Ag-Chem 8104, 8144 TerraGator Chassis Service Repair Manual (2003)

Manuals: Service Repair Manual
Year: 2003
1-Gen
GENERAL SAFETY & TORQUE SPECIFICATIONS
GENERAL
Safety Alert Symbol and Signal Words
FOLLOW SAFETY INSTRUCTIONS
Towing Other Vehicles / Trailers / Equipment
Modifications
Operating the System Safely
System Boom Safety
Overhead Electrical Power Lines
Protect Yourself
Handle Fuel Safely – Avoid Fires
Moving Parts
Maintenance and Service Safety
Hydraulic Safety
Work in a Clean Area
Understand Correct Service
Remove Paint before Welding or Heating
Batteries
Tires and Wheels
Use Proper Tools
Lift and Support Machine Properly
Avoid Eye Contact with Radar
Exhaust Fumes
Chemical Safety
Dispose of Waste Properly
TORQUE SPECIFICATIONS
General
Unified Inch Bolt and Cap screw Values
Metric Bolt and Cap screw Values
4 – Bolt Split Flange
Split Flange
Flare and Flareless Port Ends
Face Seal Port Ends
Metric Port Ends
Adapters and Tube Fittings
2-Eng.pdf
ENGINE
DESCRIPTION
REMOVAL
INSTALLATION
FUEL SYSTEM
Description
Right Fuel Tank
Left Fuel Tank
Fuel Crossover Tube
Fuel cooler
Radiator
Air to air charge air cooler
ENGINE ELECTRICAL
Engine ECU
Fuel injector control
Cruise control
Coolant temperature switch
Coolant temperature sensor
Oil pressure switch
Oil pressure sender
Charge air temperature switch
TROUBLESHOOTING
Engine fuel system bleed procedure
Checking fuel pressure
Checking turbocharger boost pressure
Retrieving the diagnostic fault codes
Engine Error Codes and Descriptions
Repair
3-Trans.pdf
TRANSMISSION
DESCRIPTION
Removal
Installation
Torsion Damper Installation
TRANSMISSION CALIBRATION
TRANSMISSION ELECTRICAL
TVP Circuit
Gear Selector Circuit
Clutch Position Circuit
Select Shift Circuit
Four Wheel Drive Circuit (8144 only)
Transmission Filter Bypass Switch
Transmission Oil Temperature Sender
Transmission TCU to Coil and Sensor Electrical Schematic
TROUBLESHOOTING
Troubleshooting 4 Wheel Drive (8144 only)
Transmission Gear Ranges and Coil/Clutch Combinations
Repair
4-RearAx.pdf
REAR AXLE, SUSPENSION & DRIVELINE
DESCRIPTION
SUSPENSION
Removal
Installation
AXLE
Removal (with spring suspension)
Installation (with spring suspension)
Removal (with optional rigid suspension)
Installation (with optional rigid suspension)
DRIVELINE
Removal
Installation
Replacing a U-joint
Replacing the hanger bearing
AXLE REPAIR
Outboard planetary
Center differential assembly
Brakes
5-FrontAx.pdf
FRONT AXLE & SUSPENSION
DESCRIPTION
SUSPENSION
Removal
Installation
AXLE
Removal
Installation
BRAKE SYSTEM
Air Chamber
Slack Adjuster
Brake Drum
Brake Shoe
Steering Cylinder Repair: (See hydraulic section)
Axle Castor: Not adjustable
Axle Camber: Not adjustable
EATON FRONT AXLE REPAIR AND ADJUSTMENTS – 8104 ONLY
King pin bushings and thrust bearings
Wheel Bearings
Tie Rod Ends
Toe-in Adjustment
Steering Stops
Steering Cylinder and Tie Rod Arms
FABCO FRONT DRIVE AXLE REPAIR AND ADJUSTMENTS 8144 ONLY
6-Hyd.pdf
HYDRAULIC SYSTEM
DESCRIPTION
STEERING CONTROL UNIT
Removal
Installation
Troubleshooting
HYDRAULIC TANK
Removal
Installation
HYDRAULIC PUMP
Removal
Installation
Troubleshooting
HYDRAULIC COOLER
Removal
Installation
HYDRAULIC STEERING CYLINDER
Removal
Repair
Installation
HYDRAULIC PRESSURE WASHER
Hydraulic Motor
Pressure Washer Pump
Hydraulic Pressure Washer Control Block
7-AirSys.pdf
CHASSIS AIR SYSTEM
DESCRIPTION
AIR COMPRESSOR
AIR DRYER
Removal
Description of Components
Installation
Troubleshooting
Component Replacement
AIR Governor
Removal
AIR STORAGE TANKS
Removal
Installation
RELAY VALVES
Removal
Installation
Pressure limiting and quick release valve
Service brake pedal
Park brake modulating valve
Brake actuators
AIR SYSTEM ELECTRICAL COMPONENTS
Air Sender
Brake light switch circuit
Park brake switches
Air Dryer Heater Power
AUXILIARY AIR ACCESSORIES
Air Horn
FOAM MARKER SYSTEM
Description
Foam Marker Pressure Regulator
Gauge
Foam Marker Enable Solenoid
Foam Marker Tank, Air Nozzle and Valves
Foam Marker Electrical System
Troubleshooting
8-Cab.pdf
CAB
DESCRIPTION
Removal
Installation
CAB FILTRATION
Primary Fresh Air Filter
Secondary Fresh Air Filter
Recirculation air filter
AIR RIDE SEAT
Removal
Installation
HEATING, VENTILATION, AIR CONDITIONING (HVAC)
Description
Air Conditioning Compressor
Air Conditioning Condenser
Receiver Dryer
Air Conditioning Evaporator/ Expansion Valve
Heater Core
HVAC ELECTRICAL TROUBLESHOOTING AND REPAIR
Checking Power on the Mode Switch (A/C or Heater)
Checking the 75 amp HVAC relay
Checking the Electronic Water Valve
Checking the Fan Speed Switch
Checking for Power at the Blower Motor with the Fans Speed Switch in Low
Checking for Power at the Blower Motor with the Fans Speed Switch in Medium
Checking for Power at the Blower Motor with the Fans Speed Switch in High
Checking for Ground at the Blower Motor
Checking Power to the Air Conditioning Compressor
Checking Power on Pin 56 of the 70 Pin Connector
Checking for Power to the Pressure Blower
9-Elect.pdf
ELECTRICAL SYSTEM
DESCRIPTION
Ignition Circuit
The Start Signal
The Run Circuit
The Neutral-Start Circuit
Fuse Block 1 (FB1) Circuit
Fuse Block 2 (FB2) Circuit
Fuse Block 3 (FB3) Circuit
Hazard Light Circuit (Upper Cab & System)
Turn Signal Circuit (Chassis & System)
Brake Light Circuit
Parking and Taillight Circuit
High and Low Headlight Circuit
Work Light Switches 1 & 2
Auxiliary Work Light Switches 3 & 4
Reverse Lights and Alarm Circuit
Dome Light and Door Switch Circuit
Electronic Instrument Panel (EIP) Power and Ground
Windshield Wiper Circuit
Air Horn Circuit
Auxiliary 3 Pin Power Plug-in Circuit
Cigarette Lighter Power Plug in Circuit
Fuel Level Sender Circuit
AM/FM Stereo Radio and Auxiliary Radio Plug in Circuit
GPS 1 and GPS 2 Plug in Circuit
Radar Speed Sensor & Radar Amplifier
10-Sheet.pdf
SHEETMETAL
Rear Hood
Front Hood Assembly
Front Grille
Battery Box
Utility Boxes
Front Fenders