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Charlatte CT5G Manual

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MODEL CT5G
CHARLATTE AMERICA, INC.
600 MOUNTAIN LANE – P.O. BOX 968
BLUEFIELD, VA 24605
TELEPHONE: (276) 326-1510
FAX: (276) 326-1602
SPARE PARTS FAX: (276) 326-3898
e-mail: charlatteus@charlatteus.com
www.CharlatteAmerica.com
www.MyCharlatte.com
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.

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Summary of Contents for Charlatte CT5G

  • Page 1 FAX: (276) 326-1602 SPARE PARTS FAX: (276) 326-3898 e-mail: charlatteus@charlatteus.com www.CharlatteAmerica.com www.MyCharlatte.com 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.
  • Page 2 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.
  • Page 3 Revision REV. DATE DESCRIPTION  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.
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  • Page 5 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.
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  • Page 7 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.
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  • Page 9 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR ALPHABETICAL INDEX CHAPTER/SECTION PAGE Accelerator Pedal Operation ....................1/3 ........3-1 Parts ......................3/2 ....Figure 3-2-16 Removal/Installation ................2/3 ........3-1 Adjustment Instructions ................2/2 Alphabetical Parts List ................3/4 ........4-1 Axle, Front Description ....................
  • Page 10 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER/SECTION PAGE Brakes, Front Adjustment ....................2/2 ........2-1 Description ....................1/2 ........2-2 Parts (Calipers) ..................3/2 ...... Figure 3-2-5 Parts (System) ..................3/2 ....Figure 3-2-15 Removal/Installation ................2/3 ........3-7 Specifications ..................
  • Page 11 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER/SECTION PAGE Electrical System Description ....................1/2 ........2-3 Diagrams ....................4/1 ........1-1 Parts ......................3/2 ......Fig. 3-2-10 Removal/Installation ................2/3 ........3-33 Specifications ..................1/1 ........1-1 Trouble Shooting (Alternator / Battery) ............ 2/4 ........4-14 Trouble Shooting (System) ..............
  • Page 12 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER/SECTION PAGE Lubrication Alphabetical Table ..............2/1 ........1-18 Lubrication Chart ..................2/1 ........1-15 Lubricants, Fluids, And Capacities ............2/1 ........1-19 Maintenance Check List ................2/1 ........1-3 Numerical Parts List ..................3/3 ........3-1 Operating (Safety) ..................
  • Page 13 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER/SECTION PAGE Steering System Description ....................1/2 ........2-2 Hose Diagram ..................2/3 ........3-31 Parts (Cylinder Installation) ..............3/2 ......Fig. 3-2-2 Parts (Power Steering System) ............... 3/2 ......Fig. 3-2-9 Parts (Steering Column Installation) ............3/2 ......Fig. 3-2-13 Removal/Installation (Steering Cylinder) ..........
  • Page 14 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER/SECTION PAGE Transmission Shift Lever Operation ....................1/3 ........3-2 Parts (Assembly) ..................3/2 ......Fig. 3-2-18 Parts (Installation) ..................3/2 ......Fig. 3-2-17 Removal/Installation ................2/3 ........3-53 Trouble Shooting ..................2/4 ........4-1 Turn Signal Switch Operation ....................

  • Page 15: Table Of Contents

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS TABLE OF CONTENTS CHAPTER/SECTION PAGE I. SPECIFICATIONS AND CAPABILITIES ......1-1 A. Dimensions ..........................1-1 B. Performance ..........................1-1 C. Transmission ..........................1-1 D. Engine ............................1-1 E.
  • Page 16 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER/SECTION PAGE 19. Heater/Defroster ......................... 2-4 20. Wiper ............................ 2-4 III. OPERATION ............... 1-3 A. Instruments/Controls ........................ 3-1 1. Footbrake Pedal ........................3-1 2. Accelerator Pedal ....................... 3-1 3. Parking Brake Lever ......................3-1 4.
  • Page 17 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 1. Tires ............................. 5-2 2. Lubrication .......................... 5-2 CHAPTER/SECTION PAGE 3. Inspection ..........................5-2 4. Protection ..........................5-2 5. Motor/Electronics ....................... 5-2 6. Engine ..........................5-2 7. Battery ..........................5-3 8. Transmission ........................5-3 9.
  • Page 18 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR THIS PAGE INTENTIONALLY LEFT BLANK Chapter 1 Contents Dec. 17...

  • Page 19: Specifications And Capabilities

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS I. SPECIFICATIONS AND CAPABILITIES A. Dimensions Length, without hitch ............... 108 inches (2743 mm) Width, overall ................60 inches (1524 mm) Height, w/o cab ............... 57 inches (1448 mm) Height, overall with cab ............

  • Page 20: Suspension

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR G. Suspension Front ..................Leaf Springs Rear ..................Leaf Springs H. Braking NOTICE FOR MORE DETAILED DESCRIPTION OF REAR DISC BRAKES, SEE CHAPTER 5 Master Cylinder Type .............. Single Circuit Brake System ................Vacuum Booster Front Type…………………………………………………………Disc...

  • Page 21: Description

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 22: Components/Systems

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 23: Rear Brakes

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 24: Tow Attachment

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 25: Operation

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS III. OPERATION A. Instruments/Controls CONSOLE PARKING BRAKE CONTROLS LEVER FOOTBRAKE PEDAL ACCELERATOR PEDAL OPERATORS COMPARTMENT FIGURE 1-3-1 Footbrake Pedal The footbrake pedal is located in the normal automotive position and operates the rear brakes.

  • Page 26: Ignition Switch / Push Button Switch

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR FUEL TRANSMISSION GAUGE SHIFT LEVER HEATER SWITCH HEADLIGHT SWITCH IGNITION SWITCH CONSOLE CONTROLS HOURMETER FIGURE 1-3-2 4. Ignition Switch / Push Button Switch 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.

  • Page 27: Transmission Shift Lever

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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”...

  • Page 28: Turn Signal Switch

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 29: Hourmeter

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 30: Check Battery Voltage Light

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 31: Water Valve Lever

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 32: Safety

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 33: Procedures

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.
  • Page 34 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.
  • Page 35 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR Move the transmission shift lever into either the “FORWARD” or “REVERSE” position. FORWARD REVERSE TRANSMISSION SHIFT LEVER (“FORWARD” / “REVERSE” POSITIONS) FIGURE 1-3-23 m. Release foot brake pedal. RELEASE FOOT BRAKE PEDAL FIGURE 1-3-24...
  • Page 36 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 37: Shutdown

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 38: Tractor Towing Procedure

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 39: Trailer Towing Procedure

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 40: Test Switch Procedure

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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 1-3-29 c.
  • Page 41 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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: 1-6-5-4. This code will be flashed out three (3) times in a row.
  • Page 42 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR Code Fault Name Injector Coil Shorted Injector Loop Open or Low‐side short to Ground Injector Coil Shorted Injector Loop Open or Low‐side short to Ground Injector Coil Shorted Injector Loop Open or Low‐side short to Ground Injector Coil Shorted Injector Loop Open or Low‐side short to Ground...
  • Page 43 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR Code Fault Name Fpump relay control ground short Fpump relay coil short to power 5VE1 low voltage 5VE1 high voltage MIL open Power Relay Coil Open Relay Control ground short Relay coil short to power...
  • Page 44 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR Code Fault Name 1632 PWM1‐Gauge1 short to power 1633 PWM2‐Gauge2 open /ground short 1634 PWM2‐Gauge2 short to power 1635 PWM3‐Gauge3 open / ground short 1636 PWM3‐Gauge3 short to power 1641 Buzzer control ground short...

  • Page 45: Shipping

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 46: Preparation For Operation

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 47: Storage

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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.

  • Page 48: Long Term Storage

    CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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. WARNING WHEN THE UNIT IS RAISED AND BLOCKED, ALWAYS USE APPROVED BLOCKING DEVICES THAT WILL SUPPORT THE UNITS WEIGHT.
  • Page 49 CHARLATTE AMERICA, INC. CT5G GASOLINE CARGO TRACTOR 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...
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