Challenger EU Hay Equipment 9226 9246 Auger Header Workshop Service Manual 79037260A – PDF DOWNLOAD

Description

Challenger EU Hay Equipment 9226 9246 Auger Header Workshop Service Manual 79037260A – PDF DOWNLOAD

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DESCRIPTION:

Challenger EU Hay Equipment 9226 9246 Auger Header Workshop Service Manual 79037260A – PDF DOWNLOAD

General information
 Introduction to this service manual:

• This service manual gives information from engineering tests, operating data, and the latest service techniques at the time of publication. Read this service manual carefully before doing any service on the machine.
• The photos and illustrations used in this service manual were current at the time of publication. Production changes can cause machines to vary from the photos and the illustrations. The manufacturer reserves the right to redesign and change machines as necessary without notification.

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.
 Table of contents
This manual has a table of contents at the front. The table of contents shows the divisions. The individual divisions also have a table of contents.
 Page numbers
All pages have two numbers, such as 0 1-2 5. The first number shows the division. The second number shows the page in the division. Page numbers occur on the lower right-hand or lower left-hand corner of each page.
 Intended use:

• This machine is designed solely for use in customary agricultural operations. Do not use this machine for any application or purpose other than those described in this manual . The manufacturer accepts no liability for damage or injury resulting from misuse of this machine.
• Compliance with the conditions of operation, service and repair as specified by the manufacturer constitute essential elements for the intended use of this machine. This machine should be operated, serviced and repaired only by qualified persons familiar with its characteristics and familiar with the relevant safety rules and procedures.
• All generally recognized safety regulations and road traffic regulations must be obey ed at all times. Any unauthorized modifications performed on this machine will relieve the manufacturer of all liability for any resulting damage or injury.

TABLE OF CONTENTS:

Challenger EU Hay Equipment 9226 9246 Auger Header Workshop Service Manual 79037260A – PDF DOWNLOAD

1 General 1-1
1 1 General information 1-3
1 1 1 Introduction to this service manual 1-3
1 1 2 Units of measurement 1-3
1 1 3 Table of contents 1-3
1 1 4 Page numbers 1-3
1 1 5 Intended use 1-3
1 1 6 Proper disposal of waste 1-3
1 2 Safety 1-5
1 2 1 Safety symbol 1-5
1 2 2 Safety messages 1-5
1 2 3 Information messages 1-5
1 2 4 Safety signs 1-5
1 2 5 A word to the technician 1-6
1 2 6 The service manual 1-7
1 2 7 Travel on public roads 1-7
1 3 Operation 1-9
1 3 1 Prepare for operation 1-9
1 3 2 General information 1-9
1 3 3 Personal protective equipment 1-10
1 3 4 Seat instructions 1-10
1 3 5 Shield and guards 1-1 1
1 3 6 Exhaust warning 1-1 1
1 3 7 Flying debris 1-1 2
1 3 8 Handrails 1-1 2
1 3 9 Agricultural chemicals 1-1 2
1 4 Maintenance 1-13
1 4 1 General maintenance information 1-1 3
1 4 2 Fire prevention and first aid 1-1 4
1 4 3 High pressure leaks 1-1 5
1 4 4 Tire safety 1-1 6
1 4 5 Replacement parts 1-1 6
1 5 Accumulators 1-17
1 5 1 Accumulators 1-1 7
1 6 Specifications 1-18
1 6 1 Dimensions and weights 1-1 8
1 6 2 Header specifications 1-1 8
1 6 3 Sickle specifications 1-1 9
1 6 4 Reel specifications 1-1 9
1 6 5 Auger specifications 1-20
1 6 6 Conditioner specifications 1-2 1
1 6 7 Lubrication specifications 1-2 2
1 6 8 Bolt torque values 1-2 3
1 7 Machine identification 1-25
1 7 1 Serial number plate 1-2 5
1 7 2 Serial number description 1-2 5
1 8 Machine description 1-26
Auger Header
79037260A
1 8 1 Crop flow – single conditioner 1-2 6
1 8 2 Crop flow – double conditioner 1-2 7
1 8 3 Skid shoes 1-2 7
1 8 4 Lean bar 1-2 7
Table of contents
1 8 5 Reel 1-2 7
1 8 6 Augers 1-2 8
1 8 7 Conditioner 1-2 8
1 8 8 Swathboard 1-2 8
1 8 9 Forming shields 1-2 8
1 9 Component access 1-29
1 9 1 End covers 1-2 9
1 9 2 Drive covers 1-2 9
1 10 Bearing replacement 1-31
1 1 0 1 Remove an eccentric locking collar 1-3 1
1 1 0 2 Install an eccentric locking collar 1-3 1
1 11 Gib key 1-33
1 1 1 1 Remove a gib key 1-3 3
1 1 1 2 lnstall a gib key 1-3 4
1 12 Troubleshooting 1-35
1 1 2 1 Sickle drive troubleshooting 1-3 5
1 1 2 2 Cutterbar troubleshooting 1-3 6
1 1 2 3 Reel troubleshooting 1-3 6
1 1 2 4 Auger troubleshooting 1-3 7
1 1 2 5 Conditioner troubleshooting 1-3 7
1 1 2 6 Windrow formation troubleshooting 1-3 7
1 1 2 7 Miscellaneous troubleshooting 1-3 8
2 Drive system 2-1
2 1 Conditioner gearbox – single conditioner 2-3
2 1 1 Remove the single conditioner gearbox 2-3
2 1 2 Disassemble the single conditioner gearbox 2-5
2 1 3 Assemble the single conditioner gearbox 2-7
2 1 4 Install the single conditioner gearbox 2-9
2 2 Conditioner gearbox – double conditioner 2-12
2 2 1 Remove the double conditioner gearbox 2-1 2
2 2 2 Disassemble the double conditioner gearbox 2-1 3
2 2 3 Assemble the double conditioner gearbox 2-1 6
2 2 4 Install the double conditioner gearbox 2-1 9
2 3 Sickle drive gearbox – left 2-22
2 3 1 Special tools 2-2 2
2 3 2 Remove the sickle drive gearbox – left 2-2 2
2 3 3 Disassemble the sickle drive gearbox – left 2-2 3
2 3 4 Assemble the sickle drive gearbox – left 2-2 5
2 3 5 Install the sickle drive gearbox – left 2-2 9
2 4 Sickle drive gearbox – right 2-30
2 4 1 Special tools 2-30
2 4 2 Remove the sickle drive gearbox – right 2-30
2 4 3 Disassemble the sickle drive gearbox – right 2-3 2
2 4 4 Assemble the sickle drive gearbox – right 2-3 4
2 4 5 Install the sickle drive gearbox – right 2-3 7
2 5 Chain adjustments 2-40
2 5 1 Adjust the drive chain – top auger 2-4 0
2 5 2 Adjust the drive chain – bottom auger 2-4 0
2 6 Auger adjustments 2-41
2 6 1 Adjust the auger stripper bars – 1 4 and 1 6 foot 2-4 1
2 6 2 Adjust the auger stripper bars – 1 8 foot 2-4 1
2 6 3 Remove the auger angles 2-4 2
2 6 4 Install the auger angles 2-4 2
2 6 5 Remove the auger pans 2-4 2
2 6 6 Install the auger pans 2-4 3
Auger Header
79037260A
Table of contents
2 6 7 Top auger 2-4 3
2 7 Top auger clutch 2-44
2 7 1 Remove the top auger clutch 2-4 4
2 7 2 Install the top auger clutch 2-4 4
2 7 3 Adjust the top auger clutch 2-4 5
2 8 Bottom auger clutch 2-46
2 8 1 Remove the bottom auger clutch 2-4 6
2 8 2 Install the bottom auger clutch 2-4 7
2 9 Top auger (14 and 16 foot) 2-48
2 9 1 Top auger components 2-4 8
2 9 2 Remove the top auger 2-4 8
2 9 3 Install the top auger 2-4 9
2 10 Top auger (18 foot) 2-51
2 10 1 Top auger components – 1 8 foot 2-5 1
2 10 2 Remove the top auger – 1 8 foot 2-5 2
2 10 3 Install the top auger – 1 8 foot 2-5 3
2 11 Bottom auger 2-54
2 1 1 1 Bottom auger components 2-5 4
2 1 1 2 Remove the bottom auger 2-5 5
2 1 1 3 Install the bottom auger 2-5 6
2 12 Auger paddles 2-58
2 1 2 1 Remove the auger paddles 2-58
2 1 2 2 Install the auger paddles 2-58
3 Hydraulic system 3-1
3 1 Conditioner roll cylinder 3-3
3 1 1 Remove the conditioner roll cylinder 3-3
3 1 2 Conditioner roll cylinder components 3-4
3 1 3 Disassemble the conditioner roll cylinder 3-4
3 1 4 Examine the conditioner roll cylinder 3-4
3 1 5 Assemble the conditioner roll cylinder 3-4
3 1 6 Install the conditioner roll cylinder 3-5
3 1 7 Adjust the pressure of the conditioner roll cylinders 3-5
3 2 Accumulator 3-6
3 2 1 Discharge the accumulator 3-6
3 2 2 Remove the accumulator 3-6
3 2 3 Install the accumulator 3-7
3 2 4 Charge the accumulator 3-8
3 3 Hydraulic reel drive 3-9
3 3 1 Remove the hydraulic reel drive 3-9
3 3 2 Install the hydraulic reel drive 3-10
4 Electrical system 4-1
4 1 Basic electrical troubleshooting 4-3
4 1 1 Basic troubleshooting procedures 4-3
4 1 2 Tools 4-4
4 1 3 Continuity check 4-4
4 1 4 Voltage check 4-5
4 2 Connectors 4-6
4 2 1 Examine a connector 4-6
4 2 2 Pins and sockets 4-6
4 2 3 Replace a Packard connector 4-7
4 2 4 Replace a Deutsch connector 4-7
4 3 Header speed sensor 4-9
Auger Header
79037260A
4 3 1 Header speed sensor 4-9
4 3 2 Adjust the header speed sensor 4-9
Table of contents
4 3 3 Test the header speed sensor 4-9
4 4 Lighting 4-11
4 4 1 Test the lighting 4-1 1
5 Cutterbar 5-1
5 1 Examine the sickle drive 5-3
5 2 Cutterbar maintenance 5-4
5 3 Cutterbar components 5-5
5 4 Cutterbar guards 5-6
5 4 1 Standard guard 5-6
5 4 2 Stub guard adjustment 5-6
5 4 3 Standard holddowns 5-7
5 4 4 Adjustable holddowns 5-7
5 5 Sickles 5-8
5 5 1 General information 5-8
5 5 2 Sickle storage 5-8
5 5 3 Sickle ty pes 5-8
5 5 4 Ex amine the sickle head 5-8
5 5 5 Sickle sections 5-8
5 5 6 Sickle components 5-9
5 5 7 Remove the sickle 5-1 0
5 5 8 Install the sickle 5-1 1
5 6 Sickle drive adjustment 5-14
5 6 1 Parallel alignment 5-1 4
5 6 2 Vertical alignment 5-1 5
5 6 3 Sickle register 5-1 5
5 6 4 Sickle drive timing 5-1 7
5 6 5 Adjust the crankshaft bearing on the sickle drive 5-1 7
5 7 Swaybar assembly 5-18
5 7 1 Sway bar components 5-1 8
5 7 2 Remove the sway bar 5-1 9
5 7 3 Replace the crankshaft bearing 5-2 0
5 7 4 Disassemble the sway bar 5-2 1
5 7 5 Assemble the sway bar 5-2 2
5 7 6 Install the sway bar 5-2 4
5 8 Shock absorber U-joint assembly 5-27
5 8 1 Remove the U-joint assembly for the shock absorber 5-2 7
5 8 2 Install the U-joint assembly for the shock absorber 5-2 7
5 9 Reel 5-29
5 9 1 Reel components 5-2 9
5 9 2 Remove the reel 5-3 1
5 9 3 Install the reel 5-3 3
5 10 Reel adjustments 5-38
5 1 0 1 Reel speed 5-3 8
5 1 0 2 Reel tine timing 5-3 9
5 1 0 3 Reel height 5-4 0
5 1 0 4 Reel fore and aft 5-4 1
5 11 Reel drive belt 5-43
5 1 1 1 Adjust the reel drive belt 5-4 3
5 1 1 2 Replace the reel drive belt 5-4 3
5 12 Reel drive chain 5-44
5 1 2 1 Adjust the reel drive chain 5-4 4
5 1 2 2 Replace the reel drive chain 5-4 4
5 13 Tine tubes and tines 5-45
5 1 3 1 General information 5-4 5
Auger Header
79037260A
Table of contents
5 1 3 2 Remove the tine tubes and tines 5-4 6
5 1 3 3 Components and assembly notes 5-4 7
5 1 3 4 Install the tine tubes and tines 5-4 8
5 14 Reel bats 5-49
5 1 4 1 Remove the reel bats 5-4 9
5 1 4 2 Install the reel bats 5-4 9
5 15 Cam follower bearing 5-51
5 1 5 1 Cam follower bearing components 5-5 1
5 1 5 2 Remove the cam follower bearing 5-5 1
5 1 5 3 Install the cam follower bearing 5-5 1
5 16 Sheave assembly bearing 5-52
5 1 6 1 Disassemble the sheave assembly bearing 5-5 2
5 1 6 2 Assemble the sheave assembly bearing 5-5 2
6 Conditioner 6-1
6 1 Conditioner adjustments – single conditioner 6-3
6 1 1 Conditioner roll pressure – single conditioner 6-3
6 1 2 Conditioner roll spacing – single conditioner 6-3
6 1 3 Conditioner roll timing – single conditioner 6-4
6 2 Conditioner adjustments – double conditioner 6-5
6 2 1 Conditioner roll pressure – double conditioner 6-5
6 2 2 Conditioner roll spacing – double conditioner 6-5
6 2 3 Conditioner roll timing – double conditioner 6-6
6 3 Drive shaft 6-7
6 3 1 Remove the drive shaft 6-7
6 3 2 Remove the timing drive shaft – solid 6-7
6 3 3 Remove the timing drive shaft – slip tube 6-8
6 3 4 Install the drive shaft 6-8
6 3 5 Install the timing drive shaft – solid 6-9
6 3 6 Install the timing drive shaft – slip tube 6-10
6 4 U-joint bearing 6-11
6 4 1 Disassemble the U-joint 6-1 1
6 4 2 Assemble the U-joint 6-1 3
6 5 Conditioner rolls – single conditioner 6-19
6 5 1 Conditioner roll components – single conditioner 6-1 9
6 5 2 Remove the conditioner roll – single conditioner 6-2 0
6 5 3 Examine the conditioner roll – single conditioner 6-2 3
6 5 4 Install the conditioner roll – single conditioner 6-2 4
6 6 Conditioner rolls – double conditioner 6-27
6 6 1 Conditioner roll components – double conditioner 6-2 7
6 6 2 Remove the rear conditioner roll – double conditioner 6-2 7
6 6 3 Remove the front conditioner roll – double conditioner 6-3 1
6 6 4 Examine the conditioner rolls – double conditioner 6-3 3
6 6 5 Install the front conditioner roll – double conditioner 6-3 4
6 6 6 Install the rear conditioner roll – double conditioner 6-3 6
7 Diagrams 7-1
7 1 How to read wiring schematics 7-3
7 1 1 Diagram numbers 7-3
7 1 2 Location grids 7-3
7 2 Diagram symbols and abbreviations 7-5
7 2 1 Harness and connector identification 7-5
7 2 2 Splices 7-5
7 2 3 Optional components 7-6
7 3 Electrical diagrams 7-7
Auger Header
79037260A
7 3 1 Harness abbreviations 7-7
Table of contents
7 3 2 Wire colors 7-7
7 3 3 Main electrical diagram 7-9
7 4 Circuit table 7-11
7 5 Connector tables 7-13
7 6 Hydraulics 7-16
7 6 1 Hy draulic schematic 7-1 7
8 Index lndex-1
Auger Header

CHALLENGER EU HAY EQUIPMENT 9226 9246 AUGER HEADER WORKSHOP SERVICE MANUAL 79037260A – PDF DOWNLOAD:

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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