Challenger Terra Gator 3244 Chassis Service Manual – PDF

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Challenger Terra Gator 3244 Chassis Service Manual – PDF DOWNLOAD

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Challenger Terra Gator 3244 Chassis Service Manual – PDF DOWNLOAD

627333-A

Language : English
Pages : 560
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Challenger Terra Gator 3244 Chassis Service Manual – PDF DOWNLOAD

627333-A

627333-A...................................................................................  1
	SERVICE MANUAL 627333-A................................................................  3
01 Introduction............................................................................  7
	Safety.................................................................................  9
		Follow Safety Instructions.........................................................  9
		Prepare for Emergencies............................................................  9
		Safety Alert Symbol................................................................ 10
		Signal Words....................................................................... 10
		Informational Messages............................................................. 10
		Important Safety Information....................................................... 11
		General Hazard Information......................................................... 11
			Pressurized Air................................................................ 12
			Asbestos Information........................................................... 12
			Electrical Storm Injury Prevention............................................. 12
			Mounting and Dismounting....................................................... 12
			Before Starting Engine......................................................... 13
			Engine Starting................................................................ 13
			Before Operation............................................................... 13
			Operation...................................................................... 13
			Parking........................................................................ 14
			Operator Station............................................................... 14
			Crushing and Cutting Prevention................................................ 14
			Hydraulic Safety............................................................... 14
			Chemical Safety................................................................ 15
		Emergency Exit From Cab............................................................ 16
		Operating The Vehicle Safely....................................................... 16
		Prevent Vehicle Runaway............................................................ 17
		Use Safety Lights and Devices...................................................... 17
		Operating On Slopes................................................................ 17
		Traveling On Public Roads.......................................................... 18
		Stopping And Parking The Vehicle................................................... 18
		System Boom Safety................................................................. 19
		Avoid Eye Contact With Radar....................................................... 19
		Exhaust Fumes...................................................................... 19
		Overhead Electrical Power Lines.................................................... 20
		Noise.............................................................................. 20
		Handle Fuel Safely - Avoid Fires................................................... 20
		Stay Clear Of Rotating Drive Lines And Moving Parts................................ 21
		Towing Other Vehicles / Trailers / Equipment....................................... 21
		Modifications...................................................................... 21
		Maintenance And Service Safety..................................................... 22
		Practice Safe Maintenance.......................................................... 22
		Chemical Safety.................................................................... 23
			Operator Cabs.................................................................. 23
		Wear Protective Clothing........................................................... 24
		Work In A Clean Area............................................................... 24
		Understand Correct Service......................................................... 25
		Use Proper Tools................................................................... 26
		Support Machine Properly........................................................... 26
		Proper Lifting Equipment........................................................... 26
		High-Pressure Fluids............................................................... 27
		Hydraulic Hoses.................................................................... 27
		Avoid Heating Near Pressurized Fluid Lines......................................... 27
		Service Cooling System Safely...................................................... 28
		Remove Paint Before Welding Or Heating............................................. 28
		Batteries.......................................................................... 28
		Tires And Wheels................................................................... 29
		Dispose Of Waste Properly.......................................................... 29
		Mobile Radio Installations......................................................... 29
		Maintenance In The Articulation Joint (Hinge) Area................................. 30
		Safety Tread and Grip Material..................................................... 30
		Safety And Service Decal Locations Chassis......................................... 31
		Safety And Service Decal Locations Cabine.......................................... 41
	General................................................................................ 45
		Service Manual..................................................................... 45
			Divisions And Page Numbers..................................................... 45
			Units Of Measurement........................................................... 45
		Replacement Parts.................................................................. 45
		Serial Number Identification Plate................................................. 46
			Serial Number Plate Machine.................................................... 46
			Engine Serial Number And Informatie Plate...................................... 47
			Transmission Serial Number..................................................... 47
			Cab Serial Number.............................................................. 48
			Operator’s Seat Serial Number.................................................. 48
			Axles.......................................................................... 48
		Maintenance Introduction........................................................... 49
		Maintenance Schedule............................................................... 49
			Tighten Wheel Bolts............................................................ 53
			Retorque Axle Bolts............................................................ 53
			Retorque Articulation Pin Bolts and Steering Cylinder Bolts.................... 53
				Articulation Pin Bolts..................................................... 54
				Steering Cylinder Bolts.................................................... 54
		Lubricants and Fluids.............................................................. 54
	Dimensions............................................................................. 55
		Vehicle Dimensions................................................................. 55
		Turning Radius..................................................................... 57
	Torque Specifications.................................................................. 59
		Torque Specifications.............................................................. 59
		Constant Torque Hose Clamps........................................................ 59
		Fastener Information............................................................... 60
			Metric Fasteners............................................................... 60
				Assembly Torque for Metric Fasteners....................................... 60
			SAE Fasteners.................................................................. 61
				Assembly Torque for SAE Fasteners.......................................... 61
				Unified Inch Bolt and Cap Screw Values..................................... 62
				Metric Bolt and Cap Screw Values........................................... 63
				4-Bolt Split Flange........................................................ 64
		Tightening Straight Thread Fittings................................................ 65
		Conversion Information............................................................. 66
	Jack Up The Machine.................................................................... 69
		Front Chassis...................................................................... 69
		Rear Chassis....................................................................... 71
			Dog Walk Chassis............................................................... 72
			Straight Chassis............................................................... 74
	Tooling list........................................................................... 77
		Tooling List....................................................................... 77
			Hoses.......................................................................... 77
			Pressure Gauge................................................................. 77
			Fitting........................................................................ 78
			Quick Connect Couplers......................................................... 79
	Index.................................................................................. 81
02 Engine.................................................................................. 83
	Introduction........................................................................... 85
		Introduction....................................................................... 85
		Specifications and Standards Concerning Fuel, Oil and Coolant...................... 85
			Fuel Quality................................................................... 85
			Oil Quality.................................................................... 85
			Coolant Quality................................................................ 85
		CAT C11 Diesel..................................................................... 85
			Specification.................................................................. 85
			Engine Oil Type................................................................ 85
		Lifting And Storage................................................................ 86
			Lifting........................................................................ 86
			Storage........................................................................ 86
		Engine Service Manual.............................................................. 86
	Engine Components...................................................................... 87
		Engine Component Locations......................................................... 87
			Left Side...................................................................... 87
			Right Side..................................................................... 88
		Sensor............................................................................. 89
			Sensor Overview................................................................ 89
			Replacement Senors............................................................. 90
			Sensor Location................................................................ 91
		Cooling............................................................................ 94
	Engine Maintenance..................................................................... 95
		Engine Valve Lash Inspect / Adjust................................................. 95
			Valve Lash Check............................................................... 96
			Valve Lash Adjustment.......................................................... 96
		Engine Removal and Installation.................................................... 98
	Index.................................................................................. 99
03 Powertrain..............................................................................101
	Transmission Service Manual............................................................103
		Transmission Service Information...................................................103
			Oil Type.......................................................................103
			Check Oil level................................................................103
	Transmission and Solenoids.............................................................105
		Theory Of Operation................................................................105
		Transmission Components............................................................106
		Transmission Oil Change Procedure..................................................107
		Transmission Calibration...........................................................109
			Calibration....................................................................109
			Calibration Process............................................................109
		System Operation Section...........................................................110
			Hydraulic System...............................................................110
			Transmission System............................................................111
			Electrical System..............................................................112
			Transmission Electrical Control System.........................................113
		Modulating Valve...................................................................114
			Install/Remove Solenoids.......................................................116
			Valve Port.....................................................................116
			Valve Operation................................................................116
				No Signal Current (Clutch Disengaged)......................................118
				Oil Flow in a De-energized Valve...........................................118
				Partial Signal Current (Modulation)........................................119
				Oil Flow in Valve with less than Maximum Signal Current....................119
				Maximum Signal Current (Clutch Fully Engaged)..............................121
		Transmission Clutch Engagement.....................................................122
	Testing and Adjusting..................................................................125
		Relief Valve.......................................................................125
			Introduction...................................................................125
			Required Tools.................................................................125
			Testing Procedure..............................................................126
			Adjusting Procedure............................................................126
		Pressure for Transmission Lubrication..............................................127
			Introduction...................................................................127
			Required Tools.................................................................127
			Test Procedure.................................................................128
		Modulating Valve...................................................................129
			Introduction...................................................................129
			Required Tools.................................................................129
			Test Procedure.................................................................130
		Hydraulic Oil Cooler...............................................................133
			Introduction...................................................................133
			Required Tools.................................................................133
			Test Procedure.................................................................134
	Transmission Troubleshooting...........................................................135
		General Troubleshooting Information................................................135
		Troubleshooting....................................................................136
			Visual Inspection..............................................................136
			Operational Checks.............................................................137
		Error Codes........................................................................138
			Error Codes 100 - 699..........................................................138
			Error Codes 699 - 999..........................................................139
			Error Codes 1000 - 2999........................................................142
	Disassembly and Assembly...............................................................145
		GEneral............................................................................145
		Cab Tipping Over...................................................................145
			Tipping Over...................................................................146
			Lower the Cab..................................................................147
		KENR6054...........................................................................148
	Drive line.............................................................................149
		Drive line Rear....................................................................149
			Straight Chassis...............................................................149
			Dog Walk Chassis...............................................................150
			Drive Shaft Hanger Bearings....................................................150
		Drive Line Front...................................................................151
		Hanger Bearing.....................................................................152
			Maintenance Hager Bearing......................................................152
				Lubrication Bearing........................................................152
				Check Roller Bearings......................................................152
				Check Cross Bearing........................................................152
			Introduction ConCentra Roller Bearing..........................................153
			Mouting Instructions...........................................................154
			Adjustment Dog Walk Tunnel.....................................................158
	Index..................................................................................167
TA19 KENR6054-00...........................................................................169
TA19 KENR6678 (Modification)...............................................................223
	img-7220704-0001.......................................................................  0
	img-7220704-0002.......................................................................232
	img-7220704-0003.......................................................................242
	img-7220704-0004.......................................................................252
	img-7220704-0005.......................................................................262
	img-7220704-0006.......................................................................272
	img-7220704-0007.......................................................................282
	img-7220704-0008.......................................................................292
	img-7220704-0009.......................................................................302
	img-7220704-0010.......................................................................312
	img-7220704-0011.......................................................................322
	img-7220704-0012.......................................................................332
	img-7220704-0013.......................................................................342
	img-7220704-0014.......................................................................352
	img-7220704-0015.......................................................................  0
04 Chassis.................................................................................361
	Brakes.................................................................................363
		Introdution........................................................................363
			Non-Asbestos Fibers Warning....................................................363
				Hazard Summary.............................................................363
				Recommended Work Practices.................................................364
				Regulatory Guidance........................................................364
			Brake Operation................................................................365
		Clean, Dry and Inspect.............................................................366
			Clean Parts....................................................................366
			Dry and Inspect Parts..........................................................366
			Apply Corrosion Protection.....................................................366
		Service Brake......................................................................367
			Release pressure...............................................................367
			Bleed Brake....................................................................367
		Brake Adjustment...................................................................368
		Parking Brake Emergency Release....................................................369
	Axle...................................................................................371
		Front Axle.........................................................................371
			Description....................................................................371
			Removal........................................................................371
			Installation...................................................................371
		Rear axle..........................................................................372
			Description....................................................................372
			Removal........................................................................372
			Installation...................................................................372
		Rear axle (Dog Walk Chassis).......................................................373
			Description....................................................................373
			Removal........................................................................373
			Installation...................................................................373
		Axle PRC2715.......................................................................374
	Chassis................................................................................375
		Introduction.......................................................................375
			Straight Chassis...............................................................375
			Dog Walk Chassis...............................................................375
			Articulation Joint.............................................................375
		Articulation Joint.................................................................376
			Disassembly Articulation Joint.................................................376
			Assembly Articulation Joint....................................................378
	Troubleshooting........................................................................379
		Troubleschooting...................................................................379
			1. Over Temp/Current...........................................................379
			2. Open Load...................................................................379
			3. Short to GND................................................................379
			4. Short to Bat/OT.............................................................379
			5. No error listed.............................................................379
		Error Codes Chassis CAN............................................................380
			600 - 650......................................................................380
			651 - 699......................................................................381
			801 - 850......................................................................382
			851 - 900......................................................................383
	Index..................................................................................385
MM9L(Modification).........................................................................387
05 Cab.....................................................................................435
	Cab....................................................................................437
		Cab................................................................................437
		Cab Filtration.....................................................................438
			General Information............................................................438
			Filter Maintenance.............................................................438
				Cleaning Cab Air Filter Element............................................438
				Primary Fresh Air Filter...................................................439
				Recirculation Filter.......................................................439
	Cab Seat...............................................................................441
		Deluxe Seat........................................................................441
			Removal........................................................................441
			Installation...................................................................443
		Diagnostics........................................................................445
		Troubleshooting....................................................................446
	HVAC...................................................................................447
		General Information................................................................447
		Theory of operation................................................................447
		Basics of Refrigeration............................................................447
		Air Conditioning Process...........................................................448
		HVAC System........................................................................449
			Electronic HVAC Controls.......................................................449
			Pressurizing Cab...............................................................449
			Removing Moisture from Cab Airflow.............................................449
			Circulation of Cab Airflow.....................................................449
			Heating Cab Airflow............................................................449
			Cooling Cab Airflow............................................................449
		Automatic Temperature Control......................................................450
			Description....................................................................450
			Troubleshooting................................................................451
				Fault Codes................................................................451
				No Display.................................................................451
				No Fan.....................................................................451
				No Heat....................................................................451
				No Cooling.................................................................451
				The system is not controlling the cab temperature properly.................451
				The evaporator core is icing up and restricting airflow....................451
				System is putting out cool air when heat is needed.........................451
				System is putting out hot air when cooling is needed.......................451
			Air Conditioning System........................................................452
				Refrigerant Compressor.....................................................452
				Refrigerant Condenser......................................................452
				Receiver/Drier.............................................................453
			A/C and Heating System Schematic...............................................454
			Compressor Clutch..............................................................454
				Clutch Operation...........................................................454
				Control for Clutch.........................................................454
			Suction (Suction Side).........................................................454
			Pumping........................................................................454
			Compression (Discharge Side)...................................................455
			Operation of Compressor........................................................455
		Refrigerant Relief Valve...........................................................455
		Temperature Sensors................................................................455
			Temperature in Cab.............................................................456
			Outside Temperature............................................................456
			Temperature of Ventilation Duct................................................456
			Probe for Evaporator Coil......................................................456
		Evaporator Coil....................................................................457
		Heater Core (Cab)..................................................................457
		Actuator Motor (Water Valve).......................................................458
		AirFlow............................................................................459
			Components for Airflow.........................................................459
			Blower Fan.....................................................................459
			Intake For Airflow.............................................................459
			Fresh Air......................................................................460
				Fresh Air Filter...........................................................460
				Maintenance for Cab Air Filter.............................................460
			Recirculation..................................................................460
				Recirculated Air Filter....................................................460
				Charcoal Air Filter........................................................461
			Head, Foot and Defrost.........................................................461
		Motor (Air Conditioning Blower)....................................................461
			Overpressure blower............................................................461
			Automatic Temperature Control (Fan)............................................462
				Auto Mode..................................................................462
				Manual Mode................................................................462
			Manual Fan Control.............................................................462
		Speed Control......................................................................462
			Automatic Fan Speed Control....................................................462
			Manual Mode Fan Speed Control..................................................462
		Actuator Motor (Damper)............................................................463
		Glossary of Terms..................................................................464
	HVAC Specification.....................................................................469
		Refrigerant Compressor.............................................................469
			Compressor.....................................................................469
			Clutch.........................................................................469
			Relief Valve...................................................................469
			Belt...........................................................................470
	HVAC Testing and Adjusting.............................................................471
		Troubleshooting Machine Preparation................................................471
		General Troubleshooting Information................................................472
		Visual Inspection..................................................................472
		Troubleshooting Faults With Service Codes (Active).................................473
			Service Codes..................................................................473
			Entering Active Troubleshooting................................................473
			Troubleshooting Using Active Diagnostics.......................................474
			Checking Temperature Sensors...................................................474
			Checking Compressor Clutch.....................................................474
			Checking Refrigerant Pressure Switches.........................................475
			Checking Actuator for Water Valve..............................................476
			Checking Blower Fan............................................................476
			Checking Mode Door Actuator....................................................476
		Troubleshooting Air Conditioner Control............................................477
			Problem List...................................................................477
			Probable Causes................................................................477
				No Display.................................................................477
				Probable Solution..........................................................477
				No Blower Fan..............................................................477
				Probable solution..........................................................477
				No Heat....................................................................477
				Probable Solution..........................................................477
				No Cooling.................................................................477
				Probable Solution..........................................................477
				System is putting out cool air when heat needed............................477
				Probable Solutions.........................................................477
				System is putting out hot air when cooling needed..........................477
				Probable Solution..........................................................477
				No Fan or Erratic Fan......................................................477
				Probable Solutions.........................................................477
				Nothing Works..............................................................478
				Probable Solution..........................................................478
				Electric Actuator for Mode of Airflow is not Moving or Working Properly....478
				Probable Solutions.........................................................478
		Refrigerant Compressor Oil - Check.................................................479
			General........................................................................479
			Complete Check of Compressor Oil...............................................479
		Refrigerant System - Charge........................................................480
			Relationship Between Temperature and Pressure (R-134a Refrigerant).............480
			Labeling Procedure.............................................................483
			Charging System................................................................483
		Complete Charge of System from a Refrigerant Tank with a Scale.....................484
		Adding Additional Refrigerant to an Air Conditioning System with Low Charge........486
		Manifold Gauge Set (Refrigerant) - Remove..........................................486
		Control Panel - Test...............................................................487
			Test Automatic Control Panel...................................................487
				Test Result................................................................487
				Speed Control for Blower Fan...............................................487
				Test Result................................................................487
				Push Button for Temperature................................................487
				Test Result................................................................487
				Push Button for Temperature................................................487
				Test Result................................................................487
				Push Button for Temperature................................................487
				Test Result................................................................487
				Control for Mode of Airflow................................................487
				Test Result................................................................487
				Control for Mode of Airflow (Defrost)......................................487
				Test Result................................................................487
	Index..................................................................................489
06 Electrical..............................................................................491
	General Information....................................................................493
		Introduction.......................................................................493
		Basic Troubleshooting Procedures...................................................493
		Tools..............................................................................494
		General Testing Procedures.........................................................495
			Visual Inspection..............................................................495
			Continuity Check...............................................................495
			Voltage Check..................................................................495
			Testing for Open Circuits......................................................495
			Finding a Break in an Open Circuit.............................................495
			Testing for Short Circuits.....................................................496
			Testing for High Resistance....................................................496
			Finding a High Resistance Circuit..............................................496
			Fuse Testing...................................................................496
			Relay Testing..................................................................496
			Diode Testing..................................................................496
		Wire Colors........................................................................497
	Electrical Sysem.......................................................................499
		Description........................................................................499
		Requirements.......................................................................499
		Definition.........................................................................499
		Component Location.................................................................500
		Primary CAN Bus Components.........................................................501
		PDM................................................................................508
			PDM1...........................................................................509
			PDM2...........................................................................509
			PDM3...........................................................................510
			2-Pack Relay Modules...........................................................510
				J1 Connector...............................................................510
				J2 Connector...............................................................510
				Relay Module 2P1...........................................................510
				Relay Module 2P2...........................................................510
			4-Pack Relay Module............................................................511
				Relay Module 4P1...........................................................511
				Relay Module 4P2...........................................................511
			Flasher Module.................................................................511
			Power Supply Block.............................................................513
	Index..................................................................................515
07 Hydraulic...............................................................................517
	Introduction...........................................................................519
		High-Pressure Fluids...............................................................519
		Hydraulic Hoses....................................................................519
		Avoid Heating Near Pressurized Fluid Lines.........................................520
		Theory of Operation................................................................520
		Tooling List.......................................................................520
		Component Location and Function....................................................521
		Pressure Measurement...............................................................525
			Steering System................................................................525
			Braking System.................................................................526
				Brake Pedal................................................................526
				Brake Accumulators.........................................................526
			Adjusting Procedure Brake System...............................................526
	Schematic..............................................................................529
		Hydraulic schematic................................................................529
		Priority Valve.....................................................................531
		Emergency Steering (option)........................................................532
	Index..................................................................................533
08 Air System..............................................................................535
	Air Compressor.........................................................................537
		Air Compressor Removal.............................................................537
		Air Compressor Installation........................................................539
	Air Tank and Pressure Control Check Valve..............................................541
		Theory of Operation................................................................541
		Air Tanks..........................................................................542
			Air Tank Removal...............................................................542
			Air Tank Installation..........................................................543
	Air Dryer..............................................................................545
		Description........................................................................545
		Air Dryer Removal..................................................................545
		Air Dryer Installation.............................................................546
		Air Dryer Components...............................................................547
			Heater.........................................................................547
			Turbo Cut-off Valve............................................................547
			Desiccant Cartridge............................................................548
			Outlet Check Valve.............................................................548
			Regeneration Valve.............................................................548
			Purge Valve....................................................................549
	Air Governor...........................................................................551
		Theory of Operation................................................................551
		Air Governor Removal...............................................................551
		Air Governor Installation..........................................................552
	Cab Air Suspension.....................................................................553
		Theory of Operation................................................................553
		Cab Air Suspension Removal.........................................................554
		Cab Air Suspension Installation....................................................555
	Pneumatic Schematic....................................................................557
		Pneumatic Schematic................................................................557
	Index..................................................................................559

DESCRIPTION:

Challenger Terra Gator 3244 Chassis Service Manual – PDF DOWNLOAD

627333-A

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. Replacement safety signs are available from local AGCO dealer. Never operate machine or equipment without proper instruction and a complete understanding of control operation.
• Learn how to properly operate machine and use all controls before operation. Do not allow anyone to operate machine, systems or perform service and maintenance procedures without proper instruction. Keep machine, all components and systems in proper working condition.
• Modifications to machine, unauthorized by AGCO, may impair functionality and safety, affect machine life and void machine warranty.

IMPORTANT SAFETY 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. Operator must be alert to potential hazards and have the necessary training, skills and tools to perform functions properly.
• Improper operation, lubrication, maintenance or repair of product can be hazardous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair of machine until reading and understanding associated information.
• Safety precautions and warnings are provided in manual and on machine. If these hazard warnings are not heeded, bodily injury or death could occur to operator or bystanders. Not every circumstance involving a potential hazard can be anticipated.
• Warnings in this publication and on machine are, therefore, not all inclusive. If a tool, procedure, work method or operating technique, not specifically recommended by AGCO is used, ensure it is safe for operator and others. Make sure machine will not be damaged or be made unsafe by operation, lubrication, maintenance or repair procedures chosen.
• Information, specifications and illustrations in publication are on basis of information available at time publication was written. Specifications, torques, pressures, measurements, adjustments, illustrations and other items can change at any time.
• These changes can affect service given to product. Obtain complete and most current information before starting any job. Local AGCO dealer has the most current information available.

G.B 07/04/25