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

Table of Contents:

• 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