Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A NOTE TO THE RECIPIENT - This packet is one component of two or more components required to comprise a complete publication. The following items, shipped under separate part number, are used with this publication: • Expandable storage binder (Binder label provided in printed material packets.) © AGCO Corporation, 2009 All rights reserved.
Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A CONTENTS INTRODUCTION.............................................................................................................................................. 01 ENGINE ........................................................................................................................................................... 02 POWERTRAIN.........................................................................................................
Label Only TERRA GATOR 3244 CHASSIS Service Manual Volume Master No.
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 01 - Introduction Contents Follow Safety Instructions .......................................................................................................................... 1-1 Prepare for Emergencies ........................................................................................................................... 1-1 Safety Alert Symbol .....................................................................................
Contents Hydraulic Hoses ....................................................................................................................................... Avoid Heating Near Pressurized Fluid Lines ........................................................................................... Service Cooling System Safely ................................................................................................................ Remove Paint Before Welding Or Heating ..................................
Safety SAFETY IMPORTANT: Any modifications to machine or systems not authorized by AGCO void warranty. This includes, but is not limited to hitches. FOLLOW SAFETY INSTRUCTIONS FIG. 1: Carefully read, learn and understand all safety messages and information in this manual and on machine's safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Make sure new machine components and repair parts include current safety signs.
Safety SAFETY ALERT SYMBOL FIG. 3: This is the safety alert symbol and it means attention, become alert, safety is involved. Look for the safety alert symbol in this manual and on safety signs on machine, it directs attention to information involving operator safety and safety of others. 0001 FIG. 3 SIGNAL WORDS Danger, warning or caution are used with the safety alert symbol. Learn to recognize these safety alerts and follow recommended precautions and safe practices.
Safety IMPORTANT SAFETY INFORMATION GENERAL HAZARD INFORMATION Most personal injuries occur during product operation, maintenance or repair and are caused by failure to observe basic safety rules and precautions. In most cases, an injury can be avoided by recognizing hazardous situations before an injury occurs. Do not start engine until area is free of personnel to avoid personal injury due to unexpected machine movement.
Safety Pressurized Air Air under pressure can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing and protective shoes. Maximum air pressure for cleaning purposes must be below 205 kPa (30 PSI). Asbestos Information AGCO equipment and replacement parts shipped from AGCO are asbestos-free. AGCO recommends use of only genuine AGCO replacement parts.
Safety Before Starting Engine Operation Start engine only from operator station. Never short across starter terminals or batteries. Shorting could damage electrical system or cause unexpected machine movement. Only operate machine while in operator seat. Seat belt must be fastened during operation. Only operate controls while engine is running. Adjust seat so full pedal travel can be achieved with operator's back against back of seat.
Safety Parking Hydraulic Safety Park on a level surface. If parking on a grade is necessary, chock machine’s tires. Machine uses high-pressure fluids for operation. If injured by escaping fluid, seek medical attention immediately. Move transmission control lever to park. Before stopping engine, move throttle control lever to low idle. Run engine at low idle speed for five minutes to allow turbocharger to cool.
Safety Chemical Safety Do not perform any maintenance on machine until all chemicals have been thoroughly rinsed from outside and entire system has been flushed. m DANGER: Contact with chemicals can cause injury or death. Select an area to fill, flush, calibrate and decontaminate machine. Select an area where hazardous chemicals will not drift or run off to contaminate people, animals, vegetation or water supply. Follow instructions on all signs and labels. Wear approved hand, eye and body protection.
Safety EMERGENCY EXIT FROM CAB FIG. 4: Understand the procedure to use the emergency exit from the Right Hand side of the cab before operating the vehicle. 1. Pull green tab located at the rear of the Right Hand Cab Window. This removes the glass seal. 2. Push out the Right Hand Cab Window and exit the vehicle. FIG. 4 OPERATING THE VEHICLE SAFELY FIG. 5: Wear a seat belt at all times. FIG. 5 FIG. 6: Make sure the operator and ladder areas are clean and dry to help prevent personal injuries.
Safety FIG. 7: When leaving the vehicle unattended, engage the Parking Brake and remove the key. FIG. 7 PREVENT VEHICLE RUNAWAY FIG. 8: Avoid possible injury or death from vehicle runaway. Never start the engine by shorting across the starter terminals. The engine will start, and the vehicle will move if normal circuitry is bypassed. Never start the vehicle's engine while standing on the ground.
Safety TRAVELING ON PUBLIC ROADS m CAUTION: This vehicle was designed for applying chemicals and fertilizers in off-road use. Do not use the vehicle for transporting product over public roads. Chemical spills may occur resulting in environmental damage. A loaded vehicle driven on public roads also runs the high risk of tire failure. Personal Injury could result. ALWAYS walk around and visually inspect the vehicle before traveling on public roads.
Safety SYSTEM BOOM SAFETY FIG. 10: If you have a system with booms, make sure no personnel or objects are ever in the path of the booms before operating them. Especially, when retracting or extending the booms. Be aware of the location of the booms at all times. Before driving on public roads, retract and lock the booms if applicable. FIG. 10 AVOID EYE CONTACT WITH RADAR FIG. 11: Radar ground sensors emit a low intensity microwave signal.
Safety OVERHEAD ELECTRICAL POWER LINES FIG. 13: Never let the vehicle come into contact with overhead power lines. All antennas must be bent over and secured in place any time overhead electrical power lines are near the vehicle. This can decrease the possibility that the vehicle may come into contact with an overhead power line when in operation or when the vehicle is transported. FIG. 13 NOISE FIG. 14: Long periods of exposure to high decibels or loud noise can cause hearing impairment or loss.
Safety STAY CLEAR OF ROTATING DRIVE LINES AND MOVING PARTS FIG. 16: Entanglement in rotating drive lines or moving components will cause serious injury or death. FIG. 16 FIG. 17: Keep all safety guards and shields in place at all times when operating the vehicle. Turn the key switch to the OFF position. Remove the key from the switch to prevent unauthorized operation of the vehicle before removing any safety guards and shields. Wear close fitting clothing.
Safety MAINTENANCE AND SERVICE SAFETY FIG. 19: Read the maintenance and safety instructions and understand them before performing any maintenance procedures. Never perform any maintenance procedures or repairs if the instructions and safety procedures are not fully understood. Only trained and qualified personnel should perform any maintenance procedures or repairs. Never modify any equipment or add attachments not approved by Challenger. FIG. 19 PRACTICE SAFE MAINTENANCE FIG.
Safety CHEMICAL SAFETY Operator Cabs FIG. 22: Some cabs use filters that MAY NOT filter out dangerous chemicals. Follow instructions given by the chemical manufacturer. Cabs labeled as "Enclosed Cabs for Pesticide Application Incorporating Respiratory Protection" or "ECPAR" comply with ASAE S525 and EPA Worker Protection Standards for operating in a pesticide environment. This does not include fumigants. (Look for the ECPAR decal to check if the cab is an ECPAR cab.
Safety FIG. 25: Clean the vehicle of hazardous chemicals after use. Hazardous chemical residue can build up on the inside and outside of the vehicle. Direct exposure to hazardous chemicals can cause serious injury or death. Potentially hazardous chemicals used with Challenger equipment include such items as fuel, lubricants, coolants, hydraulic fluid, paints and adhesives. FIG. 25 FIG.
Safety UNDERSTAND CORRECT SERVICE FIG. 29: Light your working area properly, adequately and safely. Use proper safety lights with wire safety cages. Exposed bulbs can ignite fluids. Catch draining fluids in proper containers. Never use beverage containers that could mislead personnel to drink from them. FIG.
Safety USE PROPER TOOLS FIG. 30: Make-shift tools and procedures can create safety hazards. Use only the proper equipment and procedures. Use power tools only to loosen threaded parts and fasteners. Use only U.S. tools with U.S. fasteners and metric tools with metric fasteners. FIG. 30 SUPPORT MACHINE PROPERLY FIG. 31: Never support the vehicle on cinder blocks, hollow tiles or supports that may crumble. Never work under a vehicle that is only supported by a jack. Use wheel chocks. FIG.
Safety HIGH-PRESSURE FLUIDS FIG. 33: AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. The vehicle must be stopped and cooled before checking fluids. Use caution when removing radiator caps, plugs, grease fittings or pressure taps. Never open pressure lines when they are under pressure. Release all pressure before doing maintenance or repairs on any pressure system. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Safety SERVICE COOLING SYSTEM SAFELY FIG. 36: Explosive release of fluids from pressurized cooling systems can cause serious burns. Shut off the engine. Remove the filler cap only when it is cool enough to touch with bare hands. Slowly, loosen the filler cap to the first stop to relieve any pressure before removing the cap completely. FIG. 36 REMOVE PAINT BEFORE WELDING OR HEATING FIG. 37: Avoid potentially toxic fumes and dust.
Safety TIRES AND WHEELS FIG. 39: Never weld on a wheel or rim that has a tire on it. Never attempt to mount or remove a tire unless using the proper equipment, tire safety cage, instructions, training and are qualified to perform the work safely. Failure to follow the correct procedures when mounting a tire on a wheel or rim can cause an explosion and serious injury. Tire repairs procedures must be performed by trained and qualified personnel. FIG. 39 DISPOSE OF WASTE PROPERLY FIG.
Safety MAINTENANCE IN THE ARTICULATION JOINT (HINGE) AREA FIG. 41: Before performing maintenance in the area of the articulation joint or the steering hydraulic cylinders the following procedure MUST be followed: 1. Steer the vehicle into the straight ahead position. 2. Shut the engine off and remove ignition key, lock the cab door after leaving the cab so that nobody can accidentally turn the steering wheel. 3.
Safety SAFETY AND SERVICE DECAL LOCATIONS CHASSIS m WARNING: Carefully read and understand all safety signs on your vehicle. Failure to read and understand all safety signs may result in personal injury or death. Always be aware of a safety hazard. Make sure new equipment components and repair parts include the current safety signs. 17 12 13 13 18 18 15 15 6 6 14 19 19 20 21 3 5 10 17 4 19 1 1 4 19 M00112 FIG.
Safety 6 16 2 7 17 8 12 17 9 3 10 11 M00113 FIG.
Safety FIG. 44: 1. Caution - No clearance for person in the working area of the machine. Q000115S FIG. 44 FIG. 45: 2. Warning - External hydraulic system filled with ISO VG 46. P625052-A FIG. 45 FIG. 46: 3. Caution - Do not work under the cab, when the Safety pin is not mounted. Q000116S FIG.
Safety FIG. 47: 4. Danger - No clearance for person in this area when turning vehicle. Keep distance/pinching hazard. Q000117S FIG. 47 FIG. 48: 5. Warning - Tipping over order cabin. i. Open engine hood; ii. Dismount side panels engine hood; iii. Check if there are no loose parts in the cab, and everything is ready to tip over the cab; iv. Dismount safety pin; v. Tip over cab; vi. Mount safety pin. Q625171-B FIG.
Safety FIG. 49: 6. Read and understand the operators manual. This decal is in a vertical and in a horizontal position available. Q000118S FIG. 49 FIG. 50: 7. Warning - Beware of leaking hydraulic lines/hoses. Q000119S FIG. 50 FIG. 51: 8. Secondary Fresh Air Filter. Q000134S FIG.
Safety FIG. 52: 9. Primary Fresh Air Filter. Q000133S FIG. 52 FIG. 53: 10. Warning - Radar Hazard, do not look into the radar. Q000120S FIG.
Safety FIG. 54: 11. Warning - Tire Pressure - Read Operator’s Manual. Q000121S FIG. 54 FIG. 55: 12. Danger - Explosion Hazard - Disconnect Battery. Q000122S FIG. 55 FIG. 56: 13. Warning - Remove Key Before Maintenance Rotating Blades. Q000123S FIG.
Safety FIG. 57: 14. Hazard - Hot surface, Exhaust. Q000124S FIG. 57 FIG. 58: 15. Warning - Remove Key Before Maintenance. Q000125S FIG. 58 FIG. 59: 16. Hazard - Hot FLuid, Burn Hazard. Remove Key, Read Manual, Cooldown Before Opening Radiator Pressure Cap. Q000126S FIG.
Safety FIG. 60: 17. Prohibition No Waterhose. Q000127S FIG. 60 FIG. 61: 18. Use Only Specified Diesel, See Engine Operators Manual P511414D1-01 FIG. 61 FIG. 62: 19. Retorque Wheel Bolts With 720 Nm. M619590-A FIG. 62 FIG. 63: 20. Handwash Tank. Q000128S FIG.
Safety FIG. 64: 21. Fuse Panel. See Also Chapter Lubrication and Maintenance. P503379D1 FIG. 64 FIG. 65: 22. Relay panel. See Also Chapter Lubrication and Maintenance. P624972-A FIG.
Safety SAFETY AND SERVICE DECAL LOCATIONS CABINE m WARNING: Carefully read and understand all safety signs on your vehicle. Failure to read and understand all safety signs may result in personal injury or death. Always be aware of a safety hazard. Make sure new equipment components and repair parts include the current safety signs. 25 24 23 26 27 6 28 q000146s FIG.
Safety FIG. 67: 23. Fresh Air Filter Cabine. Q000135S FIG. 67 FIG. 68: 24. Emergency EXIT. Q000129S FIG. 68 FIG. 69: 25. Danger - Electrocution Hazard Q000130S FIG.
Safety FIG. 70: 26. Warning - Wear Seat belt and hold on to steering wheel if machine tips over. Q000131S FIG. 70 FIG. 71: 27. Warning - Fall hazard. FIG. 71: Q000132S FIG.
Safety P620590-C FIG. 72 28. Tire Pressure Chart. See Also Chapter Lubricatoin And Maintenance.
General GENERAL SERVICE MANUAL This service manual has been prepared with the latest service information available at publication time. Read service manual carefully before performing any service on machine. Right-hand and left-hand, as used in manual, are determined by facing the direction machine travels when in use. Photos, illustrations and data used in manual were current at time of printing, but due to possible production changes, each machine can vary.
General SERIAL NUMBER IDENTIFICATION PLATE Write the Serial Numbers in the spaces below. Use these numbers when referring to the Terra Gator. The Serial Number Identification Plate is located inside the cab on the storage compartment panel. Serial Number Plate Machine FIG. 1: Serial Number Identification Plate, dealer sales machine. (Used by machine from MY2010.) Q627360-C FIG. 1 FIG. 2: Serial Number Identification Plate, direct sales machine. (Used by machine from MY2010.) QE770002-E FIG. 2 FIG.
General Engine Serial Number And Informatie Plate FIG. 4: The Engine Serial Number Plate is located on the upper right side of the engine block. ENGINE MODEL __________________________________________ SERIAL NUMBER __________________________________________ ARRANGEMENT NUMBER __________________________________________ Q000003S FIG. 4 FIG. 5: (1) Serial Number Location 1 Q000004S FIG. 5 Transmission Serial Number FIG. 6: Plate is located on rear of transmission.
General Cab Serial Number FIG. 7: Plate is located inside cab, below rear window, behind operator’s seat. Cab Serial _____________________________ Number: Q000005S FIG. 7 Operator’s Seat Serial Number FIG. 8: Tag (1) is located on right rear of operator’s seat. Seat Serial ____________________________ Number: Q000001S FIG. 8 Axles FIG. 9: Tag is located in the front on the top of the axle. Model: ____________________________ Serial: ____________________________ q000147s FIG.
General MAINTENANCE INTRODUCTION IMPORTANT: Perform Maintenance procedures at regularly scheduled intervals. Failure to perform regularly scheduled maintenance will result in damage to the Terra Gator components or engine. The maintenance schedule is a recommended guide for correct maintenance of the Terra Gator. DO NOT change the schedule unless you increase the frequency of service when operating the Terra Gator in very hot, cold, dusty or corrosive conditions.
General Service Item Initial 250 Hours Daily 50 100 250 500 1000 Hours Hours Hours Hours Hours/ Annual 22. Check Air Hoses x 23. Check Engine Belts and Tensioner x 24. Check Rotating Bearing x 25. Remove Plug Bottom of Fuel Tank Remove Sediment x 26. Check Cab Mounts x 27. Clean Heat Exchangers x 28. Check level Axle Oil x 29. Grease Drive Shaft Hanger Bearing x x 30. Replace Engine Oil and Filter x x 31. Clean or Replace Cab Air Filters x 32.
General 31 44 45 38 46 4 21 23 8 47 20 50 7 10 6 25 30 5 33 51 1 9 19 13 41 50 34 42 19 1 13 34 39 38 27 49 29 13 1 34 37 11 37 13 11 37 1 34 36 3 25 P000089 FIG.
General 43 12 26 44 17 31 15 16 24 14 16 15 18 18 26 21 31 44 28 28 35 41 32 40 48 35 35 32 35 40 48 P000090 FIG.
General Tighten Wheel Bolts FIG. 12: Wheel Bolt Tightening Sequence. 1. Check the axle flange and the rear mounting surface of the wheel foreign material, burs or grease. 2. Install the wheel on the axle. Make sure the wheel holes are centered over the threaded holes on the axle flange. 3. Put a small amount of multi-purpose grease on the FIRST FOUR THREADS on the bolts. Install the bolts and washers with your hand. Tighten the bolts. 4. Torque the bolts in 3 steps: 1. Tighten up to 300 Nm (221lbf.-ft); 2.
General Articulation Pin Bolts FIG. 14: Retorque the bolts (3) of the articulation joint pins every 500 hours of operation with 1300 Nm (960 lbf.-ft). 3 3 M00085 FIG. 14 Steering Cylinder Bolts FIG. 15: Retorque the steering cylinders bolts (1) every 500 hours of operation with 815 Nm (600 lbf.-ft). 1 M00119 FIG. 15 LUBRICANTS AND FLUIDS IMPORTANT: Capacities listed are APPROXIMATE. CHECK fluid levels after filling.
Dimensions DIMENSIONS VEHICLE DIMENSIONS Q000007S FIG. 1 NOTE: Specifications subject to change without notice.
Dimensions TerraGator 3244 TerraGator 3244 TerraGator 3244 Standard Long Wheel Base (LWB) Short Wheel Base (SWB) Dim Description SDT* M-M28** Fire*** SDT* M-M28** Fire*** SDT* M-M28** Fire*** A Exhaust 3860 pipe height 3889 3862 3860 3889 3862 3860 3889 3862 B Cab roof height 3761 3734 3732 3761 3734 3732 3761 3734 C Axle height 824 853 826 824 853 826 824 853 826 D Free height 411 440 413 411 440 413 411 440 413 E Articulation 4040 point to centre axle
Dimensions TURNING RADIUS Q000008S FIG. 2: Standard chassis Q000009S FIG.
Dimensions Q000010S FIG.
Torque Specifications TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS m WARNING: Mismatched or incorrect fasteners can result in damage, malfunction or personal injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torques are given in the Service Manual, if necessary. Prior to installation of any hardware, ensure that components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks.
Torque Specifications FASTENER INFORMATION Metric Fasteners Assembly Torque for Metric Fasteners Standard High Low Thread Size Torque lbf ft Torque Nm Torque lbf ft Torque Nm Torque lbf ft Torque Nm M6 x 1 9±1 12 ± 3 10 ± 1 13 ± 3 4 ±0.5 6±1 M8 x 1.25 21 ± 2 28 ± 7 22 ± 2 30 ± 7 11 ± 1 15 ± 3 M10 x 1.5 41 ± 4 55 ± 10 44 ± 4 60 ± 12 22 ± 2 30 ± 7 M12 x 1.
Torque Specifications SAE Fasteners Assembly Torque for SAE Fasteners Standard High Low Thread Size Torque lbf ft Torque Nm Torque lbf ft Torque Nm Torque lbf ft Torque Nm 1/4 - 20 9±1 12 ± 3 10 ± 1 13 ± 3 4 ±0.
Torque Specifications Unified Inch Bolt and Cap Screw Values Q000012S FIG. 2 Unified Bolt and Cap Screw Values Chart Grade 1 Size Lubricated Grade 2 Dry Lubricated Grade 5, 5.1, or 5.2 Dry Lubricated Grade 8 or 8.2 Dry Lubricated Dry Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft 1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5 5/16 7.7 5.
Torque Specifications Metric Bolt and Cap Screw Values Q000013S FIG. 3 Metric Bolt and Cap Screw Values Grade 4.8 Size Lubricated Grade 8.8 or 9.8 Dry Lubricated Grade 10.9 Dry Lubricated Grade 12.9 Dry Lubricated Dry Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5 M8 12 8.
Torque Specifications 4-Bolt Split Flange FIG. 4: Ensure sealing surfaces are free of burrs, nicks, scratches or any foreign particles. Lubricate O-ring. Position flanges and half clamps. Place lock washers on bolts and bolt through half clamps. Hand tighten bolts. Torque bolts in diagonal sequence in small increments to torque level listed for correct flange series. Q000014S FIG. 4 3000 PSI Dash Size Flange Size Bolt Size Torque lbs. In. ft. lbs. 12 3/4 3/8 - 16 300 ± 50 25 ± 4.
Torque Specifications TIGHTENING STRAIGHT THREAD FITTINGS Straight thread hydraulic fittings require precise tightening. Overtightening of hydraulic fittings ruin sealing surfaces and require replacement of damaged parts. Proper initial tightening depends on mating parts to be connected. Proceed as follows: An adapter fitting (37° flare) connected to a double flare tube assembly. Fitting must be tightened finger tight and wrenched 1/2 turn (for single flare, 1/4 turn).
Torque Specifications CONVERSION INFORMATION MULTIPLY: LINEAR AREA VOLUME MASS BY: To Get MULTIPLY BY: inches x 25,4 = millimeters (mm) x 0,03937 = inches feet x 0,3048 = meters (m) x 3,281 = feet yards x 0,9144 = meters (m) x 1,0936 = yards miles x 1,6093 = kilometers (km) x 0,6214 = miles inches x 2,54 = centimeters x 0,3937 = inches microinches x 0,0254 = micrometers (µm) x 39,37 = microinches inches² x 645,16 = millimeters² (mm²) x 0,00155 = inches² inches² x 6
Torque Specifications MULTIPLY: TORQUE VELOCITY BY: To Get MULTIPLY BY: To Get: pounds inches x 0,11298 = newtons-meter (Nm) x 8,851 = pounds inches pound - feet x 1,3558 = newton-meter (Nm) x 0,7376 = pound-feet miles/hour x 1,6093 = kilometers/hours (km/h) x 0,6214 = miles/hour feet/sec. x 0,3048 = meters/sec. (m/s) x 3,281 = feet/sec. kilometers/hr. x 0,27778 = meters/sec. (m/s) x 3,600 = kilometers/hr. miles/hours x 0,4470 = meters/sec.
Torque Specifications NOTES 1-60 627333-A
Jack Up The Machine JACK UP THE MACHINE This chapter only discript how to Jack up the Terra Gator. How to split the Terra Gator, see chapter Chassis. FRONT CHASSIS m DANGER: When the machine needs to jacked up. Be extremely careful. If the machine falls of the jack, death or serious injury can result. m DANGER: When the machine is jacked up, always place a support. Place the machine on the supports, and remove the jack underneath the machine. A jack can loose the force and the machine will fall.
Jack Up The Machine q000114s FIG. 2 m WARNING: Use proper supports. Be sure the supports can carry the weight of the chassis. Otherwise serious injury, death and damage to the machine can result. The weight of the front chassis is 9470 kg (20878 lb). m 1-62 WARNING: When the parking brake is released the vehicle does not have any park brake function. You must block the wheels to prevent the vehicle from moving. Serious personal inury or death and damge to components can result.
Jack Up The Machine REAR CHASSIS m DANGER: When the machine needs to jacked up. Be extremely careful. If the machine falls of the jack, death or serious injury can result. m DANGER: When the machine is jacked up, always place a support. Place the machine on the supports, and remove the jack underneath the machine. A jack can loose the force and the machine will fall. Death or serious injury and damage to the machine will result. m WARNING: Use proper supports.
Jack Up The Machine Dog Walk Chassis The follow figures shows how to jack up the rear side of the rear chassis. m DANGER: When the machine needs to jacked up. Be extremely careful. If the machine falls of the jack, death or serious injury can result. m DANGER: When the machine is jacked up, always place a support. Place the machine on the supports, and remove the jack underneath the machine. A jack can loose the force and the machine will fall.
Jack Up The Machine q000142s FIG.
Jack Up The Machine Straight Chassis The follow figures shows how to jack up the rear side of the rear chassis. m DANGER: When the machine needs to jacked up. Be extremely careful. If the machine falls of the jack, death or serious injury can result. m DANGER: When the machine is jacked up, always place a support. Place the machine on the supports, and remove the jack underneath the machine. A jack can loose the force and the machine will fall.
Jack Up The Machine q000144s FIG.
Jack Up The Machine NOTES 1-68 627333-A
Tooling list TOOLING LIST TOOLING LIST Hoses Partnumber Description Information E210002 200 mm (7.9 inch) Both sides Mini Mesh (Female threaded) E210003 300 mm (11.8 inch) Both sides Mini Mesh (Female threaded) E210004 450 mm (17.7 inch) Both sides Mini Mesh (Female threaded) E210006 600 mm (23.6 inch) Both sides Mini Mesh (Female threaded) E210010 1000 mm (39.
Tooling list Fitting Partnumber Description Information E210105 Mini Mesh -> 7/16 UNF Both sides Male threaded E210102 Mini Mesh -> 1/4 BSP Both sides Male threaded E210107 Mini Mesh -> Pressure Gauge 1/4 BSP Mini Mesh, Male threaded 1/4 BSP, Female threaded FIG. 3: Mini Mesh -> 7/16 UNF. Q000170S FIG. 3 FIG. 4: Mini Mesh ->1/4 BSP. Q000171S FIG. 4 FIG. 5: Mini Mesh -> Pressure Gauge 1/4 BSP. Q000172S FIG.
Tooling list Quick Connect Couplers Partnumber Description Information 681359 Testpoint 7/16 UNF DF (male) 7/16 UNF, Female threaded 833317 Testpoint 1/4 UNF DF (female) 1/4 UNF, Female threaded FIG. 6: Testpoint 7/16 UNF DF (male). q000174s FIG. 6 FIG. 7: Testpoint 1/4 NPT DF (female). q000169s FIG.
Tooling list NOTES 1-72 627333-A
Index INDEX Numerics 4-Bolt Split Flange .............................................. 1-56 A Asbestos Information ........................................... 1-4 Assembly Torque for Metric Fasteners .............. 1-52 Assembly Torque for SAE Fasteners ................. 1-53 Metric Fasteners ................................................. 1-52 Mounting and Dismounting ................................... 1-4 O Operation ..............................................................
Index NOTES 1-74 627333-A
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 02 - Engine Contents INTRODUCTION Introduction ................................................................................................................................................ Specifications and Standards Concerning Fuel, Oil and Coolant .............................................................. Fuel Quality ............................................................................................................
Contents NOTES 2-ii 627333-A
Introduction INTRODUCTION INTRODUCTION CAT C11 DIESEL The machine utilizes a diesel engine manufactured by CAT for AGCO. Specification Many of the components are mounted and operate directly with the CAT engine. This section describes troubleshooting, error codes and the proper procedures to remove and install components. Specification CAT C11 Diesel with Turbo Intercooler. • 6 Cylinder, 11.
Introduction LIFTING AND STORAGE Lifting FIG. 1: Never band the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 °. When it is necessary to remove a compnent at an angle, only use a link bracket that is properly rated for the weight. Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine.
Engine Components ENGINE COMPONENTS ENGINE COMPONENT LOCATIONS Left Side 1 2 4 3 9 5 8 6 7 Q000016S FIG. 1 1. Air Inlet; 2. Compressor; 3. Oil Fill Point; 4. Primary Fuel Filter; 5. Secondary Fuel Filter; 6. ECU; 7. Starter Motor; 8. Fuel Prime Pump; 9. Dipstick.
Engine Components Right Side 12 14 16 13 11 17 15 10 Q000017S FIG. 2 10. Oil Filter; 11. Oil Fiter Bypass; 12. Turbo Charger; 13. Exhaust Manifold; 14. Dynamo Fix Plate; 15. Cool Water Pump; 16. Exhaust Pipe Connection; 17. Output Power to Transmission.
Engine Components SENSOR Sensor Overview 11 12 1 2 6 7 3 8 4 9 5 10 Q000027S FIG. 3 Senors on the engine 1. Crankshaft Speed/Timing; 2. Camshaft Speed/Timing; 3. Timing CAL probe; 4. Fuel Temperature Sensor; 5. Atmospheric Temperature Pressure; 6. Intake Manifold (boost) Pressure; 7. Intake Manifold Air Pressure; 8. Coolant Temperature; 9. Fuel Pressure Sensor; 10. Oil Pressure; 11. Injectors; 12. ECU.
Engine Components Replacement Senors m WARNING: Ensure that the engine can not be started while this maintenance is being performed. m WARNING: Personal injury can result from fluid pressure and hot oil. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped.
Engine Components Sensor Location FIG. 4: 1. Crankshaft Speed/Timing Sensor; 1 Q000020S FIG. 4 FIG. 5: 2. Camshaft Speed/Timing Sensor; 2 Q000021S FIG. 5 FIG. 6: 3. Timing Cal probe, Adapter, Cable; 3 Q000024S FIG. 6 FIG. 7: 4. Fuel Temperature Sensor 4 Q000024S FIG.
Engine Components FIG. 8: 5. Atmospheric Pressure; 5 Q000021S FIG. 8 FIG. 9: 6. Intake Manifold (boost) Pressure; 6 Q000024S FIG. 9 FIG. 10: 7. Intake Manifold Air Temperature; 7 Q000024S FIG. 10 FIG. 11: 8. Coolant Temperature; 8 Q000026S FIG.
Engine Components FIG. 12: 9. Fuel Pressure; 9 Q000023S FIG. 12 FIG. 13: 10. Oil Pressure; 10 Q000023S FIG. 13 FIG. 14: 11. Injectors; 11 Q000016S FIG. 14 FIG. 15: 12. ECU. 12 Q000025S FIG.
Engine Components COOLING m WARNING: The cooling system operates under pressure which is controlled by the radiator pressure cap. Removing the cap while the system is hot may allow the escape of hot coolant and steam, causing serious burns. Before you remove the radiator cap allow the system to cool. Use a thick cloth and turn the radiator cap slowly to the first stops to allow pressure to escape before fully removing the cap. Avoid contact with coolant. 1 3 2 4 8 6 5 7 Q000018S FIG. 16 1.
Engine Maintenance ENGINE MAINTENANCE ENGINE VALVE LASH INSPECT / ADJUST The initial valve lash adjustment on new engines, rebuilt engines, or remanufactured engines is recommended at the first scheduled oil change. The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components. This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life.
Engine Maintenance Valve Lash Check An adjustment is not necessary if the measurement of the valve lash is in the rang shown in table below Inlet Valves Exhaust Valves Valve Lash (stopped Engine) 0,38 ± 0,08 mm (0,015 ± 0,003 inch) 0,64 ± 0,08 mm (0,025 ± 0,003 inch) TC Compression Stroke 1-2-4 1-3-5 TC Exhaust Stroke 3-5-6 2-4-6 Firing Order 1-5-3-6-2-4 NOTE: TC Exhaust stroke is 360° from Compression stroke. NOTE: The no. 1 cylinder is at the front of the engine (see picture below). FIG.
Engine Maintenance c. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the adjustemnt screw in a clockwise direction. Slide the feeler gauge between the rocker arm and the valve bridge. Continue turning the adjustment screw until a slight drag is felt on the feeler gauge. Remove the feeler gauge; d. Tighten the adjustment locknut to a torque of 30 ± 7 Nm (22 ± 5 lb ft). Do not allow the adjustment screw to turn while you are tightening the adjustment.
Engine Maintenance ENGINE REMOVAL AND INSTALLATION To make access to the engine, remove the bonnet with frame complete. Before remove the bonnet and frame check the adjustment of the bonnet, frame and cooler. During the installation of the bonnet and frame, adjust the bonnet, frame and cooler the same as it where before removal. m WARNING: Hot engine components can cause injury from burns. Before performing maintenance on engine, allow engine and components to cool.
Index INDEX actuators ............................................................ 2-13 Air Inlet ................................................................. 2-3 Atmospheric .................................................. 2-5, 2-8 Oil Fill Point .......................................................... Oil Filter ................................................................ Oil Fiter Bypass .................................................... Oil Quality .....................................
Index NOTES 2-16 627333-A
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 03 - Powertrain Contents TRANSMISSION SERVICE MANUAL Transmission Service Information ............................................................................................................. 3-1 Oil Type ............................................................................................................................................... 3-1 Check Oil level .................................................................
Contents Error Codes ............................................................................................................................................. Error Codes 100 - 699 ....................................................................................................................... Error Codes 699 - 999 ....................................................................................................................... Error Codes 1000 - 2999 .........................................
Transmission Service Manual TRANSMISSION SERVICE MANUAL TRANSMISSION SERVICE INFORMATION Information for the Caterpillar transmission used in this machine must be procured through an authorized Caterpillar transmission distributor. Oil Type Identification Initial Fill Recommended Transmission AGCO 821 XL or Equivalent 10W30 API class SF/CC Specification, J20C Transmission and Hydraulic oil Capacity 56,7 L (15 Gall) Check Oil level Check the oil level only when the oil is warm.
Transmission Service Manual NOTES 3-2 627333-A
Transmission and Solenoids TRANSMISSION AND SOLENOIDS THEORY OF OPERATION The transmission is a 16-speed forward and 3-speed reverse powershift transmission with electronically controlled hydraulic power assisted shifting. A TCU (Transmission Control Unit) sends 12 volt power to electric coils on the front of the transmission to change gear ratios. There are a total of nine clutches, which engage in different combinations of two determining the speed of the output shaft.
Transmission and Solenoids TRANSMISSION COMPONENTS 1 1 2 3 2 4 5 7 8 6 7 8 Q000061S FIG. 1 Location transmission componenten 1. PTO; 2. Charge Pump; 3. Fill Tube; 4. Dipstick; 5. Solenoids; 6. Screen Filter; 7. Output Shaft; 8. 4WD Valve.
Transmission and Solenoids TRANSMISSION OIL CHANGE PROCEDURE Start the machine and run it until the transmission oil temperature warms. This is necessary to allow the oil to flow freely during the draining procedure. Place the machine on a hard, level surface and set the parking brake. Remove the key and block the wheels. FIG. 2: Remove the drain plug (1) (spanner 1½”) at the underside of the transmission and drain the 56,7 L (15 Gall) of transmission fluid into an appropriate container.
Transmission and Solenoids FIG. 5: Reinstall the drain plug (1) (spanner 1½”) once all oil has been drained from the transmission. 1 Q000028S FIG. 5 FIG. 6: Apply a light coating of oil to the o-ring on the transmission filter. This will aid to create a tight seal. Fill the transmissoin filter with AGCO 821XL (J20C) or equivalents. Install the transmission filter (1) by hand. When the filer seal contacts the filter base, tighten the filter element by an additional turn of 270 degrees.
Transmission and Solenoids TRANSMISSION CALIBRATION IMPORTANT: Calibrate the transmission every 1000 hours of operation or annually. Also calibrate the transmission if shifting problems appear. Calibration IMPORTANT: Before starting calibration procedure, park machine in area open on all sides of machine. Do not park in front of a building, vehicle or group of people when performing this procedure. Never leave operator station during calibration.
Transmission and Solenoids SYSTEM OPERATION SECTION Hydraulic System The transmission hydraulic system provides a modulated flow of pressurized oil to the transmission. The transmission contains nine transmission clutches. The nine clutches are controlled by the nine corresponding modulating valves (transmission). The transmission provides the operator with 16 forward and 3 reverse gears.
Transmission and Solenoids Transmission System 11 1 7 2 3 8 9 4 12 5 10 6 13 14 15 16 17 FIG. 9 1. Inching Pedal; Q000045S 3. Auto Switch; Oil from sump (14) is drawn through suction filter (6) by the charge pump (5). Suction filter (6) is rated at 200 micron. Hydraulic oil filter (4) filters the oil from charge pump (5). 4. Filter; Filtered oil is supplied to following valves: 5. Charge Pump; • Modulating valves (transmission) (11); 6. Suction Filter; • Relief valve (8). 7.
Transmission and Solenoids Electrical System The transmission electrical system provides controls for the transmission hydraulic system. The transmission electrical system includes switches, sensors, and control levers. The input signals are processed by the transmission electronic control module (ECM) which then energizes the appropriate solenoid. The transmission electrical system contains the following components: • Transmission ECM; • Control inputs; • Solenoids.
Transmission and Solenoids Transmission Electrical Control System 1 14 11 2 15 16 3 17 4 18 5 19 6 20 7 21 8 22 9 13 23 10 12 Q000035S FIG. 10 1. Shift Lever Position Sensor; 21. Modulating Valve; 2. Inching Pedal Switch; 22. Modulating Valve; 3. Inching Pedal Position Sensor; 23. Service Connector. 4. Input Speed Sensor; 5. Output Speed Sensors; CAT date link (13) is a serial communication bus that is used in order to communicate with the following components: 6.
Transmission and Solenoids MODULATING VALVE FIG. 11: Nine modulating valves (1) are located on the left side of the transmission and on the front of the transmission. Each modulating valve has a designated letter, as shown. The letters have been cast into the transmission case. The designated letters are used to correlate the modulating valve to the corresponding transmission clutch. An inspection hatch is located behind the right front wheel.
Transmission and Solenoids 2 6 3 7 4 8 5 1 Q000038S FIG. 13 Schematic of modulating valve (transmission) 1. Modulating Valve (Transmission); 2. Test Port; 3. Transmission Clutch; 4. Spring; 5. Line to Sump; 6. Spool Orifice; 7. Charge Pressure Oil; 8. Solenoid. Modulating valve (1) is controlled by transmission electronic control module (ECM). The modulating valve is used by the transmission ECM to directly modulate the oil pressure that is sent to each of the nine individual transmission clutches.
Transmission and Solenoids Install/Remove Solenoids Q000043S FIG. 14 Modulating Valve Install Solenoids: • Always use new O-rings; • Lubricate the O-rings before installing; • Replace if needed a new valve. Remove Solenoids: • Remove the electric connector; • Unscrew the two bolts on the solenoid; Valve Port FIG. 15: Bottom View of Modulating Valve 1 1. To Transmission Clutch; 2. Charge Pressure Oil; 3. To Transmission Clutch. The figure shows the bottom view of the modulating valve.
Transmission and Solenoids The operation of the modulating valve is not a simple on/off cycle. The transmission ECM varies the strength of the signal current through a programmed cycle in order to control the movement of the proportional solenoid valve spool.
Transmission and Solenoids No Signal Current (Clutch Disengaged) 10 2 6 1 13 4 11 8 7 12 3 14 15 5 Q000040S FIG. 16 Modulating Valve 1. Modulating Valve; 2. Test Port; 3. To Transmission Clutch; 4. Spring; 5. Line to Sump; 6. Spool Orifice; 7. Charge Pressure Oil; 8. To Transmission Clutch; 9. Solenoid; 10. Ball; 11. Valve Spool; 12. Drain Orifice; 13. Pin; 14. Charge Pressure; 15. Sump.
Transmission and Solenoids Partial Signal Current (Modulation) 1 10 2 6 11 4 13 12 9 5 14 15 8 7 16 Q000041S FIG. 17 Modulating Valve 1. Modulating Valve; 2. Test Port; 3. Clutch; 4. Spring; 5. Line to Sump; 6. Spool Orifice; 7. Charge Pressure Oil; 8. To Transmission Clutch; 9. Solenoid; 10. Ball; 11. Valve Spool; 12. Drain Orifice; 13. Pin; 14. Charge Pressure; 15. Sump; 16. 1st Charge Pressure Reduction.
Transmission and Solenoids The increase in the signal current causes the ball and pin to further restrict the flow of oil through the drain orifice and to the sump. This causes a controlled movement of the valve spool to the right. This movement of the valve spool allows the pressure to transmission clutch (3) to increase. The modulating valve uses the variable signal current from the transmission ECM to vary the pressure output of the valve. The sequence of partial engagement is called desired slippage.
Transmission and Solenoids Maximum Signal Current (Clutch Fully Engaged) 1 6 10 2 13 4 11 12 8 7 5 14 3 15 Q000042S FIG. 18 Modulating Valve 1. Modulating Valve; 2. Test Port; 3. Clutch; 4. Spring; 5. Line to Sump; 6. Spool Orifice; In a short period of time, maximum pressure is felt at both ends of the valve spool.
Transmission and Solenoids TRANSMISSION CLUTCH ENGAGEMENT Side view of transmission 2 5 4 3 6 1 C 11 9 12 10 8 7 D F E 13 B 14 G H A 16 17 15 18 Q000044S FIG. 19 1. Input Shaft 12. Gear; 2. Gear; 13. Output Shaft; 3. Gear; 14. Planetary Carrier; 4. Gear; 15. Gear; 5. Gear; 16. Gear; 6. Gear; 17. Planetary Carries 7. Intermediate Shaft; 18. Transfer Gear shaft; 8. Gear; A - B. Planetary Carries 9. Gear; C - H. Clutch Pack 10. Gear; 11.
Transmission and Solenoids Front view Transmission 1 19 7 13 18 Q000062S FIG. 20 1. Input Shaft; 7. Intermediate Shaft; 13. Ouput Shaft; 18. Transfer Shaft; 19. Reverse Shaft Power flow for reverse gears only involves the clutches on the shaft: • Reverse Shaft (19); • Output Shaft (13). Each gear has its own combination of solenoids. No more than two clutches are engaged at the time. Also, no more than one clutch is engaged at the time on any shaft.
Transmission and Solenoids Transmission Clutch Engagement Engine RPM at 2100 Gear Reverse Shaft Input Shaft Intermediate Output Shaft Shaft Reduction Third Gear (Reverse) A - - H 3.857 Second Gear (Reverse) A - - B 4.343 First Gear (Reverse) A - - G 10.553 Neutral - - - J - First Gear - C - G 8.442 Second Gear - D - G 6.648 Third Gear - - E G 5.253 Fourth Gear - - F G 4.137 Fifth Gear - C - B 3.747 Sixth Gear - C - H 3.
Testing and Adjusting TESTING AND ADJUSTING RELIEF VALVE FIG. 1: m WARNING: Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this of injury. Always use a board or cardboard when checking for a leak. m WARNING: Personal injury can result form hydraulic oil pressure and hot oil. Q000119S FIG.
Testing and Adjusting Testing Procedure FIG. 3: Test port for the transmission hydraulic control. The relief pressure for the transmission hydraulic control system can be measured at pressure tap (1) on the transmission hydraulic control relief valve. 1. Install tooling (A) on pressure tap (1); 2. Start the engine. Warm the oil until the oil reaches 60°C (140°F); 3. Operate the engine at high idle. Observe the pressure gauge.
Testing and Adjusting PRESSURE FOR TRANSMISSION LUBRICATION FIG. 5: m WARNING: Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this of injury. Always use a board or cardboard when checking for a leak. m WARNING: Personal injury can result form hydraulic oil pressure and hot oil. Q000119S FIG.
Testing and Adjusting Test Procedure FIG. 7: Pressure tap location for lubrication test. Pressure gauges are used in the following test procedure. 1. Attach a coupler to the transmission lubrication pressure tap (1). If necessary, connect the pressure hose. Install a pressure gauge 400 kPa (58 psi) to the fitting. 2. Start the engine and warm the oil up to 60°C (140°F). 3. Run the engine at LOW idle rpm with the transmission control lever in the neutral position.
Testing and Adjusting MODULATING VALVE FIG. 8: m WARNING: Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this of injury. Always use a board or cardboard when checking for a leak. m WARNING: Personal injury can result form hydraulic oil pressure and hot oil. Q000119S FIG.
Testing and Adjusting Test Procedure FIG. 10: Transmission clutches D C Pressure gauges are used in the following test procedure. 1 The designated letters are used to correlate a modulating valve to the corresponding transmission clutch, as shown. 1. Input Shaft; 2. Intermediate Shaft; 2 F E 3. Output Shaft; 4. Transfer Gear shaft; 5. Reverse Shaft. 3 a. Clutch pack; b. Planetary Carrier; c. Clutch pack; d. Clutch pack; G e. Clutch pack; f. I H B Clutch pack; g. Planetary Carrier; h.
Testing and Adjusting FIG. 11: Modulating Valves Each modulating valve has a designated letter, as shown. The letters have been cast into the transmission housing. Log the clutch pressures in the table on the next page. There are always two clutches that are engaged for each gear selection. Neutral position only uses one clutch. See the table in order to determine the clutches that are engaged for gear selection. Q000051S FIG.
Testing and Adjusting Checklist for Transmission Clutch Pressures Gear Clutch or Valve Pressure Measurement Third gear (reverse) A H Second gear (reverse) A B First gear (reverse) A G Neutral J - First gear C G Second gear D G Third gear E G Fourth gear F G Fifth gear C B Sixth gear C H Seventh gear D B Eighth gear D H Ninth gear E B Tenth gear E H Eleventh gear F B Twelfth gear F H Thirteenth gear C J Foureenth gear D J Fifteenth gear E J Sixteent
Testing and Adjusting HYDRAULIC OIL COOLER FIG. 12: m WARNING: Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this of injury. Always use a board or cardboard when checking for a leak. m WARNING: Personal injury can result form hydraulic oil pressure and hot oil. Q000119S FIG.
Testing and Adjusting Test Procedure FIG. 14: Pressure tap location for the hydraulic cooler return oil. 1. Warm the oil to a minimum temperature of 60°C (140°F). 2. Connect tooling (A) to test port (1). 3. Start the engine. Run the engine at high idle. 4. Make sure that the temperature of the hydraulic oil is at least 60°C (140°F). Record the pressure of the hydraulic oil that is coming from the hydraulic oil cooler.
Transmission Troubleshooting TRANSMISSION TROUBLESHOOTING GENERAL TROUBLESHOOTING INFORMATION When you are attempting to define a problem with the transmission, it is necessary to perform the procedures that are contained in this section. If a problem is encountered with the planetary transmission, recalibrate the transmission prior to proceeding with investigations. A visual inspection of the system must be carried out in order to eliminate many of the less complex problems.
Transmission Troubleshooting TROUBLESHOOTING When a error is active for more than 3 seconds, it will automatically appear as a code in the transmission display. Error code will disappear when the error is not active anymore. The error code will be stored in the ECU and in the TCU When errors are shown, first check for visible malfunctions. For example, broken or loosen connectors or incorrect battery voltage.
Transmission Troubleshooting Operational Checks Operate the transmission in each direction and in speeds. Check that the transmission is operating correctly in all functions. If the transmission is not operating correctly refer to the troubleshooting information that is contained in the Engine service manual. Use in the Engine service manual the troubleshooting information in order to investigate the problem.
Transmission Troubleshooting ERROR CODES NOTE: For the complete explanation of the error code, see the troubleshooting manual of the transmission (TA 19 KENR 6678). NOTE: For the complete troubleshooting maunal (TA 19 KENR 6678) see end of this chapter. Error Codes 100 - 699 Codes Description Possible Cause 117-2 Parking brake pressure switch inputs incorrect. The signal circuit for sensor has failed. 126-16 Transmission filter plugged. Filter not renewed on time.
Transmission Troubleshooting Codes Description Possible Cause 525-1 Transmission lever position sensor signal out of range low. The position sensor has failed. The signal circuit of the sensor is shorted to the ground The sensor needs to be calibrated. The ECM has failed. This in unlikely. 525-8 Transmission lever position sensor signal abnormal. The sensor has failed. Intermittent connections or poor connections. Mechanical devices are loose. The ECM has failed.
Transmission Troubleshooting Codes Description Possible Cause 703-1 Inching pedal position sensor signal out of range low. The position sensor has failed. The signal circuit of the sensor is shorted to the ground. The sensor needs to be calibrated. The ECM has failed. This is unlikely 703-8 Inching pedal position sensor signal abnormaal. The sensor has failed. Intermittent connections or poor connections. Mechanical devices are loose. The ECM has failed. This is unlikely.
Transmission Troubleshooting Codes Description Possible Cause 735-6 Transmission clutch #2 solenoid short to ground. The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This in unlikely. 736-3 Transmission clutch #3 solenoid short to positive terminal of the battery. The solenoid has failed. The energize circuit of the solenoid is shorted to the + battery circuit. The ECM has failed. This is unlikely.
Transmission Troubleshooting Codes Description Possible Cause 739-3 Transmission clutch #6 solenoid short to positive terminal of the battery. The solenoid has failed. The energize circuit of the solenoid is shorted to the + battery circuit. The ECM has failed. This is unlikely. 739-5 Transmission clutch #6 solenoid open circuit. The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.
Transmission Troubleshooting Codes Description Possible Cause 1619-5 Backup alarm relay open circuit. The energize circuit of the relay is open. The return circuit of the relay is open. The relay has failed. The ECM has failed. This in unlikely. 1619-6 Backup alarm relay short to ground. The energize circuit of the relay is shorted to ground. The relay has failed. The ECM has failed. This is unlikely. 1666-2 Auto/Manual shift switch incorrect.
Transmission Troubleshooting Codes Description Possible Cause 2905-5 Transmission clutch #7 solenoid open circuit. The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This unlikely. 2905-6 Transmisson clutch #7 solenoid short to ground. The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.
Disassembly and Assembly DISASSEMBLY AND ASSEMBLY GENERAL Park the chassis on hard, level surface and block the wheels. Drain transmission fluid into suitable container. IMPORTANT: It is extremely important to work in clean environment when working with hydraulic systems. NOTE: Be prepared to collect and contain all fluids in an approved container. m WARNING: The transmission is extremely heavy. Care should be used while lowering the transmission with the come-along. CAB TIPPING OVER q000159s FIG.
Disassembly and Assembly Tipping Over 1. Remove the side panels, complete bonnet and bonnetframe; 2. Remove the cooler supports above the engine; 3. Remove all loose objects inside the cab. IMPORTANT: Loose objects insde the cab can cause damage during tipping over the cab. 4. Take the lock pin with retainer out of his locking position underneath the cab. And place the lock pin on the left platform, near the rotating point of the cabin; 5.
Disassembly and Assembly 12. Tipping over the cab untill the transmission can be removed/installated. m WARNING: Make sure the cab does not hit anything. Otherwise damage to the cab will by result. IMPORTANT: By tipping over the cab this far. The center of gravity is in front of the rotating point of the cab. So there is no support needed underneath the cab. Lower the Cab FIG. 5: Cab suspension and lock (4) at rear side of cab. To lower the cab act as follows: 1.
Disassembly and Assembly KENR6054 See for the complete Disassembly and Assembly manual (TA 19 KERN 6054) at the end of this chapter.
Drive line DRIVE LINE DRIVE LINE REAR m WARNING: Before performing maintenance in the area of the Articulation Joint the following procedure MUST be followed (See Safety Section) 1. Drive the vehicle to a hard level surface. Steer the vehicle into the straight ahead position. 2. Engage the park brake and turn of the engine. 3. Move the articulation Lock Turnbuckle form the Storage Position to the Transport / Maintenance Position Straight Chassis 2 5 4 1 1 3 1 q000137s FIG. 1 1.
Drive line Dog Walk Chassis 4 1 1 1 1 3 1 2 3 3 5 q000138s FIG. 2 1. Cross Bearing (6x); 2. Shaft Hanger Bearing (Loose); 3. Shaft Hanger Bearing (Fixed); 4. Drive shaft; Terra Gator 5. Rear Axle. The drive line from a Terra Gator with a dog walk chassis is divided in four parts. Two short parts and two longer parts. The drive line can make two angle’s. One to provide pivot steering and one provide the dog walk. The last part of the drive line is build in a dog walk tunnel.
Drive line DRIVE LINE FRONT 5 4 3 2 2 1 Q000063S FIG. 3 To provide the Terra Gator of a 4-wheel drive there need to be a drive line from the transmission to the front axle. 1. Transmission; 2. Cross Bearing (2x); 3. Drive shaft; 4. Disc Park Brake; 5. Front Axle.
Drive line HANGER BEARING Maintenance Hager Bearing Lubrication Bearing Grease the roller bearing every 250 hours of operation. Do not use a high pressure automatic grease gun. Do not over grease. 3 3 P000080 FIG. 4 NOTE: Never connect to an automatic central lubrication system. Check Roller Bearings Check the drive shaft bearing every 1000 hours of operation or annualy. Replace the bearing by play more than approximately 0,5 mm.
Drive line Introduction ConCentra Roller Bearing 5IF EFFQ HSPPWF CBMM CFBSJOH 5IF $PO$FOUSB TUFQQFE TMFFWF 5IF CFBSJOHT VTFE JO 4,' $PO$FOUSB CBMM CFBSJOH VOJUT BSF CBTFE PO EFFQ HSPPWF CBMM CFBSJOHT JO UIF TFSJFT 5IFTF CFBSJOHT IBWF B DPOWFY TQIFSFE PVUTJEF TVSGBDF 5IF JOOFS SJOH JT FYUFOEFE PO CPUI TJEFT BOE IBT B NVMUJ UBQFSFE CPSF GJH 5IF CFBSJOH JT TFBMFE PO CPUI TJEFT XJUI UIF IJHIMZ FGGJDJFOU 4,' ³4VQFSBHSJTFBM³ XIJDI JT DPNQMFNFOUFE CZ GMJOHFST UP DPOTJEFSBCMZ FOIBODF UIF
Drive line Mouting Instructions Q000064S FIG.
Drive line Q000065S FIG.
Drive line Q000066S FIG.
Drive line Q000067S FIG.
Drive line Adjustment Dog Walk Tunnel To adjust the dog walk tunnel follow the next instruction. IMPORTANT: The life time of the bearings will increase when the dog walk tunnel is proper installed and not grease more than specification. FIG.
Drive line 1 3 Drive direction 4 4 3 2 Q000099S FIG. 11 1. Measure from the face of the axle (180 mm); 2. Measure from the face of the axle (178 mm); 3. Torque the bolts of the cross bearing with 255 Nm; Use a ring spanner. 4. Torque the bolts of the roller bearing with the special wrench with 7,5 Nm.
Drive line Q000101S FIG. 12 Mount the parts to the bottom of the Dog Walk Tunnel.
Drive line 2 3 1 3 4 Q000102S FIG. 13 1. Fixed Bearing; 2. Sliding Bearing; 3. Position of the bearing is very important. A good aligned position increase life time of the bearings. The bearings have to been align horizontal and vertical. The horizontal alignment can be set with the shims under the bearings 4. Adjust the bar untill the dog walk tunnel in straight underneath the Terra Gator, when the Terra Gator is not in Dog walk position.
Drive line Q000103S FIG. 14 Mount the grease line the to bearings. The Grease nipples are mount at the bottom of the Dog Walk Tunnel. m 3-60 WARNING: Never connect the bearing to the central lubrication system.
Drive line Q000104S FIG. 15 Mount the bottom part of the Dog Walk Tunnel to the top part.
Drive line 1 Q000100S FIG. 16 1.
Drive line Q000105S FIG. 17 Mount the cross bearings. Torque the bolts dry with 140 Nm (105 ft lb).
Drive line NOTES 3-64 627333-A
Index INDEX Numerics G 1st Charge Pressure Reduction ......................... 3-17 4WD Valve ........................................................... 3-4 Gear .................................................................... 3-20 A Auto Shift Switch ......................................... 3-9, 3-11 Auto Switch .......................................................... 3-9 B Ball ..................................................................... 3-17 C calibration ...........................
Index screen filter ........................................................... 3-5 Service Connector .............................................. 3-11 Shaft Hanger Bearing ......................................... 3-47 Shift Lever ............................................................ 3-9 Shift Lever Position Sensor ................................ 3-11 Solenoid .................................................... 3-13, 3-17 Solenoids ....................................................
i01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
KENR6054 Table of Contents Disassembly and Assembly Section Relief Valve (Transmission Main) - Remove ......... 4 Relief Valve (Transmission Main) - Disassemble .. 4 Relief Valve (Transmission Main) - Assemble ...... 6 Relief Valve (Transmission Main) - Install ............. 8 Pump Drive - Remove ......................................... 8 Pump Drive - Install ............................................. 12 Transmission - Disassemble ................................ 15 Transmission - Assemble ............
4 Disassembly and Assembly Section KENR6054 Disassembly and Assembly Section i02648750 Relief Valve (Transmission Main) - Remove i02536685 Relief Valve (Transmission Main) - Disassemble SMCS Code: 4059-015-T3; 5069-015-T3 Disassembly Procedure Table 1 SMCS Code: 5069-011-T3 Required Tools Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
KENR6054 Illustration 2 5 Disassembly and Assembly Section g01209440 Illustration 5 g01209465 1. Remove O-ring seal (1). Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 4. Note the position of adjustment screw (7). Remove adjustment screw (7). Remove bolts (6) and cover (5). Illustration 3 g01209441 2.
6 Disassembly and Assembly Section KENR6054 i02536679 Relief Valve (Transmission Main) - Assemble SMCS Code: 5069-016-T3 Assembly Procedure Table 2 Required Tools Illustration 7 g01209507 6. Remove spool assembly (11). Tool Part Number A 1P-1853 Part Description Retaining Ring Pliers Qty 1 Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts.
KENR6054 Illustration 9 7 Disassembly and Assembly Section g01209518 Illustration 11 g01209506 4. Install spring (10), O-ring seal (9), and load piston (8). Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Install ball (12), spring (13), and retainer (14).
8 Disassembly and Assembly Section KENR6054 i02648785 Relief Valve (Transmission Main) - Install SMCS Code: 5069-012-T3 Installation Procedure Illustration 13 g01209450 6. Install O-ring seal (4). g01329210 Illustration 16 1. Install relief valve (2). 2. Install bolts (1). Tighten bolts (1) to a torque of 30 ± 4 N·m (22 ± 3 lb ft). i02648891 Illustration 14 g01209441 7. Install cover (3) and bolts (2). Tighten bolts (2) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
KENR6054 9 Disassembly and Assembly Section Start By: a. Remove the input speed sensor. Refer to Disassembly and Assembly, “Speed Sensor (Transmission) - Remove”. 3. Use Tooling (A), Tooling (B), and a suitable lifting device to reposition transmission (4) onto Tooling (C). The weight of transmission (4) is approximately 1315 kg (2900 lb). Note: The top pump drive gears can be removed without the removal of the case assembly. Only the removal of the idler gear requires the removal of the case assembly.
10 Disassembly and Assembly Section KENR6054 13. Remove bolt (20). Remove tube assembly (21). Illustration 22 g01265829 9. Remove bolt (13) and retainer (14). Use two people in order to remove gear (15). The weight of gear (15) is approximately 23 kg (50 lb). Illustration 23 g01265831 10. Use two people in order to remove gear assembly (16). The weight of gear assembly (16) is approximately 32 kg (70 lb). Illustration 25 g01265880 14. Remove tube assembly (22). Illustration 26 g01265881 15.
KENR6054 Illustration 28 11 Disassembly and Assembly Section g01265914 18. Loosen bolts (25). Use Tooling (D) in order to separate adapter (24). Remove Tooling (D). Illustration 31 g01266612 23. Remove bolts (29), cover (30), and O-ring seal (31). 19. Remove bolts (25), adapter (24), and gear (26). Illustration 32 Illustration 29 g01265924 g01265950 24. Remove bolt (32). Remove shaft (33). 20. Remove O-ring seal (27) and gear (26) from adapter (24).
12 Disassembly and Assembly Section KENR6054 g01266709 Illustration 34 26. Remove bearing (36) from gear (34). Illustration 36 g01266697 2. Install thrust discs (35). Install gear (34). i02648905 Pump Drive - Install SMCS Code: 3108-012 Installation Procedure Table 4 Required Tools Tool Part Number A 138-7575 B Part Description Qty Link Brackets 4 1U-9202 Lever Puller Hoist 1 C 1P-2420 Transmission Repair Stand 1 F 1U-8846 Gasket Sealant - Illustration 37 3.
KENR6054 Illustration 39 13 Disassembly and Assembly Section g01266763 5. Raise the temperature of bearings (28). Install bearings (28) onto gear (26). Illustration 40 Illustration 42 g01265910 8. Use Tooling (A), Tooling (B), and a suitable lifting device in order to reposition case assembly (23). The weight of case assembly (23) is approximately 365 kg (800 lb). Apply Tooling (F) to case assembly (23). Install case assembly (23). g01265924 6.
14 Disassembly and Assembly Section KENR6054 Note: If new bearings are installed, check the end play of the shaft assembly. Refer to Disassembly and Assembly, “Transmission - Assemble”. 12. Repeat Step 11 for the other retainers. 15. Apply Tooling (F) to cover assembly (9). 16. Use Tooling (A) and a suitable lifting device in order to install cover assembly (9). The weight of cover assembly (9) is approximately 60 kg (130 lb). 17. Check the end play of the shaft assembly.
KENR6054 15 Disassembly and Assembly Section i02648921 Transmission - Disassemble SMCS Code: 3002-015; 3030-015; 3150-015; 3159-015 Disassembly Procedure Table 5 Required Tools Illustration 50 g01265774 21. Use Tooling (A), Tooling (B), and a suitable lifting device in order to reposition transmission (4). The weight of transmission (4) is approximately 1315 kg (2900 lb).
16 Disassembly and Assembly Section Illustration 53 KENR6054 g01269023 2. Disconnect harness assemblies (3). Remove bolts (5) and electronic control module (4). Illustration 54 g01269055 5. Reposition harness assembly (13). Attach Tooling (A) and a suitable lifting device to cover assembly (12). The weight of cover assembly (12) is approximately 60 kg (130 lb). Remove bolts (11) and cover assembly (12). g01269041 3.
KENR6054 Illustration 59 17 Disassembly and Assembly Section g01269068 7. Use Tooling (D) in order to remove bearing cage (15). Remove shims (16). Illustration 60 Illustration 62 10. Remove ring (23). Use two people in order to remove gear (24). The weight of gear (24) is approximately 32 kg (70 lb). g01269118 Illustration 63 8. Remove O-ring seals (18) and lip seal (17). Remove bearing cup (19). Illustration 61 g01269183 g01269176 9. Remove bolt (20) and retainer (21).
18 Disassembly and Assembly Section Illustration 65 KENR6054 g01269226 14. Remove shims (31). Remove bearing cup (30) from bearing cage (27). Illustration 68 g01269287 17. Remove bearing cup (36). 15. Repeat Steps 13 and 14 for the remaining bearing cages. Illustration 69 g01329460 Note: Do not remove bolts (X). Illustration 66 g01269240 Illustration 67 g01269241 16. Remove tube assembly (33). Attach Tooling (A) and a suitable lifting device to case assembly (32).
KENR6054 Illustration 70 19 Disassembly and Assembly Section g01269430 Illustration 72 g01269438 Illustration 73 g01269440 19. Remove O-ring seals (39) from clutch assembly (38). Illustration 71 g01269435 20. Remove bolts (40). Remove reaction plate (41) and ring gear (42). Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment.
20 Disassembly and Assembly Section KENR6054 22. Remove piston (48) from housing (51). Remove seals (47) and (49) from piston (48). Illustration 74 g01269516 23. Attach Tooling (E) and a suitable lifting device to shaft assemblies (52). The weight of shaft assemblies (52) is approximately 375 kg (820 lb). Remove shaft assemblies (52). Illustration 76 g01269526 25. Place the shaft assemblies onto Tooling (G). Remove Tooling (E). Illustration 75 24. Remove ring seals (53).
KENR6054 Illustration 78 21 Disassembly and Assembly Section g01269685 27. Remove bearing cone (54), spacer (56), spacer (57), gear (58), and spacer (59) from shaft assembly (55). Illustration 79 g01269743 28. Rotate shaft assembly (55) by 180 degrees. Remove bolts (60) and remove seal carrier (61). Illustration 80 g01269746 29. Use Tooling (F) in order to remove bearing cone (62). Illustration 81 g01269751 30. Remove bearing cone (62) and spacer (63). Remove thrust washer (64) and gear (65).
22 Disassembly and Assembly Section KENR6054 Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 32. Use a suitable press and Tooling (J) in order to compress spring (72). Remove retaining ring (71). Illustration 82 g01269758 31. Remove bearings (66) and thrust washer (67).
KENR6054 Illustration 85 23 Disassembly and Assembly Section g01270206 34. Remove piston (77) from shaft assembly (55). Remove seals (76) from piston (77). Remove seal (78) from piston (77). Illustration 87 g01270211 36. Remove bearing cone (79), spacer (81), spacer (82), thrust washer (83), and gear (84) from shaft assembly (80). Remove bearings (85) and thrust washer (83). Note: The procedure for the disassembly of the clutch packs are identical. Illustration 86 g01270208 Intermediate Shaft 35.
24 Disassembly and Assembly Section Illustration 89 KENR6054 g01269966 38. Use Tooling (F) in order to remove bearing cone (89) from shaft assembly (80). Illustration 91 g01269969 40. Remove gear (93), spacer (94), thrust washer (95), and gear (96). Remove bearing (97) and thrust washer (95) from shaft assembly (80). Note: The procedure for the disassembly of the clutch packs are identical. Illustration 90 g01269968 39.
KENR6054 Illustration 93 25 Disassembly and Assembly Section g01269976 42. Remove bearing cone (98), spacer (100), and planetary carrier (101) from shaft assembly (99). Illustration 95 g01269983 44. Remove thrust washer (107), sun gear (108), spacer (109), thrust washer (110), and gear (111). Remove bearings (112) and thrust washer (110) from shaft assembly (99). Note: The procedure for the disassembly of the clutch packs are identical.
26 Disassembly and Assembly Section Illustration 97 KENR6054 g01270066 46. Use Tooling (F) to remove bearing cone (117) from shaft (99). Illustration 99 g01270078 48. Remove thrust washer (120), sun gear (121), tube (122), thrust washers (123), and gear (124). Remove bearings (125) and spacer (126) from shaft assembly (99). Note: The procedure for the disassembly of the clutch packs are identical. Illustration 98 g01270067 47.
KENR6054 Illustration 101 27 Disassembly and Assembly Section g01270092 50. Remove bearing cone (127), spacer (129), spacer (130), gear (131), and gear (132) from shaft assembly (128). Illustration 102 Illustration 103 g01270099 Note: Remove the seal rings before removal of bearing cone (137). 52. Rotate shaft assembly (128) by 180 degrees. Use Tooling (F) in order to remove bearing cone (137) from shaft assembly (128). g01270098 51. Remove spacer (133), thrust washer (134), and gear (135).
28 Disassembly and Assembly Section KENR6054 57. Remove bolts (145) and seal ring housing (146). Illustration 105 g01329472 Note: Do not remove bolts (Y). 54. Remove bolts (142). Use two people in order to remove clutch assembly (143). The weight of clutch assembly (143) is approximately 25 kg (55 lb). 55. Refer to Steps 19 through 22 for disassembly of remaining clutch assemblies. Illustration 106 Illustration 108 g01270632 58. Remove O-ring seals (147) from seal ring housing (146).
KENR6054 29 Disassembly and Assembly Section i02649079 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
30 Disassembly and Assembly Section Illustration 112 KENR6054 g01270555 Input Shaft 4. Install bearings (141) and thrust washer (139) onto shaft assembly (128). Install gear (140), thrust washer (139), and spacer (138). Raise the temperature of bearing cone (137). Install bearing cone (137). Install the seal rings after installation of bearing cone (137). Illustration 114 g01270092 6. Install gear (132), gear (131), spacer (130), and spacer (129) onto shaft assembly (128). 7.
KENR6054 Illustration 116 31 Disassembly and Assembly Section g01270067 9. Install planetary carrier (119) and spacer (118) onto shaft assembly (99). Raise the temperature of bearing cone (117). Install bearing cone (117) onto shaft assembly (99). Illustration 117 g01280580 10. Install rotor (116) and bolts (115) onto shaft assembly (99). Illustration 118 g01269983 11. Install bearing (112) onto shaft assembly (99).
32 Disassembly and Assembly Section Illustration 120 KENR6054 g01269976 13. Install planetary carrier (101) and spacer (100) onto shaft assembly (99). Raise the temperature of bearing cone (98). Install bearing cone (98) onto shaft assembly (99). Illustration 121 g01269969 Intermediate Shaft 14. Install bearing (97) onto shaft assembly (80). Install gear (96), thrust washer (95), spacer (94), and gear (93) onto shaft assembly (80). Illustration 122 g01269968 15.
KENR6054 Illustration 124 33 Disassembly and Assembly Section g01270211 Illustration 126 g01269765 Illustration 127 g01269767 17. Install thrust washer (83) onto shaft assembly (80). Install bearing (85) onto shaft assembly (80). Install gear (84), thrust washer (83), spacer (82), and spacer (81) onto shaft assembly (80). Raise the temperature of bearing cone (79). Install bearing cone (79) onto shaft assembly (80). Improper assembly of parts that are spring loaded can cause bodily injury.
34 Disassembly and Assembly Section Illustration 128 KENR6054 g01269758 20. Install the friction discs and plates (70) onto shaft (55). Install clutch plate (69). Use Tooling (H) in order to install retaining ring (68). Install thrust washer (67) and bearings (66). Illustration 130 g01269685 22. Install spacer (59), gear (58), spacer (57), and spacer (56) onto shaft assembly (55). Raise the temperature of bearing cone (54). Install bearing cone (54) onto shaft assembly (55).
KENR6054 Illustration 132 35 Disassembly and Assembly Section g01269438 Illustration 134 g01269435 26. Install ring gear (42) and reaction plate (41). Install bolts (40). Illustration 133 g01269440 Illustration 135 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 24. Install seals (47) and (49) onto piston (48). 25. Install dowels (50) onto housing (51), if necessary.
36 Disassembly and Assembly Section Illustration 136 KENR6054 g01269302 28. Use two people in order to install clutch assembly (38). The weight of clutch assembly (38) is approximately 25 kg (55 lb). Install bolts (37). Illustration 137 Illustration 139 g01269240 30. Install O-ring seal (35). Apply Tooling (L) to case assembly (32). Attach Tooling (A) and a suitable lifting device to case assembly (32). The weight of case assembly (32) is approximately 365 kg (800 lb).
KENR6054 37 Disassembly and Assembly Section 33. Repeat Steps 31 and 32 for the remaining bearing cages. 34. Install tube assembly (29) and bolt (28). Illustration 144 Illustration 142 g01281835 g01269183 37. Use two people in order to install gear (24). The weight of gear (24) is approximately 32 kg (70 lb). Install ring (23). 35. Attach Tooling (A) and a suitable lifting device to the shaft assembly. Install Tooling (K). Apply a slight lifting tension on the shaft assembly.
38 Disassembly and Assembly Section Illustration 147 KENR6054 g01269068 Illustration 150 g01269055 42. Install cover assembly (12). The weight of cover assembly (12) is approximately 60 kg (130 lb). Install bolts (11). Position harness assembly (13). Illustration 148 g01269063 40. Position shims (16). Install bearing cage (15). Illustration 151 g01281866 43. Attach Tooling (A) and a suitable lifting device to the shaft assembly. Install Tooling (K).
KENR6054 Illustration 152 39 Disassembly and Assembly Section g01269046 45. Install O-ring seal (8) and yoke (9). Install retainer (10) and bolt (7). 46. Use Tooling (A), Tooling (B), and a suitable lifting device in order to reposition transmission (6). The weight of transmission (6) is approximately 1315 kg (2900 lb). Illustration 154 g01270632 48. Install O-ring seals (147) into seal ring housing (146). Illustration 155 g01279115 49. Install seal ring housing (146) and bolts (145).
40 Disassembly and Assembly Section KENR6054 g01269023 Illustration 159 52. Install electronic control module (4) and bolts (5). Connect harness assemblies (3). End By: Illustration 156 g01280780 a. Install the input speed sensor. Refer to Disassembly and Assembly, “Speed Sensor (Transmission) - Install”. i02649518 Clutch (Front Wheel Assist) Remove SMCS Code: 3053-011-OJ; 3054-011-OJ; 3055-011-OJ Removal Procedure Illustration 157 g01279344 Table 7 Required Tools 50.
KENR6054 41 Disassembly and Assembly Section i02649529 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
42 Disassembly and Assembly Section KENR6054 2. Remove bolts (5) and shroud assembly (4). Illustration 167 Illustration 164 g01267928 g01267925 5. Remove retaining ring (11) from coupling (7). 3. Remove retaining ring (6). Remove coupling (7) and clutch assembly (8). Illustration 165 Illustration 166 Illustration 168 g01267931 Illustration 169 g01267934 g01267926 g01267927 4. Remove plates (9) and discs (10) from coupling (7).
KENR6054 43 Disassembly and Assembly Section Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 6. Use Tooling (A) and a suitable press in order to compress spring (14). Use Tooling (B) in order to remove retaining ring (12). Remove retainer (13), spring (14), and sleeve (15). Illustration 172 g01267948 9.
44 Disassembly and Assembly Section Illustration 175 KENR6054 g01267991 g01267998 Illustration 178 12. Use Tooling (D) and a suitable press in order to remove seal ring carrier (24) from shaft assembly (21). 15. Remove bearing cups (28). Note: Support shaft assembly (21) from the bottom. Clutch (Front Wheel Assist) Assemble i02649552 SMCS Code: 3053-016-OJ; 3054-016-OJ; 3055-016-OJ Assembly Procedure Table 9 Required Tools Illustration 176 g01267996 13. Remove bearing cone (25).
KENR6054 Illustration 180 45 Disassembly and Assembly Section g01267996 2. Raise the temperature of bearing cone (25). Install bearing cone (25). Illustration 181 g01274336 4. Position housing assembly (22) over the shaft assembly. Raise the temperature of bearing cone (26) and install bearing cone (26). Install lip seal (27) after adjusting the end play. g01276046 3. Raise the temperature of seal ring carrier (24) and install shaft assembly (21). Install seal rings (23).
46 Disassembly and Assembly Section KENR6054 8. Install sleeve (15), spring (14), and retainer (13). Use Tooling (B) in order to install retaining ring (12). Use Tooling (A) and a suitable press in order to compress spring (14). Illustration 186 g01267940 7. Install piston (16). Illustration 189 g01267928 9. Install retaining ring (11) onto coupling (7).
KENR6054 47 Disassembly and Assembly Section i02649577 Clutch (Front Wheel Assist) Install SMCS Code: 3053-012-OJ; 3054-012-OJ; 3055-012-OJ Installation Procedure Table 10 Required Tools Illustration 192 g01267925 11. Install clutch assembly (8) and coupling (7). Install retaining ring (6). Tool Part Number A 138-7575 Illustration 195 Illustration 193 g01267919 12. Install shroud assembly (4) and bolts (5). Illustration 194 Part Description Link Brackets Qty 2 g01267706 1.
48 Disassembly and Assembly Section KENR6054 Output Speed Sensor End By: a. Install the speed sensor for the front wheel assist. Refer to Disassembly and Assembly, “Speed Sensor for the Front Wheel Assist (Transmission) - Install”. i02528493 Speed Sensor (Transmission) Remove SMCS Code: 3175-011 Removal Procedure Illustration 199 Input Speed Sensor g01265017 1. Disconnect harness assembly (5). 2. Remove retainer (6). 3. Remove speed sensor (7). Illustration 197 g01265000 1.
KENR6054 49 Disassembly and Assembly Section Speed Sensor for Front Wheel Assist i02528503 Speed Sensor (Transmission) - Install SMCS Code: 3175-012 Installation Procedure Speed Sensor for Front Wheel Assist Illustration 201 g01267798 1. Disconnect harness assembly (9). 2. Remove retainer (10). 3. Remove speed sensor (11). Illustration 203 g01267805 1. Install O-ring seal (12). Illustration 202 g01267805 4. Remove O-ring seal (12). Illustration 204 2. Install speed sensor (11). 3.
50 Disassembly and Assembly Section KENR6054 Output Speed Sensor Illustration 205 Input Speed Sensor g01265018 1. Install O-ring seal (8). Illustration 206 Illustration 207 g01265004 1. Install O-ring seal (4). g01265017 Illustration 208 2. Install speed sensor (7). 2. Install speed sensor (3). 3. Install retainer (6). 3. Install retainer (2). 4. Connect harness assembly. 4. Connect harness assembly (1). 5. Repeat Steps 1 through 4 for the remaining output sensor.
KENR6054 51 Disassembly and Assembly Section i02649606 Modulating Valve (Transmission Clutch) Remove and Install SMCS Code: 3139-010-T3 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
52 Disassembly and Assembly Section KENR6054 4. Install washer (6) and nut (5). i02528248 5. Tighten nut (5) to a torque of 13 ± 1.5 N·m (115 ± 13 lb in). Temperature Sensor (Transmission Oil) - Remove and Install SMCS Code: 301T-010-T3 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
KENR6054 53 Disassembly and Assembly Section 2. Remove temperature sensor (2). Remove O-ring seal (3). Installation Procedure Illustration 215 g01264940 1. Install O-ring seal (3). Install temperature sensor (2). Tighten temperature sensor (2) to a torque of 15 ± 3 N·m (11 ± 2 lb ft). Illustration 216 2. Connect harness assembly (1).
54 Index Section KENR6054 Index C Clutch (Front Wheel Assist) - Assemble................ Assembly Procedure.......................................... Clutch (Front Wheel Assist) - Disassemble ........... Disassembly Procedure ..................................... Clutch (Front Wheel Assist) - Install ...................... Installation Procedure ........................................ Clutch (Front Wheel Assist) - Remove .................. Removal Procedure ...........................................
KENR6054 55 Index Section
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 04 - Chassis Contents BRAKES Introdution .................................................................................................................................................. Non-Asbestos Fibers Warning ............................................................................................................ Brake Operation .................................................................................................
Contents 651 - 699 ........................................................................................................................................... 4-19 801 - 850 ........................................................................................................................................... 4-20 851 - 900 ........................................................................................................................................... 4-21 INDEX ................................
Brakes BRAKES INTRODUTION m WARNING: Never operate the vehicle if there is any brake problem, no matter how minor. Brakes can fail causing injury or death. Non-Asbestos Fibers Warning FIG. 1: m WARNING: The following procedures for servicing brakes are recommended to reduce exposure to non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are available from AxleTech. Hazard Summary Most recently manufactured brake linings do not contain asbestos fibers.
Brakes Recommended Work Practices 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons. 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos brake linings recommend that exposures to other ingredients found in non-asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.
Brakes Brake Operation The two brake pads slide on the guide bolts in the housing. When the brake is actuated, the cup springs move the piston, adjusting screw thrust bolts and inner brake pad contacts the brake disc. When the inner brake pad contacts the brake disc, the housing shifts onto the guide bolts and the outer brake pad pressed against the brake disc also. The brake is released by hydraulic pressure.
Brakes CLEAN, DRY AND INSPECT m WARNING: Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, and emulsion-type and petroleum-base cleaners. Read the manufacturer’s instructions before using a solvent cleaner, then carefully follow the instructions. Also follow the procedures below. Wear safe eye protection; Wear clothing that protects your skin; work in a well-ventilated area; Do not use gasoline, or solvents that contain gasoline.
Brakes SERVICE BRAKE Release pressure m WARNING: Before disconnect brake lines. Be sure there is no pressure in the brake system. Even when the engine is not running there can still be high pressure in the brake system. To release the pressure of the brake system, do the follow steps: • Turn of the engine; FIG. 3: Measure point (1) priority valve. • Connect a pressure gauge to the priority valve.
Brakes BRAKE ADJUSTMENT Brake adjustment is required after installing new brake pads or brake discs, after all repairs , and to improve braking performance. Adjust the brakes when the brake is cold. The park brake must be in the released condition during the adjustment procedure. 1. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. If it is necessary to service the brake, use a jack to raise the vehicle. Support the vehicle with safety stands. 2.
Brakes PARKING BRAKE EMERGENCY RELEASE m WARNING: When the parking brake is released, the vehicle does not have any park brake function. You must block the wheels to prevent the vehicle from moving. Serious personal injury and damage to components can result. If hydraulic pressure is not available, the parking brake can be manually released using the following procedure. FIG. 4: 1. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. 2. Remove the screw cap. 3.
Brakes NOTES 4-8 627333-A
Axle AXLE FRONT AXLE Description The rear axle is an Axle Tech axle is attached directly to the frame with twelve M22 x 240 10.9 bolts. Weight of the axle approximately 1150 Kg (2535 lb) Removal Park chassis on hard, level surface and block the rear wheels. Drain axle fluid into suitable container. NOTE: Be prepard to collect and contain all fluids in an approved container. Place jacks under the machine and raise the frame until the weight is off the rear wheels.
Axle REAR AXLE Description The rear axle is an Axle Tech axle is attached directly to the frame with twelve M22 x 240 10.9 bolts. Weight of the axle approximately 1150 Kg (2535 lb) Removal Park chassis on hard, level surface and block the front wheels. Drain axle fluid into suitable container. NOTE: Be prepard to collect and contain all fluids in an approved container. Place jacks under the machine and raise the frame until the weight is off the rear wheels.
Axle REAR AXLE (DOG WALK CHASSIS) Description The rear axle is an Axle Teck axle is attached directly to the frame with twelve M22 x 300 10.9 bolts. Weight of the axle approximately 1150 Kg (2535 lb) Removal Park chassis on hard, level surface and block the front wheels. Drain axle fluid into suitable container. NOTE: Be prepard to collect and contain all fluids in an approved container. Place jacks under the machine and raise the frame until the weight is off the rear wheels.
Axle AXLE PRC2715 See for Axletech service manual see end of this chapter.
Chassis CHASSIS INTRODUCTION IMPORTANT: If bolts with self locking nuts are mounted. Do not use loctite. Bolts can be retorque if this is necessary. If bolts are mounted in a thread hole, always use Loctite 242-41. Do not retorque bolts. After retorque the bolts the adhesion of Loctite is gone. Straight Chassis By a Terra Gator with a straight chassis, is the rear axle with bolts against the chassis mounted. Retorque the rear axle bolts every 500 hours of operation.
Chassis ARTICULATION JOINT m WARNING: The Terra Gator is extremely heavy and requires proper handling equipment to safely spilt it. Failures to use proper procedures and equipment may result in personal injury or death due to crushing. The weight of the Terra Gator may be as much as 13,100 kg (28880 lb). NOTE: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies.
Chassis FIG. 2: After disassembly the concetion between the front and rear chassis. 6. Move the rear chassis backwards as much as need. Use a moveable jack to move the rear chassis. m WARNING: Be extremely careful when moving the rear chassis backwards. Keep a safe distance objects/machines. m 6 Be sure there is nobody in the working area of the chassis. to other WARNING: Never leave the rear chassis on the moveable jack. A jack can loose this force. Always place supports underneath the chassis.
Chassis Assembly Articulation Joint m DANGER: During maintenance on the Articulation Joint be extreme careful. Disassembly of the Articulation Joint can give abrupt movements of the front and rear chassis. This can lead to serious injury or death. When assembly the articulation joint follow the steps below: FIG. 3: The rear chassis is position to assembly all the connections. 1. Move the rear chassis with a moveable jack to the front chassis. 2.
Troubleshooting TROUBLESHOOTING TROUBLESCHOOTING Any errors in the CAN Buss sytem will be displayed on the RH EIP panel. See the table follwing the troubleshooting methods for error code definition. Any possible errors displayed can be diagnosed by the following 5 methods: 1. Over Temp/Current This error signals that the applicable component is attempting to draw too much current through the I/O module. Check for a shorted load, s shorted wire, or swap this component with another.
Troubleshooting ERROR CODES CHASSIS CAN 600 - 650 Error Code Module Number Pin Number Failure 646 I/O MODULE 6 J3 PIN 4 Over temp/current FOGLIGHTS 647 I/O MODULE 6 J3 PIN 4 Open load 648 I/O MODULE 6 J3 PIN 5 Over temp/current BEACON LIGHTS 649 I/O MODULE 6 J3 PIN 5 Open load 650 I/O MODULE 6 J3 PIN 6 Over temp/current WORKLIGHT #5 (loaction on rear side of the application) 4-18 Function FOGLIGHTS BEACON LIGHTS 627333-A
Troubleshooting 651 - 699 Error Code Module Number Pin Number Failure Function 651 I/O MODULE 6 J3 PIN 6 Open load WORKLIGHT #5 (Location on rear of application) 652 I/O MODULE 6 J3 PIN 7 Over temp/current WORKLIGHT #6 (On system) 653 I/O MODULE 6 J3 PIN 7 Open load 654 I/O MODULE 6 J3 PIN 8 Over temp/current WORKLIGHT #7 (On system) 655 I/O MODULE 6 J3 PIN 8 Open load 664 I/O MODULE 6 J3 PIN 4 Over temp/current LH END ROW 665 I/O MODULE 6 J3 PIN 4 Open load 666 I/O MODULE
Troubleshooting 801 - 850 Error Code Module Number Pin Number Failure 810 I/O MODULE 3 J3 PIN 4 Over temp/current LOW BEAMS 811 I/O MODULE 3 J3 PIN 4 Open load 812 I/O MODULE 3 J3 PIN 5 Over temp/current HIGH BEAMS 813 I/O MODULE 3 J3 PIN 5 Open load 814 I/O MODULE 3 J3 PIN 6 Over temp/current WORK LIGHT #1 (location engine hood) 815 I/O MODULE 3 J3 PIN 6 Open load 816 I/O MODULE 3 J3 PIN 7 Over temp/current WORK LIGHT# 2 (location engine hood) 817 I/O MODULE 3 J3 PIN 7 Ope
Troubleshooting 851 - 900 Error Code Module Number Pin Number Failure Function 851 HC MODULE 7 J3 PIN 6 Open load REVERSE LIGHTS 852 HC MODULE 7 J3 PIN 7 Over temp/current LEFT TURN SIGNAL 853 HC MODULE 7 J3 PIN 7 Open load 854 HC MODULE 7 J3 PIN 8 Over temp/current RIGHT TURN SIGNAL 855 HC MODULE 7 J3 PIN 8 Open load 860 HC MODULE 7 J3 PIN 11 Over temp/current WORK LIGHTS #4 861 HC MODULE 7 J3 PIN 11 Open load WORK LIGHTS 4 873 MASTER J2 pin 26 Open load FUEL LEVEL 87
Troubleshooting NOTES 4-22 627333-A
Index INDEX A S Articulation Joint ................................................. 4-13 Short to Bat/OT ................................................... 4-17 Short to GND ...................................................... 4-17 Straight Chassis ................................................. 4-13 B Bleed Brake .......................................................... Brake Adjustment ................................................. Brake lining ..............................................
Index NOTES 4-24 627333-A
Planetary Drive Axles Pont Double Reduction Maintenance Manual 9L Manuel de maintenance 9L Models/Módeles PRC2715 PRC2725 PRC2726 PROC2715 PROC2725 Issued 9-06 Edité Septembre 06
Service Notes Before You Begin This maintenance manual describes the correct service and repair procedures for all AxleTech planetary axle models listed on front cover. The information contained in this manual was current at time of printing and is subject to change without notice or liability. You must follow your company procedures when you service or repair equipment or components. You must understand all procedures and instructions before you begin to work on a unit.
Table of Contents Exploded Views Axle Housing Assembly With Forced Cooling Option .....................................................................................1 Axle Housing Assembly – Heavy Housing Using Recessed Carrier Mounting ..............................................2 Axle Housing With Trunnion Option ................................................................................................................3 Heavy Axle Housing With Central Actuation Service Brake – Top Inlet Port ...
Table of Contents Section 4: Assembly Axle Assembly...............................................................................................................................................24 Assembly of the Axle Housing Components with Central Actuation Wet Disc Brake Feature Option .........25 Install Carrier into Axle Housing Assembly ...................................................................................................26 Axle Housing Plugs Assembled ...................................
Exploded View Axle Housing Assembly With Forced Cooling Option 7 8 3 7 9 3A Item 1 2 2A 3 11 6 4 2 5 4 2A 3 2 3A Description AXLE HOUSING 11 2 Item Description CAPSCREW 7 BLEEDER SCREW MAGNETIC PLUG- FORCE COOLING OUTLET PORT 8 BREATHER ASSEMBLY FILL PLUG 9 SHIM FILL PLUG - FORCE COOLING INLET PORT 10 STUD 4 HARDENED WASHER 11 BRAKE ACTUATION PORT FITTING 5 CAPSCREW 3A 10 1 6 MAGNETIC PLUG 10 Page 1
Exploded View Axle Housing Assembly – Heavy Housing Using Recessed Carrier Mounting 1 3 2 4 2 8 7 5 2 6 Item Description Item Description 1 AXLE HOUSING 5 LOCK NUT 2 MAGNETIC PLUG 6 HARDENED WASHER 3 FILL PLUG 7 CAPSCREW 4 STUD 8 CAPSCREW Page 2
Exploded View Heavy Axle Housing With Central Actuation Service Brake – Top Inlet Port 2 1 11 10 15 5 6 9 14 13 4 3 7 12 9 8 9 Item Description Item Description 1 AXLE HOUSING 9 MAGNETIC PLUG 2 TOP INLET PORT CENTRAL ACTUATION 10 BLEEDER SCREW 3 HYDRAULIC TEE FITTING 11 FILL PLUG 4 TUBING ASSEMBLY 12 HARDENED WASHER 5 CONNECTOR FITTING ASSEMBLY 13 CAPSCREW 6 SHIM 14 CAPSCREW 7 TUBE ASSEMBLY 15 WET DISC BRAKE INSPECTION PORT PLUG 8 STUD Page 4
Exploded View Heavy Axle Housing With Central Actuation Service Brake – Front Inlet Port 16 13 12 14 15 6 5 4 2 8 10 9 11 Item 1 7 Description AXLE HOUSING 4 1 4 Item 9 3 Description CAPSCREW 2 CONNECTOR FITTING ASSEMBLY 10 CAPSCREW 3 STUD 11 CENTRAL ACTUATION FRONT INLET PORT 4 MAGNETIC PLUG 12 HYDRAULIC TEE FITTING 5 BLEEDER SCREW 13 TUBE ASSEMBLY 6 FILL PLUG 14 TUBE ASSEMBLY 7 SHIM 15 CLIP, BRAKE TUBE 8 HARDENED WASHER 16 CAPSCREW Page 5
Exploded View Planetary Wheel End Components 24 20 21 22 25 19 18 23 13 12 13 28 26 29 8 27 9 1 2 15 31 14 3 30 Item 1 Description SPINDLE 2 Item 17 5 17 7 6 17 Description SOCKET HEAD CAPSCREW 18 PLANETARY SUN GEAR HUB AND CUP ASSEMBLY 19 THRUST WASHER 4 WHEEL BEARING NUT 20 SPRING HOUSING 5 LOCK PLATE 21 HARDENED WASHER 6 DRIVE FLANGE 22 SOCKET HEAD CAPSCREW 7 O-RING 23 SNAP RING 8 PLANETARY SPIDER ASSEMBLY 24 AXLE SHAFT 9 PLANETARY PINION 25 AXLE S
Exploded View W3H Shaft Speed Wet Disc Service Two Friction Disc Brake 7 8 9 6 5 4 3 2 3 2 1 Item Description Item Description 1 BACKING PLATE 6 D-RING PISTON SEAL 2 FRICTION DISC (ROTATING) 7 STATIONARY DISC DOWEL 3 STATIONARY DISC 8 SPRING GUIDE DOWEL 4 PISTON 9 RETURN SPRING 5 D-RING PISTON SEAL Page 7
Axle Cross-Section Views Rigid Mount Axle — No Brake WHEEL END ASSEMBLY AXLE SHAFT DIFFERENTIAL CARRIER Rigid Mount Axle — with Service Brake and Parking Brake WHEEL END ASSEMBLY AXLE SHAFT DIFFERENTIAL CARRIER PARKING BRAKE W3H SHAFT SPEED SERVICE BRAKE Trunnion Mount Axle — No Brake WHEEL END ASSEMBLY AXLE SHAFT DIFFERENTIAL CARRIER TRUNNION MOUNT (OSCILLATING) TRUNNION MOUNT (OSCILLATING) Trunnion Mount Axle — with Service Brake WHEEL END ASSEMBLY AXLE SHAFT DIFFERENTIAL CARRIER Page 8 T
Section 1 Introduction Description The AxleTech PROC2715 and PRC2715 axle family is a single speed planetary axle series. Key features in this axle family are: • Hypoid ring and pinion gearing in the carrier assembly. • Carrier assembly available with standard differential or a hydraulically actuated differential lock (HDL) option. • Carrier available with trunnion feature option or standard differential. • Thrust screw standard in carrier shell. • Axle with a “trunnion” feature option.
Section 2 Removal & Disassembly Removal and Disassembly from the Vehicle ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury can result.
Section 2 Removal & Disassembly NOTE: If the trunnion adapter located on the axle housing bowl side must be removed, use the following recommended procedure: Figure 2.5. Figure 2.6 Figure 2.5 BUSHING TRUNNION ADAPTER TRUNNION BRACKET SEAL SEAL THRUST WASHER CAPSCREW 1. Remove the (10) M12 capscrews from the adapter assembly to housing attachment. NOTE: Liquid gasket was applied at original production assembly. 2. Safely set the trunnion adapter assembly on the work bench for later inspection. 3.
Section 2 Removal & Disassembly Figure 2.7 M18 CAP SCREWS AND WASHERS 5. Remove O-Ring from inner side of ring gear. For safety, remove M18 lock nuts while wheel end is still supported by studs, assemble (2) M18 capscrews with washers through spindle flange and planetary ring gear mounting holes and assemble (2) nuts with washers onto capscrew threads so the ring gear cannot fall off the spindle flange. Figure 2.9. 6.
Section 2 Removal & Disassembly 2. Remove the socket head M8 capscrews from the cover on the planetary wheel end. Figure 2.11. Figure 2.11 M8 CAPSCREW 5. Remove the (3) M8 socket head capscrews that retain the driver to wheel hub. Figure 2.13. Figure 2.13 DRIVER O-RING COVER O-RING NOTE: These capscrews had a medium strength thread locker applied at original production assembly. 3. Remove the cover and O-ring from the driver. Figure 2.12. Figure 2.
Section 2 Removal & Disassembly 9. Remove both the inner and outer bearing cones, planetary hub assembly, and TRS toric ring metal face seal half from the spindle. Wrap the inner and outer bearing cones to prevent contamination and set aside for later cleaning, inspection and re-assembly. ! CAUTION Care should be taken to store the (2) halves of the face seal to protect them from damage and saved for reassembly later when required. 10. Remove the loose TRS face seal from the spindle.
Section 2 Removal & Disassembly Do Not Remove the Planetary Pinion Shafts from the Planet Spider Figure 2.18 SPRING DOWEL D-RING SEALS SPRING NOTE: The planetary pinion shafts are not serviceable items. Be careful not to bump or damage the pinion shafts. ! THRUST WASHER CAUTION The planetary pinion shafts are not serviceable items and must not be pressed out of the planetary spider shaft. The planetary pinion shafts are precisely "fixture located" in the spider by a heavy press fit.
Section 2 Removal & Disassembly Figure 2.19 SHIM Disassembly of Wet Brake Actuation Tubing Assembly If the axle being serviced has a wet disc brake with central actuation, then there will be internal wet brake actuation tubing assemblies in the axle housing assembly. These tubing assemblies will be accessible for service when the carrier assembly, axle shaft and planetary wheel ends are removed. “The following service procedure is recommended to disassemble the brake tubing assemblies, if required. 1.
Section 3 Prepare Parts for Assembly NOTE: For the axle equipped with the wet brakes, there are O-ring oil fill/drain plugs. The lower (3) plugs are magnetic plugs. These plugs must be removed and cleaned. ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, and emulsion-type and petroleum-base cleaners.
Section 3 Prepare Parts for Assembly ! CAUTION Damage to bearings can result when they are rotated and dried with compressed air. 3. Except for bearings, parts can be dried with compressed air. • There is a visible roller groove in the cup or cone inner race surfaces. The groove can be seen at the small- or large-diameter end of both parts. Figure 3.2. Figure 3.2 Prevent Corrosion On Cleaned Parts 1. Apply axle lubricant to cleaned and dried parts that are not damaged and are to be re-assembled. 2.
Section 3 Prepare Parts for Assembly • There is damage on the rollers and on the surfaces of the cup and cone inner race that touch the rollers. Figure 3.4. Figure 3.4 ETCHING AND PITTING • The planetary ring gear should be checked for signs of heavy wear, teeth chipping or scoring or deep scratches around the O-ring groove diameters.
Section 3 Prepare Parts for Assembly Planetary Spider Shaft Inspect the planetary spider shaft for any signs of wear, burrs, scratches or other damage to the planetary pinion shafts. Inspect the splines where the driver is mounted for signs of wear and the snap ring groove for wear or burrs. Wheel End Spindle Inspect the planetary spindle for any damage or scratches to the bearing journals. The face seal bore should be inspected to review for scratches to the seal bore.
Section 3 Prepare Parts for Assembly be less than that shown in Table 1. Replace the entire disc pack if one disc needs replacing. Table 1. Minimum Brake Disc Thickness Disc Type Part Number Minimum Thickness Friction A3281L1260 0.192 Inch (4.87 mm) Stationary 3281M1261 0.167 Inch (4.24 mm) 2. The splines on the friction disc should be reviewed for wear or cracks evident on the spline teeth. The backing plate and stationary disc should be inspected for scratches on the mating surface to the friction disc.
Section 3 Prepare Parts for Assembly Repairing or Replacing Parts Replace worn or damaged parts of an axle assembly. The following are some examples to check for repair and possible replacement: • Replace any fastener if corners of the head are worn. • Replace washers if damaged. • Replace oil seals or grease seals at the time of axle repair. • Clean parts and apply new liquid gasket material where required when the axle is assembled.
Section 4 Assembly Axle Assembly General comments to be applied to the Axle Assembly Procedures and Recommendations: 1. Clean and dry all surfaces to which sealant or adhesive will be applied. 2. Clean and dry all threads of capscrews or holes to which thread locker will be applied. 3. Apply thread locker to capscrew threads in through holes, and into tapped holes when blind holes. 4.
Section 4 Assembly Assembly of the Axle Housing Components with Central Actuation Wet Disc Brake Feature Option ! WARNING Use straps to lift axle housing into safe axle workstand with lifting straps. Care should be taken to secure the axle housing so personal injury or component damage does not occur. ! WARNING Take care when using lifting devices. When you use a lifting strap, inspect the strap for damage before you use it. Do not use a lifting strap to shock load or drop load a component.
Section 4 Assembly 8. Tighten the M12 banjo fittings by holding the banjo stationary while using a wrench to tighten its bolt per “Torque Table” in section 6. 9. Tighten the tee-fitting to inlet port nut, refer to “Torque Table” in section 6. 10. Tighten the banjo-fitting to hydraulic brake tube nuts (11/16”), per “Torque Table” in section 6. 11. Install any internally mounted brake tube clips over the tube. Install Carrier into Axle Housing Assembly 1.
Section 4 Assembly Axle Housing Plugs Assembled Figure 4.4 Trunnion Mount Axle Assembly With Wet Brake WET DISC BRAKE INSPECTION PORT FILL PLUG 1. Install the (1.06”) non-magnetic oil fill plug with O-ring assembly into the upper carrier bowl area of the axle housing. Tighten per “Torque Table” in section 6. 2. Install the (3) (1.06”) axle magnetic drain plugs with O-ring assemblies into the axle housing in the bottom of the carrier bowl and at the bottom of each axle flange.
Section 4 Assembly Axle Shaft, Thrust Washer, Snap Ring, Sun Gear Assembly Figure 4.8 Complete this assembly for each axle shaft to be assembled. Note there are a long and short axle shaft to be assembled. Figure 4.7. LARGE D RING SMALL D RING Figure 4.7 RETURN SPRING SPRING GUIDE DOWEL SPRING HOUSING AXLE SHAFT FRICTION DISC ENGAGES SUN GEAR SUN GEAR SNAP RING SUN GEAR AXLE SHAFT SNAP RING 1. Slide the planetary sun gear on the axle shaft planetary splines.
Section 4 Assembly 5. Apply a thin coat of oil to the wet brake piston bore and install the wet brake piston and D-Ring assemblies into the axle housing flange bore, including the lead-in chamfer area. 6. Place the piston and D-Rings assembly against the lead chamfer in the piston housing. 7. Oscillate the piston 15-20 degrees easily by hand. Easy movement indicates good fit and piston is well centered and seated against the lead chamfer in the axle housing flange.
Section 4 Assembly 4. Install the backing plate with flat surface toward friction disc, into the axle housing flange, aligning the slots in the plate with the (6) dowels. If assembly has two friction discs, refer to Figure 4.13 for sequence of discs. Figure 4.13 STATIONARY DISC DOWEL BACKING PLATE STEP SURFACE FRICTION DISC WHEEL END ASSEMBLY 2. Install a stationary disc against the piston into the axle housing flange aligning the slots in the disc with the (6) axle housing flange dowels. 6.
Section 4 Assembly 4. A piece of thin shim stock ~0.0254mm (0.001”) is to be inserted in several places around the diameter to check the ring gear is properly seated. 5. Install (2) bolts, nuts and washers, for safety. An optional assembly method is as follows if a press is not used: 1. Apply a light coat of grease to the O-Ring. 2. Install the O-Ring into the groove of the planetary ring gear face. Care should be taken not to twist or damage the O-Ring during assembly. 3.
Section 4 Assembly Figure 4.17 ! Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-base cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer’s instructions and these procedures: SPINDLE BEARING SPACER 7. Slide the spacer over the spindle and against the spindle shoulder tapping with a brass rod to properly seat the wheel bearing spacer.
Section 4 Assembly ! ! CAUTION ® Do not use Stanosol or any other liquid that leaves an oily film and does not evaporate quickly, since this may result in incorrect seating of the Toric Ring in the housing, resulting in seal leakage. A. Wet the rubber Toric Ring with isopropyl alcohol and install it onto the formed seal ring so that it is seated at the bottom of the seal ring ramp and against the retaining lip. Figure 4.19. Figure 4.
Section 4 Assembly 8. Follow the same procedure to install the other half of the face seal assembly onto the wheel spindle. Figure 4.22. 2. If required, adjust the seal standout height by using the following methods. • If the standout height cannot be brought into specification: Remove the seal and repeat the installation procedure. Figure 4.22 ! CAUTION Push or pull the Toric Ring and face seal only. Do not push or pull directly on the seal ring. This can cause component damage. A.
Section 4 Assembly Wheel Hub to Spindle Assembly NOTE: Complete the assembly of the wheel hub to the spindle. Before installing the wheel hub onto the spindle, however, keep the following points in mind to ensure correct sealing between the faces of the Toric Ring: 1. Check both sealing faces carefully to make sure they are clean and free of any dirt, debris, lint, and even human hair. ! CAUTION • If the seals are not aligned correctly: The seals will move.
Section 4 Assembly 5. Apply a light coat of oil to the bearing cone rollers and install the outer bearing cone onto the spindle. Figure 4.27. Figure 4.27 OUTER BEARING CUP TRS FACE SEAL BEARING CONE 15. Add a few drops of medium strength thread locker to each capscrew threads to install the (3) lock plate M8 capscrews and tighten per “Torque Table” in section 6. Safely set the planetary wheel hub, planetary ring gear, and spindle assembly on a workbench.
Section 4 Assembly Method 1: 3. Apply a light coat of grease to the planetary pinion gear bore and assemble the (33) needle rollers into the planet gear bore until there is no further space to add additional needle rollers. Figure 4.28. If new needle rollers are being used in the planetary gear assembly, they must be from the same vendor, and belong to the same tolerance group (0.002mm). Figure 4.
Section 4 Assembly NOTE: Use care not to damage or twist the O-ring during assembly. 3. Apply a light coat of grease to the O-ring that will be fitted onto the driver pilot diameter and install O-ring onto the driver against the flange. Care should be taken to not twist or damage the O-ring during this assembly. Figure 4.30. Figure 4.30 Install the Planetary Wheel End Assembly On the Axle Housing ! CAUTION Take care when using lifting devices.
Section 4 Assembly Figure 4.32 Axle Air Leak Test SHIM Place axle in a safe test stand mounted with carrier input pinion horizontal for this assembly test. 1. Install a pressure gauge that will clearly read up to 140 kPa (1.4 Bars, 20 psi) into the axle housing breather port (7/16”-20 UNF). 2. Connect an air line with a shut off valve. 3. Apply 55 kPa(0.55 Bars, 8 psi) and lock pressure on. DOWEL 2.
Section 4 Assembly Re-Installation into Vehicle Please follow the vehicle OEM recommendations to re-install the axle into the vehicle chassis. Once the axle has been re-installed safely within the vehicle chassis, the following steps to re-connect the axle is recommended (if they do not conflict with OEM assembly instructions): 1. Reconnect the hydraulic differential lock actuation line and torque inlet fitting to OEM recommended value. 2.
Section 5 Lubrication LUBRICATION Breather ! CAUTION Cover the breather when steam cleaning the axle housing to prevent water from entering the axle housing and contaminating the oil. Damage to components will result. Breathers release pressure and vacuum condensation to help maximize oil and component life. Seals ! CAUTION Always use the correct tools and procedures when replacing seals to prevent incorrect installation and leaking seals. Seals keep lubrication in and dirt out of a component.
Section 5 Lubrication Lubrication Specification The axles covered by this manual all have a hypoid gear set in the carrier assembly that requires extreme pressure EP type lubricant in the GL5 oil classification. The planetary wheel end's oil and the wet disc brakes' coolant oil, if equipped with wet disc brakes, have a common sump with the carrier's oil.
Section 6 Torque TORQUE TABLE THREAD SPEC TYPE LOCATION THREAD TORQUE N•m (lb-ft) COMPOUND [1] nominal FASTENERS medium-strength 38.3 (28.2) 33.5 (24.7) – 43.1 (31.8) medium-strength 38.3 (28.2) 33.5 (24.7) – 43.1 (31.8) capscrew L30 Allen Head Carrier: Bearing Cap (Adj. Ring Lock) medium strength 33.0 (24.3) 28 (20.7) - 38(28) capscrew L45 hex-head medium-strength 132 (97.4) 119 (87.7) - 145 (107) 0il 119 (87.8) 107 (78.9) - 131 (96.
Section 7 Special Tools How to Make a Yoke Bar 1. Measure dimensions A and B of the yoke you are servicing. Figure 7.1. Figure 7.3 PULL BEARING Figure 7.4 PULL BEARING Figure 7.1 2. Calculate dimensions C and D of the yoke bar by adding 0.125-0.250-inch to dimensions A and B of the yoke. Figure 7.2. Figure 7.2 ! WARNING Wear safe clothing and eye protection when you use welding equipment. Welding equipment can burn you and cause serious personal injury.
Section 7 Special Tools Figure 7.5 TOOL 1 Figure 7.8 TOOL 5 Ø184 APPROX REAR TRUNNION BUSHING REMOVAL 100 80 5 INNER WHEEL BEARING CONE INSTALLAITON 165.1 1.6 x 45° 260 ø140 ø159.2 ± 0.4 163.5 ± 0.4 Ø161 ± 0.4 10 Ø180 MAX Figure 7.6 TOOL 2 AND 3 3/4-10 UNC-28 OR M18 X 1.5-6H SHARP INSIDE CORNER 50 Figure 7.9 TOOL 6 M12 x 1.75-6H 25 ø177.8 Ø252 ± 0.4 FOR TOOL #2 INNER CUP INSTALLATION Ø238 ± 0.4 FOR TOOL #3 OUTER CUP INSTALLATION Figure 7.
Section 7 Special Tools Figure 7.11 USE MODIFIED RING PART NO. 3305K1753 TOOL 860901008T WHEEL BEARING NUT ADJUSTMENT Figure 7.
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 05 - Cabin Contents CAB Cab ............................................................................................................................................................ Cab Filtration ............................................................................................................................................. General Information ............................................................................
Contents Intake For Airflow .............................................................................................................................. Fresh Air ............................................................................................................................................ Recirculation ...................................................................................................................................... Head, Foot and Defrost ..................................
Cab CAB CAB Cab has a Roll Over Protection Structure (ROPS). m CAUTION: Roll Over Protection Structure (ROPS) is manufactured to meet strict safety standards. No attempt should be made to alter ROPS in any manner (i.e. welding, drilling, etc.) Cab has been designed for operator safety, comfort and convenience. Cab is control center of Terra Gator. Operator can easily monitor and adjust Terra Gator functions using conveniently located controls.
Cab CAB FILTRATION General Information m CAUTION: Chemical residue may be present in dirt on filter elements. Wear protective gear while servicing filter elements. Cab is pressurized. Primary and recirculation filter purify cab’s internal air. NOTE: Key must be in OFF position before servicing cab filters. FIG. 1: Location of cab air filters. 1 1. Primary fresh air filter; 2. Secondary fresh air filter; 3. Recirculation filter.
Cab Primary Fresh Air Filter Primary fresh air filter is located in roof overhang in front of the cab. Filter removes dust particles drawn into air system and is partially cleaned each time cab door is closed, when back pressure flushes primary air filter. Before removing filter, close all windows and door. Back pressure from cab helps dislodge loose dirt on underside of filter. m WARNING: Inadequate sealing may cause filter malfunction and personal injury could result.
Cab Filter life is affected by environmental conditions and should be replaced when odor, taste or other symptom of contamination is detected. m WARNING: Inadequate sealing may cause filter malfunction. Personal injury could result. Isoamyl acetate, which has a banana-like odor, may be used to check seal. Periodically inspect door gasket for damage. NOTE: Store replacement filters in original packaging in a clean dry area away from exposure to any chemicals.
Cab Seat CAB SEAT DELUXE SEAT Seat is a self-contained air ride seat with its own air compressor under seat base to provide air for air spring. Seat is mounted on top of HVAC cabinet. m CAUTION: Turn off engine and remove key from ignition. Removal FIG. 1: Remove two bolts (1) holding shift console to right-hand side of seat. Lower shift console to floor. 1 1 M411008 FIG. 1 FIG. 2: Using tilt control lever (1), raise steering column up to a vertical position to allow seat removal. 1 M424002 FIG.
Cab Seat FIG. 4: Loosen and remove two bolts (1) on left-hand side of base plate. 1 1 M411004 FIG. 4 FIG. 5: With height adjustment button (1) air to the seat suspension to the highest position to aid in removal. NOTE: If the seat is not in highest position while lift the seat of the mounting plate. The suspension of the seat will travel out before come of the mounting plate. 1 M424006 FIG. 5 FIG. 6: Disconnect pigtail electrical connector (1) on lower right-hand rear corner of seat.
Cab Seat Installation Lift seat into cab and place on HVAC cabinet. m CAUTION: Use caution extremely heavy. as seat is NOTE: Align bolts with holes on HVAC cabinet. FIG. 8: Turn the ignition key to the Accessory position or ON position. With height adjustment button (1) lift seat up to its highest position to aid in installation. 1 M424006 FIG. 8 FIG. 9: Install two bolts (1) on right-hand side and tighten. 1 1 M411003 FIG. 9 FIG. 10: Install two bolts (1) on left-hand side and tighten.
Cab Seat FIG. 11: Connect pigtail electrical connector (1) on lower right-hand rear corner of seat. Pigtail from harness is labeled SEAT. 1 M424003 FIG. 11 FIG. 12: Lift shift console back into position, install bolts (1) and tighten. 1 1 M411008 FIG. 12 FIG. 13: With backrest recline adjustment lever (1) lift seat back into normal operating position. 1 M411002 FIG.
Cab Seat DIAGNOSTICS It is possible to read the diagnostic of the seat. Inside the suspension of the seat there is an electronic controller box with a LED at the front, pointing to the left side of the seat. The LED flashing at different frequents. Every different frequency has is own specification. Flashing Frequency Continuous Description Correction No damper connection or bad damper coil. Check connection / Replace damper. + 4Hz The controller is bad should be replaced. Replace controller.
Cab Seat TROUBLESHOOTING QSeat Troubleshooting-Model FIG.
HVAC HVAC GENERAL INFORMATION Heating, Ventilation and Air Conditioning (HVAC) along with components and schematics are covered in this section. THEORY OF OPERATION The compressor is the central part of the A/C system. The compressor has a suction and discharge side, or a low and high side. On the high side of compressor, marked “dis” on compressor head, refrigerant is discharged from compressor. In condenser, during sub cooling process, refrigerant changes from a gas to a liquid.
HVAC AIR CONDITIONING PROCESS FIG. 1: Refrigerant is drawn into compressor as a cool/cold low-pressure vapor, is compressed and then moves out as a hot, high-pressure vapor to condenser. Cooled high-pressure liquid is stored in receiver/drier until it is released to evaporator by expansion valve. EXPANSION VALVE EVAPORATOR HEAT MOVES FROM REFRIGERANT TO OUTSIDE AIR CONDENSER RE SU ES PR OR W AP LO V Liquid refrigerant passes through a metered orifice in expansion valve and into evaporator core.
HVAC HVAC SYSTEM FIG. 2: HVAC system is located under operator seat.
HVAC AUTOMATIC TEMPERATURE CONTROL 7 6 4 5 4 5 1 2 3 Climate Control FIG. 3 Description The Automatic Temperature Control (ATC) allows for true interior cab temperature control and continuously variable blower fan speed through the use of advanced microprocessor and sensor technology. 1. ON / OFF - Powers vehicle Heater-A/C control system on or off. The LED numeric display is illuminated when the unit is turned on. The display will show the current set point temperature. 2.
HVAC Troubleshooting To display diagnostics, depress key three times. Digital display shows any active fault codes. Repeatedly pressing key scrolls through active codes. Each code displayed should be addressed until No Faults code E00 is displayed.
HVAC Air Conditioning System Refrigerant Compressor FIG. 4: Refrigerant Compressor (1) Belt-driven and located on engine’s left front, magnetic clutch is used to engage compressor. Compressor separates the low and high pressure sides of system and is basically a pump with two functions: • Raising refrigerant temperature and pressures by compression. • Functioning as a pump to circulate required volume of refrigerant and refrigerant oil around system.
HVAC Then refrigerant vapor reaches pressure and temperature that induces a change of state, a large quantity of heat is transferred to outside air and refrigerant changes to a high-pressure cool liquid and moves to receiver/drier. See Systems Operation/Testing and Adjusting, Refrigerant Condenser for additional information. Receiver/Drier FIG. 7: Receiver/drier (1) stores liquid refrigerant to ensure a steady flow to thermostatic expansion valve is maintained under widely different operating conditions.
HVAC A/C and Heating System Schematic Two sensors monitor refrigerant pressure: • Pressure sensor for side of high pressure • Pressure sensor for side of low pressure Pressure sensor on side of high pressure ensures pressure does not go too high or too low. If either occurs, compressor shuts off to protect system. Pressure sensor on side of low pressure ensures pressure does not go too low. If this occurs, compressor shuts off to protect system. Compressor Clutch Clutch Operation FIG.
HVAC Compression (Discharge Side) As pressure increases so does temperature of saturation. Compressor changes refrigerant from a low to a high pressure vapor. Change must occur for latent heat of condensation to be produced when refrigerant is sent through condenser. Operation of Compressor FIG.
HVAC Temperature in Cab Temperature of inside cab airflow is measured by temperature sensor in HVAC unit. Cab airflow is drawn through recirculation filter and passed sensor. Outside Temperature Outside temperature is measured by sensor located near drive motor for rear window wiper. Temperature of Ventilation Duct Temperature of cooled or heated air in ventilation duct is measured by a sensor (5) located in blower fan housing. Probe for Evaporator Coil FIG.
HVAC EVAPORATOR COIL FIG. 12: Evaporator Operation Evaporator (1) is located in HVAC unit in front of heater coil. Evaporator transfers heat in cab to refrigerant. Evaporator receives liquid refrigerant, with low pressure and temperature. Since pressure of liquid refrigerant is low, temperature of saturation of refrigerant is low. As temperature of saturation changes, refrigerant changes from liquid to vapor. Blower fan exposes evaporator coil to air inside cab.
HVAC ACTUATOR MOTOR (WATER VALVE) FIG. 14: Water Valve with Actuator Motor Water valve (1) controls amount of water flowing into heater core. Foreign matter on outside surface of heater core can cause a poor exchange of heat. Heating system loses capability to heat when heater core gets dirty. Clean outside surface of heater core when system is checked. Valve actuator is used to control water valve with sixteen positions available and is dependent on amount of heat required.
HVAC AIRFLOW Components for Airflow Airflow Components HVAC Unit Air Filter (Fresh Air) Air Filter (Recirculation) Damper Control (Deluxe Cab) Inlet for Recirculated Air Inlet for Fresh Air Blower Fan Sealing Area Blower Fan FIG. 16: Internal components with rear cover removed Blower (1) is located in HVAC unit and has: • Inlet for fresh air and inlet for recirculated air. • Outlet for vents on left side of the cab. • Outlet for vents on front console. • Outlet for vents on right side of cab.
HVAC Fresh Air FIG. 17: Fresh air flow The fresh air flow comes from the blower which is located underneath the seat. The air flow goes underneath the cab floor mat to the dashboard console. Inside the dashboard goes the air flow through the air gates into the cab. The arrows in the figure shows the air flow. q000262s FIG. 17 Fresh Air Filter FIG. 18: Fresh Air Filter Fresh air is drawn through cab filter (1) located above windshield.
HVAC Charcoal Air Filter FIG. 20: Charcoal Air Filter IMPORTANT: To maintain proper cab pressurization, baffle must be in the fully raised position when used with charcoal filter. When used with a standard cab filter, baffle must be in fully lowered. Charcoal filter (1) is used in conjunction with a baffle on cab air filter cover. Life of filter is affected by environmental conditions and should be replaced when odor, taste or other symptoms of contamination are detected.
HVAC Automatic Temperature Control (Fan) Auto Mode Fan speed is system determined based on difference between setpoint and actual cab temperature. A large difference in temperature results with faster fan speed. Heating or cooling occurs if cab is too hot or cold. Fan speed is held at a minimum when cab is heating or cooling quickly and overshoots setpoint temperature. In automatic mode, fan speed is limited by temperature of outlet duct.
HVAC ACTUATOR MOTOR (DAMPER) FIG. 23: Actuator Motor Schematic Actuator Motor (1) Inside Actuator (2) 2-Pin Connector (3) Actuator motor is used in one position on HVAC system to control a damper for airflow of defrost for front window. NOTE: Refer to table in Systems Operation, Control Module for details on operation of actuators. 2 1 3 N011803012 FIG.
HVAC GLOSSARY OF TERMS accumulator - a refrigerant storage and filtering component used in place of a receiver-drier in CCOT air conditioner systems activated alumina - chemical receiver-driers as a desiccant agent used in air block - an assembly used to direct air pressure to control devices air conditioning - control of air movement, humidity and temperature by mechanical or other means in a vehicle air operated water valve - a valve in vehicle cooling (heater) system controlled by air pressure capil
HVAC cycling clutch orifice tube (CCOT) system - a system using an expansion tube (fixed orifice tube) and an accumulator in place of expansion valve and receiver-drier cycling clutch system - a temperature control system which monitors operation of compressor clutch dehumidify - to remove moisture (humidity) from air in the cab or defog windshield density - ratio of mass to it’s volume desiccant - an agent used in an air conditioning system to dry or remove moisture by absorption; found in receiver-drier o
HVAC heater core - an assembly of metal tubing and fins used to exchange heat from engine coolant to cab air Hg - symbol for mercury in Periodic Table of Elements HVAC - heating, ventilation and air conditioning high load condition - circumstance when air conditioning system is operating at maximum capacity to cool a given environment high pressure cutout switch - a switch which cuts out compressor clutch if pressure in system rises above a pre-set level high pressure lines - lines carrying high pressure re
HVAC rotary vane compressor - a type of compressor which uses internal vanes rather than pistons to operate and pump refrigerant through system thermostat - a temperature sensitive switch used to control system temperature by cycling compressor on and off rotating coil clutch - an old type clutch where magnetic coil is part of clutch pulley - now replaced universally by stationary coil design where coil is bolted to compressor body thermostatic expansion valve - a valve which senses evaporator outlet tub
HVAC NOTES 5-32 627333-A
HVAC Specification HVAC SPECIFICATION REFRIGERANT COMPRESSOR Compressor 1 q000314s FIG. 1 FIG. 1: Torque for oil plug (1) 8 to 12 Nm (71 to 107 lbf in) NOTE: Oil plug is pressurized Type of compressor .............................................................................................. Sanden International 4872-6000 Type of 4C-2959 Air Conditioner Lubricant.....................................................................................................SP-15 Oil capacity of compressor .......
HVAC Specification Belt 2 MA3012004 FIG. 2 FIG. 2: Belt (2)...............................................................................................................................................................PV10 135-2151 Belt Tightener spring force at 25 degrees ....................................... 12.4 to 15.8 Nm (9.1 to 11.
HVAC Testing and Adjusting HVAC TESTING AND ADJUSTING TROUBLESHOOTING MACHINE PREPARATION • All charging and leak testing must be done in a wellventilated area. m • Avoid any physical contact with refrigerant as contact can cause frostbite. • Always wear goggles when working on or testing any part of the air conditioning system. • Place a clean cloth over any open valve or connection. • Never weld, solder or steam clean any charged components.
HVAC Testing and Adjusting GENERAL TROUBLESHOOTING INFORMATION • Presence of frost on accumulator is normal, the thickness of frost depends on outside temperature and humidity. • Low refrigerant charge causes losses of cooling and lubrication in compressor, results in failed compressor. • Perform regular maintenance on refrigerant service units and change vacuum pump oil. • Overcharge of refrigerant causes a loss of cooling ability.
HVAC Testing and Adjusting TROUBLESHOOTING FAULTS WITH SERVICE CODES (ACTIVE) Entering Active Troubleshooting The active diagnostics displays information on the control panel. This information will assist in servicing HVAC unit. 2. Press button for outside temperature three times in succession to view stored error codes. Service Codes ERROR CODE PROBLEM 1. Turn on control panel. 3. Press and hold button for outside temperature for five seconds to view active diagnostics. 4. LED should display CAB.
HVAC Testing and Adjusting Troubleshooting Using Active Diagnostics Several systems diagnostics.
HVAC Testing and Adjusting Checking Refrigerant Pressure Switches Use the following to verify operation of refrigerant pressure switches: NOTE: Test should be performed in air temperatures greater than 21 degrees C (70 degrees F), clutch may not engage below that temperature. If necessary, use a heat source to warm outside air temperature. 1. Turn rotary switch to Head-Foot position. 2. Set temperature control to maximum heat. 3.
HVAC Testing and Adjusting Checking Actuator for Water Valve Checking Mode Door Actuator Use the following to verify water valve actuator operation: Use the following to verify mode door actuator operation: 1. Verify engine coolant system is full of coolant. 2. Turn switch to Head-Foot position. 3. Enter active troubleshooting, refer to Entering Active Troubleshooting for instructions about active troubleshooting. 4. CAB is first code displayed, continue to sensor being verified.
HVAC Testing and Adjusting TROUBLESHOOTING AIR CONDITIONER CONTROL Probable Solution Problem List No Cooling Problems listed below are discussed in more detail. • No display • No blower fan • No heat • No cooling • System is putting out hot air when cooling is needed. • No HVAC system function • No fan or erratic fan • Electric actuator for airflow is not moving or working properly. Probable Causes 1. Replace water valve. 1. Turn down heat with control button. 2.
HVAC Testing and Adjusting Nothing Works None of the following components work: • Fan • Compressor clutch • Water control valve 1. Check for error code 17. See Systems Operation/Testing And Adjusting, Troubleshooting Faults With Service Codes for information on checking error codes. 2. Verify control module is receiving 12 volts of power. NOTE: Use a voltmeter to check voltage. This can be verified by disconnecting and connecting DT connector (four pin) on control module.
HVAC Testing and Adjusting REFRIGERANT COMPRESSOR OIL CHECK General A special refrigerant oil is used in the air conditioning system, the oil mixes completely with refrigerant so all components receive lubrication. A check of the refrigerant oil in the compressor will give an indication of the amount of oil in the system. NOTE: Generally, when there is a major loss of oil, check compressor oil.
HVAC Testing and Adjusting • If the amount of oil drained from compressor is less than 177 mL (6 fl oz), add 177 mL (6 fl oz) to 237 mL (8 fl oz) of new refrigerant oil. If too much oil is added to system and a total of more than 325 mL (11 fl oz) of oil is in system, cooling capacity will be reduced. If too little oil has been added to system, compressor may fail due to a lack of lubrication.
HVAC Testing and Adjusting Relationship Between Temperature and Pressure (R-134a Refrigerant) Relationship Between Temperature and Pressure (R-134a Refrigerant) Temperature Degrees C (degrees F) Pressure kPa (PSI) Temperature Degrees C (degrees F) Pressure kPa (PSI) −18 C (0.0 F) 44 kPa (6.4 PSI) 6 C (43.0 F) 261 kPa (37.9 PSI) −17 C (2.0 F) 51 kPa (7.4 PSI) 7 C (44.0 F) 263 kPa (38.9 PSI) −16 C (4.0 F) 59 kPa (8.5 PSI) 7 C (45.0 F) 275 kPa (39.9 PSI) −14 C (6.0 F) 66 kPa (9.
HVAC Testing and Adjusting Relationship Between Temperature and Pressure (R-134a Refrigerant) Relationship Between Temperature and Pressure (R-134a Refrigerant) Temperature Degrees C (degrees F) Pressure kPa (PSI) Temperature Degrees C (degrees F) Pressure kPa (PSI) 27 C (80.0 F) 595 kPa (86.3 PSI) 47 C (117.0 F) 1120 kPa (162.5 PSI) 27 C (81.0 F) 607 kPa (88.0 PSI) 48 C (118.0°F) 1138 kPa (165.1 PSI) 28 C (82.0 F) 618 kPa (89.7 PSI) 48 C (119.0 F) 1156 kPa (167.6 PSI) 28 C (83.
HVAC Testing and Adjusting Labeling Procedure Attach a cable strapped label to air conditioning system indicating system charge. Charging System • Charge system with correct refrigerant, measured by weight. amount of NOTE: After system has been recovered and evacuated, charge with correct amount of refrigerant measured by weight. NOTE: An accurate refrigerant charge is only determined by weight or temperature of evaporator core.
HVAC Testing and Adjusting COMPLETE CHARGE OF SYSTEM FROM A REFRIGERANT TANK WITH A SCALE Use of a refrigerant tank and scale is necessary to charge system using the following procedure. NOTE: Engine can not be running when charging system with a liquid. 1 2 6 4 3 10 5 E 7 F 8 9 11 g00669264 FIG. 2 FIG.
HVAC Testing and Adjusting 1. Find refrigerant capacity for system. 2. Install high and low pressure hoses and purge hoses, refer to Testing and Adjusting, Manifold Gauge Set (Refrigerant) - Install. 3. Hand tighten charging hose from manifold gauge set directly to valve on refrigerant tank. Open valve on top of refrigerant tank to allow the flow of refrigerant through charging hose to manifold gauge set. 4.
HVAC Testing and Adjusting ADDING ADDITIONAL REFRIGERANT TO AN AIR CONDITIONING SYSTEM WITH LOW CHARGE IMPORTANT: Failure to properly follow procedure may cause compressor failure. The following procedure is NOT the preferred method for charging an air conditioning system, the preferred method of measuring refrigerant is by weight. IMPORTANT: If system has no refrigerant, evacuate system before charging. Refrigerant charge should be measured by weight.
HVAC Testing and Adjusting CONTROL PANEL - TEST Test Automatic Control Panel Control for Mode of Airflow (Defrost) 1. Change control for mode of airflow to defrost. Test Result Test Result 1. LED will briefly flash 8888. 1. Clutch for refrigerant compressor should engage. 2. Airflow should be directed to vents for defrost. Speed Control for Blower Fan 1. Turn HVAC system on. Test Result 1. LED should display last setpoint selected. 2.
HVAC Testing and Adjusting NOTES 5-52 627333-A
Index INDEX A A/C and Heating SystemSchematic ................... 5-18 A/C system ......................................................... 5-11 Actuator Motor ........................................... 5-22, 5-27 Actuator Motor (Damper Assembly) ................... 5-27 Actuator Motor (Water Valve) ............................. 5-22 Air Compressor ............................................. 5-5, 5-6 Air Conditioning .................................................. 5-11 Air conditioning ..............
Index L LED Display ....................................................... 5-13 Liquid Refrigerant ............................................... 5-12 Low Pressure Flow ............................................. 5-18 M Machine Preparation for Troubleshooting .......... Magnetic Clutch ................................................. Manual Fan Speed Switch ................................. Manual Mode Fan Speed Control ...................... Moisture ...................................................
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 06 - Electrical Contents GENERAL INFORMATION Introduction ................................................................................................................................................ Basic Troubleshooting Procedures ............................................................................................................ Tools .......................................................................................
Contents NOTES 6-ii 627333-A
General Information GENERAL INFORMATION INTRODUCTION The electrical system can be divided into four sections: • Engine; • Operator’s Station; • Electro Hydraulic; • Lighting. Current to electrical systems is provided by a high output alternator with a built-in voltage regulator. These high output alternators are needed because, under certain conditions, very high amperage demands are required. The 12-volt batteries wired parallel have a double negative ground-one to engine frame and one to starter.
General Information TOOLS FIG. 1: The basic tool needed to troubleshoot the electrical system is a portable digital voltmeter-ohmmeter (otherwise known as a volt-ohm meter, DVOM, or multimeter). A volt-ohm meter is not expensive or complicated when purchasing a volt-ohm meter, it is useful to have a resistance range with scale to be able to check low values or resistance on solenoids or clutch coils. Refer to the instructions accompanying your volt-ohm meter for operating procedures.
General Information GENERAL TESTING PROCEDURES Visual Inspection Carefully inspect the complete wiring harness for damage. Check for loose or broken wires. Make sure the connect terminals are fully seated and locked in the connector. Insure that the terminals are clean and not damaged. Continuity Check A continuity check is a test used to find whether a circuit is complete. The circuit can be a single wire, a single component or a combination of wires and components.
General Information Testing for Short Circuits Fuse Testing A short circuit is defined as an unintended, low resistance current path. This means that the current is taking a shorter path than it was intended in the original circuit. This could be a result of two or more wires rubbing together (copper to copper) or a wire rubbing the system ground (copper to iron). To test a fuse pull the fuse from the slot and visually inspect for broken pins, corroded contact and a broken connection internally.
General Information WIRE COLORS Color Function Blue Machine Functions Clear Shielded Ground Gray Ground (Dirty Ground) Gray/Black Ground (Clean Ground) Green CAN Bus Low Light Green Communications Signals Orange AutoGuide Pink Lights Purple Hazards and Flashers (Flasher Module) Red Power (Dirty Power) Red/White Power (Clean Power - Straight From Battery) Tan Transmission White Cruise Control (Engine Inputs and Outputs) Yellow CAN Bus High (Or Sense Wire) 627333-A 6-5
General Information NOTES 6-6 627333-A
Electrical Sysem ELECTRICAL SYSEM DESCRIPTION Manual has been written as an aid in troubleshooting problems that may occur in machine CAN bus electrical system. Manual is arranged in order or error codes with some additional sections following for circuits that are not associated with a code. REQUIREMENTS This manual is to be used by a qualified technician with basic knowledge of electrical systems. Technician must have a multimeter and experience in using the meter.
Electrical Sysem COMPONENT LOCATION 11 8 7 6 5 4 3 1 2 9 10 11 1 9 10 2 3 4 5 6 7 8 Q000163S FIG. 2 Component layout: 1. Master Module; 2. PDM 1 (Power Distribution Modules); 3. PDM 2; 4. PDM 3; 5. 2 - Pack Relay Modules; 6. 4 - Pack Relay Modules; 7. Flasher Module; 8. Power Supply Block; 9. I/O Module 3 (underneath the engine); 10. I/O Module 5 (underneath the engine); 11. I/O Module 7.
Electrical Sysem PRIMARY CAN BUS COMPONENTS FIG. 3: Master Module Master Module is located behind the right rear curved panel on outside of the cabin. To access panel loosen hand nut located in center of curved panel. Master module accepts signals from switches and other modules in cab, translates, and transfers those commands via a two-wire shielded harness to I/O (Input/Output) interface module.
Electrical Sysem Master Module J1 J2 28 Section 2 Input 28 - 29 Section 3 Input 29 - 30 Section 4 Input 30 - 31 Section 5 Input 31 - 32 Right-Hand End Row Input 32 - 33 - 33 - 34 - 34 - 35 - 35 - 36 - 36 - 37 - 37 - 38 - 38 - 39 - 39 - 40 Main BSO Input 40 - 41 - 41 - 42 - 42 - 43 - 43 - 44 - 44 - 45 - 45 - 46 - 46 CAN A Low 47 - 47 CAN A High 48 - 48 CAN B Low 49 - 49 CAN B High 50 Ground 50 Ground 6-10 627333-A
Electrical Sysem FIG. 4: I/O Interface Module I/O modules accept commands or signals from master module and activate respective component(s). I/O module also accepts signals from components outside cab and forwards them back to master module. Number of I/O modules used varies depending on application system. J2 (gray) pin 1 is 12 volts and pin 12 ground. Power for pin 1 comes from PDM 1 F9 fuse. Same on J3 plug (black). J2 pins 2, 3 and 4 are module identification pins.
Electrical Sysem FIG.
Electrical Sysem Connectors J2 and J3 can be configured for different applications.
Electrical Sysem FIG. 6: CAN Harnesses 1. Stub Cabling 3 2 4 2. T-Connectors 3. Terminators 4. J1939 Backbone 1 Q000088S FIG. 6 FIG. 7: Back Harness Connector 1 Pin A to C should be 2.5 volts. 3 Pin B to C should be 2.3 volts. Pin A to B should be 0.0 volts. 1. A - CAN High (yellow) 2. B - CAN low (green) 3. C - CAN shield (grey) I/O module connectors: J2 (gray) and J3 (black).
Electrical Sysem FIG. 9: Power Distribution Two panels are located behind right rear curved panel on outside of cab. To access panel loosen hand nut located in center of curved panel. Components mounted on are as follows: 9 8 11 1 1. CAN Master Module 5 2. PDM1 3. PDM2 2 10 7 4. PDM3 5. 2-Pack Relay Module (2P1 and 2P2) 6. 4-Pack Relay Module (4P1) 7. Flasher Module 8. HVAC 75 Amp Relay 9. HVAC 30 Amp Fuse 10. +10 VDC Power Terminal 4 11. Ground Terminal 3 6 Q000083S FIG.
Electrical Sysem PDM 4 3 1 6 5 2 Q000083S FIG. 10 Power Distribution Modules (PDM). Three PDM are located on main distribution panel. All three modules contain both relays and fuses. All relays in each PDM are represented with a green LED which signals relay is active. All fuses in each PDM are represented by a red LED which indicates fuse is blown. PDM1 and PDM2: Low current - Circuits supply up to 15 amps.
Electrical Sysem PDM1 FIG. 11: PDM1 - Upper Mounted Low Current Module Circuits as follows: FUSE RATING DESCRIPTION F1 10A ECM-UNSWITCHED F2 10A IGNITION SWITCH UNSWITCHED F3 15A HAZARD KEY OFF UNSWITCHED F4 10A ECM/REMOTE THROTTLE F5 10A 4P1 POWER F6 15A HVAC PRESSURE BLOWER F7 10A MASTER MODULE / SYSTEM SWITCHES F8 15A AIR DRYER F9 15A POWER BUS SYTEM F10 5A DASH F11 5A FLASHER Q000076S FIG. 11 PDM2 FIG.
Electrical Sysem PDM3 FIG. 13: PDM3: High Current - Each circuit supplies up to 30 amps. PDM 3 has 4 relays which each supply power to 1 fuse; meaning 4 fuses individually switched. FUSE RATING DESCRIPTION F1 5A ACCESSORY PLUG / RADIO / GPS F2 20A WORK LIGHTS 3 (OPTIONAL) F3 15A HVAC PRESSURE BLOWER F4 25A SEAT Q000078S 2-Pack Relay Modules FIG. 13 FIG. 14: 2-Pack Relay Modules (2P1 and 2P2) 2-Pack relay modules contain 2 independent non-replaceable relays.
Electrical Sysem 4-Pack Relay Module FIG. 15: 4-Pack Relay Module 4-Pack relay modules contain 4 independent non-replaceable relays. All relays share a common ground. Module housing contains 4 green LEDs to indicate which relays are on. Each output can source a maximum of 15 amps. Relay pin are as follows: PIN RELAY FUNCTION 1 3 COMMON INPUT 2 3 COIL INPUT 3 4 COIL INTPUT 4 4 N.O. OUTPUT 5 3 N.O. OUPUT 6 4 COMMON INPUT 7 2 COMMON INPUT 8 1 COIL INPUT 9 2 COIL INPUT 10 1 N.O.
Electrical Sysem PIN FUNCTION 1 GROUND 2 NOT USED 3 LEFT TURN INPUT 4 RIGHT TURN INPUT 5 +12 VDC INPUT 6 HAZARD INPUT 7 RIGHT B OUTPUT 8 LEFT A OUTPUT 9 NOT USED 10 NOT USED 11 RIGHT A OUTPUT 12 LEFT B OUTPUT FLASHER MODULE LOGIC TABLE INPUTS HAZARD IGNITION LH TURN RH TURN OFF OFF X X OFF ON OFF OFF ON OFF X X ON ON OFF OFF X ON ON OFF X ON OFF ON X ON ON ON LH: A RH: A LH: A RH: B OFF OFF OFF OFF OFF OFF OFF OFF 65 FPM 65 FPM OFF OFF
Electrical Sysem Power Supply Block FIG. 17: Power Supply Block Chassis power supply block is located on panel next to master module. This block receives power (1) from 100 amp circuit breaker in battery box next to master battery disconnect switch. Power block receives ground (2) from master battery disconnect switch in battery box. Purpose of this divider block is to split power and ground to be used by I/O module and 4-pack relay module. Power and ground are split to 12 sources.
Electrical Sysem NOTES 6-22 627333-A
Index INDEX I Numerics 2P1 ..................................................................... 2P2 ..................................................................... 2-Pack Relay Module ......................................... 4P1 ..................................................................... 4-Pack Relay Module ......................................... 6-15 6-15 6-15 6-15 6-15 A Air Pressure ......................................................... 6-7 B Back Harness Connector ............
Index NOTES 6-24 627333-A
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 07 - Hydraulic Contents INTRODUCTION High-Pressure Fluids ................................................................................................................................. Hydraulic Hoses ......................................................................................................................................... Avoid Heating Near Pressurized Fluid Lines .....................................................
Contents NOTES 7-ii 627333-A
Introduction INTRODUCTION HIGH-PRESSURE FLUIDS FIG. 1: AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. The vehicle must be stopped and cooled before checking fluids. Use caution when removing radiator caps, plugs, grease fittings or pressure taps. Never open pressure lines when they are under pressure. Release all pressure before doing maintenance or repairs on any pressure system.
Introduction AVOID HEATING NEAR PRESSURIZED FLUID LINES FIG. 3: Never heat by welding, soldering or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to personnel and bystanders. FIG. 3 THEORY OF OPERATION The steering on the 3244 is hydraulically controlled.
Introduction COMPONENT LOCATION AND FUNCTION 4 6 9 1 2 7 5 4 3 5 8 5 8 Q000091S FIG. 4 Component layout: 1. Hydraulic Oil Tank; 2. Hydraulic Gear Pump; 3. Priority Valve; 4. Steering Unit; 5. Steering Cylinder; 6. Hydraulic Oil Cooler; 7. Application System Hydraulics; 8. Pivot Point; 9. 3 Accumulators.
Introduction FIG. 5: Hydraulic oil tank (1) is located behind the Cab. The hydraulic tank is filled with 200 L (52.8 gall). Hydraulic oil is drawn out of tank by gear pump through suction strainer. Oil from application system is returned into tank through filter on top of the tank. 1 Q000092S FIG. 5 FIG. 6: Hydraulic oil pump (2) is mounted on the left PTO of the gearbox. The hydraulic pump is a displacement gear pump. The pump draws oil from the reservoir and sends oil flow to the priority valve.
Introduction FIG. 8: The steering unit (4) is mounted to the front of the cab. The steering unit is a closed center distribution valve that is connected to the steering wheel in the Terra Gator. When the operator turns the steering wheel, the unit sends a load sense signal to the priority valve on the pump. This will send an amount of flow (CF-port) through the steering unit to the 2 steering cylinders.
Introduction FIG. 11: m WARNING: The cooling system operates under pressure which is controlled by the radiator pressure cap. Removing the cap while the system is hot may allow the escape of hot coolant and steam, causing serious burns. Before you remove the radiator cap, allow the system to cool. Use a think cloth and turn the radiator cap slowly to the first stops to allow pressure to escape before fully removing the cap. Avoid contact with coolant. Q000126S FIG.
Introduction PRESSURE MEASUREMENT NOTE: Components must be clean. Before disassembly procedure, exterior of component should be thoroughly cleaned to prevent dirt from entering internal mechanism or system. IMPORTANT: Ensure fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of machine. Be prepared to collect fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Introduction Braking System Brake Pedal FIG. 13: The test point (2) of the brake pedal is located next to the Steering Unit. 2 The pressure on the brake pedal has be to between 0 40 bar (0 - 580 PSI) depends on the force which pressing the brake pedal down. q000145s FIG. 13 Brake Accumulators The pressure in the accumulator has to be between 110 - 140 bar (1595 - 2030 PSI). Adjusting Procedure Brake System See below for the correct adjusting procedure of the braking system. FIG.
Introduction FIG. 15: • When pressure is incorrect at 110 bar (1595 PSI), adjust it. To adjust the pressure turn (2) clockwise to increase and turn counterclockwise to decrease. • When the pressure decreases to 85 bar (1232 PSI), an alarm inside the cab will go off. 2 Q000109S FIG.
Introduction NOTES 7-10 627333-A
Schematic SCHEMATIC HYDRAULIC SCHEMATIC Q619399S FIG.
Schematic 3 2 4 1 5 Q000107S FIG. 2 1. Tank, Filter and Cooler; 2. Priority Valve; 3. Brakes; 4. Orbitrol; 5.
Schematic PRIORITY VALVE The priority valve receives hydraulic pressure from the hydraulic pump mounted on the transmission and controls the flow to the steering system and the auxiliary hydraulic systems. The steering system maintains priority over the braking system. As the steering wheel is turned, pressure to the steering unit drops, which drops the pressure in the line and shifts the priority valve to supply more oil to the steering unit. Priority valve has four ports and a construction hole.
Schematic EMERGENCY STEERING (OPTION) FIG. 4: The electric motor (1) of the emergency steering will activated when a sensor of the priority valve (2) detect a fall of the oil pressure. The oil pressure has to fall below the 10 bar. When the emergency steering is activated, a warning light (3) on the armrest will light up, and there will be an acoustic sound inside the cab. IMPORTANT: Never use the emergency steering longer as strictly necessary. Approximately 40 seconds.
Index INDEX A Accumulators ....................................................... 7-3 Air Conditioner Condenser ................................... 7-5 Application System Hydraulics ............................. 7-3 auxiliary hydraulic systems ................................ 7-13 B Brake System ....................................................... 7-8 Brakes ................................................................ 7-12 steering cylinders ..................................................
Index NOTES 7-16 627333-A
Contents Challenger ® Terra Gator 3244 Chassis SERVICE MANUAL 627333-A 08 - Air System Contents AIR COMPRESSOR Air Compressor Removal ........................................................................................................................... 8-1 Air Compressor Installation ........................................................................................................................ 8-3 AIR TANK AND PRESSURE CONTROL CHECK VALVE Theory of Operation ................................
Contents NOTES 8-ii 627333-A
Air Compressor AIR COMPRESSOR The chassis air system consists of an engine mounted, direct driven air compressor, an air drier and two storage tanks. The first tank is called a wet tank because most condensation occurs in this tank as the air cools from being compressed. The second tank is called a dry tank since little condensation occurs in that tank. From the dry tank, air is sent out to the R-12 relay valve for service brakes and to the R-14 relay valve for the parking brakes.
Air Compressor FIG. 2: Remove two bolts (1) at rear of compressor holding compressor mount to engine block. 1 N072412003 FIG. 2 FIG. 3: Support air compressor (1). Air compressor weighs approximately 23 kg (51 lb). Remove two bolts (2) at front of engine holding compressor to timing gear housing. Slide compressor back to disengage gear teeth. Remove gasket with compressor. 1 2 N072412004 FIG.
Air Compressor AIR COMPRESSOR INSTALLATION NOTE: Keep all parts clean from contaminants. Contaminants can cause rapid wear and shortened component life. Install mounting bracket to back of air compressor with two bolts. Inspect air compressor gasket and replace if necessary. Install gasket between air compressor and timing gear housing. Apply thread locking compound to mounting bolts. Mount compressor to engine with four bolts, ensuring gear meshes properly in timing gear housing.
Air Compressor NOTES 8-4 627333-A
Air Tank and Pressure Control Check Valve AIR TANK AND PRESSURE CONTROL CHECK VALVE THEORY OF OPERATION There are two air tanks in the standard air system. The wet tank and the dry tank. The wet tank collects condensation from compression and has a drain valve to remove moisture. Compressed air flows from the wet tank to the dry tank. The dry tank supplies air to the braking and accessory systems. There is a pressure control check valve (PCCV) mounted in the output port of the wet tank.
Air Tank and Pressure Control Check Valve AIR TANKS NOTE: All orientation directions are in relation to the driver’s position. FIG. 1: Tanks (1) are mounted underneath the engine (2). The wet tank collects condensation that can be released by operating drain valve (3) on bottom of tank. 2 1 3 q000175s FIG. 1 Air Tank Removal NOTE: For example we use the wet tank. FIG. 2: Mark and disconnect signal air hose (1) from wet tank (2) to air governor. Disconnect supply hose (3) from air dryer.
Air Tank and Pressure Control Check Valve Air Tank Installation NOTE: For example ew use the wet air tank. NOTE: Always use new O-rings and O-ring washers. NOTE: Be sure to apply a thin film of oil to the O-rings on all fittings. FIG. 4: Install 3/4-16 MJIC straight adapter (1) into inlet port with M22 O-ring (2) and M22 trust washer (3). 4 5 Install 3/8 MNPT x 1/4 MJIC adapter (4) into a M22-1-1/2 OR x 3/8 FNPT adapter (5).
Air Tank and Pressure Control Check Valve FIG. 7: Attach inlet hose (1) to 0.75 fitting on rear end of tank. Attach signal line (2) to governor to 0.25 fitting on rear end of tank. 3 2 Attach outlet hose (3) to adapter on front of tank. Tighten clamps once tank and lines are positioned correctly. 1 q000176s FIG.
Air Dryer AIR DRYER DESCRIPTION The air dryer is plumbed from the compressor to the wet tank and is mounted in front of the coolers. The dryer can be identified by a small regeneration hole in the back of the inlet port, which is visible when the fitting is removed. The dryer uses a 12-volt heater. The heater turns on at 7 degrees C (45 degrees F) and off at 30 degrees C (86 degrees F). Minimum governor cut-out pressure is 793 kPa (115 psi). Maximum system pressure is 1034 kPa (150 psi).
Air Dryer AIR DRYER INSTALLATION NOTE: Use thread locking compound on all plugs and fittings. FIG. 3: Assemble elbow fitting (1) into inlet port. Assemble straight fitting (2) into outlet port. Assemble governor (3) to straight fitting (4) on dryer. 2 4 Bolt dryer/governor assembly to cabinet or plate. 3 1 M6205001 FIG. 3 FIG. 4: Attach supply hose (1) from compressor to elbow fitting in inlet port. Attach air tank delivery hose (2) to straight fitting.
Air Dryer AIR DRYER COMPONENTS FIG. 5: Air dryer assembly. (1) Heater (2) Turbo Cut-off Valve (3) Desiccant Cartridge (4) Outlet Check Valve (5) Regeneration Valve (6) Purge Valve 3 4 2 5 1 6 M6205002 FIG. 5 Heater FIG. 6: Heater is located in air dryer base. Heater prevents water that collects in air dryer from freezing. The heater consists of a cylindrical resistive-type heating element and small circular thermostat. Heater is 12-volt. To replace heater, disconnect electrical plug.
Air Dryer Desiccant Cartridge FIG. 8: Desiccant cartridge is a steel housing containing filter elements needed to filter and dry system air. m WARNING: To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Remove all pressure from the air system before you disconnect any component, including the desiccant cartridge. Pressurized air can cause serious personal injury.
Air Dryer Remove four mounting bolts and valve housing assembly. Spring and cap will fall out. Remove rubber diaphragm. Clean and inspect diaphragm lip groove. If groove is damaged so that a tight seal cannot be maintained, replace air dryer. Install new diaphragm with its lip in groove. DO NOT GREASE THE DIAPHRAGM. Install new spring and cap with cap lip facing out. Install valve housing assembly with new lubricated O-ring and filter over orifice. Install new mounting bolts and tighten to 6 Nm (53 lbf in).
Air Dryer NOTES 8-14 627333-A
Air Governor AIR GOVERNOR THEORY OF OPERATION The air governor is directly mounted to the air dryer and controls the opening of the purge valve when the air pressure in the tanks reaches 7,93 to 8,61 bar (115 to 125 psi). Then the purge valve should stay open until the air pressure falls to 6,55 to 7,23 bar (95 to 105 psi), when the purge valve should close to refill the tanks. AIR GOVERNOR REMOVAL m WARNING: Remove all air pressure from the tanks before disconnecting any air hoses.
Air Governor AIR GOVERNOR INSTALLATION NOTE: Use an approved thread locking compound on all plugs and fittings. FIG. 3: Install 1/8 NPT plugs in ports (B), (C), (D), and (E). Install breather in EXH port (1). Install elbow adapter in port (F). 2 1 Pressure adjusting cover (2) is on top of governor. Port-A (A) is where governor connects to air dryer. D E A F C B M6235008 FIG. 3 FIG.
Cab Air Suspension CAB AIR SUSPENSION THEORY OF OPERATION The cab has air ride suspension. The air ride suspension has twin air bags that are filled with compressed air from the air system. A height control valve regulates the amount of air pressure in the air bags. A lateral control rod keeps the cab located in the center of the machine while allowing the cab to move up and down. There are two shock absorbers that control the bounce of the cab.
Cab Air Suspension CAB AIR SUSPENSION REMOVAL FIG. 2: Tip over the cab. IMPORTANT: Don’t leave any loose obkects in the cabin which can cause any damage during tipping over the cabin. 1. Remove side panels engine hood; 2. Take the lock pin with retainer out of his locking position underneath the can. And place the lock pin on the left platform, near the roatating point of the cabin; 3. Open the engine hood; IMPORTANT: Keep a clearence of 2 meter (80 inch) front of the vehicle. 4.
Cab Air Suspension CAB AIR SUSPENSION INSTALLATION FIG. 4: Place the suspension in the support on the chassis. Place and thighten the three bolts (1) holding the suspension to the chassis. Connect air line to height control valve. 1 1 q000181s FIG. 4 FIG. 5: Lower the cab. 1. Remove the lock pin from it’ locking position; m DANGER: Make sure there’s nobody under the cab. 2. Open the knob (CCW) on the handpump, to depressurize the system.
Cab Air Suspension NOTES 8-20 627333-A
Pneumatic Schematic PNEUMATIC SCHEMATIC PNEUMATIC SCHEMATIC This section shows the pneumatic schematic and the legend that describes the text and symbols used on the schematic. 6 7 3 10 11 4 13 5 12 8 9 2 1 Q621558S FIG.
Pneumatic Schematic The following callouts are indicated on the graphic.
Index INDEX A Air Compressor .................................................... 8-1 Air Compressor Installation .................................. 8-3 Air Compressor Removal ..................................... 8-1 Air Dryer ...................................................... 8-9, 8-15 Air Dryer Components ........................................ 8-11 Air Dryer Installation ........................................... 8-10 Air Dryer Removal ................................................
Index NOTES 8-24 627333-A
