Property of American Airlines

Transcription

1 MODEL CT5G 600 MOUNTAIN LANE P.O. BOX 968 BLUEFIELD, VA TELEPHONE: (276) FAX: (276) SPARE PARTS FAX: (276) AMERICAN AIRLINES - E 12/8/17 THIS GUIDE IS TO BE USED ONLY WITH THE MODEL CT5G. OTHER MODELS IN THIS SERIES MAY HAVE OPERATING FEATURES UNLIKE THE MODEL CT5G.

2 REVISION LOG Revision REV. DATE DESCRIPTION A 2/2/17 Initial American Airlines Revision B 3/16/17 C 6/13/17 D 6/29/17 E 12/8/17 Updated Front Axle Installation in Chapter 3 Parts to show Bolt Guard and Front Axle Spacer. Updated Radiator Part Numbers and added Parking Brake Kit for the C6 Transmission in Engine/Transmission Installation in Chapter 3 Parts. Updated Electrical Components in Chapter 3 Parts. Updated Tire And Wheel Assembly in Chapter 3 Parts. Updated CT5G Wiring Diagram in Chapter 4 Electrical System. Added Diagnostic Manual showing various fault codes for the MSG425 Engine in Chapter 5 Vendor Manuals. Updated Covers & Guards in Chapter 3 Parts. Added new decals to Tractor Trim & Decals in Chapter 3 Parts. Updated part number for power steering hose in Power Steering System in Chapter 3 Parts. Updated part numbers for wiper motor, wiper arm, and wiper blade in Cab Assembly in Chapter 3 Parts. Added Push Button Switch to Section 3. Added Test Switch & Test Switch Procedure to Section 3. Added Water Valve Lever & Fan Speed Toggle Switch for Heater Box to Section 3. Updated Rubber Bumper for Front Axle in Front Axle Installation in Chapter 3 Parts. Added Engine Parts & GM Transmission to Engine / Transmission Installation in Chapter 3 Parts. Updated Fuel Tank Installation in Chapter 3 Parts. Added part number for Banjo Bolt in Power Steering System in Chapter 3 Parts. Updated Electrical Components in Chapter 3 Parts. Added Push Button Switch Kit to Drivers Control Panel in Chapter 3 Parts. Updated Accelerator Pedal Harness in Accelerator Pedal Installation in Chapter 3 Parts. Added Shift Arm Setup for GM Transmission in Transmission Shifter Installation in Chapter 3 Parts. Updated Drive Shaft Assembly & Installation in Chapter 3 Parts. REVISION LOG CONTINUED ON FOLLOWING PAGE

3 Revision REV. DATE DESCRIPTION E 12/8/17 Added Counterweight Wedge to Covers & Guards in Chapter 3 Parts. Added Sliding Window Assembly to Cab Assembly in Chapter 3 Parts. Updated Tractor Trim & Decals in Chapter 3 Parts. Updated Wiring Diagram & Component Location in Chapter 4 Electrical System. Added Dash Harness Wiring Diagram (Ignition Switch) to Chapter 4 Electrical System Added Dash Harness Wiring Diagram (Push Button Switch) to Chapter 4 Electrical System. Added Dash Harness Wiring Diagram (GM Transmission / Push Button) to Chapter 4 Electrical System. Added Switch Panel Diagram to Chapter 4 Electrical System. Updated MSG425 Service Parts Manual in Chapter 5 Vendor Manuals. Added Application Guide, Parts & Accessories Manual, & Transmission Technician s Guide for GM Transmission to Chapter 5 Vendor Manuals.

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5 NOTICE THIS GUIDE IS NOT INTENDED TO BE A COMPLETE OPERATING OR SERVICE MANUAL OR GUIDE. IT IS PREPARED ON THE BASIS THAT THE INDIVIDUAL OPERATING THIS UNIT IS TRAINED IN THE OPERATION OF UNITS OF THIS TYPE AND HAS SPECIAL TRAINING TO OPERATE THIS UNIT. FURTHER, IT IS ASSUMED THAT THE INDIVIDUAL WILL TAKE NECESSARY PRECAUTIONS TO ENSURE SAFE OPERATION FOR HIMSELF AND FOR OTHERS. THE TEXT IN NO WAY COVERS ALL POSSIBLE CONTINGENCIES OR OPERATING PROCEDURES. THIS GUIDE IS DESIGNED TO BE OF GENERAL ASSISTANCE. IF PROCEDURES OR CONDITIONS ARE ENCOUNTERED WHICH ARE NOT INCLUDED IN THIS GUIDE, THE OPERATOR SHOULD GET EXPERT ASSISTANCE BEFORE ATTEMPTING TO OPERATE OR REPAIR THE MACHINE. FOR THE CHARLATTE COMPANY SERVICE DEPARTMENT, CALL (276) CHARLATTE OF AMERICA, INC. ASSUMES NO RESPONSIBILITY FOR THE PERFORMANCE OR OPERATION OF THIS UNIT IF IT IS ALTERED IN ANY MANNER. NOTICE SOME ILLUSTRATIONS IN THIS GUIDE MAY SHOW GUARDS OR COVERS REMOVED FOR THE PURPOSES OF CLARITY. NEVER OPERATE UNIT WITHOUT ALL GUARDS AND COVERS IN PLACE. SOME ILLUSTRATIONS IN THIS GUIDE MAY SHOW UNITS WITH OPTIONAL EQUIPMENT INSTALLED. THIS OPTIONAL EQUIPMENT MAY BE PURCHASED FROM CHARLATTE OF AMERICA, INC. SOME ILLUSTRATIONS IN THIS GUIDE MAY BE OF PROTOTYPE MODELS. PRODUCTION MODELS MAY VARY IN SOME DETAIL. CONTINUING IMPROVEMENT AND ADVANCEMENT OF PRODUCT DESIGN MAY CAUSE CHANGES TO YOUR MACHINE WHICH MAY NOT BE INCLUDED IN THIS PUBLICATION. EACH PUBLICATION IS REVIEWED AND REVISED, AS REQUIRED, TO UPDATE AND INCLUDE THE CHANGES IN LATER ADDITIONS. CHARLATTE OF AMERICA, INC. RESERVES THE RIGHT TO MODIFY OR MAKE CHANGES WITHIN A SPECIFIC MODEL GROUP WITHOUT NOTICE AND WITHOUT INCURRING ANY LIABILITY TO RETROFIT UNITS PREVIOUSLY SHIPPED FROM THE FACTORY. CONTACT CHARLATTE OF AMERICA, INC. FOR MAINTENANCE THAT IS NOT COVERED IN THIS PUBLICATION.

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7 IMPORTANT SAFETY INSTRUCTIONS This guide provides important information to familiarize you with safe operating and maintenance procedures for the Model CT5G. Even though you may be familiar with similar equipment, you MUST read and understand this guide before attempting to operate or maintain this unit. Safety is everyone s business and must be one of your primary concerns. Knowing the guidelines covered in the following paragraphs will help provide for your safety, for the safety of those around you, and for the machine s proper operation. LOOK FOR THESE SYMBOLS WHICH POINT OUT ITEMS OF EXTREME IMPORTANCE TO YOU AND YOUR CO-WORKERS SAFETY. READ AND UNDERSTAND THOROUGHLY. HEED THE WARNING AND FOLLOW THE INSTRUCTIONS. WARNING WARNING SAFETY NOTES MUST BE FOLLOWED. YOUR MISTAKE MIGHT RESULT IN SERIOUS INJURY OR DEATH TO YOURSELF OR OTHERS. CAUTION CAUTION SAFETY NOTES ARE ALSO VERY IMPORTANT. THEY POINT OUT TO YOU WHERE YOUR MISTAKES COULD CAUSE PHYSICAL HARM TO YOU OR OTHERS, OR DAMAGE TO THE MACHINE. NOTICE NOTICE IS USED TO NOTIFY PEOPLE OF INSTALLATION, OPERATION, OR MAINTENANCE INFORMATION WHICH IS IMPORTANT BUT NOT HAZARD-RELATED.

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9 ALPHABETICAL INDEX CHAPTER/SECTION PAGE Accelerator Pedal Operation... 1/ Parts... 3/2... Figure Removal/Installation... 2/ Adjustment Instructions... 2/2 Alphabetical Parts List... 3/ Axle, Front Description... 1/ Parts (Assembly)... 3/2... Fig Parts (Installation)... 3/2... Fig Removal/Installation... 2/ Specifications... 1/ Axle, Rear Description... 1/ Parts (Assembly)... 3/2... Fig Parts (Installation)... 3/2... Fig Removal/Installation... 2/ Specifications... 1/ Trouble Shooting (Rear Drive)... 2/ Battery Parts... 3/2... Fig Removal/Installation... 2/ Trouble Shooting (Alternator / Battery)... 2/ Brake Bleeding... 2/ Brake Lights Operation... 1/ Brake, Parking Adjustment... 2/ Description... 1/ Operation... 1/ Parts... 3/2... Figure Removal/Installation... 2/ Troubleshooting... 2/ Brake Pedal / Master Cylinder / Vacuum Booster Operation... 1/ Parts... 3/2... Fig Removal/Installation... 2/ Alphabetical Index Page 1 of 6

10 CHAPTER/SECTION PAGE Brakes, Front Adjustment... 2/ Description... 1/ Parts (Calipers)... 3/2... Figure Parts (System)... 3/2... Figure Removal/Installation... 2/ Specifications... 1/ Brakes, Rear Adjustment... 2/ Description... 1/ Parts (Calipers)... 3/2... Figure Parts (System)... 3/2... Figure Removal/Installation... 2/ Specifications... 1/ Cab Assembly Description... 1/ Parts... 3/2... Figure Chassis Description... 1/ Parts (Covers & Guards)... 3/2... Figure Parts (Decal Placement)... 3/2... Figure Specifications... 1/ Check Battery Voltage Operation... 1/ Check Engine Light Operation... 1/ Check Oil / Coolant Temperature Operation... 1/ Component Removal/Installation... 2/3 Components/Systems... 1/ Description... 1/2 Dimensions... 1/ Drawing And Parts List... 3/ Drive Shaft Description... 1/ Parts... 3/2... Fig Removal/Installation... 2/ Trouble Shooting... 2/ Alphabetical Index Page 2 of 6

11 CHAPTER/SECTION PAGE Electrical System Description... 1/ Diagrams... 4/ Parts... 3/2... Fig Removal/Installation... 2/ Specifications... 1/ Trouble Shooting (Alternator / Battery)... 2/ Trouble Shooting (System)... 2/ Engine Description... 1/ Parts (Installation)... 3/2... Fig Removal/Installation... 2/ Specifications... 1/ Trouble Shooting... 2/ Exhaust System Parts (Installation)... 3/2... Fig Removal/Installation... 2/ Fan Speed Toggle Switch (Heater Box) Operation... 1/ Figure Index... 3/ Fuel System Description... 1/ Diagram (Fuel Lines)... 2/ Operation (Gauge)... 1/ Parts (Tank)... 3/2... Fig Removal/Installation... 2/ General Maintenance Instructions... 2/ Headlight Switch Operation... 1/ Horn Button Operation... 1/ Hourmeter Operation... 1/ Ignition Switch Operation... 1/ Instruments/Controls... 1/ Lighting Circuit Description... 1/ Operation... 1/ Parts... 3/2... Figure Alphabetical Index Page 3 of 6

12 CHAPTER/SECTION PAGE Lubrication Alphabetical Table... 2/ Lubrication Chart... 2/ Lubricants, Fluids, And Capacities... 2/ Maintenance Check List... 2/ Numerical Parts List... 3/ Operating (Safety)... 1/ Operation... 1/3 Operators Dash Panel Assembly... 3/2... Fig Performance... 1/ Preparation For Initial Use... 2/ Preparation For Operation... 1/ Preparation For Shipping... 1/ Pre-Start Inspection... 1/ Preventative Maintenance Schedule... 2/ Procedures... 1/ Safety... 1/ Seat Parts... 3/2... Figure Servicing Shipping... 1/4 Shutdown (Procedure)... 1/ Specifications... 1/1 Starting (Procedure)... 1/ Starting (Safety)... 1/ Steering Stops Adjustment... 2/ Alphabetical Index Page 4 of 6

13 CHAPTER/SECTION PAGE Steering System Description... 1/ Hose Diagram... 2/ Parts (Cylinder Installation)... 3/2... Fig Parts (Power Steering System)... 3/2... Fig Parts (Steering Column Installation)... 3/2... Fig Removal/Installation (Steering Cylinder)... 2/ Removal/Installation (Steering Valve)... 2/ Specifications... 1/ Trouble Shooting... 2/ Stopping (Safety)... 1/ Storage (Long Term)... 1/ Storage (One Month)... 1/ Suspension, Front Description... 1/ Parts... 3/2... Figure Specifications... 1/ Suspension, Rear Description... 1/ Parts... 3/2... Figure Specifications... 1/ Test Switch Operation... 1/ Procedure... 1/ Tires/Wheels Description... 1/ Parts... 3/2... Figure Removal/Installation... 2/ Specifications Toe In Adjustment... 2/ Tractor Towing (Procedure)... 1/ Trailer Towing (Procedure)... 1/ Transmission Description... 1/ Parts (Installation)... 3/2... Fig Removal/Installation... 2/ Specifications... 1/ Trouble Shooting... 2/ Alphabetical Index Page 5 of 6

14 CHAPTER/SECTION PAGE Transmission Shift Lever Operation... 1/ Parts (Assembly)... 3/2... Fig Parts (Installation)... 3/2... Fig Removal/Installation... 2/ Trouble Shooting... 2/ Turn Signal Switch Operation... 1/ Vendor List... 3/ Vendor Manuals... 5/1 Warranty Information... 3/ Water Valve Lever (Heater Box) Operation... 1/ Alphabetical Index Page 6 of 6

15 CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS TABLE OF CONTENTS CHAPTER/SECTION PAGE I. SPECIFICATIONS AND CAPABILITIES A. Dimensions B. Performance C. Transmission D. Engine E. Electrical System F. Chassis G. Suspension H. Braking I. Front Axle J. Steering System K. Rear Axle L. Tire/Wheel II. DESCRIPTION A. Description Of Unit B. Components/Systems Chassis Front Steer Axle Front Suspension Front Brakes Steering System Rear Axle Rear Brakes Rear Suspension Parking Brake Wheels / Tires Engine Transmission Drive Shaft Fuel System Electrical System Lighting Circuit Tow Attachment Cab Assembly Contents

16 CHAPTER/SECTION PAGE 19. Heater/Defroster Wiper III. OPERATION A. Instruments/Controls Footbrake Pedal Accelerator Pedal Parking Brake Lever Ignition Switch / Push Button Switch Transmission Shift Lever Fuel Gauge Headlight Switch Turn Signal Switch Heater Switch Horn Button Hourmeter Brake Lights Check Engine Light Check Oil / Coolant Temperature Light Check Battery Voltage Light Low Fuel Light Test Switch Water Valve Lever Fan Speed Toggle Switch B. Safety Pre-Start Inspection Starting Operating Stopping C. Procedures Starting Shutdown Tractor Towing Procedure Trailer Towing Procedure Test Switch Procedure IV. SHIPPING A. Preparation For Shipping B. Preparation For Operation V. STORAGE A. One Month Storage Tires Lubrication Battery Engine B. Long Term Storage Contents

17 1. Tires Lubrication CHAPTER/SECTION PAGE 3. Inspection Protection Motor/Electronics Engine Battery Transmission Chassis Contents

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19 CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS I. SPECIFICATIONS AND CAPABILITIES A. Dimensions Length, without hitch inches (2743 mm) Width, overall inches (1524 mm) Height, w/o cab inches (1448 mm) Height, overall with cab inches (1981 mm) Wheelbase inches (1600 mm) Ground Clearance inches (150 mm) B. Performance Gross Weight lbs. Drawbar (maximum) lbs. Speed (maximum) mph C. Transmission D. Engine (3629 kgs.) (2267 kgs.) (24 km/h) Manufacturer Ford Model... C-6 2 Speed Automatic (1-Speed Reverse w/cooler) Manufacturer Ford Fuel... Gasoline Model... MSG 425 E. Electrical System F. Chassis Voltage, Accessories..12 Volt D.C. Mild steel formed and welded construction. NOTICE FOR MORE DETAILED DESCRIPTION OF THE TRANSMISSION, SEE CHAPTER 5. NOTICE FOR MORE DETAILED DESCRIPTION OF THE ENGINE, SEE CHAPTER 5. Page 1-1 Jan. 17

20 G. Suspension Front... Leaf Springs Rear... Leaf Springs H. Braking Master Cylinder Type... Single Circuit Brake System... Vacuum Booster Front Type Disc Disc Thickness.663 inch (.55 min) Rear Type... Disc Pad Thickness (minimum) mm (0.125 in) Disc Thickness (minimum) mm (0.787) Parking Type... Over Center Handle I. Axle, Front Type... Paillard Spindle Support... Roller Bearings J. Steering System Type... Power Steering Operator Control... Rotary Valve Axle Control... Double Acting Cylinder K. Axle, Rear Type... PRM Marine (Newage) Ratio total L. Tire/Wheel NOTICE FOR MORE DETAILED DESCRIPTION OF REAR DISC BRAKES, SEE CHAPTER 5 NOTICE FOR MORE DETAILED DESCRIPTION OF REAR AXLE, SEE CHAPTER 5 PNEUMATIC Front Tire Size X 10 Wheel Type x 4.0 E Number of Lugs... 5 Rear Tire Size /75 R16 Wheel Type x 5.00 Number of Lugs... 8 Page 1-2 Jan. 17

21 CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS II. DESCRIPTION A. Description Of Unit The tractor incorporates four wheels, two rear driving and two front steering. Power is supplied by an internal combustion engine which drives the rear wheels through an automatic transmission. The frame, suspension, axles, and brakes are designed for heavy towing operations in confined spaces. MODEL CT5G TRACTOR FIGURE Page 2-1 Jan. 17

22 B. Components/Systems 1. Chassis The chassis is fabricated of formed steel plates that are then welded in a fixture to assure parts interchange ability. The entire assembly is then cleaned, primed, and painted. 2. Front Steer Axle The front steer axle is cast as a solid beam to prevent fabrication joints. To this beam are attached the spindles, leaf springs, and steering cylinder. 3. Front Suspension FRONT STEER AXLE / SUSPENSION FIGURE Leaf springs are used to supply ride control and support to the front of the tractor. These springs are angled to permit wheel clearance in tight turn situations. This produces a good ride, excellent stability, and minimal maintenance. 4. Front Brakes The front brakes are disc type with actuation supplied by 1/2 of the master cylinder. 5. Steering System The steering consists of a hydraulic pump on the engine, rotary valve (attached to the steering wheel), hydraulic hoses, and a steering cylinder (attached to the front axle). As the steering wheel is turned, pressurized fluid from the pump is metered by the rotary valve in small increments to the steering cylinder, which turns the front wheels. To assure steering in emergency situations, the rotary valve will move fluid without the pump; however greater force is required from the operator to turn the steering wheel. 6. Rear Axle The rear axle is designed for this particular unit and permits the engine/transmission to deliver driving force through a drive shaft. Page 2-2 Jan. 17

23 7. Rear Brakes Self adjusting disc type brakes are used on the rear of the tractor and are actuated by ½ of the master cylinder. (See Chapter 5 for more detailed information.) 8. Rear Suspension The rear suspension consists of leaf springs, which are mounted to the rear of the axle by mounting blocks to maintain the correct mounting location. 9. Parking Brake To prevent movement when parked and for potential emergency situations, a hand operated braking system is included. An over-center handle applies the brakes through rods and a bell crank attached to a brake lever located on the transmission. 10. Wheels/Tires High capacity three or two-piece wheels and tires are used. The three-piece wheels are made in three parts: the main wheel, the removable bead, and the locking ring. The twopiece wheels consist of inner and outer halves bolted together. Various tire options are available upon request. 11. Engine The tractor is equipped with an internal combustion engine. (See page 1-2 and Chapter 5 for more detailed information). 12. Transmission The tractor is equipped with an automatic transmission. The transmission is equipped with two or three speeds forward and one speed reverse. (See page 1-2 and Chapter 5 for more detailed information). 13. Drive Shaft The drive shaft utilizes two universal joints and a sliding spindle coupling to deliver effective and quiet power transfer between the transmission and drive axle. 14. Fuel System The fuel system consists of the fuel tank, connecting lines, filter, pump, and regulator. The fuel tank is constructed of aluminized steel with welded seams and is pressure tested to ensure safe operation. 15. Electrical System Electrical power is supplied by a 12 bolt battery and a belt driven alternator mounted to the engine. The system is a 12 volt direct current with negative ground. 16. Lighting Circuit All lights are controlled from the operator console and use standard 12 volt automotive bulbs. The complement of lights and related accessories depends on the requirements of the application. Page 2-3 Jan. 17

24 17. Tow Attachment Towing attachments of almost any type can be used on either or both ends of the tractor. 18. Cab Assembly A cab is available as an option for this tractor. The structure is composed of steel, has a front windshield, rear window, and other available options. 19. Heater / Defroster With the cab option a heater / defroster assembly is added. The heater / defroster is powered by the 12 volt system. 20. Wiper A windshield wiper is included with the cab option and is powered by the 12 volt system. Page 2-4 Jan. 17

25 CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS III. OPERATION A. Instruments/Controls CONSOLE CONTROLS FOOTBRAKE PEDAL 1. Footbrake Pedal OPERATORS COMPARTMENT FIGURE The footbrake pedal is located in the normal automotive position and operates the rear brakes. This operation is carried out through a dual master cylinder/brake booster with a proportioning valve that supplies the proper pressure to the rear brakes. 2. Accelerator Pedal The accelerator pedal is located in the normal automotive position, and it is used to regulate the speed of the unit. 3. Parking Brake Lever NOTICE A REGENERATIVE BRAKING SYSTEM IS TURNED ON BY RELEASING THE ACCELERATOR. THIS SYSTEM USES THE GENERATOR PROPERTIES OF THE DRIVE MOTOR TO SLOW THE TRACTOR BY CHARGING THE BATTERY DURING COASTING OR DOWNHILL OPERATION. ADDITIONAL BREAKING IS OBTAINED BY PRESSING THE FOOTBRAKE PEDAL. The parking brake lever is located to the right of the operator s seat. It is operated by pulling the handle to apply the brakes. NOTICE PARKING BRAKE LEVER ACCELERATOR PEDAL THE ADJUSTMENT KNOB IS LOCKED SO THAT ONLY TRAINED PERSONNEL ARE PERMITTED TO MAKE THE ADJUSTMENTS. Page 3-1

26 HEATER SWITCH FUEL GAUGE TRANSMISSION SHIFT LEVER HEADLIGHT SWITCH 4. Ignition Switch / Push Button Switch CONSOLE CONTROLS FIGURE The unit will either have an ignition switch or a push button switch. The ignition switch is located to the right of the steering wheel on the operator s dash. The switch has a RUN position and a momentary Start position that returns to RUN when released. To start the unit, turn the switch clockwise until the unit starts then release the switch. The push button switch is located to the right of the steering wheel on the operator s dash. Press the button once, and the outer ring will flash green. Wait until the outer ring becomes a solid green and press again to start the unit. Once the unit is parked, and placed back into neutral, press the button once to turn the unit off. OR IGNITION SWITCH / PUSH BUTTON SWITCH FIGURE HOURMETER IGNITION SWITCH READY TO START WHEN OUTER RING IS A SOLID GREEN Page 3-2

27 5. Transmission Shift Lever The transmission shift lever is located on the right of the steering wheel on the operators dash and has three (3) positions: NEUTRAL, REVERSE and FORWARD. Pull the lever towards the rear of the unit to place the machine in the FORWARD mode, and push the lever towards the front of the unit to place the machine in the REVERSE mode 6. Fuel Gauge TRANSMISSION SHIFT LEVER FIGURE The fuel gauge is located to the right of the steering wheel on the operators dash. This gauge continuously displays the amount of fuel in the unit. 7. Headlight Switch OR FUEL GAUGE FIGURE The headlight switch is located to the left of the steering wheel on the operators dash. Turning the switch clockwise will illuminate the headlights of the unit, and this will be indicated by the blue light beside the switch illuminating. Turning the switch counterclockwise will turn the headlights off. HEADLIGHT SWITCH FIGURE Page 3-3

28 8. Turn Signal Switch The turn signal light switch is located to the left of the steering wheel, below the headlight switch, on the operators dash. Rotating the switch to the right (clockwise) will operate the turn signals on the right side of the tractor. Rotating the switch to the left (counterclockwise) will operate the turn signals on the left side of the tractor. While the turn signals are active, this will be indicated by indicator light located to the right of the switch. To turn the turn signals off, return the switch to the middle neutral position. 9. Heater Switch TURN SIGNAL SWITCH FIGURE The heater switch is located to the left of the steering wheel, above the headlight switch, on the operators dash. Turning the switch clockwise will activate the heater. Turning the switch counter clockwise will deactivate the heater. 10. Horn Button HEATER SWITCH FIGURE The horn button is located on the steering column. To actuate the horn, depress the button and hold in this position for the desired amount of time and release. HORN BUTTON FIGURE Page 3-4

29 11. Hourmeter The hourmeter indicator is located to the right of the steering wheel, below the fuel gauge, on the operators dash. The hourmeter shows the total number of key hours the unit has been in service. 12. Brake Lights HOURMETER INDICATOR FIGURE The brake lights are activated automatically by a switch located near the brake pedal assembly when the brake pedal is depressed. 13. Engine Light The engine light is located to the right of the steering wheel, beside the fuel gauge, on the operators dash. If the light is illuminated, the unit is currently experiencing a fault and should be checked. ENGINE LIGHT FIGURE Check Oil / Coolant Temperature Light The check oil / coolant temperature light is located to the right of the steering wheel, below the check engine light. If the light is illuminated, the unit is currently experiencing low oil pressure and/or the engine is overheating. The unit should be stopped immediately and checked. CHECK OIL PRESSURE OR COOLANT TEMPERATURE LIGHT FIGURE Page 3-5

30 15. Check Battery Voltage Light The check battery voltage light is located to the right of the steering wheel, below the check oil / coolant temperature light. If light is illuminated, the charging system is not charging the battery with proper voltage, and should be checked. 16. Low Fuel Light CHECK BATTERY VOLTAGE LIGHT FIGURE The low fuel light is located to the right of the steering wheel next to the fuel gauge. The light will illuminate when the fuel tank is depleted to an 1/8 of fuel left. If the light is illuminated, the fuel tank needs resupplied with fuel. 17. Test Switch LOW FUEL LIGHT FIGURE The test switch is located under the dash, to the right of the steering wheel. With the engine off, and the ignition on, flipping the switch up will activate the troubleshooting procedure. Flipping the switch down will deactivate the procedure. See page 3-15 for test switch procedure. TEST SWITCH FIGURE Page 3-6

31 18. Water Valve Lever The water valve lever is located on the left side of the Heater Box. Push the lever towards the front of the unit to open the valve. Pull the valve lever to the rear of the unit to close the valve. 19. Fan Speed Toggle Switch WATER VALVE LEVER FIGURE The fan toggle switch is located on the left side of the Heater Box. When the switch is in the standard position the fan is on low speed. Flipping the switch up will activate the fan s high speed. FAN SPEED TOGGLE SWITCH FIGURE Page 3-7

32 B. Safety This tractor is designed to travel on relatively smooth terrain and to tow freight and cargo to and from the aircraft. COMPLETE understanding of the operation and use of this unit is required to maintain a safe environment for the operator and other persons in the work area. 1. Pre-Start Inspection a. Read this entire guide before attempting to operate this unit. You should be familiar with the controls and their functions before the unit is energized. b. Inspect the unit by performing a pre-operational inspection. Have any malfunctioning, broken or missing parts corrected or replaced before use. c. Verify that all maintenance has been performed. d. Verify that all instruction and safety labels are in place and legible. These are as important as any other equipment on the machine. e. Clean any foreign material from the unit and operator s compartment. f. Check that all covers are closed before operating unit. 2. Starting a. Do not operate any controls located inside the operator s compartment from outside the operator s compartment to prevent the unit from hitting you or other personnel. 3. Operating a. Operation and servicing of this unit must be performed by properly trained and authorized persons only. b. Always make sure that no person or obstruction is in your line of travel before starting the unit into motion. c. Never climb onto, or climb out of the unit while it is in motion. d. Do not operate the unit with any part of your body outside of the operator s compartment. e. Use extreme caution and be observant when maneuvering unit or working in close quarters or blind travel areas. Slow down and sound horn when operating unit in this type of area. f. Never carry passengers outside of the passenger s seat to prevent the passengers from being thrown off or crushed between the unit and outside objects. g. Always look in all directions before changing your direction of travel. h. Always follow all safety rules of each particular airline when operating unit. i If problems or equipment malfunctions are encountered while operating the unit, it must be properly shutdown and repaired. Continuing to use malfunctioning equipment can not only be unsafe for the operator and other personnel, but can lead to further damage to the unit as well. 4. Stopping a. Always set the parking brake when the unit is not in operation. b. Consider the size and weight of the unit when allowing for maneuverability and braking. This situation is magnified in severe weather conditions and on grades. c. Always park the unit on solid level ground. If this is not possible, chock all four (4) wheels in both directions. d. Use proper flags, warnings or barriers when parking in areas of traffic. Page 3-8

33 C. Procedures 1. Starting a. For maximum safety observe all safety precautions specified at the beginning of this section. b. Enter the operator s compartment. WARNING NEVER TRY TO ADJUST THE OPERATOR S SEAT WHILE THE UNIT IS IN MOTION. c. The unit is equipped with an adjustable seat that can be adjusted closer to or farther from the foot pedals. If adjustment is required: aa. Lift the seat adjustment lever located on the lower front of the seat and slide the seat to a comfortable position relative to the foot and hand controls and release the lever. d. If necessary, adjustment should be made to the tilt of the console. e. Buckle seat belt, if equipped. f. Ensure that the transmission shift lever is in the neutral position, and that the hand brake is applied. TRANSMISSION SHIFT LEVER ( NEUTRAL POSITION) FIGURE g. Rotate the ignition switch clockwise to the IGNITION position. After 8 second delay rotate the ignition switch to the START position. Once the engine starts release the ignition switch to the RUN position. If ignition switch will not rotate to Start position, return to OFF position for a 20 second delay and repeat. IGNITION SWITH (ROTATE CLOCKWISE) FIGURE Page 3-9

34 h. If the unit is equipped with the push button switch, press the button once, and the outer ring will flash green. Wait until the outer ring becomes a solid green and press again to start the unit. PRESS BUTTON PRESS BUTTON AGAIN ONCE OUTER LAYER BECOMES A SOLID GREEN PRESS BUTTON SWITH FIGURE i. Apply foot brake pedal and hold in the depressed position. DEPRESS FOOT BRAKE PEDAL FIGURE j. Turn on any required accessories such as lights, work lights, or beacons. k. Release the parking brake. RELEASED PARKING BRAKE FIGURE CAUTION PRESS HARD ON THE BRAKE PEDAL BEFORE SHIFTING OUT OF NEUTRAL OR CHANGING VEHICLE DIRECTION. THE SHIFTER WILL NOT BE ABLE TO BE MOVED OUT OF NEUTRAL UNTIL THE SHIFT LOCK ALLOWS IT. Page 3-10

35 l. Move the transmission shift lever into either the FORWARD or REVERSE position. FORWARD TRANSMISSION SHIFT LEVER ( FORWARD / REVERSE POSITIONS) FIGURE m. Release foot brake pedal. RELEASE FOOT BRAKE PEDAL FIGURE WARNING REVERSE BE SURE NO PERSONS OR OBJECTS ARE IN THE DIRECTION OF TRAVEL BEFORE PRESSING ACCELERATOR PEDAL. n. Slowly press the accelerator pedal to accelerate the unit. SLOWLY PRESS THE ACCELERATOR PEDAL FIGURE Page 3-11

36 CAUTION THE UNIT MUST BE COMPLETELY STOPPED BY PRESSING THE BRAKE PEDAL, BEFORE A DIRECTION CHANGE CAN BE MADE. WARNING THE TRANSMISSION SHIFT LEVER MUST BE IN THE NEUTRAL POSITION AND THE PARKING BRAKE SET PRIOR TO THE OPERATOR EXITING THE OPERATOR S COMPARTMENT. WARNING TO PREVENT TRACTOR COASTING WITH THE MOTOR NOT RUNNING, THE PARKING BRAKE MUST BE IN THE SET POSITION. NOTICE THE UNIT IS EQUIPPED WITH POWER STEERING. DUE TO THE WEIGHT OF THE UNIT, STEERING IS DIFFICULT WHEN STOPPED. THIS LOAD IS INCREASED WHEN THE FOOT BRAKE IS APPLIED. WHENEVER POSSIBLE TURN THE WHEELS WITH THE BRAKE PEDAL RELEASED AND THE MACHINE MOVING. WARNING STOPPING THE TRACTOR IS MUCH SLOWER WHILE TOWING HEAVY LOADS, ON GRADES, AND DURING INCLEMENT WEATHER. IF TWO OR ALL THREE OF THESE ARE PRESENT THE PROBLEM IS MULTIPLIED. Page 3-12

37 2. Shutdown a. Drive the unit to its designated parking place. b. Stop the unit by releasing the accelerator pedal and depressing the brake pedal. c. Set the parking brake by pulling the parking brake lever to the up position. PARKING BRAKE LEVER (APPLIED) FIGURE WARNING ALWAYS SET THE PARKING BRAKE WHEN THE UNIT IS NOT IN OPERATION. d. Move the direction shift lever to the NEUTRAL position. DIRECTION SHIFT LEVER (NEUTRAL) FIGURE e. Turn OFF all accessories. f. Turn the ignition switch to the OFF position. If equipped with the push button switch, press the switch to turn the unit off. IGNITION SWITCH / PUSH BUTTON SWITCH FIGURE Page 3-13

38 3. Tractor Towing Procedure (Disabled Vehicle) WARNING IT IS NOT POSSIBLE WITHIN THE SCOPE OF THIS GUIDE, TO ANTICIPATE ALL POSSIBLE ARRANGEMENTS FOR TOWING A DISABLED UNIT. BEFORE ATTEMPTING TO TOW ANY VEHICLE, YOU MUST TAKE ALL POSSIBLE PRECAUTIONS TO PROTECT THE OPERATORS AND ANYONE AROUND BOTH VEHICLES FROM BEING INJURED BY EITHER THE TOWING VEHICLE, TOWING DEVICES OR THE VEHICLE BEING TOWED. THE PRIMARY TOWING DEVICE BEING USED (CABLES, BARS, ETC.) AND THE TOWING VEHICLE MUST BE STRONG AND HEAVY ENOUGH TO MAINTAIN CONTROL OF BOTH VEHICLES THROUGH ALL CONDITIONS TO BE ENCOUNTERED AT ALL TIMES. SAFETY CHAINS OR OTHER SAFETY DEVICES MUST BE USED IN CASE OF FAILURE OF THE PRIMARY TOWING DEVICE. ALL OPERATORS MUST BE ALERT AT ALL TIMES TO PREVENT EITHER UNIT FROM RUNNING AWAY OR RUNNING OUT OF CONTROL DURING TOWING. THE VEHICLE TO BE TOWED MUST BE SECURELY COUPLED TO THE TOWING VEHICLE BEFORE THE PARKING BRAKE IS RELEASED ON THE DISABLED UNIT. THE OPERATOR OF THE TOWING VEHICLE MUST BE IN PLACE IN THE TOWING VEHICLE WITH THE BRAKES APPLIED BEFORE THE BRAKES OF THE DISABLED VEHICLE ARE RELEASED. a. Set the parking brake of the disabled unit by pulling the parking brake lever to the up position. b. Couple the towing vehicle securely to the disabled unit. WARNING ALWAYS BE SURE THAT NO ONE IS IN BETWEEN THE TOWING VEHICLE AND THE DISABLED VEHICLE. IF THE FRONT WHEEL OF THE DISABLED VEHICLE IS IN CONTACT WITH THE GROUND THE DISABLED VEHICLE WILL HAVE TO BE STEERED. IF TOWING WITH THE REAR WHEELS LIFTED, DO NOT USE THE REAR HITCH AS THE LIFTING POINT AS THIS WILL CAUSE THE TRACTOR TO TILT AND POSSIBLY OVERTURN. c. Ensure that the directions shift lever is in the neutral position. d. Release the parking brake of the disabled unit and begin towing the unit. e. Once the destination is reached, stop both vehicles and set the parking brake on the disabled unit before removing the towing device. The disabled unit should be chocked in both directions at all four (4) wheels for additional stability. WARNING FAILURE TO SET THE PARKING BRAKE ON THE DISABLED UNIT BEFORE REMOVING THE TOWING DEVICE COULD ALLOW THE DISABLED UNIT TO ROLL AWAY UNCONTROLLED. Page 3-14

39 4. Trailer Towing Procedure Trailers are used in many configurations. The operator must be familiar with the style used in his work area. Two basic steering systems are found on these trailers, two wheel steer and four wheel steer. On the two wheel steer unit the front axle pivots in the center and is part of the tow bar. This system produces rear end swing (the corners of the trailers fill an area wider than the trailer when turning). CAUTION WHEN DRIVING, THE OPERATOR MUST REMAIN AWARE OF THIS EXTRA WIDTH WHILE MOVING AMONG OBSTACLES. ON THE FOUR WHEEL STEER TRAILERS THE FRONT AND REAR AXLES PIVOT ON TURNTABLES THAT ARE CONNECTED DIAGONALLY SO THAT THE WHEELS TURN IN OPPOSITE DIRECTIONS. THIS PERMITS THE TRAILER TO TRACK AND PREVENTS REAR END SWING WHEN TURNING. CAUTION THE OPERATOR MUST BECOME AWARE OF THE PARKING BRAKE SYSTEM USED ON THE TRAILERS IN HIS WORK AREA. Page 3-15

40 5. Test Switch Procedure a. Take the unit to a proper maintenance area, and apply the parking brake. b. Unbolt and remove the lower dash cover. LOWER DASH COVER REMOVE LOWER DASH COVER FIGURE c. If equipped with the ignition switch turn the ignition switch to the on position (ignition), leaving the engine off. If equipped with the push button switch, press the button once to turn unit on. Do not press a second time to start the engine. IGNITION SWITCH (ON POSITION) / PUSH BUTTON SWITCH FIGURE d. Flip the test switch up to activate the troubleshooting procedure. ACTIVATE TEST SWITCH FIGURE Page 3-16

41 e. Once the test switch is activated the sequence will start, with the engine light flashing the code three times in a row. The default code will be the first sequence displayed: This code will be flashed out three (3) times in a row. If is the only code that the engine light flashes, there are no fault codes present. If there are fault codes present, the three (3) or (4) digit fault codes will be flashed out after the default code. Once all of the faults have been flashed; will be flashed again and the sequence will start again. For further assistance with diagnostic problems, the complete diagnostic manual can be found on our website: mycharlatte.com. For a list of faults see the table below: Code Fault Name DTC 11 Intake CAM/Distributor Position DTC 16 Never crank synced at start DTC 91 FP low voltage DTC 92 FP high voltage DTC 107 MAP Low Voltage DTC 108 MAP High Pressure DTC 111 IAT higher than expected 1 DTC 112 IAT low voltage DTC 113 IAT high voltage DTC 116 ECT higher than expected 1 DTC 117 ECT/CHT Low Voltage DTC 118 ECT/CHT High Voltage DTC 121 TPS1 lower than TPS2 DTC 122 TPS1 low voltage DTC 123 TPS1 high voltage DTC 127 IAT higher than expected 2 DTC 129 BP low pressure DTC 134 EGO open/lazy pre cat 1 DTC 140 EGO open/lazy post cat 1 DTC 154 EGO open/lazy pre cat 2/post cat 1 DTC 160 EGO open/lazy post cat 2 DTC 171 AL high gasoline bank1 DTC 172 AL low gasoline bank1 DTC 174 AL high gasoline bank2 DTC 175 AL low gasoline bank2 DTC 182 FT Gasoline Low Voltage DTC 183 FT Gasoline High Voltage DTC 187 FT Gaseaous fuel low voltage DTC 188 FT Gaseaous fuel high voltage DTC 217 ECT higher than expected 2 DTC 219 Max govern speed override DTC 221 TPS1 higher than TPS2 DTC 222 TPS2 low voltage DTC 223 TPS2 high voltage DTC 236 TIP Active DTC 237 TIP Low Voltage DTC 238 TIP High Voltage DTC 261 Injector Loop Open or Low side short to Ground Page 3-17

42 Code Fault Name DTC 262 Injector Coil Shorted DTC 264 Injector Loop Open or Low side short to Ground DTC 265 Injector Coil Shorted DTC 267 Injector Loop Open or Low side short to Ground DTC 268 Injector Coil Shorted DTC 270 Injector Loop Open or Low side short to Ground DTC 271 Injector Coil Shorted DTC 273 Injector Loop Open or Low side short to Ground DTC 274 Injector Coil Shorted DTC 276 Injector Loop Open or Low side short to Ground DTC 277 Injector Coil Shorted DTC 279 Injector Loop Open or Low side short to Ground DTC 280 Injector Coil Shorted DTC 282 Injector Loop Open or Low side short to Ground DTC 283 Injector Coil Shorted DTC 285 Injector Loop Open or Low side short to Ground DTC 286 Injector Coil Shorted DTC 288 Injector Loop Open or Low side short to Ground DTC 289 Injector Coil Shorted DTC 301 Emissions/catalyst damaging misfire DTC 302 Emissions/catalyst damaging misfire DTC 303 Emissions/catalyst damaging misfire DTC 304 Emissions/catalyst damaging misfire DTC 305 Emissions/catalyst damaging misfire DTC 306 Emissions/catalyst damaging misfire DTC 307 Emissions/catalyst damaging misfire DTC 308 Emissions/catalyst damaging misfire DTC 326 Knock 1 Excessive Signal DTC 327 Knock 1 sensor Open DTC 331 Knock 2 Excessive Signal DTC 332 Knock 2 sensor Open DTC 336 Crank sync noise DTC 337 Crank loss DTC 341 Cam sync noise DTC 342 Cam loss DTC 420 Gasoline cat monitor DTC 430 Gasoline cat monitor DTC 524 Oil pressure low DTC 562 Battery Voltage Low DTC 563 Battery Voltage High DTC 601 Flash checksum invalid DTC 604 RAM failure DTC 606 COP failure DTC 615 Start relay coil open DTC 616 Start relay control ground short DTC 617 Start relay coil short to power DTC 627 Fpump relay coil open Page 3-18

43 Code Fault Name DTC 628 Fpump relay control ground short DTC 629 Fpump relay coil short to power DTC 642 5VE1 low voltage DTC 643 5VE1 high voltage DTC 650 MIL open DTC 685 Power Relay Coil Open DTC 686 Relay Control ground short DTC 687 Relay coil short to power DTC 1111 Fuel rev limit DTC 1112 Spark rev limit DTC 1121 FPP1/2 simultaneous voltages out of range DTC 1122 FPP1/2 do not match each other or the IVS DTC 1151 CL high LPG DTC 1152 CL low LPG DTC 1153 CL high NG DTC 1154 CL low NG DTC 1155 CL high gasoline bank1 DTC 1156 CL low gasoline bank1 DTC 1157 CL high gasoline bank2 DTC 1158 CL low gasoline bank2 DTC 1161 AL high LPG DTC 1162 AL low LPG DTC 1163 AL high NG DTC 1164 AL low NG DTC 1165 LPG cat monitor DTC 1166 NG cat monitor DTC 1171 Megajector delivery pressure higher than expected DTC 1172 Megajector delivery pressure lower than expected DTC 1173 Megajector comm lost DTC 1174 Megajector voltage supply high DTC 1175 Megajector voltage supply low DTC 1176 Megajector internal actuator fault detection DTC 1177 Megajector internal circuitry fault detection DTC 1178 Megajector internal comm fault detection DTC 1512 AUX analog PU1 low DTC 1521 CHT higher than expected 1 DTC 1522 CHT higher than expected 2 DTC 1561 AUX analog PD2 high DTC 1612 RTI 1 loss DTC 1613 RTI 2 loss DTC 1614 RTI 3 loss DTC 1615 A/D loss DTC 1616 Invalid interrupt DTC 1628 CAN addresss conflict failure DTC 1629 J1939 TSC1 message receipt lost DTC 1631 PWM1 Gauge1 open / ground short Page 3-19

44 Code Fault Name DTC 1632 PWM1 Gauge1 short to power DTC 1633 PWM2 Gauge2 open /ground short DTC 1634 PWM2 Gauge2 short to power DTC 1635 PWM3 Gauge3 open / ground short DTC 1636 PWM3 Gauge3 short to power DTC 1641 Buzzer control ground short DTC 1642 Buzzer open DTC 1643 Buzzer control short to power DTC 1644 MIL control ground short DTC 1645 MIL control short to power DTC 2111 Unable to reach lower TPS DTC 2112 Unable to reach higher TPS DTC 2115 FPP1 higher than IVS limit DTC 2116 FPP2 higher than IVS limit DTC 2120 FPP1 invalid voltage and FPP2 disagrees with IVS DTC 2121 FPP1 lower than FPP2 DTC 2122 FPP1 high voltage DTC 2123 FPP1 low voltage DTC 2125 FPP2 invalid voltage and FPP1 disagrees with IVS DTC 2126 FPP1 higher than FPP2 DTC 2127 FPP2 low voltage DTC 2128 FPP2 high voltage DTC 2130 IVS stuck at idle, FPP1/2 match DTC 2131 IVS stuck off idle, FPP1/2 match DTC 2135 TPS1/2 simultaneous voltages out of range DTC 2139 FPP1 lower than IVS limit DTC 2140 FPP2 lower than IVS limit DTC 2229 BP high pressure DTC 2300 Primary Loop Open or Low side Short to Ground DTC 2301 Primary Coil Shorted DTC 2303 Primary Loop Open or Low side Short to Ground DTC 2304 Primary Coil Shorted DTC 2306 Primary Loop Open or Low side Short to Ground DTC 2307 Primary Coil Shorted DTC 2309 Primary Loop Open or Low side Short to Ground DTC 2310 Primary Coil Shorted DTC 2312 Primary Loop Open or Low side Short to Ground DTC 2313 Primary Coil Shorted DTC 2315 Primary Loop Open or Low side Short to Ground DTC 2316 Primary Coil Shorted DTC 2318 Primary Loop Open or Low side Short to Ground DTC 2319 Primary Coil Shorted DTC 2321 Primary Loop Open or Low side Short to Ground DTC 2322 Primary Coil Shorted DTC 2618 Tach output ground short DTC 2619 Tach output short to power Page 3-20

45 CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS IV. SHIPPING A. Preparation For Shipping 1. Engine a. Disconnect both battery cables from the battery b. Drain coolant from radiator and engine block. c. Drain fuel from the fuel cell into DOT approved container. Put cap on fuel cell but leave loose. d. Disconnect fuel lines from fuel pump and allow the lines to drain. After the lines are dry then reconnect them to the fuel pump. e. See Chapter 5 for more detailed information. 2. Entire Unit a. If equipped, cab doors and windows must be secured. b. The tractor should be blocked and secured to the vehicle being used for transport. c. Any areas of the tractor that require attention due to missing or damaged components should be tagged on the tractor and noted on all shipping documents. CAUTION THE SUSPENSION ON THE TRACTOR AND THE SUSPENSION ON THE HAULING DEVICE MAY PRODUCE A HARMONIC CONDITION IF BOTH ARE FREE TO OPERATE; THEREFORE, THE TRACTOR SHOULD BE BLOCKED SO THERE IS NO LOAD ON THE SPRINGS. Page 4-1 Dec. 16

46 B. Preparation For Operation 1. Unloading a. Prior to unloading the unit from the hauling device, remove all blocks from the suspension. b. After the tractor is unloaded, remove the door and window restraints. c. Inspect the tractor for damage and check for tagged items on the tractor and on the shipping documents. d. Make all repairs. 2. Maintenance a. Torque the wheel nuts. aa. Front 150 ft.lb.(20.7 mk) bb. Rear 150 ft.lb.(20.7 mk) NOTICE HAVE ALL NECESSARY REPAIRS PERFORMED BY A QUALIFIED TECHNICIAN. b. Check that all fuel lines are connected and tight and that all drain valves are closed. c. Add fuel to the fuel cell and check for any leaks. d. Add coolants to radiator and reservoir then check for any leaks. e. Check all other fluid levels. (For proper levels, types, and locations see Maintenance Section.) f. Reconnect the battery cables to the battery. g. Test drive the unit before placing the unit back into service. Page 4-2 Dec. 16

47 CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS V. STORAGE A. One Month Storage 1. Tires a. The unit should be raised and securely blocked to prevent tires from contacting the ground and tire pressure reduced to 20 P.S.I. 2. Lubrication a. Completely grease, lubricate, and check all fluid levels as indicated in the Lubrication Section of this guide. 3. Battery a. The battery should be removed from the unit and stored separately in a cool dry location without direct sunlight. The temperature should be maintained between 32 F (0 C) and 90 F (32 C). 4. Engine WARNING WHEN THE UNIT IS RAISED AND BLOCKED, ALWAYS USE APPROVED BLOCKING DEVICES THAT WILL SUPPORT THE UNITS WEIGHT. AT LEAST FOUR (4) BLOCKING DEVICES SHOULD BE USED, TWO SHOULD BE PLACED UNDER THE FRONT AXLE AND TWO SHOULD BE PLACED UNDER THE REAR AXLE (ONE PER SIDE). a. See Chapter 5 for more detailed information. b. Drain oil from the crankcase. c. Drain coolant from the radiator and engine block. d. Drain fuel from the fuel cell into DOT approved container. Put cap on fuel cell but leave loose. e. Disconnect fuel lines from fuel pump and allow the lines to drain. After the lines are dry reconnect them to the fuel pump. Page 5-1 Dec. 16

48 B. Long Term Storage 1. Tires a. The unit should be raised and securely blocked to prevent tires from contacting the ground and tire pressure reduced to 20 P.S.I. 2. Lubrication a. Completely grease, lubricate, and check all fluid levels as indicated in the Lubrication Section of this guide. 3. Inspection a. A complete inspection should be made of the entire unit and a list of any problems, malfunctions or missing components should be attached to the unit to prevent hazardous operation when returned to service. 4. Protection a. If the unit is to be stored outside, a breathable cover should be considered. Sufficient air flow must be available to prevent a buildup of condensation that can cause more damage than exposure to the elements. 5. Motor/Electronics a. DO NOT SEAL ANY ELECTRIC MOTOR. Condensation readily forms inside the motor frame and can damage the internal components. Water must be prevented from dripping on, flowing into, or flooding the motor and other electrical components. 6. Engine WARNING WHEN THE UNIT IS RAISED AND BLOCKED, ALWAYS USE APPROVED BLOCKING DEVICES THAT WILL SUPPORT THE UNITS WEIGHT. AT LEAST FOUR (4) BLOCKING DEVICES SHOULD BE USED, TWO SHOULD BE PLACED UNDER THE FRONT AXLE AND TWO SHOULD BE PLACED UNDER THE REAR AXLE (ONE PER SIDE). a. See Chapter 5 for more detailed information. b. Drain oil from the crankcase. c. Drain coolant from the radiator and engine block. d. Drain fuel from fuel cell into DOT approved container. Put cap on fuel cell but leave loose. e. Disconnect fuel lines from fuel pump and allow the lines to drain. After the lines are dry reconnect them to the fuel pump. f. Clean linkages and other external moving parts then coat with a light oil. g. Plug any engine openings to prevent debris and insects from entering. CAUTION EXTENDED STORAGE CAN DAMAGE ENGINE SEALS. Page 5-2 Apr. 11

49 7. Battery a. The battery should be removed from the unit and stored separately in a cool dry location without direct sunlight. The temperature should be maintained between 32 F (0 C) and 90 F (32 C). b. Charge battery using a low current charge (3 amps or less) every 2 months. 8. Transmission a. See Chapter 5 for more detailed information. b. Drain transmission fluid and refill with new fluid. 9. Chassis CAUTION EXTENDED STORAGE CAN DAMAGE TRANSMISSION SEALS. a. Completely lubricate any moving parts as indicated in the Lubrication Section of this guide. b. Touch up any paint chips or flaws. c. Coat any bare metal with metal preservative or a light coating of grease or oil to prevent the onset of rust. d. Cover the seats if unit is stored outside. Page 5-3 Dec. 16