Challenger Terra Gator 3244 Chassis. Manual - part 102

627333-A  

5-i

Contents

Challenger

®

Terra Gator 3244

Chassis

SERVICE MANUAL

627333-A

05 - Cabin

Contents

 CAB

Cab ............................................................................................................................................................ 5-1

Cab Filtration  ............................................................................................................................................. 5-2

General Information ............................................................................................................................. 5-2

Filter Maintenance ............................................................................................................................... 5-2

CAB SEAT

Deluxe Seat  ............................................................................................................................................... 5-5

Removal .............................................................................................................................................. 5-5

Installation ........................................................................................................................................... 5-7

Diagnostics ................................................................................................................................................ 5-9

Troubleshooting ....................................................................................................................................... 5-10

HVAC

General Information  ................................................................................................................................. 5-11

Theory of operation .................................................................................................................................. 5-11

Basics of Refrigeration ............................................................................................................................. 5-11

Air Conditioning Process  ......................................................................................................................... 5-12

HVAC System .......................................................................................................................................... 5-13

Electronic HVAC Controls  ................................................................................................................. 5-13

Pressurizing Cab  ............................................................................................................................... 5-13

Removing Moisture from Cab Airflow ................................................................................................ 5-13

Circulation of Cab Airflow  .................................................................................................................. 5-13

Heating Cab Airflow ........................................................................................................................... 5-13

Cooling Cab Airflow ........................................................................................................................... 5-13

Automatic Temperature Control ............................................................................................................... 5-14

Description ........................................................................................................................................ 5-14

Troubleshooting ................................................................................................................................. 5-15

Air Conditioning System  .................................................................................................................... 5-16

A/C and Heating System Schematic  ................................................................................................. 5-18

Compressor Clutch ............................................................................................................................ 5-18

Suction (Suction Side) ....................................................................................................................... 5-18

Pumping ............................................................................................................................................ 5-18

Compression (Discharge Side)  ......................................................................................................... 5-19

Operation of Compressor  .................................................................................................................. 5-19

Refrigerant Relief Valve ........................................................................................................................... 5-19

Temperature Sensors  .............................................................................................................................. 5-19

Temperature in Cab  .......................................................................................................................... 5-20

Outside Temperature  ........................................................................................................................ 5-20

Temperature of Ventilation Duct ........................................................................................................ 5-20

Probe for Evaporator Coil .................................................................................................................. 5-20

Evaporator Coil  ........................................................................................................................................ 5-21

Heater Core (Cab)  ................................................................................................................................... 5-21

Actuator Motor (Water Valve)  .................................................................................................................. 5-22

AirFlow ..................................................................................................................................................... 5-23

Components for Airflow  ..................................................................................................................... 5-23

Blower Fan  ........................................................................................................................................ 5-23

627333-A  

5-1

Cab

 CAB

CAB

Cab has a Roll Over Protection Structure (ROPS).

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CAUTION: Roll Over Protection Structure

(ROPS) is manufactured to meet strict

safety standards. No attempt should be

made to alter ROPS in any manner (i.e.

welding, drilling, etc.)

Cab has been designed for operator safety, comfort and

convenience.

Cab is control center of Terra Gator. Operator can easily

monitor and adjust Terra Gator functions using

conveniently located controls.

NOTE: Put identification marks on all hoses, on all hose

assemblies, on all wires on all hose assemblies,

on all wires, and on all tube assemblies for

installation purposes. Plug all hose assemblies

and all tube assemblies. This helps to prevent

fluid loss, and helps keep contaminants from

entering the system.

IMPORTANT: Care must be taken to ensure that fluids

are contained during performance of inspection,

maintenance, testing, adjusting and repair of

the machine. Be prepared to collect the fluid

with suitable containers before opening any

compartment or disassembling any component

containing fluids.

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WARNING: Hot engine components can

cause injury from burns. Before

performing maintenance on the engine,

allow the engine and the components to

cool.

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WARNING: Personal injury can result

from contact with refrigerant.

Contact with refrigerant can cause frost

bite. Keep face and hands away to help

prevent injury.

Protective goggles must always be worn

when refrigerant lines are opened, even if

the gauges indicate the system in empty

of refrigerant.

Always use precaution when a fitting is

removed. Slowly loosen the fitting. If the

system is still under pressure, release it

slowly in a well ventilated area.

Personal injury or death can result from

inhaling refrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas

through a lit cigarette or other smoking

method or inhaling fumes released from a

flame contacting air conditioner

refrigerant gas, can cause bodily harm or

death.

Do not smoke when servicing air

conditioners or wherever refr0igerant gas

may be present.

Use a certified recovery and recycling cart

to properly remove the refrigerant from the

air conditioning system.

Cab

5-2

627333-A  

CAB FILTRATION

General Information

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CAUTION: Chemical residue may be

present in dirt on filter elements. Wear

protective gear while servicing filter

elements.

Cab is pressurized. Primary and recirculation filter

purify cab’s internal air.

NOTE: Key must be in OFF position before servicing

cab filters.

FIG. 1: Location of cab air filters.

1. Primary fresh air filter;

2. Secondary fresh air filter;

3. Recirculation filter.

Filter Maintenance

Inspect cab air filter every 250 hours of operation, clean

or replace if necessary. Replace cab air filter every

1000 hours or once a year, whichever comes first.

IMPORTANT: Periodic sweeping and/or vacuuming of

cab interior is recommended. Headliners and

cowlings should be wiped clean or vacuumed

periodically. The unit’s exterior should be

washed down to reduce potential contact with

hazardous material. Disposal of wash water,

cloths and vacuumed material should be

handled according to published regulations

and pesticide label instructions.

IMPORTANT: Become familiar with Chemical Safety

before machine operation.

Cleaning Cab Air Filter Element

1. Hold filter and tap on flat surface with dirty side

down. Dust will fall off. Tapping too hard can cause

damage.

2. Compressed air can also be used, below air

through element in opposite direction of normal

airflow.

FIG. 2:

IMPORTANT: Keep nozzle a minimum of 25.4 mm (1

inch) from surface. Excessive air pressure

causes damage.

NOTE: Cab air filter is partially cleaned each time cab

door is closed when back pressure flushes

primary air filter.

FIG. 1

q000298s

3

1

2

FIG. 2

Q000162S

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5-3

Cab

Primary Fresh Air Filter

Primary fresh air filter is located in roof overhang in

front of the cab.

Filter removes dust particles drawn into air system and

is partially cleaned each time cab door is closed, when

back pressure flushes primary air filter. Before

removing filter, close all windows and door. Back

pressure from cab helps dislodge loose dirt on

underside of filter.

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WARNING: Inadequate sealing may

cause filter malfunction and personal

injury could result. Isoamyl Acetate,

which has a banana-like odor, may be

used to check seal. Periodically inspect

door gasket for damage.

IMPORTANT: Once filter is removed from its protective

packaging, immediate installation must follow.

Exposure to the environment reduces validity

of filter.

NOTE: Store replacement filters, in original packaging,

in a clean dry area away from exposure to any

chemicals. If stored in cab, floor should be free

of any foreign material.

Remove Secondary (Vapor Particulate) Fresh Air Filter,

clean or replace.

NOTE: Vapor absorption or carbon section of filters,

cannot be cleaned. Replace filter if odor, taste

or other indication of contamination is

detected.

Recirculation Filter

Recirculation filter purifies air for HVAC pressurization

fan and draws air from inside cab. Filter must be in

place or pressurization fan motor will fail prematurely.

Recirculation filter in the only filter for pressurization

fan.

NOTE: Optional charcoal filters are available from your

local dealer.

NOTE: Any chemical contaminants allowed into cab

while door is open will be filtered.

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WARNING: Charcoal filter is used to

lower levels of contamination in cab

during spraying operations. It does not

replace or eliminate need for personal

protective devices. Follow all

recommendations of chemical

manufacturer regarding personal

protection, handling and disposal of

chemicals.