanceChecks

2.1.5Two(2)MonthsorEvery500HoursMaintenanceChecks

Table2-2-4:MonthlyorEvery200HoursMaintenanceChecks

No. Item Monthly/200HourChecks

1

Engine System

Change engine oil

2 Change oil filter cartridge.

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

4 Inspect radiator hoses and clean radiator exterior.

5

Brake System

Check park brake operation. With the park brake handle in ‘lock’ position, the trac-tor 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. Fol-low 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.

10Axles

Change drive axle and reduction gear box oil.

11 Lube the drive shaft joints.

12 Operator Compartment/

Cab

Lube the adjusting slides beneath the operator’s seat.

13 Lube the throttle linkage.

14 Lube the cab door handles (if equipped).

15Steering System

Check power steering fluid level (when applicable).

16 Hood Lube the hood latches and hinges.

17 Fittings Lube all grease fittings.

Table2-2-5:Two(2)MonthsorEvery500HoursMaintenanceChecks

No. Item TwoMonths/500HourChecks

1Engine System

Change engine fan belt.

2 Axles Check ball joints and tie rod ends looseness.

3 Wheels Inspect front wheel bearings; clean and repack.

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CD444-38M 2 - 2 - 5July 2019 (Rev A)


2.1.6Six(6)MonthsorEvery1000HoursMaintenanceChecks

2.1.7Yearlyor2000HoursMaintenanceChecks

Table2-2-6:Six(6)MonthsorEvery1000HoursMaintenanceChecks

No. Item Six(6)Months/1000hourChecks

1 Engine System

Check PCV valve

2 Adjust valve clearance

3Transmis-

sionChange transmission fluid and filter.

4Axles

Check the differential and reduction gear box bolts are tightened to 41 ft-lb (55.6 Nm).

5 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.

6Hydraulic System

Change hydraulic fluid and clear magnetic drain plug of debris.

7Brake

SystemCheck cylinder compression.

8Electrical System

Check battery and cable connectors.

9Hoses and Fastenings

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

Table2-2-7:Yearlyor2000HoursMaintenanceChecks

No. Item Yearly/2000HoursChecks

1Engine System

Replace the Air Cleaner element every year or every 6 cleanings. Also replace if the primary element is stained heavily.

2ElectricalSystem

Change spark plugs.

3Air Intake System

Check intake pipe and clamp bands.

4

Fuel System

Change fuel filter.

5 Clean fuel tank.

6 Change fuel pipe clamps.Prop

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2.1.8Every2Yearsor4000HoursMaintenanceChecks

Table2-2-8:Every2Yearsor4000HoursMaintenanceChecks

Item 2Years/4000HoursChecks

1 Engine SystemReplace hoses and hose clamps, if checked and found that hoses are swollen, hardened or cracked.

2 Cooling System

Change engine coolant.

3 Change radiator hoses and band clamps.

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CD444-38M 2 - 2 - 7July 2019 (Rev A)


Serial Number:Manufacture Date:

Service Requirement in Hours Daily 50 100 200Check/ensure all controls are in good working order

Check fuel level

Check Lubricating oil level (If necessary top up)

Check engine coolant level

Check engine coolant system for leaks and cleanliness

Check the pressure of the pneumatic tires

Check tire treads, remove any foreign objects

Check the operation and aiming of the headlights

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

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

Check exhaust system including exhaust after treatment components for leaks.Check coolant, oil, fuel, and vacuum hoses/pipes for leaks, damage, deterioration and correct routing.Check Fan Belt

Check underneath for oil leaks and damage

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

Check nuts and bolts for tightness. If required, torque to specified torque.

Change engine oil.

Check battery charge

Check the drive axle U-bolts and tighten if required

Check drive axle and reduction gear box oil level

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

Check fuel hoses for sign of wear or damage

Check king pins and steer pin for looseness

Check all visible electrical wiring for security, correct routing and evidence of chafing or heat damageChange Oil Filter Cartridge

Check/Change Fuel Filter

Clean Air filter Element

Adjust Fan belt (if necessary)

Clean/Adjust Spark Plug (if necessary)

Check park brake operation.

Check service brake operation

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

Lube the parking brake lever pivots

Check the alternator belts; tighten, if necessary

Inspect radiator hoses and clean radiator exterior.

Lube the drive shaft joints

Lube the adjusting slides beneath the operator’s seat

Lube all grease fittings

Lube the hood latches and hinges

Lube the cab door handles (if equipped)

TUG Model MA-38 (Kubota Gas Engine) Tow Tractor

ID Number:Date:

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2 - 2 - 8 CD444-38MJuly 2019 (Rev A)


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Notes

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CD444-38M 2 - 2 - 9July 2019 (Rev A)


* Change more often when operating under dusty conditions.

Serial Number:Date:

Service Requirement in Hours 500 1000 2000 4000Change fuel cartridge for filter

Check intake air pipes for damage

Inspect front wheel bearings; clean and repack

Check ball joints and tie rod ends looseness

Change Fan Belt

Replace lubricating oil.

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

Adjust Valve Clearance

Change drive axle and reduction gear box oilCheck cylinder compression

Check battery and cable connectors

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

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

Change Fuel pipe and clamps

Clean Fuel Tank

Replace dry air filter.

Change hydraulic fluid and clear magnetic drain plug of debris.

Change transmission fluid and filter.

Clean Radiator and water jacket

Change Spark Plug

Replace fuel pre-filter.

Change radiator hoses and clamp bands

Change Air Cleaner Element*

Check intake pipe and clamp bands

Change intake pipe and clamp bands

Change rubber piping related oil seperator

Replace Coolant

Change radiator hoses and band clamps

Change breather tube

Date:ID Number:

TUG Model MA-38 (Kubota Gas Engine) Tow Tractor

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2 - 2 - 10 CD444-38MJuly 2019 (Rev A)


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CD444-38M 2 - 3 - 1July 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.

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Figure2-3-1:JackingPoints

3.2.2FluidLevelChecks

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

3.2.3EngineOilLevel

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

2. Pull up the dipstick and wipe clean.

3. Return 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: Check the engine oil level before starting or more than 5 minutes after stopping the engine.

NOTE: Maintain the oil level between the grooved region.

Jacking Points

Jacking Points

Jacking Points

Jacking Points

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4. When the oil level is below the dipstick grooved region, add oil through the oil filler to the bring thelevel up to the grooved area.

5. After adding oil, wait more than 5 minutes and check the oil level again. It takes some time for theoil to drain down to the oil pan.

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. Perform 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 “Full” and “Low” markings on the radiator or reservoir/ expan-sion tank.

CAUTION:

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

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

NOTE:

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

WARNING:

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

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

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

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4. When the coolant level is below the “Low” marking, get the specified pre-mixed solution.

5. Remove the radiator cap and check to see that coolant reaches the supply port

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

7. Re-tighten radiator cap.

8. Check all drain shutoff-valves.

3.2.4.1ChangingEngineCoolant

1. To drain coolant, always open both drain shutoff-valves and simultaneously open the radiator capas well.

2. Remove the overflow pipe of the radiator pressure cap to drain the recovery tank.

3. Use prescribed coolant 2.22 US gal (8.4L).

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 neutral (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 operating temperature.

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: With the radiator cap kept closed, a complete drain of water is impossible.

CAUTION:An improperly tightened radiator cap or a gap between the cap and the seat quickensloss of coolant.

NOTE:

To remedy quick decrease in engine cooling capacity:

1. Check for any dust and dirt between the radiator fins and tube. If any, remove themfrom the fins and the tube.

2. Check the tightness of the fan belt. If loose, tighten it securely.

3. Check the internal blockage in the radiator hose. If scale forms in the hose, clean withthe scale inhibitor or its equivalent.

NOTE:The transmission oil level must be checked with the engine running at its normal operatingtemperature.

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5. Return the shift level to the neutral (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”.

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.

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.

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

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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.

WARNING:

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

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

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Notes

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3.3ServiceandLubricationPoints

Following are the service and lubrication locations for the MA-38

Figure2-3-2:ServiceandLubricationPoints

12

3

613

2

4

1

14 5

15

1110 9

8

7

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Table2-3-2:ServiceandLubricationPoints

3.4Adjustments

3.4.1FanBeltAdjustment

1. Stop the engine and remove the key.

2. Apply moderate thumb pressure to belt between the pulleys.

3. If tension is incorrect, loosen the alternator mounting bolts.

No. Description SpecificationCapacity

(Approximate)

1 Radiator Coolant Delo ELC 50/502.22 US gal

(8.4 L)

2 Engine Oil SAE 10W-302.51 US gal

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

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

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

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

9 Newage Drive Axle SAE 80W-90 2.6 US gal (10 L)

*5 qt. (4.7 L)

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

11 Drive Shaft Joints 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

WARNING:

BE SURE TO STOP THE ENGINE AND REMOVE THE KEY BEFORE CHECK-ING THE BELT TENSION.

BE SURE TO REINSTALL THE DETACHED SAFETY SHIELD AFTER MAIN-TENANCE OR CHECKING.

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4. Then use a lever placed between the alternator and the engine block and pull the alternator outuntil the deflection of the belt falls within acceptable limits.

5. Replace fan belt if it is damaged.

3.4.2ServiceBrakeAdjustment

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.

3.4.3ParkBrakeAdjustments

The park brake lever is connected by mechanical linkage to the parking brake caliper on the transmission output shaft. When the lever is in the “lock” position, the mechanism activates the caliper which squeezes the pads and holds the tractor from moving. Perform the following steps to adjust the park 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” (25.4 mm) from the end of the adjustment range.

4. Loosen the set screw on the brake module housing and thread in the brake module housing untilthe pad assembly contacts the disk completely.

5. Back off the brake module until a flat on the housing lines up with the set screw and tighten the setscrew securely.

6. When necessary, the arm on the park brake caliper can be pulled off the spline and clocked up ordown. Reinstall locknut once arm is at desired angle and torque locknut to 9-12 lb-ft (12.2-14.9Nm).

7. Adjust the parking brake yokes by removing the clevis pins and threading the yokes in or out ofeach other until the brake pads are just about to engage the caliper when the park brake handle isin the released position.

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

9. Engage parking brake and un-chock the wheels.

CAUTION:If belt is loosen or damaged and the fan is damaged, it could result in overheats orinsufficient charging.

NOTE: This length should be 9/10 in (+ 3/50 in) or 2.28 cm (+0.1524cm).

NOTE:Ensure the proximity sensor activates properly. With ignition on, the amber light on the back ofthe sensor should turn on when the park brake is released and turn off when it is applied.Prop

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3.4.4SteeringGearBoxAdjustment

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.

3.4.5Toe-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 m), is required for this adjustment.

3.4.5.1FrontSideofTires

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°).

3.4.5.2RearSideofTires

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

3.4.6CabDoorAdjustment

To adjust a cab door:

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

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

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

2. Hold door in desired position

3. Tighten bolts to secure.

3.4.7VerticalHeadlightAdjustment

1. Loosen the nut on the horizontal bolt.

2. Aim headlight in desired position.

3. Tighten the nut.

3.4.8HorizontalHeadlightAdjustment

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.

3.4.9ShifterAdjustment

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.

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.

5. Clean the area around the oil filter head.

6. Loosen and remove the engine oil drain plug.

7. Allow the oil to drain.

8. Install and tighten the drain plug.

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

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

NOTE: Oil will drain easier when the oil is warm.

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

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

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

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

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

15. Screw in the cartridge by hand.

16. When the gasket contacts the seal surface, tighten the cartridge by hand.

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.

20. After the new cartridge has been replaced, the engine oil level normally decreases a little. Thus,run the engine for a while and check the engine oil level.

21. Add oil if necessary.

22. Check the engine oil filter for leakage.

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

24. Return the unit to service.

3.5.2EngineAirFilterReplacement


2. Apply the park brake.

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

NOTE: If you tighten the cartridge with a wrench, it will be tightened too much.

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 Kubota Manual provided in Chapter 5 for engine 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.

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.

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

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

6. Remove and clean out the dust cup before it becomes half full with dust; usually once a week, orevery day if the working surroundings are dusty.

7. Remove the primary filter.

8. Wipe the inside air cleaner clean with cloth if it is dirty or wet.

9. When dry dust adheres to the filter, blow compressed air from the inside turning the filter. Pressureof compressed air must be under 30 psi (205 kPa).

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

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

12. Install the new primary filter.

13. Install the air cleaner dust cup with "TOP" indicated on the rear of the cup in the up position.

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

15. 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.

CAUTION:

Since the air cleaner employed on this engine is a dry type, never apply oil to it.

Open the evacuator valve once a week under ordinary conditions or daily when used ina dusty place. This will get rid of large particles of dust and dirt.

CAUTION: Avoid touching the primary filter except when cleaning.

NOTE: Maintain reasonable distance between the nozzle and the filter.

NOTE:Replace the primary filter every year or every 6 cleanings. If the primary filter is stained heav-ily, replace it soon. At this time, replace the inner element too.

CAUTION: To protect the engine, do not remove the inner element in servicing the primary filter.

CAUTION:If the dust cup is mounted incorrectly, dust or dirt does not collect in the cup, anddirect attachments of the dust to the element will cause its lifetime to shorten to a greatextent.

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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.

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


WARNING:



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.

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2. Apply the park brake.


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

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

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

7. Protect all bearings from contamination.

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

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

3.5.5BrakeAssembly:WheelCylinderBleed


2. Chock the wheels and apply park brake.

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


5. Disconnect the batter cables of the batteries.

6. Refer to the Newage service manual in Chapter 5 and perform detailed steps as outlined.

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

8. Reconnect the battery cables to the battery.

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.

3.5.6FuelFilterChange


2. Turn off the engine.

3. Apply the parking brake.


5. Close the fuel shutoff valve located on the underside of the fuel tank.

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

7. Loosen p-clamp and hose clamps on the fuel Filter.

8. Replace filter.

9. Secure p-clamps and hoses on the filter.

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.

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

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

11. Flush the Tank.

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

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Tow Tractor Model MA-38 Maintenance Manual

Chapter 2Section 3

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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

WARNING:



Problem Cause Correction

1 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.

2White exhaust gas

is observed

Excessive engine oil. Reduce to specified level.

Piston ring and liner worn or stuck.

Replace.

Defective valve stem seal. Replace.

3Excessive black exhaust gas is

observed

Fuel system is bad. Check the fuel system.

Fuel is extremely poor quality. Replace fuel.

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4Difficult to Start

Engine

Fuel doesn't flow.

Check the fuel tank, fuel filter, fuel hoses and fuel pump.

As fuel will be filtered by the filter, if there should be water or other for-eign matters on the filter, clean the filter.

Valve clearance is not as speci-fied.

Adjust valve clearance when the engine is cold.

Engine oil becomes thick in cold weather and engine cranks slow.

Change grade of oil according to the weather (temperature).

Low compression

Bad valve or excessive wear of rings, pistons and liners cause insuf-ficient compression. Replace with new parts.

Battery is discharged and the engine will not crank.

Charge battery.

In winter, always remove battery from machine, charge fully and keep indoors. Install in machine at time of use.

Clogged air cleaner Clean or replace.

Spark plug electrodes are wet with gasoline.

Dry electrode and restart.

Defective starter. Repair or replace.

Defective main switch. Repair or replace.

Vapor LockCheck fuel hose plumbing is correct and fuel hoses are not routed next to hot components.

Disconnection Check the wire harness.


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5When output is

insufficient

Compression is insufficient.

Bad valve or excessive wear of rings, pistons and liners cause insuf-ficient compression. Replace with new parts.

Fuel is insufficient. Check fuel system.

Overheating of moving parts.

Check lubricating oil system.

Check to see if lubricating oil filter is working properly.

Filter element deposited with impuri-ties would cause poor lubrication. Change element.

Check to see if the clearance of bearing is within factory specs.

Valve clearance is not as speci-fied.

Adjust valve clearance when the engine is cold.

Air cleaner is dirty. Clean or replace.

Defective spark plug. Clean or replace.

Defective ignition coil. Replace.


6Engine suddenly

stops

Lack of fuel.

Check the fuel tank and refill the fuel, if necessary.

Also check the fuel system for air or leaks.

Moving parts are overheated due to shortage of lubrication oil or improper lubrication.

Check amount of engine oil with oil level gauge.

Check lubricating oil system.

Replace oil filter cartridge.

Vapor LockCheck fuel hose plumbing is correct and fuel hoses are not routed next to hot components.

Clogged air cleaner Clean or replace.


7Lubricant oil con-

sumption is exces-sive.

Oil leaking from oil seal, gasket, etc.

Replace.

Defective valve stem seal. Replace.

Piston ring and liner worn or stuck.

Replace.


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2 - 4 - 4 CD444-38MJuly 2019 (Rev A)


4

4.2AlternatorTable2-4-2:AlternatorTroubleshooting

8 Engine overheats

Engine oil insufficient.Check oil level. Replenish oil as required.

Fan belt broken or elongated. Change belt or adjust belt tension.

Coolant insufficient. Replenish coolant.

Excessive concentration of anti-freeze.

Use only specified pre-mixed cool-ant.

Radiator net or radiator fin clogged with dust.

Clean net or fin carefully.

Inside of radiator or coolant flow route corroded.

Clean or replace radiator and parts.

Defective fan or radiator or radia-tor cap.

Replace defective parts.

Defective thermostat.Check thermostat and replace if necessary.

Defective temperature sensor.Check temperature with thermome-ter and replace if necessary.

Overload running. Reduce load.

Head gasket defective or water leakage.

Replace parts.

No. Problem Cause Correction

1 Noisy alternator

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

Alternator bearings worn or dam-aged.

Replace alternator.

2Alternator output consistently high

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

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


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nes

CD444-38M 2 - 4 - 5July 2019 (Rev A)


4.3RearAxleTable2-4-3:DriveAxleTroubleshooting

4.4SteeringTable2-4-4:SteeringTroubleshooting


Rear axle noise

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

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

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

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

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


1Manual steering

difficult

Steering gearbox not lubricated. Check lubrication.

Drag link joints not greased. Add grease to joints.

King pins not greased. Add grease to kin pin.

2Power steering

difficult

King pins not greased. Add grease to kin pin.

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

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

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

3Front wheel

appears to wobble

Lug nuts loose. Torque lugs to proper value.

King pin worn. Check studs and king pins.

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

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nes

2 - 4 - 6 CD444-38MJuly 2019 (Rev A)


4

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

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n Airli

nes

CD444-38M 2 - 4 - 7July 2019 (Rev A)


4.6ElectricalSystem4.6.1Battery

Table2-4-6:BatteryTroubleshooting

4.6.2Lights(12VoltSystem)

Table2-4-7:LightsTroubleshooting


Battery will not stay charged

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

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

Wire is broken. Check for breaks in wiring.

Component is draining battery with ignition off.

Check for large current draw with vehi-cle off.


1Poor, intermittent, or

no headlight

Blown fuse or tripped circuit breaker.

Check fuse or circuit breaker.

Headlight burned out. Replace LED Bulb.

Switch damaged.

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

Wired incorrectly.Check wiring & ground connec-tions.


no stop lights



Taillight burned out. Check bulbs or lamps.

Brake pressure switch damaged. Check brake light switch.

Wired incorrectly.Check wiring and ground connec-tions.

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nes

2 - 4 - 8 CD444-38MJuly 2019 (Rev A)


4

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

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nes

CD444-38M 2 - 4 - 9July 2019 (Rev A)


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.

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2- 4 - 10 CD444-38MJuly 2019 (Rev A)


Chapter 2Section 4

Propert

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CD444-38M 2 - 5 - 1July 2019 (Rev A)


Section5:SystemSchematics

This section provides electrical and hydraulic information for diagnosing and correcting problems with theMA-38 Tow Tractor.The following pages display schematics to assist in the location of electrical wiringand hydraulic routing.

Propert

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2- 5 - 2 CD444-38MJuly 2019 (Rev A)


Chapter 2Section 5

Propert

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CD444-38M 2 - 5 -3July 2019 (Rev A)

5.1ElectricalSchematics

Figure2-5-1:MA-38StandardElectricalSchematic7188829_RevB(Page1of6)

118

80

12 VOLTBATTERY

93

G7

HORN

SWITCHHORN

NEUTRALRELAY

85

86

104

87

3090

SWITCHIGNITION

6

2

1

5

3 4

P19

(D27)

MASTERRELAY

87

30

86

85

(D10)

(D25)

80 REVERSERELAY

85

86

87

30

HORNRELAY

85

86

87

30

F6 15 AMP

F5 10 AMP

F3 15 AMP

F8 CIRCUIT BREAKER 15 AMP

F9 15 AMP

F7 15 AMP

F2 15 AMP

F1 CIRCUIT BREAKER 15 AMP

FUSE BOX

GROUND BUSBAR (D23)

12

11

10

98

7654321

-

117

93

N

93

IGN2

12

IGN

2

R

IGN15

117

HORN PWR

HORN PWR

HO

RN P

WR

HO

RN P

WR

HO

RN P

WR

HORN PWR

104

IGN3

103

IGN8

IGN8

103

13 SHEET 2

SHEET 6IGN1

114P SHEET 2

IGN4

IGN

7

112 SHEET 2IGN4

IGN11

IGN7 IGN7

IGN11 66 SHEET 4

115 115 SHEET 3

IGN10 IGN10

TCU BAT SHEET 3BA

T1

BAT1

BAT1

TCU IGN SHEET 3

IGN5

F4 15 AMP

113 113

IGN6

63

IGN9

P2

IGN

1

IGN2

SHEET 2

SP1114

P2

SP36

SHEET 5

MVP1

ECM

P266

114

P2

P2

P263

IGN1

IGN3

D27

P2

103

P2

IGN

15

G1 SHEET 3G2 SHEET 3G3 SHEET 2G4 SHEET 2G5 SHEET 3

G6 SHEET 4

G7

G7

G7

G7

G8 SHEET 4

G9 SHEET 3

P212

SHEET 213

(OPTION)

P2112

P2

NP2

P2

TCM BATP2

TCM IGNP2

POWERSTUD

ENGINESHEET 6

SHEET 6

R

G10 SHEET 2

ALL

IGN

WIR

ES

ALL IGN WIRES

SPL

SPL

HBAT

(HALL SYSTEM)SHEET 2

(BOTTOMOF STARTER)

NOT USED

NOT USED

ORHALL SYSTEM

(OPTION)

1, 2, 4, 5, AND 6ARE CONNECTED

DURING START

1, 3, 4, 5, AND 6ARE CONNECTEDDURING IGNITION

SHEET 6

SHEET 6

GROUNDSTUD

ENGINETO

1

11

14

13

10

12

6

7

5

8

32

4

15

9

SHT 3

SHT 3

SHEET 5

SHEET 5

SHT 6

TO STARTER

12

7

4

9

5 21

6

1122

20

14

28

26

30

16

18

24

8

3

10

12

19

13

27

25

29

15

17

23

CB

CB

CB

CB

CB

CB

CB

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2 - 5 -4 CD444-38MJuly 2019 (Rev A)

Tow Tractor Model MA-38 Chapter 2Maintenance Manual Section 5


RIGHT FRONTHEAD LIGHT

LEFT FRONTHEAD LIGHT

PSWITCH

BRAKE LIGHTPRESSURE

BRAKE/TAIL LIGHTRIGHT REAR

BRAKE/TAIL LIGHTLEFT REAR

54

53

106

107

- +

SHIFTERBACK LIGHT

83

D5

D3

D5

D3

D8

D8

D7

D7

(D1)

-+

BRAKE WARNING PRESSURE SWITCH

10

BRAKE WARNING LIGHT

BRKWRN

BRKWRN

P

1

2

110

FUELSENDER

PRESSURE

P

SWITCHPRESSURE

TRANSMISSIONNO

(N.O.)

P25

1 2 3 4 5 6 1 2 3 4 5 6

P24

MVP1

MVP

1

CAN

H+

SHEET 3

CAN

L-

SHEET 3

G4

P88

FOOT

5+VD

C

5+VD

C1

5+VDC2

5+VD

C2

APS

2

APS2

APS

2

APS2

111

111

APS

1 SI

G

GN

D

GND

SP30

APS

1 G

ND

APS2 GND

APS

2 G

ND

84

114SHEET 1

SP2

RIGHTREV LIGHT

SP5LEFT

REV LIGHT

12

SHEET 1

OR(OPTION)

(OPTION)

(D11)

D7

D7

REVERSEALARM

D28

SP8

SP37

95

7189

84

101

83A

D7

HEADLIGHT SWITCH OPTIONS(D20)

THROTTLE

78

77

D7

G3

MVP DISPLAY

SP4

D7

D7

(SHEET 4)

(SHEET 4)

G6

G6

12

83D8

(TURN SIGNAL OPTION SHEET 4)

1

2

APS1

G6

95 G6

STD

(OPTION)

95

WIRED TO IGN)(HEADLIGHTSNO SWITCH

(OPTION)

BOTTOM OF PAGESEE OPTIONS

(D20)

(OPTION)

CN12A CN12B

NC

NC NC

(LOCATION: DASH)

G6

SHEET 4G6

G6 SHEET 4

G6 SHEET 4

12

12

120 OHMS

D

E

F

B

A

C

13

OR

95

WIRED TO IGN)(HEADLIGHTSNO SWITCH

(OPTION)

AND

89

101

71 89

101

71 89

101

71

+

-

BATT

ERY

STA

RT

IGN

/ACC

HALL 12V CONTROLLER

4-PIN TWIST LOCK CONNECTOR

GREEN ILLUMINATED PUSH BUTTON IGNITION

G10

OUT OF FUEL SIGNAL

2

3

1

4

5

6

GRA

Y

RED

BLU

E

GLOW PLUG SIGNAL

ORANGE

BLACK

PURPLE

SHEET 1

NOT USED NOT USED

CONNECT TO P19

(OPTION)

P31P5

P31P5

NORMAL OPERATION:LOW FUEL(240 OHMS)-HIGH FUEL(33 OHMS)APS1 MIN(0.9V)-MAX(3.6V)APS2 MIN(0.5V)-MAX(1.7V)

1

1

2

2

4

5

9

9

2

1

12

74

3

6

1

2

SHT 1

SHT 4

SHT 1

SHT 1

SHT 1

SHT 4

SP31

SP28

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CD444-38M 2 - 5 -5July 2019 (Rev A)


1

18 A

WG

YEL

+12

V

3

20 A

WG

BLK

GN

D

4 8 2

GRY

/ORN

SIG

NA

L BE

LT U

P SE

NSO

R

7

7

BRN

/BLK

SIG

NA

L

29

5

8

S5

123 4

18 A

WG

YEL

+12

V

20 A

WG

BLK

GN

D

20 A

WG

BLK

GN

D

S6

GRY

/YEL

SIG

NA

L

20 A

WG

BLK

GN

D

PC5ATH

MHTH

WH

T/RE

D C

AN

1 H

TWISTEDPAIR

18 AWG BLK GROUND

6

18 A

WG

YEL

+12

V

TCU

TWISTEDPAIR

TWISTEDPAIR

TWISTEDPAIR

WH

T/BL

K CA

N1-

LTWISTED

PAIRTWISTED

PAIR

WHT/BLK CAN1-L

WHT/RED CAN1 H

18 AWG YEL +12V

4L70E 2010 SPECIAL TRANSMISSION (INCHING) TCU MODULE 2800

C6 PC5A

C5C61C8 2 3 4 5 6 7 8

YEL/

RED

AN

A IN

2

YEL/

LT.G

RN A

NA

IN 3

YEL/

LT.B

LU A

NA

IN 4

YEL/

WH

T A

NA

IN 5

VIO

/WH

Y PW

M 5

VIO

/ORN

PW

M 6

PNK/

WH

T D

IG O

UT

5

PNK/

ORN

DIG

OU

T 6

1C7 2 3 4 5 6 7 8

46 47 48 49 51 52 55 56 10 30 31 32 33 34 35 36

GRY

/PN

K D

IG IN

8

BRN

/RED

DIG

IN 1

0

BRN

/LT.

BRN

DIG

IN 1

1

BRN

/LT.

BLU

DIG

IN 1

2

BRN

/WH

T D

IG IN

13

BRN

/ORG

DIG

IN 1

4

BRN

/YEL

DIG

IN 1

5

BRN

/PN

K D

IG IN

16

92

17 G2

V-

V+

SIG

PX

1 2 34

NO

T U

SED

P30

90

PX

PARK BRAKEPROXIMITY SENSOR

(PNP)+12V W/ BRAKEDISENGAGED

G2

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

SWITCH

SHIFT

PRESSUREP

G5

INHIBIT

(D2)

BRAKE

NO

TU

SED

ENABLESHIFT

LIGHT

18

SPL 34

(INDICATES SHIFTING ABILITY)

(SEL)

1

2

17

17115SHEET 1

NSHEET 1

RSHEET 1

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

BAC5

CAN INTERFACE DIAGNOSTIC PLUG

CA

N H

I +

CAN

LO

W -

SHIE

LD G

ND

G9

C

SP 22

SP 23

CANL-

CAN

H+

CANL-

CAN

L-

(LOCATION: LH RAIL FRAME)

SHEET 4

SHEET 4CANH+ CANH+SHEET 2

SHEET 2

CAN

H+

CAN

L-

SHEET 4

SHEET 4

SHEET 4

SHEET 4

MAIN HRN

SHT 1

SHT 1

SHT 1

SHT 5 SHT 5

Propert

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2 - 5 -6 CD444-38MJuly 2019 (Rev A)



8

WH

T/RE

D C

AN

1 H

S3

15

12

42

S2

18 A

WG

BLK

GRO

UN

D

GRY

/WH

T D

I-5

PNK/

LT G

RN C

K TR

AN

S LT

40

5

1P3

11

TCU

IGN

TCU

IGN

YEL

12VO

LTS

IGN

10

20

RED

+12

V BA

TTTC

U B

AT

2 3

ORG

/BLK

TACH

IN

G1

1

WH

T/BL

K CA

N1-

L

16

S4

7

6

MAIN HRN

TRANS

24

TCU BAT

TCU IGN

C4

ORG

+5V

SEN

S

21 45

WH

T TP

S SI

G

BLK

SIG

GN

D

9 46

DHMH

C4A

OUTPUTSHAFTSPEED

SENSOR

B

ORG

/RED

TO

SS +

BLK/

WH

T SE

NSO

R G

ND

2523

AC3

OPTIONALCOM

NOT REQUIREDFOR USE

B

RED

SER

IAL

RX

WH

T RS

232

GN

D

2728

C

BLK

SERI

AL

TX

26

C2

53

A

4L70E TRANSMISSION (INCHING)

B

PWM

8-PN

K/RE

D-S

HIF

T SO

L B

PWM

7-PN

K/BL

K-SH

IFT

SOL

A

C

18 A

WG

-YEL

-LIIN

E PR

ESS

+

PWM

1-VI

O/B

LK-L

INE

PRES

S -

E

18 A

WG

-YEL

-PO

WER

F

DN

1-G

RY/B

LK-IM

S A

G

DN

2-G

RY/R

ED-IM

S C

H

DN

3-G

RY/L

T G

RN-IM

S B

JK L

DN

4-G

RY/L

T BL

U-IM

S P

ORN

/LT

GRN

-TU

RB S

PEED

+

AD

6-YE

L/O

RN-T

FT

M R S T

BLK/

WH

T-SE

NSO

R G

ND

VIO

/LT

GRN

-FW

D-C

L

VIO

/BLU

-REV

-CL

VIO

/WH

T-TC

C O

N/O

FF

VIO

/RED

-TCC

PW

M P

RESS

U

1119 2 3 4 538 50 9 13 14 41 12BL

K/W

HT-

IMS

GN

D

BLK/

WH

T TU

RBO

SPE

ED -

37

NV

S7

S1

54 18

DP W

4L70E TRANSMISSION (INCHING) TCU MODULE 2800

TWISTEDPAIR

TWISTEDPAIR

C1

YEL 12VOLTS IGN

18 AWG YEL +12V

BLK SIG GND

CANL-

CANH+

18 AWG YEL +12V

BLK SIG GND

CAN1-H

CAN1-L

GND

+12V

NO

TU

SED N

OT

USE

D

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

NO

TU

SED

SHEET 1

SHEET 1

SHEET 1

APS

1 SI

G

APS1 SIGSHEET 2

SHEET 3

SHEET 3

SHEET 3

SHEET 3

SHEET 3

SHEET 3

NO

TU

SED

Propert

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CD444-38M 2 - 5 -7July 2019 (Rev A)


FRONTWIPERMOTOR

FRONTWIPER

SWITCH

66W

HT

BLK

62 G8

CABHEATERMOTOR

M

M

6365

HEATERSWITCH

SWITCH

DOMELIGHT

DOMELIGHT

D7

(D17)

113SHEET 1

LED LIGHTBEACON

FLASHING/

LT20

FLASHUNIT

YEL

BEACONPROGRAMING

WIRE

+

-

ROTATING

63SHEET 1

HL

M FANVENTILATION

(OPTION)

CAB

M4

G8

68

C

WORKLIGHTSWITCH(D29)

116

OPTION

+

-WORKLIGHT

8383

54

56

53

5451

+

PILOT LT

CONTROL SWITCHTURN SIGNAL

83

58

-52

51

53

LEFT FRONTTURN LT

RIGHT FRONTTURN LT

5556

LED TURN

FLASHERSIGNAL

XL

1N5406DIODE

1N5406DIODE

SHEET 2

SHEET 2

SP6

(D8)

OPTIONAL LED TURN SIGNAL CONTROLLER WIRING

(D6)

RIGHT REARTURN LT

(D7)

55A

SP 7

55

(D4)

10

LEFT REARTURN LT

(D7)

56A11

83SHEET 2

D7

D7

G6

SHEET 2

SHEET 2

SP3

G6

SHEET 1 G6

SHEET 2

G6

G6

G6

G6

G6

G6

G6

G6

(D9)

1

7

5

4

3

1

2

12

2

58

58

58

(D26)

(D21)

6

8 G6

CAB HRN

MAIN HRN

(OPTION)

(OPTION)

+

-

MAIN HRN

CAB HRN

G6

G6

63

113

G6

68

5

9

9

9

SHT 1SHT 1SP35

Propert

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2 - 5 -8 CD444-38MJuly 2019 (Rev A)



ENGINE VIC1

(RED) 109

PUMPFUEL

M (WHT) 108

(P1)

117SHEET 1

ECMSHEET 1

ALL SWITCHES, RELAYS SHOWN IN DE-ENERGIZED POSITIONSALL SWITCHES, RELAYS SHOWN IN DE-ENERGIZED POSITIONS

C

D

F

A

P

N

(D30)

SHEET 3

SHEET 3

CANL-

CANH+

MANIFOLD

FUELPRESSURE

(TO ENGINE POWER STUD)

(TO ENGINE POWER STUD)

+ -

TWISTED PAIR

R

E

G

H

B

L

J

S

M

K

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USEDNOT USEDNOT USED

NOT USEDNOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USEDNOT USEDNOT USED

NOT USED

ENGINE HARNESS

NOT USED

ALL FUSES AND RELAYS LOCATED IN ENGINE FUSEBOX ON SHEET 1

1 2

2 1

SHEET 1

GROUNDSTUD

ENGINE

SHEET 1(TO BATTERY GROUND)

(TO BATTERY GROUND)

SHT 1

SHT 1

SPK_COIL1A

SPK_COIL2B

SPK_COIL2A

SPK_COIL1B

INJ1_LS

INJ4_LS

INJ2_LS

INJ3_LS

KNK1-

KNK1+

CAM-

CAM+

CRANK+

MAP

STARTER

AUX_PWM5 REC

DBW-

TPS1

AUX_ANA_PU3

DBW+

GOV1

EGOH_1

EGO2

EGOH_2

CAN1-

5V_EXT1

GND

ECT

OIL PRESS

AUX_ANA_PD2

AUX_PWM2

GND

5VRTN1

SPK_GND

AUX_ANA_PD1

CAN1+

SPEED+

AUX_DIG3

AUX_DIG2

TPS2

AUX_PWM5

SPEED-

EGO1

AUX_DIG4

AUX_ANA_PU2

IAT

AUX_PWM6

VSW

AUX_PWM3

RELAY

MIL

5V_RTN2

5V_EXT2

FPP1

AUX_ANA_PU1

AUX PWM3_REC

TACH

1 2

1 2

1 2

1 2

21

21

21

1 2

1 2

1 2

21

CRANK-

ABCD

1 2 3

4 5 6

A C

B D

B D

A C

1

1

Joint A

FPP2_IVS

VBAT

AUX PWM1

A

B

C

D

5A FUSE

30A FUSE

15A FUSE

15A FUSE

1

5

3

2

64

67

65

66

52

5126

25

27

28

23

36

82

80

48

47

21

62

22

61

14

15

19

20

35

37

38

13

53

31

54

32

87

74

79

73

90

44

78

89

72

83

84

43

85

39

40

42

34

50

41

29

30

12

469

81

ECM(2/2)

COIL_CYL_#1

COIL_CYL_#2

COIL_CYL_#3

COIL_CYL_#4

INJ_CYL_#1

INJ_CYL_#2

INJ_CYL_#3

INJ_CYL_#4

Joint A

Knock sensor

Crank sensor

Cam sensor

Joint CJoint D

TMAP(BOOST)

Joint CJoint D

Joint A

Joint DJoint A

Joint D

Throttle actuator

O2 sensorPost Catalyst

O2 sensorPre Catalyst

DIAG_TOOL Connector

CAN Tool

Coolant Temperature Sensor

Oil Switch

Joint C

Joint D

Joint A

Alternator

Starter

STARTER

Starter Relay

VSW

Fuel Pump Relay

FUEL PUMP

Power Relay

ECM

ECM(1/2)

Joint D

Joint C

2

Joint D

10A FUSE

Joint A

IGNITION

A

B

C

D

60A FUSE

Joint C

Joint D

50A FUSE

POWR_FMOLEX 19432-0013

POWR_MMOLEX 19433-0013

EFFECTIVE ON SERIALNUMBER 2023056

Propert

y of A

merica

n Airli

nes


CD444-38M 2 - 5 -9July 2019 (Rev A)

5.2HydraulicSchematics

Figure2-5-7:MA-38HydraulicSchematicHYD-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 -10 CD444-38M July 2019 (Rev A)

Propert

y of A

merica

n Airli

nes

Documents

Property of American€¦ · Chapter 2 Tow Tractor Model MA-38 Section 1 Maintenance Manual Chapter 2: Preventive Maintenance Section 1: Introduction - - - - ... 2.1.6 Six (6) Months