TUG GT-50DZ User manual

Operation, Maintenance, and Parts Manual
MODEL
GT-50DZ
"TOW TRACTOR
WITH DEUTZENGINE
Aircraft Ground Support Equipment CD274
produced by
m_lIKETIIll _EIVlCE$
Ti_TALm Jlrum_wi

STEWART &STEVENSON SERVICES, INC. FRONT MATI'ER
AIRCRAFTGROUND SUPPORT EQUIPMENT
RECORD OFREVISIONS
PROPERTY OF:
COMPANY:
ADDRESS:
CITY STATEZIPCODE
REVISION DATA
CHECK EACHREVISION RECEIVED, AND INSERT THEREVISED AND SUPPLEMENTARY
PAGESIN YOUR. MANUAL.
DATE OF ORIGINAL PUBLICATION: AUGUST 1994
REVISION DATE
1 October ]994
2November 1994
3 December 1994
4March1995
5 March1997
6
7
CD274 i
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STEWART & STEVENSON SERVICES, INC. FRONT MAI-I.Va¢.
AIRCRAFTGROUND SUPPORT EQUIPMENT
LIST OF EFFECTIVE PAGES
Title Page Orig MI02007-1 and MI02007-2 Orig
Record of Revisions-i Rev 5 MI02008-1 and MI02008-2 Orig
Listof EffectivePages-iiand iii Rev5 MI02008-3 RevI
Manual Table of Contents-ivthin x Rev 3 MI02008-4 Orig
List of Figures-xi thin xiii Rev 3 MI02009-1 and MI02009-2 Orig
List of Tables-xiv Rev 3 MI02009-3 Rev 1
Introductlon-xv Rev 3 MI02009-4 Ofig
Unit Idenfification-xv Rev 3 MI02010-1 and MI02010-2 Orig
Technical Assistance-xvi Rev 3 MI02010-3 Rev 1
Safety Precautions-xvii Rev5 MI02010-4 Orig
How To Use This Manual-xviii Rev 3 MI02011-1 and MI0201I-2 Orig
MI02011-3 Rev1
CHAPTER 1 MI02011-4Orig
I-TOC-ithra 1-TOC-iv (3rig MI03006-1 thru MI03006-4 Orig
1-1-1 thin I-1-4 Rev 1 MI03007-I and MI03007-2 Rev 1
1-1-5 thin 1-1-12 Orig MI03008-1 thru MI03008-6 Orig
l-2-1 and 1-2-2 Orig MI03009-1 and MI03009-2 Orig
1-2-3 and 1-2-4 Rev 1 MI04007-1 Orig
1-2-5 Orig MI04007-2 Rev2
1-2-6 Rev I MI04009-1 and MI04009-2 Rev 2
1-2-7 Rev3 MI04010-1 and MI04010-2 Orig
1-2-8 Rev 1 MI06003-1 Rev 3
1-2-9 Rev 3 MI06003-2 thin MI06003-4 Orig
1-2-10 Rev 1 MI08004-1 Orig
1-2-11 Rev 3 MI08004-2 Rev 1
1-2-12 Rev 1 MI08005-1 Orig
I-2-13 Rev 3 MI08005-2 Rev 1
I-2-14 RevI MI09012-1thraMI09012-4 Orig
1-3-1 and 1-3-2 Rev 3 MII2001-1 Rev 1
1-3-3 Rev 2 MI12001-2 Orig
1-3-3 Rev 2 M/99003-1 and MI99003-2 Orig
1-3-4 Orig MI99003-3 Rev4
1-3-5Rev I MI99003-4 Orig
1-3-6 thin 1-3-9 Rev 3 M199003-5 Rev 4
1-3-10 Rev1 MI99003-6 Rev1
1-4-1 thra 1-4-4 Ofhg MI99004-1 thru MI99004-4 Rev 4
1-5-1 0fig
I-5-2 Rev I CHAPTER 3
1-5-3thru1-5-6 Orig 3-TOC-iand3-TOC-ii Orig
3-1-1 Rev1
CHAPTER 2 3-1-2 Orig
2-TOC-i and 2-TOC-ii Orig 3-2-1 Rev 4
2-1-1 Rev 5 3-2-2 thra 3-2-8 Orig
2-1-2 thin 2-1-4 0fig
2-2-1 and 2-2-2 Ofig CHAPTER 4
2-2-3 and2-2-4 Rev 44-TOC-i Orig
2-2-5 and 2-2-6 Orig 4-TOC-ii Rev 1
2-2-7 Rev 5 4--1-1 thin 4-1-4 Drig
2-2-8 thin 2-2-10 Orig 4-2-1 Rev 4
2-3-I thru 2-3-4 Orig 4-2-2 Orig
4-3-1 and 4-3-2 Orig
MI01004-1 Orig 4-3-3 thru 4-3-10 Rev 3
MI01004-2 Rev 1 4-3-11 Rev 2
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STEWART & STEVENSON SERVICES, INC. FRONT MArIER
AIRCRAFT GROUND SUPPORT EQUIPMENT
LIST OF EFFECTIVE PAGES
4-3-12 Rev3 CHAPTER5
4-3-13thra4-3-15 Rev2 5-TOC-i Rev4
4-3-16 Rev3 5-TOC-ii Orig
4-3-17thru4-3-22 Rev2
4-3-23 Rev3 CHAFIER6
4-3-24 Rev2 6-TOC-i Orig
44 1thin443 Orig 6-TOC-ii Rev2
444 Rev4
4 g 5 and 4-4-6 Rev 3 OPTION 1
4_7 Orig 6-1-1 Rev4
4 4 8thin 4-4-10 Rev 3 6-1-2 Orig
4-4-11 thin 4-4-20 Orig 6-1-3 thru 6-1-9 Rev 4
4-4-21 Rev3 6-1-10 Orig
4-4-22 Rev4
4-4-23 Rev3 OPTION2
4-4-24 Rex"4 6-2-1 Orig
4 4 25 Rev 3 6-2-2 Rev4
4 4 26 thru 4-4-39 Orig 6-2-3 and 6-2-4 Orig
4-4-40thru 4-4-40B Rev 4
4-4-41 Orig INDEX-1 thin INDEX-4 Orig
4_442and44 43 Rev3
4-4-44thru4-4-47 Orig
44 48 and 4449 Rev3
4-4-50 thru4-4-59 Orig
4.4 60thru4-4-63 Rev3
4-4-64 Rev 2
d4.65 Rev3
4-4-66 thru 4-4-69 Orig
44 70and4 471 Rev3
4472 Orig
4, el73 Rev 3
4"!.74 thru 4-4-80 Orig
4-4-81 Rev 3
4-4-82 Orig
4-4-83 Rev 3
"!.4 84 Rev 4
4-4-85 thru 4-4-94Deleted
12941092 (4sheets) Rev A
4-4-95 thru 4-4-98Orig
4-4-99thru4 4 102 Rev1
44103 Rev2
4-4-104 thru 4-!.107 RevI
4-4-108 Rev4
12941675(2 sheets) RevA
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STEWART & STEVENSON SERVICES,INC. FRONT MAJtbR
AIRCRAFT GROUND SUPPORT EQUIPMENT
MANUAL TABLE OF CONTENTS
DESCRIPTIONCHAPTER/SECTION/PAGE
Record of Revisions Front Matter/i
L'rst of Effective Pages FrontMatter/ii
Manual Table of Contents Front Matter/'lii
List of Ftgures Front Matterflx
Listof Tables Front Matter/xii
Imroduction FrontMatter/xiii
Unit Identification FrontMatter/xiii
Technical Assistance Front Matter/xiv
Safety Precautions Front M_nar/xv
How to Use This Manual Front M_ner/xvi
CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS
SECTION 1 GENERAL DESCRIPTION ..................................... I-1-1
1.1INTRODUL-i_ON ............................................. 1-1-1
1.2 UNIT DESCRIPTION .......................................... 1-t-I
1.3 ENGINE ................................................... 1-1-3
1.4TRANSMISSION ............................................. 1-1-3
1.5 DRIVE LINE ASSEMBLY...................................... 1-1-3
1.6 FUEL SYSTEM .............................................. 1-1-3
1.7 AIRINTAKESYSTEM ........................................ 1-1-4
1.8 EXHAUST SYSTEM .......................................... 1-1-4
1.9 LUBRICATION SYSTEM ....................................... 1-1-4
1.10 COOLING SYSTEM .......................................... 1-1-4
1.11 STEERING SYSTEM .......................................... 1-1-4
1.12 BRAKE SYSTEM ............................................ 1-1-6
1.12.5Parking Brake ............................................... 1-1-9
1.13 LIFTCAB (OPTIONAL) ....................................... 1-1-9
1.14 _.IF_-t RICAL SYSTEM. ....................................... 1-1-9
1.14.2 Engine Starting and Battery Charging Circuits ........................ 1-1-10
1.14.3 Brake Booster Motor Circuit. ................................... 1-1-I0
1.14.4 Engine RunRelay Circuit. ..................................... 1-1-10
1.14.5 HornCircu'rt................................................ 1-1-10
1.14.6 EnginelnsmmaentCircuit. ..................................... 1-1-10
1.14.7 Light Circuit. .............................................. 1-1-10
1.14.8 WarningLight Circuit. ........................................ 1-1-11
1.14.9 Auxiliary Light Circuit. ....................................... I-1-11
1.14.11Engine Coolant Heater (Optional) ................................. 1-1-12
1.14.12 Engine Fuel]Water Separatorand Fuel Heater(Optional) ................. 1-1-12
1.14.13 Cab Circuits (Optional) ........................................ 1-1-12
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AIRCRAFr GROUND SUPPORTEQUIPMENT
MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTION CHAPTER/SECTION/PAGE
SECIION 2OPERATION ............................................... 1-2-1
2.1 PRE-OPERATIONAL CHECKS .................................. 1-2-1
2.2 OPERATING PROCEDURES .................................... 1-2-3
2.3 SHUTDOWN PROCEDURE ...... .,.............................. 1-2-4
2.4 CONTROLS AND INDICATORS ................................. 1-2-7
SECTION 3 SPECIFICATIONS .......................................... 1-3-1
3.1 INTRODUCI'ION ............................................ 1-3-1
3.2 SPECIFICATION TABLES ..................................... 1-3-1
3.3 POINTS OF SERVICE, SPECIFICATION, AND CAPAISITL_S............ 1-3-4
SECTION 4 SHIPPING ................................................. 1-4-1
4.1 INTRODUCTION............................................. 1-4-1
4.2 TUzDOWN POINTS .......................................... 1-4-1
4.3 LII'TING ................................................... 1-4-1
4.4 PREPARING ENGINE ......................................... 1-4-1
4.5 PREPARING UNIT ........................................... 1-4-2
4.5.1 Batteries................................................... 1-4-2
4.5.2 Windshields(Cab Option Only)................................... 1-4-2
4.5.3 Control Panel (Without Cab Option Only) ............................ 1-4-2
4.5.4 WarningBeacons............................................. 1-4-2
4.6 MARKING ................................................. 1-4-2
4.7 RECEIVING EQUIPMENT ...................................... 1-4-2
4.7.1 Inventory................................................... 1--4-2
4.7.2 _on .................................................. 1-4-2
4.7.3 Notification................................................. 1-4-2
4.8 PREPARING UNIT FOR SERVICE ................................ 1-4-2
4.8.1 Windshields(Cab Option Only)................................... 1-4-2
4.8.2 Warningbeacon(s)............................................ 1-4-2
4.8.3 Air Cleaner................................................. 1-4-3
4.8.4 Batteries................................................... 1--4-3
4.8.5 Engine..................................................... 1-4-3
4.8.6 ControlPanel (Without Cab OptionOnly)............................ 1-4-3
4.8.7 Markings................................................... 1-4-3
SEuIION 5 STORAGE ................................................. 1-5-1
5.1 SHORT-TERM STORAGE ...................................... 1-5-1
5.1.1 Engine..................................................... 1-5-1
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AIRCRAFTGROUND SI.YPPORT EQUIPMENT
MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTION CHAPTER/SECTION/PAGE
5.1.2 Transmission ................................................ 1-5-1
5.1.3 Drive Axles ................................................. 1-5-1
5.1.4Tires ...................................................... I-5-1
5.1.5 Batteries ................................................... 1-5-1
5.2 RETURN TRACTOR TO OPERATION Al--tv_,RSHORT-TERM STORAGE... 1-5-1
5.2.1 Tires...................................................... 1-5-1
5.2.2 Batteries ................................................... 1-5-2
5.2.3 Engine..................................................... 1-5-2
5.2.4 Transmission ................................................ 1-5-2
5.3 LONG-TERM STORAGE ....................................... 1-5-2
5.3.1 Engine..................................................... 1-5-2
5.3.2 Batteries ................................................... 1-5-4
5.3.3 Driveaxles................................................. 1-5-4
5.3.4 Transmission................................................ 1-5-4
5.3.5 Tires...................................................... 1-5-4
5.3.6 Windows (Cab Option Only) ..................................... 1-5-4
5.4 RETURN TRACTOR TO OPERATION A.t--t__&LONG-TERM STORAGE .... 1-5-4
5.4.1 Tires...................................................... 1-5-4
5.4.2 W'mdows(CabOptionOnly)..................................... 1-5-5
5.4.3 Batteries .................................................... 1-5-5
5.4.4 Engine..................................................... 1-5-5
5.4.5 Transmission................................................ 1-5-5
5.4.6 Driveaxles................................................. 1-5-5
CHAPTER 2 MAINTENANCE
SECTION 1 PREVENTIVE MAINTENANCE SCHEDULE ........................ 2-1-1
1.1 /NTRODUcq iON ............................................ 2-1-1
1.2 HOW TO USE THE PREVEN'HVE MAINTENANCE SCHEDULE ........ 2-1-1
SECTION 2 TROUBLESHOOTING ........................................ 2-2-1
2.1 INTRODU Ci'J.ON ............................................ 2-2-1
2.2 HOW TO USE THE TROUBLESHOOTING TABLES ................... 2-2-1
2.3 OBTAINING FACTORY ASSISTANCE ............................ 2-2-1
SECTION 3 MAINTENANCE INSTRUCTIONS ............................... 2-3-1
3.1 INTRODUCTION ............................................. 2-3-1
3.2 HOW TOUSE THE MAINI'f=NANCE INSTRUCTIONS(MI) ............. 2-3-1
3.3 LISTOFEVt"t_C-IiV'E MAINTENANCE INSTRUCTIONS............... 2-3-2
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STEWART & STEVENSON SERVICES,INC. FRONT MATI_R
AIRCRAFT GROUND SUPPORTEQUIPMENT
MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTION CHAPTER/SECTION/PAGE
CHAPTER 3 OVERHAUL
SECTION1 OVERHAUL DATA .,........................................ 3-1-1
1.1 MODEL GT-50DZ TOW TRACTOR OVERHAUL ............. ......... 3-1-1
1.2 ENGINE................................................... 3-1-t
1.3 TRANSMISSION ............................................. 3-1-1
1.4 AXL_-S.................................................... 3-1-1
SECTION2 REMOVAL AND INSTATJ.ATION ............................... 3-2-1
2.1 ENGINEANDTRANSMISSION ASSEMBLY REMOVAL ............... 3-2-1
2.2 ENGINE AND TRANSMISSION ASSEMBLY INSTAT.T.ATION
PROCEDURE_ .............................................. 3-2-4
2.3 AXIFREMOVAL PROCEDURES ................................ 3-2-4
2.4 A.,roF. ]NSTAt.r,ATION PROCEDURES ............................ 3-2-6
CHAPTER4PARTS
SECTION 1 PARTS LIST............................................... 4-1-1
1.1 INTRODUCTION ............................................. 4-1-1
1.2 PARTSLIST................................................ 4-1-1
1.2.2 Figure and Index Number Colnrnr_................................. 4-1-2
1.2.3 Part Number Cohmm.......................................... 4-1-2
1.2.4 Manufacturer's Code ........................................... 4-1-2
1.2.5 Description Column........................................... 4-1-2
1.2.6 Quantity Colnmn .............................................. 4-1-2
1.3 HOW TOLOCATEPARTS ..................................... 4-1-2
1.4 HOW TO ORDER PARTS ...................................... 4-1-3
SEt.'tlON 2 MANUFACqu-RER'S CODES ................................... 4-2-1
SECTION 3 ALPHA-NUMERIC INDEX ..................................... 4-3-1
3.1 INTRODUt_'iiON ............................................. 4-3-1
SEctlON 4GROUPINDEX............................................. 4 4 1
GROUP 1 TOW TRACTOR ASSEMBLY ................................... 4 4 3
1.1 TOW TRACTOROVER_T.t. VIEW ............................... 4 4 4
1.2 OPERATOR'S COMPARTMENT ................................. 4 4 8
1.3 CAB MODEL 416 (OPTION) ................................... 4 4 12
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STEWART & STEVENSON SERVICES, INC.FRONT MATIP.,R
AIRCRAFT GROUND SUPPORT EQUIPMENT
MANUAL TABLE OF CONTENTS (CONT.)
DESCRIPTIONCHAPTER/SECTION/PAGE
GROUP 2 DRIVE LINE .............................................. 4 4 19
2.1 ENGINE AND TRANSMISSION ASSEMBLY ...................... 4.420
2.2 ENGINE ANDTRANSMISSION CONNECTION .................... 4422
2.3 DRIVE LINE ASSEMBLY .................................... 4 4.24
2.4 STEERABLE AXLE HOUSING ................................. 4426
2.5 STEERABLE AXI.I_ DU_t-t!RENTIAL ............................ 44 28
2,6 STEERABLE AXI,I_ STEERING PARTS .......................... 44 30
2.7 STEF,RA.BLE AXLE PLANETARY HUBREDUCERS ................. 44 32
2.8 RIGID AX'IF,HOUSING ...................................... 4 4 34
2.9 RIGID AXLE DIPPP.,RENTIAL ................................. 44 36
2.10 RIGID AXI,F,PLANETARYHUBREDUCERS ...................... 4 4 38
GROUP 3 BRAKE SYSTEM COMPONENTS ............................... 4441
3.1BRAKE LINKAGE AND MASTER CYLINDER/.................... 4 4 42
HYDRAULIC BOOSTER
3.2 BRAKE HYDRAULIC BOOSTER ASSEMBLY ..................... n_, 44
3.3 BRAKE SYSTEM HYDRAULIC BOOSTER CIRCUIT ................ _ 4 "!.6
3.4 HYDRAULICBRAKESYSTEM ................................ 4 4 48
3.5 FRONT BRAKE ASSEMBLY .................................. 4 450
A,4
3.6 REARBRAKEASSEMBLY ..................................... 52
nA
3.7 PARKING BRAKE LINKAGE .................................... 54
3.8 PARKING BRAKE ASSEMBLY ................................ 44 56
GROUP 4 FUEL SYSTEM COMPONENTS ................................ 4 4 59
4.1 FUELSYSTEM WiTH FUEL FILTER/WATER ..................... 4 4 60
SEPARTOR (OPTION)
4.3 THROTILE CONTROL ...................................... 44 64
GROUP 5 GOVERNOR ADJUSTMENT (NOT USED REFER TO GROUP 4) ........ 4 4 67
GROUP 6 LUBRICATION SYSTEM FOR ENGINE AND TRANSMISSION ......... 4 4 69
6.1 TRANSMISSION LUBE OILSYSTEM ........................... 4 470
6.2 ENGINE LUBE OILSYSTEM .................................. 4 4 72
GROUP7 ENGINE COOLING SYSTEM COMPONENTS ...................... 4 4 75
7.1 ENGINE COOLING SYSTEM .................................. 4 4 76
GROUP 8 ENGINE AIR INTAKE AND EXHAUST SYSTEM ................... 4 4 79
8.1 AIR INLETASSEMBLY ...................................... 4 4 80
8.2 EXHAUST SYSTEM ......................................... 44 82
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STEWART & STEVENSON SERVICES, INC. FRONT MAI-I_R
AIRCRAFT GROUND SUPPORT EQUIPMENT
MANUAL TABLE OF CONTENTS (CONT,)
DESCRIPTION CHAPTER]SECTION/PAGE
GROUP9 r::J.F.Cq'P,ICAL SYSTEM COMPONENTS .......................... 4 4 85
9.1 OPERATOR CONTROL PANEL ASSEMBLY...................... 4-4.-86
9.2 ELECTRICAL PARTS ........................................ 4-4-90
GROUP 10 GENERATOR(NOT USED) ................................... _ 4 95
GROUP 11 NOT USED ............................................... d 4 97
GROUP 12 STEERING SYSTEM COMPONENTS ............................ _I4 99
12.1 STI=_,P,ING COLUMN ....................................... 4 4 100
12.2 HYDRAULIC STEERING VALVE ASSEMBLY .................... 4 4 102
12.3 HYDRAULIC FILTERASSEMBLY............................. d 4 104
12.4 HYDRAULIC STEERING PUMP............................... ,! _ 106
12.5 HYDRAULIC STEERING SYSTEM ............................. _ _ 108
CHAI:q'F__ 5 DRAWINGS
TABLE OF CONTENTS ..................................... 5-TOC-i
CHAPTER 6 OPTIONS AND MANUFACTURER'S DATA
TABLE OF CONTENTS ..................................... 6-TOC-i
OPTIONAL EQUIPMENT - INTRODUCTION ................... 6-INTRO-i
1. GT50 STr::_.RING OPTIONS .................................... 6-1-1
1.1 DESCRIPTION.............................................. 6-1-1
1.1.1 STI=_-RING MODES .......................................... 6-1-1
1.1.2 ACTIONOFFRONT AX[]:. .................................... 6-1-1
1.1.3 ACIION OF REAR AXLE ..................................... 6-1-1
1.2 OPERATION ............................................... 6-1-1
1.2.1 TRACK ST'_RING MODE ..................................... 6-1-1
1.2.2 COORDSTEERINGMODE " 6-1-1
1.2.3 CRAB STt_'RRING MODE ...................................... 6-1-1
1.3 MAINTV_.NANCE ............................................ 6-1-3
1.3.1 PREVENTIVE MAINTI_NANCE ................................. 6-1-3
1.3.2 TROUBLESHOOTING ........................................ 6-1-3
1.3.3 ADJUSTMENTS............................................. 6-1-3
1.5 DRAWINGS................................................ 6-1-9
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