TUG M3 Guide

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Maintenance

Chapter 2-Contents Aug, 1997 p. 2
Maintenance
SECTION PAGE
E. MAIN POWER ("IGNITION") SWITCH REMOVAL .......................................................................2
F. MAIN POWER ("IGNITION") SWITCH INSTALLATION ...............................................................2
G. MASTER CYLINDER REMOVAL ..................................................................................................3
H. MASTER CYLINDER INSTALLATION...........................................................................................3
I. STEER VALVE REMOVAL.............................................................................................................3
J. STEER VALVE INSTALLATION..................................................................................................... 4
K. TIRES AND WHEELS ...................................................................................................................4
M. ACCELERATOR PEDAL INSTALLATION: ....................................................................................6
N. HYDRAULIC STEERING PUMP REMOVAL .................................................................................6
O. HYDRAULIC STEERING PUMP INSTALLATION .........................................................................7
P. BRAKE BOOSTER PUMP REMOVAL ..........................................................................................8
Q. BRAKE BOOSTER PUMP INSTALLATION...................................................................................8
R. REPLACE DRIVE MOTOR BRUSHES .........................................................................................9
S. DRIVE MOTOR(S) REMOVAL ....................................................................................................10
T. DRIVE MOTOR(S) INSTALLATION............................................................................................. 11
U. CONTACTOR TIPS REMOVAL/REPLACEMENT ....................................................................... 11
V. BATTERY REMOVAL/REPLACEMENT:......................................................................................13
W. SERVICE BRAKES REMOVAL/INSTALLATION .........................................................................13
X. PLANETARY REDUCTION HUBS REMOVAL ............................................................................14
Y. PLANETARY REDUCTION HUBS INSTALLATION ....................................................................14
IV. ADJUSTMENTS......................................................................................................................................1
A. PARK BRAKE ................................................................................................................................1
B. SERVICE BRAKE ADJUSTMENT.................................................................................................1
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Chapter 2-Contents Aug, 1997 p. 3
SECTION PAGE
C. VERTICAL HEADLIGHT ADJUSTMENT.......................................................................................1
D. FRONT SPRING PRELOAD ADJUSTMENT ................................................................................2
E. BLEED REAR BOOSTED BRAKES (CONT) ................................................................................4
V. INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE .........................................................1
A. SAFETY PREREQUISITES...........................................................................................................1
B. PROCEDURE ................................................................................................................................1
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Chapter 2-Contents Aug, 1997 p. 4
(This Page Intentionally Left Blank)
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Chapter 2: Maintenance Sept. 1995 Section 2-1 p. 1
I. SERVICING
A complete preventive maintenance checklist is included in Chapter 5 of this manual (Appendices).
See section 5-1.
A. GENERAL PREPARATIONS FOR USE:
1. Battery
Assuming a minimum 80% charge, the duration of usable charge of the M3 battery will
vary from several hours to perhaps a day or more, depending on many factors. Variables
that affect length of usable charge include the percentage of initial day's charge, intensity
of use, size and condition of battery, weight of towed loads as well as environmental
factors such as ambient temperature. The battery should be fully charged before the unit
is put into service on a daily basis. For a complete discussion on battery charging cycles
and electrolyte maintenance, see chapter 1-5.
(a) Check the battery fluid level. Top up with distilled or approved drinking water, as
necessary.
(b) Connect the battery cables, if disconnected, positive first.
2. Brake System
(a) Check master cylinder fluid level.
Should the brake system require fluid, the master cylinder is located behind the
console panel to the right of the steering wheel. Master cylinder reservoir should be
topped off with a high quality brake fluid, DOT 3 or better.
The second brake fluid reservoir is located in the right service compartment above
the hydraulic pump (See Figure 1). The brake booster pump that provides braking
power to the rear wheels.
If low, check for leaks in brake lines.
Figure 1
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Chapter 2: Maintenance Sept. 1995 Section 2-1 p. 2
I. SERVICING
A. GENERAL PREPARATIONS FOR USE:
2. Brake System (cont)
(b) Service brakes should be tested for pedal firmness and braking effectiveness.
(c) Check park brake. With the main switch in the off position, the park brake should
hold the unit in place on a 10% grade.
IMPORTANT: Drive train has no "park" position and must rely on park brake to
prevent vehicle from rolling. Always make sure park brake is properly
adjusted before putting vehicle into service.
Adjust park brake cable tension by rotating cap
handle on park brake lever.
3. Check Tire Inflation.
4. Check hydraulic fluid level.
(Refer to lubrication section, ch. 2-1B)
Figure 1: Brake System Layout
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Chapter 2: Maintenance Sept. 1995 Section 2-1 p. 3
B. PREVENTIVE MAINTENANCE SCHEDULE (SEE ALSO: PREVENTATIVE MAINTENANCE
CHART IN APPENDICES CHAPTER)
THE TRACTOR SHOULD BE MAINTAINED IN ACCORDANCE WITH THE FOLLOWING
SCHEDULES:
1. Daily; Check:
(a) That all controls are in good working order. Report a faulty TUG control and do not
use until repaired.
(b) Battery charge level.
(c) Hydraulic fluid level.
(d) Battery electrolyte level
(e) The pressure of the pneumatic tires:
Drive Wheels 60 psi
Steer Wheels 40 psi
WARNING: Do not change pneumatic tire for cushion tire or vice versa
without first consulting TUG Manufacturing Corporation. Tires of a different
type or make, tread or material can reduce the load capacity or affect safety.
(f) The tire treads for damage. Remove any stone, etc.
(g) The operation of the headlights and if aimed correctly.
(h) The operation of backup, tail, stop and turn signal lights (if so equipped).
(i) The operation of the cab marker lights, the heater, the wiper and cab light, if
equipped.
(j) The horn.
2. Weekly or 50 Hour Check:
(a) Lug Nut tightness: The wheel lug nuts are tightened to 125 ft. - lbs.
WARNING: Lug nuts must be retightened to 125 ft. - lbs. after any change of a
wheel and anytime the lug nuts have been loosened for any reason, and at the
intervals specified in this Preventive Maintenance Section.
(b) The level of the brake fluid in the master cylinder & brake booster. If low, top up as
necessary.
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Chapter 2: Maintenance Sept. 1995 Section 2-1 p. 4
Figure 3
CHECK
I. SERVICING
B. PREVENTIVE MAINTENANCE SCHEDULE (CONT)
3. Monthly or 200 Hour Check:
(a) The Parking Brake
With the parking brake handle in ‘lock’ position, the tractor should not move on an 10
or less percent grade. If the tractor does not move, no adjustment is necessary, but
if the tractor rolls, then adjustment is advised. Follow the recommended adjustment
instructions in this Section.
(b) Power steering fluid.
(c) Planetary Reduction Hub fluid level.
(d) The adjusting slides beneath the operator’s seat.
(e) The service brake pedal pivot.
(f) The parking brake linkage.
(g) The throttle linkage.
(h) The steering axle & king pins adjustment.
(i) The sliding pins on the
rear brake calipers.
(j) All grease fittings.
(k) Console and battery
cover latches and
hinges.
(l) Cab door handles (if
equipped).
4. Two (2) Months or 400 Hours;
Check:
Inspect Front wheel bearings;
clean and repack.
5. Yearly or 2400 Hours
(a) Drain, flush and refill the hydraulic brake system, and bleed the brake system.
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Chapter 2: Maintenance Sept. 1995 Section 2-1 p. 5
(b) Drain, flush and refill the hydraulic
steering system.
(c) Drain & refill planetary drive hubs.
(See Figure 3 and Chapter 5 Supplement)
6. Lubricant Chart
(a) Schematic
ITEM # COMPONENT/SYSTEM
1 STEER CYLINDER ENDS
2 KING PINS (TOP)
3 TIE ROD ENDS
4 KING PINS (BOTTOM)
5 WHEEL BEARINGS
6 PLANETARY REDUCTION HUBS
7 HYDRAULIC PUMP
8 BRAKE BOOSTER PUMP
(b) Alphabetical Table
Component/System Lubricant Type or Specification
Adjusting Slides, Seat, Operator’s Multipurpose lithium-based grease
Axle Hubs, Front Multipurpose lithium-based grease
Brake Calipers. Rear Silicon Base Grease
Cab Door Handles Multipurpose lithium-based grease
Hydraulic Brake System Brake Fluid, DOT 3, Extra Heavy Duty
Power Steering Fluid Transmission Fluid; Dexron Type II
Steering King Pins Multipurpose lithium-based grease
Figure 4
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Chapter 2: Maintenance Sept. 1995 Section 2-1 p. 6
B. PREVENTIVE MAINTENANCE SCHEDULE
6. Lubricant Tables (cont.)
(c) Lubricant to Component/System Table:
Hydraulic Fluid, DOT 3, Extra Heavy Duty: Hydraulic Brake System
Multipurpose Lithium based Grease: Adjusting Slides, Seat, Operator’s
Axle Hubs, Front
Brake Pedal Pivot
Cab Door Handles
Drive Shaft Joints
Hood Latch and Hinges
Parking Brake Linkage
Steer King Pins
Rear Brake Calipers
(d) Lubricant to (Commercially Available) Product Table
Hydraulic Fluid, DOT 3, Extra Heavy Duty
-Lockheed Super 105 Hydraulic Fluid
Multipurpose Lithium-based Grease
-Texaco Marfak Multipurpose 2
Silicon Base Grease
-Ford Part No. D7AZ-19A-331-A
Planetary Reduction Hub Fluid
-Amzoil Lubricant
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