Challenger EU Applicators TerraGator TG7300C TG8300C Flotation Chassis Workshop Service Manual

Description

Challenger EU Applicators TerraGator TG7300C TG8300C Flotation Chassis Workshop Service Manual – PDF DOWNLOAD

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Challenger EU Applicators TerraGator TG7300C TG8300C Flotation Chassis Workshop Service Manual – PDF DOWNLOAD

Size: 208 MB
Format: PDF
Language: English
Brand: Challenger
Type of Machine: Applicators
Type of document: Workshop Service Manual
Model: Challenger EU Applicators TerraGator TG7300C TG8300C Flotation Chassis
Number of Pages: 1218 pages
Date Modified: 08/2019
Part Number: 79037159C

DESCRIPTION:

Challenger EU Applicators TerraGator TG7300C TG8300C Flotation Chassis Workshop Service Manual – PDF DOWNLOAD

Service manual
1.1.1 Units of measurement
Measurements are given in metric units followed by the equivalent in US units. Hardware sizes are given in
millimeters for metric hardware and inches for US hardware.
1.1.2 Replacement parts
To receive your parts quickly, have the following information:
Correct part description and part number
Model number of the machine
Serial number of the machine
1.1.3 Product identification information
Each machine has an identification plate with the model number and the serial number.
The product identification number (Pl N) is used to
identify a machine.
The manufacturer’s plate contains the PIN.
The serial numbers identify the engines,
transmissions, and attachments.

TABLE OF CONTENTS:

Challenger EU Applicators TerraGator TG7300C TG8300C Flotation Chassis Workshop Service Manual – PDF DOWNLOAD

1 General 1-1
11 Service manual 1-3
111 Units of measurement 1-3
112 Replacement parts 1-3
113 Product identification information 1-3
114 Transmission serial number plate 1-3
115 Serial number definition 1-4
116 Engine serial number plate 1-4
12 Lubrication and maintenance 1-5
121 Maintenance introduction 1-5
122 Maintenance symbols 1-5
123 Maintenance chart 1-6
124 Daily maintenance schedule 1-7
125 Maintenance schedule 10 to 1000 hours 1-7
126 Maintenance Schedule 2000 to 4000 hours 1-9
127 Lubricants and fluids 1-10
128 Lubricant filling reminders 1-11
13 Important safety information 1-12
131 Prepare for operation 1-12
132 Fire prevention and first aid1-13
133 Safety symbol 1-14
134 Safety messages1-14
135 Information messages 1-14
136 General hazard information 1-15
137 Pressurized air 1-16
138 Asbestos information 1-16
139 Electrical storm injury prevention 1-16
1310 Mount and dismount the machine 1-16
1311 Before starting the engine 1-16
1312 Start the engine 1-17
1313 Before operating the machine 1-17
1314 Operate the machine 1-17
1315 Park the machine 1-18
1316 Operator station 1-19
1317 Cut and crush prevention 1-19
1318 Boom safety 1-19
1319 Fuel safety 1-19
1320 Hydraulic safety 1-20
1321 Chemical safety 1-20
1322 Exit the cab in an emergency 1-22
1323 Engine safety1-22
1324 Safety lamps and marking devices use 1-24
1325 Operating on slopes 1-24
1326 Roading on public roads 1-24
1327 Avoid eye contact with radar 1-25
1328 Exhaust fumes 1-25
1329 Electrical power lines overhead 1-25
1330 Shield and guards 1-26
1331 Towing 1-26
1332 Modifications1-27
1333 A word to the operator 1-27
1334 Work in a clean area 1-28
Applicator Chassis
Support the machine correctly 1-28
Maintenance safety 1-28
High pressure leaks 1-32
2 Engine, fuel, and exhaust system 2-1
21 Engine system 2-9
211 Remove the serpentine belt 2-9
212 Install the serpentine belt 2-9
213 Remove the water pump belt 2-10
214 Install the water pump belt 2-11
215 Remove the alternator 2-12
216 Install the alternator 2-13
217 Remove the cooling package2-14
218 Install the cooling package 2-19
219 Remove the radiator core 2-23
2110 Install the radiator 2-25
2111 Remove the hydraulic cooler and transmission cooler 2-28
2112 Install the hydraulic cooler and transmission cooler 2-30
2113 Remove the air conditioning condenser 2-32
2114 Install the air conditioning condenser 2-34
2115 Remove the air intake assembly 2-35
2116 Install the air intake assembly 2-39
2117 Remove the air cleaner filter 2-42
2118 Install the air cleaner filter 2-43
2119 Remove the fan 2-43
2120 Install the fan2-47
2121 Remove the air compressor 2-50
2122 Install the air compressor 2-52
2123 Remove the starter 2-54
2124 Install the starter 2-55
2125 Remove the engine 2-55
2126 Install the engine 2-61
22 Safety instructions 2-67
23 To the user 2-69
231 Engine type designations 2-69
232 Location of the engine serial number 2-70
233 Marking of the electronic control unit 2-71
234 Engine lifting 2-71
24 Engine construction 2-73
241 Technical data 2-73
2411 Principal dimensions and data 2-73
2412 Fuel system 2-73
2413 Lubrication system 2-73
2414 Cooling system 2-73
2415 SCR system technical data 2-74
Cylinder block2-74
Flywheel housing 2-74
Valve mechanism 2-74
Cylinder head2-75
Crank mechanism 2-75
Timing gears 2-76
Lubrication system 2-77
2481 Oil pressure regulating valve2-78
2482 Oil filter and oil cooler 2-78
Cooling system 2-78
2491 Thermostat 2-79
2410 Air control system 2-80
Applicator Chassis
79037159C
Table of contents
24101 2 stage turbocharging 2-81
24102 Interstage charge air cooling 2-81
24103 Throttle valve 2-81
2411 Fuel system 2-82
2412 SCR system 2-83
24121 SCR system overview 2-83
24122 SCR system components and their functions 2-84
24123 Supply module connectors and filters 2-85
24124 Dosing module connections2-85
2413 Engine control system 2-86
25 Technical data 2-87
251 Cylinder block2-87
252 Cylinder liners2-87
253 Cylinder head2-88
254 Valves and rockers 2-89
255 Tappets and push rods2-90
256 Camshaft 2-90
257 Crankshaft 2-90
258 Flywheel 2-92
259 Timing gears 2-92
2510 Connecting rod 2-93
2511 Piston, rings and pin 2-93
2512 Lubrication system 2-94
2513 Oil pump 2-95
2514 Thermostat 2-95
2515 Turbocharger 2-95
26 Tightening torques 2-96
2 7 Special tools 2-98
2 71 Cylinder block tools 2-98
272 Timing gear and flywheel housing tools 2-100
273 Cylinder head and valve mechanism tools 2-101
274 Crank mechanism tools 2-103
275 Coolant pump tools 2-104
276 Fuel system tools2-105
277 SCR system tools 2-109
278 Electronic diagnostic tool 2-110
2781 EDT diagnostic terminal 2-111
2782 Diagnostic terminal components 2-111
28 Liquid quality requirements2-113
281 Lubricating oil quality requirements 2-113
282 Coolant quality requirements 2-113
283 Fuel quality requirements 2-114
2831 Biodiesel blends 2-115
2832 Engine output depending on fuel quality2-117
29 Terminal diagram 2-118
210 Cylinder block 2-122
2101 Measure the cylinder liner wear 2-122
2102 Remove the cylinder liner 2-122
2103 Do a check for the cylinder block 2-122
2104 Changing camshaft bushing 2-123
2105 Fitting plug at camshaft rear end2-124
2106 Oversize bushings for camshaft 2-124
2107 Fitting plug at camshaft rear end (oversize bushings)2-124
2108 Install the cylinder liner 2-125
2109 Remove the block heater 2-127
21010 Install the block heater 2-127
211 Flywheel housing 2-128
Applicator Chassis
79037159C
Table of contents
2111 Remove the flywheel housing 2-128
2112 Install the flywheel housing 2-128
2113 Changing crankshaft rear oil seal 2-129
212 Cylinder head 2-130
2121 Removing cylinder head 2-130
2122 Removing valves 2-130
2123 Do a check for the cylinder head 2-130
2124 Replace the valve guides 2-132
2125 Machine the valve seat 2-132
2126 Replace the valve seat rings2-132
2127 Grinding valves 2-133
2128 Fittingvalves 2-134
2129 Install the cylinder head 2-134
213 Valve mechanism with hydraulic lash adjustment 2-136
2131 How to recognize an engine with hydraulic lash adjusters 2-136
2132 Remove the valve cover 2-136
2133 Install the valve cover 2-137
2134 Pre-adjustment of the hydraulic lash adjusters 2-137
2135 Reconditioning the valve mechanism 2-137
2136 Compressing the oil out from the hydraulic lash adjusters 2-138
2137 Assembling the valve mechanism with the hydraulic lash adjusters2-139
2138 Pre-adjusting the hydraulic lash adjusters 2-140
2139 Changing camshaft or camshaft gear 2-142
214 Crankshaft 2-143
2141 Removing the crankshaft 2-143
2142 Checking crankshaft 2-143
2143 Replace the crankshaft gears 2-144
2144 Installing the crankshaft 2-144
2145 Crankshaft hub piece 2-145
2146 Viscose type vibration damper 2-146
215 Connecting rods and pistons 2-147
2151 Removing pistons together with connecting rods 2-147
2152 Changing connecting rod bearings 2-147
21521 Piston pin bushing 2-147
21522 Big-end bearing 2-148
2153 Checking connecting rod 2-148
2154 Replace the piston rings 2-149
2155 Checking pistons 2-150
2156 Install the piston pin 2-151
2157 Install the piston together with the connecting rod 2-151
216 Flywheel 2-152
2161 Changing starter ring gear on flywheel 2-152
2162 Remove the flywheel 2-152
2163 Fitting flywheel 2-152
217 Timing gear assembly 2-153
2171 Removing timing gear casing 2-153
2172 Install the timing gear housing 2-154
2173 Power take-off 2-156
2174 Fan drive device 2-157
218 Lubrication system 2-158
2181 Oil pressure regulating valve 2-158
2182 Remove the oil sump 2-158
2183 Remove the suction pipe of the oil pump 2-158
2184 Install the suction pipe of the oil pump 2-159
2185 Removing and dismantling lubricating oil pump 2-160
2186 Assembling and fitting lubricating oil pump 2-160
2187 Install the oil sump gasket 2-161
Table of contents
21871 Install the oil sump gasket, metal gasket 2-161
21872 Install the oil sump gasket, paper gasket 2-161
21873 Install the oil sump gasket, cork gasket 2-162
Install the oil sump, self-carrying oil sump and cast oil sump 2-162
Install the oil sump, stamped steel oil sump 2-164
Piston cooling nozzles 2-164
Removing the oil cooler 2-165
Fitting the oil cooler 2-166
Remove the oil filter adapter 2-166
Install the oil filter adapter2-167
Oil sump capacity 2-167
Closed crankcase ventilation 2-167
218161 Remove the closed crankcase ventilation system components 2-167
218162 Installing the closed crankcase ventilation system components 2-168
Cooling system 2-169
2191 Remove the distribution pipe of the coolant 2-169
2192 Install the distribution pipe of the coolant 2-169
2193 Removing the thermostat 2-169
2194 Testing the thermostat 2-170
2195 Replace the thermostat 2-170
2196 Remove the coolant pump and the thermostat housing 2-170
2197 Install the coolant pump and the thermostat housing 2-170
2198 Reconditioning coolant pump 2-171
21981 Coolant pumps with standard bearings2-171
21982 Coolant pumps with heavy duty bearings 2-174
2199 Installing the cylinder head connection part2-174
21910 Remove the idler pulleys, the belt tightener and the belt pulley 2-175
21911 Install the idler pulleys, the belt tightener and the belt pulley 2-176
Air control system maintenance 2-177
2201 Checking the air cleaner 2-177
2202 Checking the inlet and exhaust pipes 2-177
2203 Remove the actuator of the turbocharger 2-178
2204 Install the actuator of the turbocharger 2-178
2205 Remove the exhaust manifold and the turbochargers2-179
2206 Removing the turbocharger 2-180
220 7 Checking the turbocharger2-180
2208 Install the high-pressure turbocharger 2-181
2209 Install the exhaust manifold and the turbochargers 2-181
22010 Remove the ICAC 2-182
22011 Install the ICAC 2-183
22012 Remove the intake manifold 2-183
22013 Install the intake manifold 2-184
Fuel system 2-185
2211 Bleed the fuel system 2-185
2212 Measuring fuel feed pressure 2-185
2213 Remove the fuel filters 2-186
2214 Install the fuel filters 2-186
2215 Remove the injector overflow pipe 2-187
2216 Install the injector overflow pipe 2-187
2217 Inspecting injectors 2-187
22171 Remove the injectors (CRIN3) 2-188
22172 Install the injectors (CRIN3) 2-189
2218 High-pressure pump 2-191
22181 Remove the high-pressure pump 2-191
22182 Install the high-pressure pump 2-191
2219 Rail 2-192
22191 Removing the rail 2-193
22192 Install the rail 2-194
Applicator Chassis
79037159C
Table of contents
22193 Removing the pressure control valve 2-194
22194 Fitting the pressure control valve 2-195
22195 Removing the pressure sensor 2-195
22196 Fitting the pressure sensor 2-195
22110 Troubleshooting of the Common rail fuel system 2-195
221101 Testing the suction pressure between the fuel tank and the fuel prefilter
2-195
221102 Testing the suction pressure between the fuel pre-filter and the feed
pump 2-197
221103 Testing the feed pressure between the feed pump and the fuel main
filter 2-199
221104 Testing the feed pressure between the main fuel filter and the highpressure
pump 2-200
221105 Testing the total return quantity from the injectors 2-201
221106 Testing the return quantity from the injectors 2-203
221107 Testing the pressure control valve leakage 2-208
221108 Testing the pressure release valve leakage2-210
221109 Testing the return line pressure 2-213
222 SCR system 2-214
2221 SCR system maintenance2-214
2222 Mounting of SCR system components 2-214
2223 Removing the supply module 2-215
2224 Installing the supply module 2-215
2225 Removing the hydraulic connectors 2-216
2226 Installing the hydraulic connectors 2-216
2227 Replace the main filter and the inlet filter of the supply module 2-216
2228 SPN 521008 FMI 1 2-217
22281 Solve the DEF pressure build-up failure 2-218
22282 Supply module lifting capacity test2-220
22283 Solve the failure when the SM lifting capacity test is not OK 2-221
22284 Solving the failure when the SM lifting capacity test is OK 2-223
2229 SPN 521025 FMI 31, SPN 521026 FMI 31 2-224
22291 Cleanup of the SCR catalyst 2-226
22292 Make the dosing rate test 2-227
22293 Checking the quality of DEF 2-231
223 Engine control system 2-233
2231 Remove the bracket of the electronic control unit 2-233
2232 Install the bracket of the electronic control unit 2-233
2233 Remove the electronic control unit 2-233
2234 Install the electronic control unit 2-233
2235 Replace the electronic control unit 2-234
2236 Replace an empty electronic control unit (ECU) 2-235
2237 Wiring sets2-235
22371 Injector wiring sets 2-236
22372 Sensor and actuator wiring sets 2-237
22373 Wiring set for intake air heater 2-237
22374 Sensors of the engine control system 2-237
2238 Remove the wiring harnesses 2-240
2239 Install the wiring harnesses 2-241
224 Prepare the long block replacement 2-243
225 Parts for the long block replacement 2-244
2251 Delivery content of the long block engine 2-244
2252 The parts that must be removed from the old engine2-244
2253 Other parts of the long block replacement 2-245
226 Remove the engine 2-246
227 Engine lifting 2-247
2271 Lift the engine 2-247
Table of contents
Disassemble the engine 2-249
2281 Remove the wiring harnesses 2-249
2282 Remove the electronic control unit 2-249
2283 Remove the bracket of the electronic control unit 2-250
2284 Remove the exhaust manifold and the turbochargers 2-250
2285 Removing the EGR system 2-251
2286 Change oil filter 2-251
2287 Removing the oil cooler 2-251
2288 Remove the oil filter adapter 2-252
2289 Remove the ICAC 2-252
22810 Remove the distribution pipe of the coolant 2-253
22811 Remove the fuel filters 2-254
22812 Remove the closed crankcase ventilation system components 2-254
22813 Removing the rail 2-254
22814 Remove the high-pressure pump 2-255
22815 Remove the block heater 2-255
22816 Remove the intake manifold 2-255
22817 Remove the coolant pump and the thermostat housing 2-256
22818 Remove the idler pulleys, the belt tightener and the belt pulley 2-256
22819 Remove the valve cover 2-256
22820 Remove the injectors (CRIN3) 2-257
228201 Remove the injector overflow pipe 2-258
22821 Remove the flywheel 2-259
22822 Remove the oil sump 2-259
22823 Remove the suction pipe of the oil pump 2-259
22824 Remove the flywheel housing 2-259
Assemble the engine 2-260
2291 Prepare the new long block 2-260
2292 Install the flywheel housing 2-260
2293 Changing crankshaft rear oil seal 2-261
2294 Install the suction pipe of the oil pump 2-262
2295 Install the oil sump gasket2-263
2296
22951 Install the oil sump gasket, metal gasket2-263
22952 Install the oil sump gasket, paper gasket2-263
22953 Install the oil sump gasket, cork gasket 2-263
Install the oil sump, self-carrying oil sump and cast oil sump 2-264
Install the oil sump, stamped steel oil sump 2-265
Fitting flywheel 2-266
Install the high-pressure pump 2-266
Install the rail 2-267
Installing the closed crankcase ventilation system components 2-267
Install the fuel filters 2-268
229121 Install the injector overflow pipe 2-268
Install the injectors (CRIN3) 2-269
Install the valve cover 2-270
Install the idler pulleys, the belt tightener and the belt pulley 2-270
Install the intake manifold2-270
Install the coolant pump and the thermostat housing 2-271
Install the block heater2-271
Install the distribution pipe of the coolant 2-272
Install the ICAC 2-272
Install the oil filter adapter2-273
Fitting the oil cooler 2-273
Change oil filter 2-273
Fitting the EGR system 2-274
Install the exhaust manifold and the turbochargers 2-274
Install the electronic control unit 2-276
Install the bracket of the electronic control unit 2-276
Applicator Chassis
79037159C
Table of contents
22928 Install the wiring harnesses 2-276
230 Engine lifting 2-278
2301 Lift the engine 2-278
231 Install the engine 2-280
232 After the long block change2-281
2321 Starting the engine after major maintenance 2-281
2322 Update the engine software 2-281
2323 Break in the engine 2-281
233 Fuel system 2-283
2331 Fuel tank 2-283
23311 Fuel tank description 2-283
23312 Remove the fuel tanks 2-283
23313 Disassemble the left hand fuel tank 2-285
23314 Disassemble the right hand fuel tank2-286
23315 Assemble the left hand fuel tank 2-287
23316 Assemble the right hand fuel tank 2-288
23317 Install the fuel tanks 2-288
2332 DEF tank 2-290
23321 Remove the DEF tank2-290
23322 Disassemble the DEF tank2-292
23323 Assemble the DEF tank 2-293
23324 Install the DEF tank 2-294
2333 Remove the primary fuel filter/water separator 2-295
2334 Install the primary fuel filter/water separator 2-296
2335 Remove the secondary fuel filter 2-297
2336 Install the secondary fuel filter 2-298
2337 Prime the fuel system 2-298
2338 Remove the fuel lines 2-298
2339 Install the fuel lines 2-301
23310 Replace the inline fuel strainer 2-304
234 Exhaust system 2-305
2341 Remove the exhaust system 2-305
2342 Install the exhaust system2-309
3 Axles 3-1
31 Rear axle 3-5
311 Rear axle description 3-5
312 Remove the rear axle 3-5
313 Install the rear axle 3-8
32 Rear axle differential carrier 3-12
321 Rear axle differential carrier introduction 3-12
3211 Standard differential carrier 3-14
322 Remove and disassemble the rear axle differential carrier 3-14
3221 Remove hardware secured with locking compound 3-15
3222 Remove the differential carrier from the axle housing 3-15
3223 Remove the differential and ring gear from carrier 3-16
3224 Do a check of the rotating resistance of the differential gears 3-18
3225 Disassemble the differential and ring gear assembly 3-19
3226 Remove the drive pinion and bearing cage from carrier 3-21
3227 Disassemble the drive pinion and bearing cage 3-23
323 Prepare the rear axle differential carrier parts for assembly 3-26
3231 Clean and inspect the yokes3-26
3232 Clean the axle components 3-27
3233 Clean the rough parts 3-27
3234 Clean the axle assemblies 3-27
3235 Dry the parts after cleaning 3-27
3236 Prevent the corrosion on cleaned parts 3-27
Applicator Chassis
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324
325
326
327
Table of contents
Inspect and repair the rear axle differential parts 3-28
3241 Repair and welding on axle housings 3-28
3242 Prepare the axle 3-28
3243 New hardware with thread locking compound 3-29
3244 Original or used hardware 3-30
3245 Apply thread locking compound and silicone gasket material 3-30
3246 Repair the carrier-to-housing joint 3-31
Repair or replace the rear axle single reduction differential carrier parts 3-33
Gear sets 3-33
Assemble and install the rear axle differential carrier 3-35
32 71 Assemble the drive pinion bearings and bearing cage 3-36
3272 Install the one piece pilot bearing on drive pinion with retainer ring 3-37
3273 Install the drive pinion 3-38
3274 Set the pinion bearing preload 3-38
3275 Shim pack thickness for a new drive pinion 3-44
3276 Install the drive pinion bearing cage and shim pack into carrier 3-46
3277 Install tight fit yokes and POSE™ seal 3-47
3278 Install any type yoke with a unitized pinion seal 3-48
3279 Clean, inspect, and install the yoke after installing a unitized pinion
seal 3-49
32 710 Assemble the differential and ring gear assembly 3-50
32711 Install the differential and ring gear assembly 3-53
32 712 Set the differential bearing preload 3-55
32 713 Do a check of the ring gear run-out 3-57
32714 Do a check of the gear set tooth contact patterns- backlash 3-58
32 715 Adjust the ring gear backlash 3-62
32716 Adjust the thrust screw 3-64
32717 Install the differential carrier into axle housing 3-65
32 718 Torque value for fasteners 3-66
32 719 Carrier repair stand specifications 3-72
32720 Unitized pinion seals and seal drivers 3-73
33 Rear axle planetary 3-74
331 Planetary wheel end exploded views 3-74
3311 Identifying the planetary wheel-end 3-76
Remove and disassemble the rear axle planetary 3-79
3321 Remove the planetary spider assembly 3-80
3322 Disassemble the planetary spider assembly 3-80
3323 Remove the planetary ring gear and the axle shaft 3-81
3324 Prepare to remove the planetary ring gear hub and wheel hub 3-81
3325 Remove the brake components 3-84
3326 Remove the spindle 3-85
Prepare the planetary wheel end parts for assembly 3-85
3331 Clean the ground or polished parts 3-86
3332 Clean the planetary wheel end parts with rough finishes 3-86
3333 Clean the planetary wheel end axle assemblies 3-86
3334 Dry the cleaned planetary wheel end parts 3-86
3335 Prevent the corrosion on planetary wheel and parts 3-86
3336 Inspect the planetary wheel end components 3-86
3337 Inspect the planetary wheel end bearings3-87
3338 Repair or replace the planetary wheel end parts 3-88
3339 Weld repairs on the planetary wheel ends3-88
33310 Remove the bolts fastened with liquid adhesive 3-88
33311 Clean the fasteners 3-89
33312 Apply the silicone gasket material 3-89
33313 Flush the lube from axle 3-89
Assemble and install the rear axle planetary 3-90
3341 Install the spindle 3-91
3342 Install the brake shoes 3-93
3343 Prepare to install the planetary ring gear hub and wheel hub 3-93
3344 Install the ring gear and axle shaft 3-98
3345 Assemble the planetary spider assembly 3-98
3346 Install the planetary spider assembly 3-99
335 Rear axle lubrication 3-100
336 Planetary wheel end specifications 3-102
Rear brakes 3-104
Brake components and operation 3-104
Remove the brake components 3-104
Inspect the brake parts 3-109
Inspect the brake drums 3-109
Clean and inspect the brake components3-110
Install the brake components 3-111
Adjust the drum brakes 3-113
Maintain the drum brakes 3-115
Inspect the drum brakes and maintenance intervals 3-115
Lubricate the cam brakes 3-115
Lubricate the S-cam bushings 3-116
Lubricate the rollers and anchor pins 3-116
Reline the brakes 3-116
34131 Important information on linings and primary shoe locations 3-117
3414 Overhaul the drum brakes 3-118
3415 Troubleshoot the drum brakes 3-118
3416 Drum brake torque specifications 3-119
Slack adjusters 3-121
351 Rear automatic slack adjuster 3-121
3511 Rear automatic slack adjuster theory of operation 3-121
3512 Anti-seize compound 3-123
3513 Remove the automatic slack adjusters 3-124
3514 Remove and disassemble the S-cam 3-125
3515 Assemble and install the S-cam 3-125
3516 Mount the automatic slack adjuster to the S-cam 3-125
3517 Install the automatic slack adjusters 3-126
352 Assemble and install the clevis 3-127
353 Verify the slack adjuster angle 3-128
354 Inspect the brake system 3-128
355 Template method 3-129
356 Brake slack adjuster position (BSAP) method 3-131
357 Adjust the automatic slack adjusters3-131
358 Commercial vehicle safety alliance (CVSA) guidelines 3-132
Tag axle assembly 3-134
361 Tag axle 3-134
362 Operate the tag axle 3-134
363 Adjust the tag axle pressure 3-135
Rear axle maintenance 3-138
371 Clean the breather for the rear axle 3-138
3 72 Do a check of the rear axle oil 3-138
3 73 Change the rear axle oil 3-139
4 Frame and suspension 4-1
41 Frame 4-3
411 Standard chassis 4-3
42 Fork assembly 4-4
421 Fork assembly theory of operation 4-4
422 Remove the fork 4-4
423 Install the fork 4-8
Applicator Chassis
79037159C
Table of contents
5 Steering system 5-1
51 Steering system components5-3
511 Steering pump theory of operation 5-3
512 Remove the steering pump 5-3
513 Install the steering pump 5-6
514 Priority valve theory of operation 5-8
515 Remove the priority valve 5-8
516 Install the priority valve 5-11
51 7 Steering unit theory of operation 5-13
518 Remove the steering unit 5-13
519 Install the steering unit 5-14
5110 Steering cylinder and sensor 5-15
51101 Steering cylinder theory of operation 5-15
51102 Remove the steering cylinder 5-16
51 103 Install the steering cylinder 5-18
51104 Steering sensor theory of operation 5-20
51105 Remove the steering sensor 5-20
51106 Install the steering sensor 5-21
52 Hydraulic cylinder disassembly and assembly 5-24
521 Remove the head gland (wrap-in wire) 5-24
522 Remove the head gland (with external threads) 5-25
523 Remove the head gland (with internal threads) 5-27
524 Remove the head gland (retaining ring) 5-28
525 Remove the rod assembly 5-29
526 Remove a threaded piston 5-30
527 Remove a lock nut piston 5-32
528 Remove the piston seal 5-33
529 Remove the head gland seal 5-34
5210 Install the piston seal 5-35
5211 Install the head gland seal 5-36
5212 Install the head gland (wrap-in wire) 5-38
5213 Install the head gland (with external threads) 5-40
5214 Install the head gland (with internal threads) 5-41
5215 Install the head gland (retaining ring) 5-42
5216 Install a threaded piston 5-43
5217 Install a lock nut piston 5-45
5218 Install the rod assembly 5-47
53 Steering system component specifications 5-49
531 Steering pump specifications 5-49
532 Steering cylinder specifications 5-50
533 Steering ball socket specifications 5-51
534 Steering unit specifications5-51
535 Suction strainer specifications 5-52
536 Steering angle sensor specifications 5-53
6 Drive train system 6-1
61 Transmission theory 6-3
611 Transmission theory of operation 6-3
612 Transmission cooling circuit theory 6-3
62 Transmission removal 6-4
621 Remove the transmission 6-4
63 Transmission disassemble and assemble 6-9
631 Remove the transmission insert 6-9
632 Install the transmission insert 6-15
633 Replace the high pressure limiting valve 6-24
634 Replace the transmission purge valve 6-27
Applicator Chassis
79037159C
Table of contents
635 Remove the servo and lubrication pump 6-29
636 Install the servo and lubrication pump 6-33
637 Remove the transmission housing cover 6-39
638 Disassemble the transmission housing cover 6-42
639 Disassemble the transmission housing 6-44
6310 Assemble the transmission housing 6-45
6311 Assemble the transmission housing cover 6-50
6312 Install the transmission housing cover 6-51
64 Transmission installation 6-56
641 Install the transmission 6-56
65 Transmission control unit (TCU) removal and installation 6-59
651 Remove the TCU 6-59
652 Install the TCU 6-60
66 Transmission maintenance 6-62
661 Do a check of the transmission oil 6-62
662 Change the transmission oil 6-62
663 Charge the transmission high pressure circuit 6-64
6 7 Machine transport6-67
671 Operate the machine in limp-home mode 6-67
672 Prepare for towing – engine operation 6-70
673 Prepare for towing – engine not operating6-73
674 Tow procedure 6-73
68 Transmission components removal and installation 6-75
681 Clutch pedal 6-75
6811 Remove the clutch pedal assembly 6-75
6812 Install the clutch pedal assembly 6-76
6813 Remove the clutch pedal position switch 6-76
6814 Install the clutch pedal position switch 6-77
6815 Adjust the clutch pedal position switch 6-78
682 Thermal bypass valve theory of operation 6-78
6821 Remove the thermal bypass valve 6-79
6822 Install the thermal bypass valve 6-80
683 Radar speed sensor 6-81
6831 Remove the radar speed sensor 6-81
6832 Install the radar speed sensor 6-82
69 Transmission test and adjust6-84
691 Calibrate the lever 6-84
692 Calibrate the drive pedal 6-85
693 Calibrate the clutch pedal6-86
694 Calibrate the transmission range 6-86
695 Calibrate the CVT transmission 6-87
696 Calibrate the turbo clutch 6-87
697 Calibrate the radar6-88
698 Calibrate the wheel speed 6-89
699 Calibrate the wheel speed and radar 6-90
6910 Test points for the transmission hydraulics 6-91
6911 Measure the transmission pressures 6-92
6912 Supply pressures test 6-92
6913 Do a high pressure test 6-95
6914 Do an inspection of the turbo clutch solenoid and clutch pressure limiting valves 6-98
6915 Do a test of the turbo clutch solenoid and clutch pressure limiting valves 6-99
69151 Do a check of the turbo clutch solenoid valve 6-100
610 Drivetrain removal and installation 6-101
6101 Drivetrain components and description 6-101
6102 Remove the flywheel coupling assembly 6-102
6103 Install the flywheel coupling assembly 6-103
6104 Engine to transmission driveshaft introduction 6-104
Applicator Chassis
79037159C
Table of contents
61041 Remove the engine to transmission driveshaft 6-105
61042 Disassemble the engine to transmission drive shaft 6-107
61043 Assemble the engine to transmission drive shaft 6-109
61044 Install the engine to transmission driveshaft 6-110
6105 Transmission to axle driveshaft introduction6-112
61051 Remove the front driveshaft 6-112
61052 Install the front driveshaft 6-113
61053 Remove the rear driveshaft 6-114
61054 Disassemble the rear driveshaft 6-115
61055 Assemble the rear driveshaft 6-117
61056 Install the rear driveshaft 6-119
6106 Replace the hanger bearing 6-119
6107 Replace the U-joint 6-121
611 Powertrain specifications 6-122
6111 Transmission specifications 6-122
6112 Engine to transmission driveshaft specifications 6-123
6113 Transmission to axle driveshaft specifications 6-123
6114 Thermal bypass valve specifications 6-124
6115 Clutch pedal position switch specifications 6-125
6116 Radar specifications 6-125
7 Air system 7-1
71 Air system operation 7-3
72
711 Air system theory of operation 7-3
712 Air system component location 7-5
713 Air brake system description7-6
714 Park brake system 7-7
715 Service brake system 7-7
Air system disassembly and assembly 7-10
72 1 Air compressor theory of operation 7-10
72 2 Air tank 7-10
72 21 Air tank theory of operation7-10
72 22 Remove the wet air tank 7-10
72 23 Install the wet air tank 7-11
72 24 Remove the primary dry air tank 7-13
72 25 Install the primary dry air tank 7-14
72 26 Remove the secondary dry air tank 7-16
72 27 Install the secondary dry air tank 7-17
72 28 Pressure control check valve (PCCV) theory of operation 7-20
72 29 Remove the air system PCCV 7-20
72 210 Install the air system PCCV 7-21
Air dryer 7-21
72 31 Air dryer theory of operation7-21
72 32 Air dryer components 7-22
72 33 Remove the air dryer 7-22
72 34 Replacing air dryer components 7-25
72 35 Install the air dryer 7-28
Park brake modulating valve theory of operation 7-30
Remove the park brake modulating valve7-30
Install the park brake modulating valve 7-31
Service brake valve theory of operation 7-33
Remove the service brake valve 7-33
Install the service brake valve 7-34
Rear brake actuator theory of operation 7-35
Remove the rear brake actuator 7-36
Install the rear brake actuator 7-37
Relay valve theory of operation 7-39
Remove the R14 relay valve 7-39
Applicator Chassis
Install the R14 relay valve 7-40
Remove the R12 relay valve 7-42
Install the R12 relay valve 7-43
Air governor theory of operation 7-44
Air governor 7-44
72 191 Remove the air governor 7-44
72 192 Install the air governor 7-45
Cab air suspension theory of operation 7-46
Remove the cab air suspension 7-47
Install the cab air suspension 7-48
Tank fill coupler 7-50
72 231 Removing the tank fill coupler 7-50
72 232 Installing the tank fill coupler 7-51
72 24 Remove the pressure switch 7-51
72 25 Install the pressure switch 7-53
72 26 Remove the pressure protection valve 7-53
72 27 Install the pressure protection valve 7-54
Air system component specifications 7-56
731 Air compressor specifications 7-56
732 Air tank specifications 7-57
733 Pressure control check valve specifications 7-58
734 Air governor specifications 7-59
735 Air dryer specifications 7-60
736 R12 relay valve specifications 7-61
737 R14 relay valve specifications 7-62
738 Park brake specifications 7-63
739 Service brake valve specifications 7-64
7310 Service brake pressure switch specifications 7-64
7311 Service brake pressure transducer specifications 7-65
7312 Rear brake actuator specifications 7-65
8 Hydraulic system 8-1
81 Hydraulic system component location 8-3
811 Hydraulic component location and function 8-3
82 Hydraulic component removal and installation 8-7
821 Hydraulic gear pump theory of operation 8-7
822 Remove the hydraulic gear pump 8-7
823 Disassemble the hydraulic gear pump 8-8
824 Assemble the hydraulic gear pump 8-11
825 Install the hydraulic gear pump 8-13
826 Troubleshoot the hydraulic gear pump 8-15
827 Hydraulic tank 8-16
82 71 Hydraulic tank theory of operation 8-16
82 72 Remove the hydraulic tank 8-16
82 73 Disassemble the hydraulic tank 8-18
8274 Assemble the hydraulic tank8-20
8275 Install the hydraulic tank8-22
Hydraulic oil cooler theory of operation 8-23
Tag axle cylinder and valve8-23
8291 Tag axle cylinder theory of operation 8-23
8292 Remove the tag axle cylinder 8-23
8293 Install the tag axle cylinder 8-25
8294 Tag axle hydraulic valve block theory of operation 8-27
8295 Remove the tag axle hydraulic valve block8-27
8296 Install the tag axle hydraulic valve block 8-29
83 Hydraulic maintenance 8-31
831 Adjust the pressure compensator 8-31
Applicator Chassis
79037159C
Table of contents
84 Hydraulic system component specifications 8-32
841 Hydraulic gear pump specifications 8-32
842 Hydraulic tank specifications 8-33
843 Filler assembly specifications 8-33
844 Return filter specifications 8-34
845 Pressure washer hydraulic block specifications 8-34
846 Tag axle hydraulic valve block specifications 8-35
847 Tag axle cylinder specifications 8-36
9 Electrical 9-1
91 General Information 9-11
911 Introduction to the electrical system 9-11
912 Basic electrical troubleshooting procedures 9-11
913 Electrical service tools 9-11
914 Test a fuse 9-12
915 Test a relay 9-12
916 Test a diode 9-12
92 Accuterminal module 9-14
921 Code 0D100 9-14
922 Code 0D101 9-14
923 Code 0D102 9-14
924 Code0D103 9-14
925 Code 0D105 9-14
926 Code 0D1069-14
927 Code 0D107 9-14
928 Code 0D108 9-14
929 Code0D109 9-14
9210 Code 0D110 9-14
9211 Code 0D111 9-14
9212 Code 0D112 9-14
9213 Code 0D113 9-15
9214 Code 0D10A 9-15
9215 Code 0D10B 9-15
9216 Code 0D10C 9-15
9217 Code 0D10D 9-15
9218 Code 0D10E 9-15
93 Armrest module 9-16
931 Code 3100 9-16
932 Code 3101 9-16
933 Code3102 9-16
934 Code 3103 9-16
935 Code 3107 9-16
936 Code 3108 9-16
937 Code3109 9-16
938 Code 3120 9-16
939 Code 3130 9-16
9310 Code 3140 9-16
9311 Code 317F 9-16
94 Automatic steering module 9-17
941 Code 181019-17
942 Code 181029-17
943 Code 18104 9-17
944 Code 18108 9-17
945 Code 18110 9-17
946 Code 18111 9-17
947 Code 18112 9-17
948 Code 1811C 9-17
Applicator Chassis
79037159C
Table of contents
949 Code 1812A 9-17
9410 Code 1812C 9-17
9411 Code 18130 9-18
9412 Code 18132 9-18
9413 Code 18133 9-18
9414 Code 18134 9-18
9415 Code 18136 9-18
9416 Code 18137 9-18
9417 Code 1813A 9-18
9418 Code 1813B 9-18
9419 Code 1813C 9-18
9420 Code 18140 9-18
9421 Code 1814A 9-19
9422 Code 1814B 9-19
9423 Code 1815C 9-19
9424 Code 1815D 9-19
9425 Code 18166 9-19
9426 Code 18169 9-19
9427 Code 1816A 9-19
9428 Code 1816B 9-19
9429 Code 1816C 9-19
9430 Code 1816D 9-19
9431 Code 18170 9-19
9432 Code 1817F 9-19
9433 Code 18180 9-19
9434 Code 181819-20
9435 Code 18182 9-20
9436 Code 18183 9-20
9437 Code 183009-20
9438 Code 183419-20
9439 Code 18371 9-20
9440 Code 183 729-20
95 Console module 9-21
951 Code 2100 9-21
952 Code 2101 9-21
953 Code 2102 9-21
954 Code 2103 9-21
955 Code 2104 9-21
956 Code 210D 9-21
957 Code 210F 9-21
958 Code 2111 9-21
959 Code 2114 9-21
9510 Code 2118 9-21
9511 Code 21199-21
9512 Code 211A 9-21
9513 Code 211 B 9-21
9514 Code 211 E 9-21
9515 Code 211 F9-22
9516 Code 2120 9-22
9517 Code 2133 9-22
9518 Code 2137 9-22
9519 Code 2141 9-22
9520 Code 21449-22
9521 Code 21469-22
9522 Code 2180 9-22
9523 Code 2181 9-22
9524 Code 21829-22
9525 Code 2183 9-22
Applicator Chassis
79037159C
Table of contents
9526 Code 2190 9-23
9527 Code 2191 9-23
9528 Code 2192 9-23
9529 Code 2198 9-23
9530 Code 2242 9-23
9531 Code 2243 9-23
9532 Code 2340 9-23
9533 Code 2345 9-23
9534 Code 2347 9-23
96 Electrical controller module 9-24
961 Code 0F100 9-24
962 Code 0F101 9-24
963 Code 0F102 9-24
964 Code 0F105 9-24
965 Code 0F106 9-24
966 Code 0F107 9-24
967 Code 0F108 9-24
968 Code 0F109 9-24
969 Code 0F10A 9-24
9610 Code0F10B9-24
9611 Code 0F10C9-24
9612 Code 0F110 9-24
9613 Code 0F117 9-24
9614 Code 0F118 9-24
9615 Code 0F11 D 9-25
9616 Code 0F12B 9-25
97 Engine module 9-26
9 71 Code 1100 9-26
972 Code 1101 9-26
973 Code 1103 9-26
974 Code 1104 9-26
975 Code 1105 9-26
976 Code 1106 9-26
977 Code 1107 9-26
978 Code 117A 9-26
979 Code 117D 9-26
9710 Code 117E 9-26
9 711 Code 117F 9-27
9 712 Code 119A 9-27
9 713 Code 119E 9-27
9714 Code 119F 9-27
9715 Code 1110 9-27
9 716 Code 11A0 9-27
9717 Code 11A1 9-27
9718 Code 11B0 9-27
9719 Code 11C0 9-27
9720 Code 11E0 9-27
9721 Code 19110 9-28
9 722 Code 19111 9-28
9723 Code 19112 9-28
9724 Code 19113 9-28
9 725 Code 19114 9-28
9726 Code 19115 9-28
9727 Code 19116 9-28
9728 Code 19117 9-28
9729 Code 19118 9-28
9730 Code 19119 9-28
9731 Code 1911A 9-28
Code 1911 B 9-28
Code 1911C 9-28
Code 1911 D9-28
Code 1911 E 9-29
Code 1911 F 9-29
Code 19120 9-29
Code19121 9-29
Code 19122 9-29
Code 19123 9-29
Code 19124 9-29
Code 19125 9-29
Code 19126 9-29
Code 19127 9-29
Code 19128 9-29
Code 191299-29
Code 1912A 9-29
Code 1912B 9-29
Code 1912C 9-30
Code1912D 9-30
Code 1912E 9-30
Code 1912F 9-30
Code 19130 9-30
Code19131 9-30
Code 19132 9-30
Code 191339-30
Code 191349-30
Code 19135 9-30
Code 19136 9-30
Code 191379-30
Code 19138 9-30
Code 19139 9-30
Code 1913A 9-31
Code 1913B 9-31
Code 1913C 9-31
Code1913D9-31
Code 1913E 9-31
Code 1913F 9-31
Code 19140 9-31
Code 19141 9-31
Code 19142 9-31
Code 19143 9-31
Code 19144 9-31
Code 191459-31
Code 191469-31
Code 19147 9-31
Code 19148 9-32
Code 19149 9-32
Code 1914A 9-32
Code 1914B 9-32
Code 1914C 9-32
Code 1914D9-32
Code 1914E9-32
Code 1914F9-32
Code 191509-32
Code19151 9-32
Code 19152 9-32
Code 19153 9-32
Code 19154 9-32
Table of contents
Code 19155 9-32
Code 19156 9-33
Code 19157 9-33
Code 191589-33
Code 191599-33
Code 1915A 9-33
Code 1915B 9-33
Code 1915C 9-33
Code1915D 9-33
Code 1915E 9-33
Code 1915F 9-33
Code 19160 9-33
Code 19161 9-33
Code 19162 9-33
Code 19163 9-33
Code 19164 9-34
Code 19165 9-34
Code 19166 9-34
Code 19167 9-34
Code 19168 9-34
Code 19169 9-34
Code 1916A 9-34
Code 1916B 9-34
Code 1916C 9-34
Code 1916D9-34
Code 1916E 9-34
Code 1916F 9-34
Code 19170 9-34
Code 19171 9-34
Code 191 72 9-35
Code 191 73 9-35
Code 191 74 9-35
Code 191 75 9-35
Code 191 76 9-35
Code 191 77 9-35
Code 191 78 9-35
Code 191 79 9-35
Code 1917 A 9-35
Code 191 7B 9-35
Code 191 7C9-35
Code 191 7D9-35
Code 191 7E 9-35
Code 191 7F 9-35
Code 191809-36
Code19181 9-36
Code 19182 9-36
Code 19183 9-36
Code 19184 9-36
Code 19185 9-36
Code 19186 9-36
Code 19187 9-36
Code 19188 9-36
Code 191899-36
Code 1918A 9-36
Code 1918B 9-36
Code 1918C 9-36
Code 1918D9-36
Code 1918E 9-37
Table of contents
97148 Code 1918F 9-37
97149 Code 19100 9-37
97150 Code 19160 9-37
97151 Code 19163 9-37
97152 Code 19164 9-37
97153 Code 1916D 9-37
97154 Code 1916E 9-37
97155 Code 1916F 9-37
97156 Code 19170 9-37
97157 Code 33100 9-37
98 Error management 9-38
981 Code 1F1B0 9-38
982 Code 1 F1B1 9-38
983 Code 1F1FF 9-38
984 Code 1 F3C1 9-38
985 Code 1 F3C0 9-38
99 Machine module 9-39
991 Code 38100 9-39
992 Code 38101 9-39
993 Code 38102 9-39
994 Code 38103 9-39
995 Code 38104 9-39
996 Code 38105 9-39
997 Code 381069-39
998 Code 381079-39
999 Code 381089-40
9910 Code 38109 9-40
9911 Code 3810A 9-40
9912 Code 3810B 9-40
9913 Code 3810C 9-40
9914 Code 3810D 9-40
9915 Code 3810E 9-40
9916 Code 3810F 9-40
9917 Code 381109-40
9918 Code 38111 9-41
9919 Code 38112 9-41
9920 Code 38113 9-41
910 Machine information module 9-42
9101 Code 14100 9-42
9102 Code 14101 9-42
911 Transmission module 9-43
9111 Code 4104 9-43
9112 Code 4105 9-43
9113 Code 4106 9-43
9114 Code 4107 9-43
9115 Code 4108 9-43
9116 Code 4119 9-43
9117 Code4120 9-43
9118 Code 4121 9-44
9119 Code 4122 9-44
91110 Code 4123 9-44
91111 Code 4124 9-44
91112 Code 4125 9-44
91113 Code 4126 9-44
91114 Code 4128 9-44
91115 Code 4129 9-45
91116 Code 412A 9-45
Code 412B 9-45
Code 412C 9-45
Code 412D 9-45
Code 412E 9-45
Code 412F 9-45
Code 4131 9-46
Code 4132 9-46
Code 4133 9-46
Code 4142 9-46
Code 4144 9-46
Code 4145 9-46
Code 4146 9-46
Code 4147 9-47
Code 4148 9-47
Code 4149 9-47
Code 4150 9-47
Code 4156 9-47
Code 4158 9-47
Code 4159 9-47
Code 4161 9-48
Code 4162 9-48
Code 4163 9-48
Code 4164 9-48
Code 4165 9-48
Code 4166 9-48
Code 4167 9-48
Code 4168 9-49
Code 41 70 9-49
Code 41 71 9-49
Code 41 76 9-49
Code 41 77 9-49
Code 41 78 9-49
Code 41 79 9-49
Code 4182 9-50
Code 4183 9-50
Code 4184 9-50
Code 4185 9-50
Code 4186 9-50
Code 41879-50
Code 4189 9-50
Code 418A 9-51
Code 418B 9-51
Code 418C 9-51
Code 418D 9-51
Code 418E 9-51
Code 418F 9-51
Code 4194 9-51
Code 41A 1 9-52
Code 41A2 9-52
Code 41A3 9-52
Code 41A4 9-52
Code 41A5 9-52
Code 41A6 9-52
Code 41AF 9-52
Code 41 BO 9-53
Code 41 B 1 9-53
Code 41 B2 9-53
Code 41 B5 9-53
Table of contents
91175 Code 41B7 9-53
91176 Code41BC 9-53
911 77 Code 41 E 1 9-53
911 78 Code 41 E2 9-54
911 79 Code 41 E3 9-54
91180 Code 41 E4 9-54
91181 Code41E5 9-54
91182 Code 41 E6 9-54
91183 Code 41 E7 9-54
91184 Code 41 E9 9-54
91185 Code 41 EA 9-55
91186 Code 41 EB 9-55
91187 Code41EC 9-55
91188 Code 41 ED 9-55
91189 Code 41 EE 9-55
91190 Code 41 EF 9-55
91191 Code 41F0 9-55
91192 Code 41F1 9-56
91193 Code 41F2 9-56
91194 Code 41F3 9-56
91195 Code 4240 9-56
91196 Code 4241 9-56
91197 Code 42BB 9-56
91198 Code 42BE 9-56
91199 Code 42BF 9-57
911100 Code 42C0 9-57
911101 Code 42C1 9-57
911102 Code 42C2 9-57
911103 Code 42C3 9-57
911104 Code 42C4 9-57
911105 Code 42C5 9-57
911106 Code 42C6 9-57
911107 Code 42C7 9-58
911108 Code 42C8 9-58
911109 Code 42C9 9-58
911110 Code 42CA 9-58
911111 Code 42CB 9-58
911112 Code 42CC 9-58
911113 Code 42CD 9-58
911114 Code 42CE 9-59
911115 Code 42D0 9-59
911116 Code 4202 9-59
912 Schematics 9-60
Air dryer schematic 9-60
Alternator excite schematic9-61
Ancillary CAN schematic 9-62
Auxiliary schematic 9-63
Autoguide schematic 9-65
Backup alarm schematic 9-66
Beacon schematic 9-67
Brake schematic 9-68
Cut off coil network schematic 9-69
CVT clutch schematic 9-70
CVT sensors schematic 9-72
Dash navigator schematic 9-75
Dash/LCP master schematic 9-76
Engine Nox sensor master schematic 9-77
EXT J1 Master schematic 9-78
Applicator Chassis
79037159C
Table of contents
91216 EXT J2 master schematic 9-79
91217 ZE master schematic 9-80
91218 Foot throttle schematic 9-82
91219 Fuel level schematic 9-83
91220 Horn schematic 9-84
91221 HVAC schematic 9-85
91222 Ignition schematic 9-87
91223 GEP master schematic 9-89
91224 CEAGUIDE master schematic 9-92
91225 RS232 schematic 9-93
91226 5V sensor power schematic 9-96
91227 12V sensor power schematic 9-97
91228 Battery power schematic 9-98
91229 Engine power schematic 9-100
91230 Switch power schematic 9-101
91231 Unswitched power schematic 9-105
91232 Cab ground schematic9-107
91233 Chassis ground schematic 9-109
91234 Hood light schematic 9-111
91235 Clearance light schematic 9-112
91236 Cab interior light schematic 9-113
91237 Rear brake lights schematic 9-114
91238 Lights- AFWL schematic 9-116
91239 Lightbar/smart yield schematic 9-118
91240 Mirrors schematic 9-119
91241 Internal GPS receiver output schematic 9-127
91242 GPSschematic 9-128
91243 Engine schematic 9-130
91244 NIDEC A CAN schematic 9-132
91245 ISO CAN schematic 9-133
91246 GD chassis CAN schematic 9-136
91247 Engine CAN schematic 9-138
91248 RSP master schematic 9-140
91249 MFA master schematic 9-147
91250 Gateway master schematic 9-148
91251 Engine interface master schematic 9-149
91252 Radio schematic 9-150
91253 Radar schematic 9-151
91254 Raven CAN schematic 9-152
91255 Reverse alarm schematic 9-154
91256 RTX correction internal schematic 9-155
91257 Seat schematic 9-156
91258 Smarttrax master schematic 9-157
91259 Starter schematic 9-159
91260 Stalk switch schematic 9-160
91261 Tag axle schematic 9-161
91262 Phoenix 200 schematic 9-162
91263 Wiper motor schematic 9-163
91264 Worklight 2 / EAME boomrest schematic 9-164
91265 Worklight 3 schematic 9-166
91266 Worklight4schematic 9-167
913 Components 9-170
9131 DEFmodule 9-170
9132 DEF tank sensor 9-175
9133 Fuel level sensor 9-177
9134 Downstream NOx sensor 9-179
9135 Upstream NOx sensor 9-182
9136 Reverse alarm 9-184
Applicator Chassis
79037159C
Table of contents
914
10 Cab
101
102
103
9137 Tag axle solenoid 9-186
9138 CVT pressure 1 sensor 9-188
9139 CVT pressure 2 sensor 9-190
91310 Transmission components 9-192
91311 Axle pinion shaft sensor 9-197
Electrical components 9-199
9141 Remove the horn 9-199
9142 Install the horn 9-199
9143 Remove the battery 9-200
9144 Install the battery 9-201
10-1
Cab removal and installation10-3
1011 Remove the standard ride cab 10-3
1012 Install the standard ride cab10-8
1013 Removetheairridecab 10-12
1014 lnstalltheairridecab 10-18
Cab components10-24
1021 Remove the seat 10-24
1022 Install the seat 10-25
1023 Remove the multifunction armrest 10-26
1024 Install the multifunction armrest 10-28
1025 Remove the AccuTerminal10-30
1026 Install the AccuTerminal 10-31
10261 Install the AccuTerminal screen 10-32
1027 Remove the dash cluster 10-33
1028 Install the dash cluster 10-34
1029 Remove the steering column 10-36
10210 Install the steering column 10-38
10211 Remove the steering console 10-39
10212 Install the steering console 10-41
10213 Remove the radio 10-42
10214 Install the radio 10-42
10215 Remove the satellite radio antenna (if equipped) 10-43
10216 Install the satellite radio antenna (if equipped) 10-44
10217 Remove the heating and cooling controls 10-45
10218 Install the heating and cooling controls 10-46
10219 Remove the lighting control panel 10-47
10220 Install the lighting control panel 10-48
10221 Remove the windshield washer tank 10-48
10222 Install the windshield washer tank 10-49
10223 Remove the windshield wiper motor 10-50
10224 Install the windshield wiper motor 10-51
10225 Remove the instructor seat 10-52
10226 Install the instructor seat 10-53
Cab maintenance10-55
1031 Cab air filters 10-55
1032 Change the primary fresh air filter 10-56
1033 Change the secondary clean air filter 10-57
1034 Change the recirculation air filter 10-58
1035 Clean the cab air filter element 10-59
1036 Do a check of the windshield washer reservoir 10-59
1037 Do a check of the cab mount bolts 10-60
11 Air conditioning and heating system 11-1
111 Air conditioning components 11-3
1111 Remove the air conditioning compressor 11-3
Applicator Chassis
79037159C
Table of contents
1112 Install the air conditioning compressor 11-6
11 13 Remove the air conditioning receiver/dryer 11-8
1114 Install the air conditioning receiver/dryer11-10
112 System operation and controls 11-11
1121 System operation 11-11
1122 HVAC system 11-12
1123 Electronic HVAC controls 11-12
1124 Cab pressure 11-12
1125 Cab airflow moisture 11-12
1126 Circulation of the cab airflow 11-12
112 7 Cab airflow increased temperature 11-12
1128 Cab airflow decreased temperature 11-12
1129 Refrigerant system sensors 11-13
11210 Refrigerant pump 11-13
11211 Compression ( Discharge side) 11-13
11212 Temperature control switch 11-13
113 Testing and adjusting 11-14
1131 Machine prepared troubleshooting 11-14
1132 General troubleshooting information11-14
1133 Automatic temperature control panel test 11-15
1134 Troubleshoot with service codes 11-16
1135 Enter advanced diagnostics 11-17
1136 Troubleshoot using advanced diagnostics 11-18
114 Basic air conditioning system testing 11-21
1141 Visual inspection 11-21
1142 System failure 11-21
115 Do a check of the system pressure 11-22
1151 Manifold gauge set 11-22
1152 Install the manifold gauge 11-22
1153 Use manifold gauge test11-23
1154 Examine the air temperature 11-23
1155 Data results 11-24
1156 Pressure-temperature chart 11-24
1157 Base line performance test 11-24
1158 Refrigerant recovery 11-25
1159 Refrigerant contamination 11-25
11510 Recovery 11-25
11511 Moisture in a refrigerant system 11-26
11512 Results of pressure on water boiling points 11-26
11513 Boiling temperature of water at converted pressures 11-27
11514 Before evacuation 11-28
11515 System evacuation 11-28
116 Refrigerant recovery 11-30
1161 Refrigerant recovery tools 11-30
1162 Refrigerant recovery 11-30
1163 Flush the refrigerant system 11-31
1164 Test refrigerant leak with dye 11-31
1165 Test refrigerant leak with a leak detector 11-31
1166 Do a check of the compressor oil 11-32
1167 Refrigerant temperature/pressure chart 11-32
1168 Charge the system 11-34
1169 Charge the system with a scale 11-35
11610 Add more refrigerant to a low charge 11-37
11611 Remove the manifold gauge set 11-37
12 Chassis 12-1
121 Engine cover 12-3
Applicator Chassis
79037159C
Table of contents
1211 Engine cover description 12-3
1212 Remove the engine cover 12-3
1213 Disassemble the engine cover 12-5
1214 Assemble the engine cover12-7
1215 Install the engine cover 12-8
13 Wheels 13-1
131 Wheels and tires removal and installation 13-3
1311 Remove the front wheel 13-3
1312 Install the front wheel 13-5
1313 Remove the rear wheel 13-6
1314 Install the rear wheel 13-7
1315 Tighten the wheel mounting hardware 13-7
1316 Maintain the wheel nuts 13-8
1317 Tires 13-8
1318 Inflate the tire13-8
1319 Replace the tire 13-9
13110 Tire charts 13-9
14 Accessories 14-1
141 Cabinet 14-3
1411 Storage cabinet 14-3
14111 Storage cabinet description 14-3
14112 Remove the storage cabinet14-3
14113 Install the storage cabinet 14-4
1412 Accessory box 14-5
14121 Accessory box description 14-5
14122 Remove the accessory box 14-6
14123 Install the accessory box 14-7
1413 Utility box 14-8
14131 Utility box description 14-8
14132 Remove the utility box 14-8
14133 Install the utility box 14-9
142 Mirrors and work lamps 14-11
1421 Mirror and work lamp description 14-11
1422 Remove the front work lamps 14-11
1423 Install the front work lamps 14-12
1424 Remove the amber flashing lamps 14-14
1425 Install the amber flashing lamps 14-14
1426 Remove the mirror and work lamp support 14-14
1427 Install the mirror and work lamp support14-15
1428 Remove the front mirrors 14-16
1429 Install the front mirrors 14-16
14210 Remove a cab mirror 14-16
14211 Install a cab mirror 14-17
143 Rinse Tank 14-18
1431 Rinse tank description 14-18
1432 Remove the rinse tank 14-18
1433 Disassemble the rinse tank 14-19
1434 Assemble the rinse tank 14-19
1435 Install the rinse tank 14-20
144 Pressure washer system (optional) 14-21
1441 Pressure washer theory of operation 14-21
1442 Pressure washer hydraulic block theory of operation 14-21
1443 Remove the pressure washer pump 14-21
1444 Install the pressure washer pump 14-22
1445 Remove the pressure washer hydraulic block 14-24
Applicator Chassis
79037159C
Table of contents
1446 Install the pressure washer hydraulic block 14-25
1447 Remove the hose reel 14-26
1448 Install the hose reel 14-26
1449 Remove the water filter 14-27
14410 Install the water filter 14-28
14411 Maintain the pressure washer 14-28
145 Step and platform 14-29
1451 Cab step and platform description 14-29
1452 Remove the cab step and platform 14-29
1453 Disassemble the cab step and platform 14-31
1454 Assemble the cab step and platform 14-33
1455 Install the cab step and platform 14-34
1456 Remove the accessory steps 14-36
1457 Install the accessory steps 14-37
15 Special tools 15-1
151 List of special tools 15-3
16 Diagrams 16-1
161 Hydraulic 16-3
1611 Hydraulic schematic 16-5
162 Transmission16-7
1621 Transmission hydraulic schematic 16-9
163 Pneumatic 16-11
1631 Pneumatic schematic 16-13
164 Component location charts 16-15
1641 Headlamp harness connector location diagram 16-15
1642 Ground cable connector location diagram 16-15
1643 Alternator harness connector location diagram 16-16
1644 Chassis harness connector location diagram 16-16
1645 Battery box connector location diagram 16-17
1646 Cab electrical panel connector location diagram 16-17
1647 Cab bulkhead connector location diagram 16-18
1648 Cab top harness connector location diagram 16-18
1649 Cab middle harness connector location diagram 16-19
17 Index lndex-1Service manual
1.1.1 Units of measurement
Measurements are given in metric units followed by the equivalent in US units. Hardware sizes are given in
millimeters for metric hardware and inches for US hardware.
1.1.2 Replacement parts
To receive your parts quickly, have the following information:
Correct part description and part number
Model number of the machine
Serial number of the machine
1.1.3 Product identification information
Each machine has an identification plate with the model number and the serial number.
The product identification number (Pl N) is used to
identify a machine.
The manufacturer’s plate contains the PIN.
The serial numbers identify the engines,
transmissions, and attachments.

CHALLENGER EU APPLICATORS TERRAGATOR TG7300C TG8300C FLOTATION CHASSIS WORKSHOP SERVICE MANUAL:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V