1. Manuals
  2. Brands
  3. TUG Manuals
  4. Tractor
  5. M3
  6. Maintenance manual

TUG M3 Maintenance Manual

Electric tow tractor
Hide thumbs Also See for M3:
Table of Contents

Advertisement

Quick Links

Maintenance

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the M3 and is the answer not in the manual?

Questions and answers

Related Manuals for TUG M3

Summary of Contents for TUG M3

  • Page 1 Maintenance...
  • Page 2 Maintenance SECTION PAGE MAIN POWER ("IGNITION") SWITCH REMOVAL ............... 2 MAIN POWER ("IGNITION") SWITCH INSTALLATION ............... 2 MASTER CYLINDER REMOVAL ....................3 MASTER CYLINDER INSTALLATION ................... 3 STEER VALVE REMOVAL ......................3 STEER VALVE INSTALLATION ..................... 4 TIRES AND WHEELS ........................4 ACCELERATOR PEDAL INSTALLATION: ..................
  • Page 3 SECTION PAGE VERTICAL HEADLIGHT ADJUSTMENT ..................1 FRONT SPRING PRELOAD ADJUSTMENT ................2 BLEED REAR BOOSTED BRAKES (CONT) ................4 INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE ............1 SAFETY PREREQUISITES ......................1 PROCEDURE ..........................1 Chapter 2-Contents Aug, 1997 p. 3...
  • Page 4 (This Page Intentionally Left Blank) Chapter 2-Contents Aug, 1997 p. 4...
  • Page 5 GENERAL PREPARATIONS FOR USE: 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.
  • Page 6 SERVICING GENERAL PREPARATIONS FOR USE: Brake System (cont) Service brakes should be tested for pedal firmness and braking effectiveness. 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"...
  • Page 7 CHART IN APPENDICES CHAPTER) THE TRACTOR SHOULD BE MAINTAINED IN ACCORDANCE WITH THE FOLLOWING SCHEDULES: Daily; Check: That all controls are in good working order. Report a faulty TUG control and do not use until repaired. Battery charge level. Hydraulic fluid level.
  • Page 8 SERVICING PREVENTIVE MAINTENANCE SCHEDULE (CONT) Monthly or 200 Hour Check: 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.
  • Page 9 Drain, flush and refill the hydraulic steering system. Drain & refill planetary drive hubs. (See Figure 3 and Chapter 5 Supplement) Lubricant Chart Schematic ITEM # COMPONENT/SYSTEM STEER CYLINDER ENDS KING PINS (TOP) TIE ROD ENDS KING PINS (BOTTOM) WHEEL BEARINGS PLANETARY REDUCTION HUBS HYDRAULIC PUMP Figure 4...

  • Page 10: Preventive Maintenance Schedule

    PREVENTIVE MAINTENANCE SCHEDULE Lubricant Tables (cont.) 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...

  • Page 11: Disconnect The Battery

    3. WAIT 10 SECONDS, THEN TURN THE KEY OFF. DIAGNOSTICS: The SC2000 controller in your M3 Tow Tractor contains a powerful fault diagnostic system that must be used in conjunction with a portable electronic diagnostics computer. This device, referred to in the following pages as a "handset"...
  • Page 12 Diagnostic LED Handset Plugs Chapter 2: Maintenance Mar, 1996 Section 2-2 p. 2...
  • Page 13 TROUBLESHOOTING (CONT) CAN CONTROLLER A sophisticated yet easy to use hand held adjustment unit, called the Can Controller is used to make adjustments to the controller and select configurations. The CAN Controller is also used as a diagnostic tool displaying the status of all voltages, currents and temperatures within the controller together with the condition of all the controllers switch and analogue inputs.
  • Page 14 TROUBLESHOOTING (CONT) TRACTION PERSONALITIES (CONTROLLER ADJUSTMENTS) Cal. Parameter Adjusted Min Settings Max. SettingsMax Settings Step Size Factory Settings Ref. (All Units) (500A units) (650A units) (all units) (all units) 1.1.1 Current Limit Min. Setting 500A 650A 10 Amps 500A 1.1.2 Acceration Delay Max.
  • Page 15 TRACTION FAULT MESSAGES Message No. of Flashes Description Check (on) Traction Operational “Sequence Fault” Direction or FSl sw at power up Dir and FS1 in neutral, Wiring “2 Dir Fault” Two directions selected together Only one direction selected, Wiring “SRO Fault” Dir sw selected >2secs after FSl Dir first then FS1, FS1 wiring “Seat Fault”...
  • Page 16 TROUBLESHOOTING (CONT) STATUS Status indicators provide information on the voltages and currents of various components both within the controller and throughout the tractor. The normal status readings available are as follows: Key on - Not Driving Battery Voltage: 0 - 127 volts. 80-86 volts Traction Motor Voltage Left: 0 - 127 volts.
  • Page 17 SC2000 FAULT FINDING FLOW CHARTS Two Flash Fault (2FF) - Procedure Fault CAN Calibrator Display Message CONDITION CHECK Direction or FS1 1. Direction & FS1 are in Sequence Selected at Key Neutral at Key Switch On Fault? Switch on. 2. Wiring is Correct 1.
  • Page 18 SC2000 FAULT FINDING FLOW CHARTS Three Flash Fault (3FF) - Bypass Contactor Welded CAN Calibrator Display Message CONDITION CHECK 1. Bypass contactor 1. Direction & FS1 are in MOFSET Short circuit. Neutral at Key Switch On S/C? 2. Mofsets short 2.
  • Page 19 Four Flash Fault (4FF) - Contactor Fault or Motor Open Circuit (O/C) - Contactor Fault or Motor Short Circuit (S/C) CAN Calibrator Display Message CONDITION CHECK 1. Contactor coil wiring. Forward Forward contactor 2. Contactor power cable O/C? did not close. wiring.
  • Page 20 TROUBLESHOOTING (CONT) SC2000 FAULT FINDING FLOW CHARTS Four Flash Fault (4FF) - Contactor Fault or Motor Short Circuit (cont) CAN Calibrator Display Message CONDITION CHECK 1. Welded contactor tips. Contactor Forward or Reverse 2. Contactor power cable S/C? contactor short circuit. wiring.
  • Page 21 SC2000 FAULT FINDING FLOW CHARTS (CONT) Five Flash Fault (5FF) - Capacitor Fault CAN Calibrator Display Message CONDITION CHECK 1. Power cable wiring. Capacitor Main capacitors not 2. Charge resistor Fault? charging at power up. open circuit. 3. Replace controller. field short circuit.
  • Page 22 SC2000 FAULT FINDING FLOW CHARTS Six Flash Fault (6FF) - Accelerator Fault CAN Calibrator Display Message CONDITION CHECK 1. Accelerator pedal 1. Accelerator pedal is at Acceler. depressed with rest at key switch on. Fault? key switch on. 2. Accelerator wire off. 2.
  • Page 23 SC2000 FAULT FINDING FLOW CHARTS Seven Flash Fault (7FF) - Low Battery Voltage CAN Calibrator Display Message CONDITION CHECK 1. Correct battery voltage. Battery Battery Voltage < low Low? battery personality 2. Power connections, fuses, etc. 3. Battery charge level. 4.
  • Page 24 TROUBLESHOOTING (CONT) SC2000 FAULT FINDING FLOW CHARTS (CONT) Eight Flash Fault (8FF) - Over Temperature CAN Calibrator Display Message CONDITION CHECK 1. Current limit setting. Thermal Traction heatsink > 75°C. Cutback? 2. Mounting and heatsink of controller. 3. Bypass operating. 4.
  • Page 25 SC2000 FAULT FINDING FLOW CHARTS Nine Flash Fault (9FF) - Accelerator Fault CAN Calibrator Display Message CONDITION CHECK 1. Contactor coil 1. Contactor coil drive pin Coil short circuit. connected directly to B+. S/C? 2. Contactor coil 2. Contactor coil short circuit.
  • Page 26 TROUBLESHOOTING (CONT) SC2000 FAULT FINDING FLOW CHARTS (CONT) One Flash Fault (1FF) - Personality or configuration error. CAN Calibrator Display Message CONDITION CHECK Personality or Reconfigure and check Error? configuration error. all personalities. Chapter 2: Maintenance Mar, 1996 Section 2-2 p.
  • Page 27 SC2000 FAULT FINDING FLOW CHARTS (CONT) LED off - Unit will not power up or controller faulty. CAN Calibrator Display Message CONDITION CHECK 1. Battery connected and Coil Controller unable to keyswitch on. S/C? auto-failsafe check. 2. Fuses ok. 3. Supply wiring. 4.
  • Page 28 TROUBLESHOOTING (CONT.) 72/80 VOLT SYSTEMS COMPLAINT CAUSE CORRECTION 1. Partial or complete loss of (a) Main Switch in "Off" posi- (a) Turn main power switch on. 12V power (automotive tion. systems) (b) No 80v power going into (b) Check inline fuse. converter.
  • Page 29 TROUBLESHOOTING (CONT.) COMPLAINT CAUSE CORRECTION 1. Excessive pedal travel or (a) Low fluid level (a) Add fluid, bleed system, pedal goes to floor consis- check for leaks. tently. (b) Hydraulic system. (b) Refer to master cylinder. (c) Loose or improper attach- (c) Repair or replace as re- ment of pedal, pedal quired.
  • Page 30 TROUBLESHOOTING (CONT. COMPLAINT CAUSE CORRECTION 3. Noise at wheels when (a) Worn or scored brake rotors (a) Inspect, repair or replace as brakes are applied-squeaks & pads. required. or chatter. (b) On disc brakes- missing or (b) Replace disc brake pads. damaged brake pad insula- tors (c) Burrs or rust on caliper that...

  • Page 31: Parking Brake

    PARKING BRAKE COMPLAINT CAUSE CORRECTION 1. Parking brake will not hold. (a) Parking brake cable out of (a) Adjust parking brake cable. adjustment. (b) Parking brake linkage, (b) Repair or replace linkage as release lever & clevis. reqd. 2. Parking brake will not (a) Manual release brake (a) Repair or replace manual release or fully return.
  • Page 32 J. 12 VOLT LADDER SCHEMATIC Chapter 2: Maintenance Mar, 1996 Section 2-2 p. 22...
  • Page 33 K. M3 COMPLETE WIRING DIAGRAM Chapter 2: Maintenance Aug, 1997 Section 2-2 p. 23...
  • Page 34 Chapter 2: Maintenance Aug, 1997 Section 2-2 p. 24...
  • Page 35 III. REMOVAL/INSTALLATION The following procedures for removal and installation of vehicle components outline the steps and precautions to take when removing items for replacement or repair. WARNING! WHEN TESTING AN ELECTRIC VEHICLE, JACK THE DRIVE WHEELS OFF THE GROUND AND SECURE IN THIS POSITION WITH JACK STANDS OF ADEQUATE CAPACITY. DANGER - AVOID DEATH - WHEN TESTING THE CONTROLLER, DO NOT TOUCH HIGH VOLT- AGE CONNECTIONS EXCEPT WITH PROPER TEST EQUIPMENT.
  • Page 36 III. REMOVAL/INSTALLATION (CONT) SHIFTER ASSEMBLY REMOVAL WARNING! DISCONNECT BATTERY AND DISCHARGE CAPACITORS PRIOR TO BEGINNING THIS OPERATION. Unscrew shifter knob. Remove rubber boot retainer ring & rubber boot. Remove (2) mounting fasteners. Slide shifter down through mounting hole. Remove wiring. SHIFTER ASSEMBLY INSTALLATION Hold shifter assembly without knob UNDER mounting hole in approximate mounted position.

  • Page 37: Master Cylinder Removal

    Slide switch into console door switch mounting hole. Thread on outside mounting ring. Attach wiring. MASTER CYLINDER REMOVAL Open Console door. Remove brake lines from cylinder body. Plug brake line ports or drain brake fluid into appropriate container. Remove (2) mounting bolts and nuts. Slide master cylinder off of push rod.

  • Page 38: Tires And Wheels

    III. REMOVAL/INSTALLATION(CONT) STEER VALVE INSTALLATION Attach hydraulic lines (see diagram) to steer valve. Align steer valve with column so that line ports face toward front of vehicle. Wire attachment points should be on driver's right side of column. Slide steer valve assembly up through mounting hole. Hold assembly together as bolts are worked through holes and column flange, and into steer valve.

  • Page 39: Accelerator Pedal Removal

    Install the wheel to the hub with five (5) lug nuts and torque to 125 ft. - lbs. ACCELERATOR PEDAL REMOVAL: Note: Accelerator Pedal Assembly on the Tug model M3 is a specialized Morse control that combines the pedal and cable assemblies into a single assembly. Removal and installation instructions in this section assume complete removal of this assembly.
  • Page 40 III. REMOVAL/INSTALLATION(CONT) ACCELERATOR PEDAL INSTALLATION: Remove left side service access panel. Remove console cover plate (between seats). Open console access door. Work cable through pedal mount opening, through console area and out to electrical service area. Connect cable tip to accelerator box lever. Locate accelerator box.
  • Page 41 NOTE: USE BACK UP WRENCHES ON ALL MATING FITTINGS. Gently rotate pump to reveal access to hydraulic line connections. Remove hydraulic lines at elbows. Remove pump & reservoir assembly. Power Brakes Figure 2 Power Steering HYDRAULIC STEERING PUMP INSTALLATION Place pump & reservoir assembly into floor of right side service bin, reservoir end toward rear of vehicle.
  • Page 42 III. REMOVAL/INSTALLATION(CONT) HYDRAULIC STEERING PUMP INSTALLATION (CONT) Connect electrical wiring. Top off hydraulic fluid in reservoir. Replace right side access panel. BRAKE BOOSTER PUMP REMOVAL WARNING! DISCONNECT BATTERY AND DISCHARGE CAPACITORS PRIOR TO BEGIN- NING THIS OPERATION: TURN THE IGNITION KEY ON. DISCONNECT THE BATTERY.
  • Page 43 Due to their placement in the drive tube, each set of brushes must be accessed from a different angle. Provisions have been made in the design of the M3 Tow Tractor so that all four brush placements in each of the two drive motors are accessible without removing the drive motors.
  • Page 44 III. REMOVAL/INSTALLATION(CONT) REPLACE DRIVE MOTOR BRUSHES (CONT) From top of vehicle, replace third set of brushes. Access fourth set through access hatch in battery compartment. Replace fourth set of brushes in both drive motors. Replace brush protection rings. Replace access panels. Jack vehicle back down to floor.
  • Page 45 DRIVE MOTOR(S) INSTALLATION WARNING! DISCONNECT BATTERY AND DISCHARGE CAPACITORS PRIOR TO BEGINNING THIS OPERATION: TURN THE IGNITION KEY ON. DISCONNECT THE BATTERY. WAIT 10 SECONDS, THEN TURN THE KEY OFF. Note: Motor cover is the sloped access panel located in the center-rear of the vehicle just behind the battery.
  • Page 46 III. REMOVAL/INSTALLATION CONTACTOR TIPS REMOVAL/REPLACEMENT (CONT) DISCONNECT THE BATTERY. WAIT 10 SECONDS, THEN TURN THE KEY OFF. Figure 3 Remove left side service cover. Locate individual contactor or contactors to be serviced. Disconnect all attached electrical cables using 17mm open-end wrench. Rotate conductor bars out of the way if applicable.

  • Page 47: Battery Removal/Replacement

    Carefully remove center springs (2) from center post of middle contacts. Slide lower contactor tip set off of insulator posts, replace. Replace center set. Remove upper contactor tips using wrench, replace. Replace inner and outer center springs. Reattach contactor tips cover, thread in and tighten (2) slot screws. Attach electrical cables and conductor bars (if applicable).
  • Page 48 III. REMOVAL/INSTALLATION (CONT) PLANETARY REDUCTION HUBS REMOVAL (CONT) WAIT 10 SECONDS, THEN TURN THE KEY OFF. Chock front tires. Jack rear of tractor, secure with jack stands beneath rear bumper. Remove tire. Follow instructions for removal of drive motor(s). Drive motors must be removed to access hub mount plates.

  • Page 49: Park Brake

    PARK BRAKE Discussion When properly adjusted, the parking brake will prevent the M3 Tow Tractor from rolling when parked on a 15% grade. Engaging a properly adjusted parking brake should not require an excessive amount of force, however some slight resistance will be present when engaging.
  • Page 50 FRONT SPRING PRELOAD ADJUSTMENT Discussion: Due to the variations in battery weight available in the M3, the front springs should be adjusted to provide the appropriate front wheel camber. The appropriate camber setting is +1 degree past vertical (see figure 1). Adjusting the front spring preload adjusts the...
  • Page 51 Tighten lock nuts; replace console access cover. BLEED REAR BOOSTED BRAKES The rear brakes on the M3 tow tractor are boosted by a hydraulic pump located in the right side service compartment. Whereas the bleeding process for the rear brakes is straightforward, there...
  • Page 52 ADJUSTMENTS BLEED REAR BOOSTED BRAKES (CONT) IMPORTANT: DO NOT remove the brake booster reservoir. Doing so will break the seal between the reservoir and the pump, and cause leakage. Chapter 2: Maintenance Sept. 1995 Section 2-4 p. 4...
  • Page 53 INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE SAFETY PREREQUISITES Use only duty-rated jacks and jack stands. Floor jack should be rated for a minimum of two tons. Jack stands should be rated for at least one ton each. Except in emergency situations, tractor should be parked on flat, high quality concrete surface before jacking.
  • Page 54 (This Page Intentionally Left Blank) Chapter 2: Maintenance Aug, 1996 Section 2-5 p. 2...

Table of Contents