Challenger Terra Gator 3244 Chassis. Manual - part 114

 

  Index      Challenger     Challenger Terra Gator 3244 Chassis - service repair manual 2009 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  112  113  114  115   ..

 

 

Challenger Terra Gator 3244 Chassis. Manual - part 114

 

 

627333-A  

5-49

HVAC Testing and Adjusting

1. Find refrigerant capacity for system.

2. Install high and low pressure hoses and purge

hoses, refer to Testing and Adjusting, Manifold

Gauge Set (Refrigerant) - Install.

3. Hand tighten charging hose from manifold gauge

set directly to valve on refrigerant tank. Open valve

on top of refrigerant tank to allow the flow of

refrigerant through charging hose to manifold

gauge set.

4. Loosen hose at manifold gauge set for two to three

seconds and tighten connection, this will purge air

from line.

5. Place refrigerant tank on scale so valve is at

bottom. Check weight of tank.

NOTE:  A heater blanket may be required when

charging an air conditioning system with a

partially full refrigerant tank.

6. Open high pressure valve on manifold gauge set.

This action allows liquid refrigerant to charge

system through the high pressure side of

compressor.

7. Check weight of refrigerant tank often as weight will

decrease as refrigerant enters the system. When

required amount of refrigerant (system capacity)

has entered system, close valve and high pressure

valve. Closing valves stops flow of refrigerant. For

example, 1.8 kg (4 lb) of refrigerant has entered a

system with 1.8 kg (4 lb) capacity.

8. For correct system operation, disconnect charging

hose and conduct a performance check.

5-50

627333-A  

HVAC Testing and Adjusting

ADDING ADDITIONAL REFRIGERANT TO 
AN AIR CONDITIONING SYSTEM WITH 
LOW CHARGE

IMPORTANT: Failure to properly follow procedure may

cause compressor failure. The following

procedure is NOT the preferred method for

charging an air conditioning system, the

preferred method of measuring refrigerant is by

weight.

IMPORTANT: If system has no refrigerant, evacuate

system before charging. Refrigerant charge

should be measured by weight.

NOTE: The following is only applicable if the inlet air

temperature at condenser is between 21 °C

(70.0 °F) and 32 °C (90.0 °F) and may be

repeated a second time to achieve proper

charge method.

1. Connect manifold gauge set to discharge and

service ports on compressor.

2. Ensure low and high pressure valves are closed on

the manifold gauge set.

3. Turn valve on tank counterclockwise to release

refrigerant to charging hose.

NOTE: Ensure cylinder of refrigerant is upright to allow

refrigerant to enter system as a gas.

4. Loosen hose connection on charging hose at

manifold gauge set for two to three seconds, then

tighten connection. This action allows air to be

released from charging hose.

5. Start engine and operate at 1000 rpm.

6. Move temperature control knob to MAXIMUM cool

and move fan switch to HIGH.

NOTE: Recovering refrigerant and evacuating system

is preferred method for charging air conditioning

system. After system has been recovered and

system has been evacuated, system needs to

be charged with the correct amount of

refrigerant measured by weight.

7. Open low pressure valve on manifold gauge set to

release refrigerant into low pressure hose, this

connects to suction service valve on the

compressor. Check pressure gauge and note gauge

reading, should not exceed normal operating ranges

during procedure. Slowly add refrigerant until

accumulator is cool. Temperature of vents inside

cab should decrease during procedure.

8. After accumulator becomes cool, add 0.34 kg

(0.750 lb) of refrigerant to system for reserve,

measure by weight.

9. To prevent additional flow of refrigerant into

compressor, close low pressure valve. Allow system

to stabilize for five minutes, the inlet and outlet on

accumulator should be cool.

NOTE: If low pressure valve is opened completely,

reading will appear excessively high until

system becomes fully charged.

10. Gauge reading for low pressure valve should be

within normal range after system is charged. Gauge

reading for high pressure valve should be within

normal range after charging system. If gauge

readings are within normal range, go to Step 11, if

not go to Step 12.

11. If pressure on suction side or discharge pressure

becomes too high, system is overcharged.

Completely close valve on refrigerant tank to shut off

flow of refrigerant to charging hose. Shut off engine,

recover charge and evacuate system and recharge

system to correct charge.

12. Move air conditioning controls to OFF and stop

engine.

13. Remove manifold gauge set.

MANIFOLD GAUGE SET (REFRIGERANT) 
- REMOVE

Remove charging hoses properly to prevent a low

system charge. For accurate refrigerant charge, remove

refrigerant from charging hoses referring to the following:

1. Allow compressor to continue operating. Close

valve on high pressure side, located near charging

ports. Disconnect high pressure hose from air

conditioning system.

2. Open high and low pressure valves at gauge set.

Refrigerant in hoses will be removed by compressor

through low pressure hose.

3. Close valve on low pressure side, located near the

charging ports. Disconnect low pressure hose from

air conditioning system and system is now charged.

NOTE: After manifold gauge set is removed, cap

charging valves.

627333-A  

5-51

HVAC Testing and Adjusting

CONTROL PANEL - TEST

Test Automatic Control Panel

Test Result

1. LED will briefly flash 8888.

Speed Control for Blower Fan

1. Turn HVAC system on.

Test Result

1. LED should display last setpoint selected.

2. Blower fan should be circulating air, temperature

selected will determine speed of blower and should

increase relative to the difference of temperature.

Push Button for Temperature

1. Set temperature to highest setting 32 °C (90 °F).

2. Set control for blower fan in auto.

Test Result

1. Speed of blower fan changes to full speed.

2. Heating system will turn on.

a. Water valve should open.

b. Temperature of supply line at heater core

should increase as engine temperature

increases.

Push Button for Temperature

1. Set temperature to lowest setting 15.5 °C (60 °F).

2. Set blower control to auto.

Test Result

1. Speed of blower fan changes to full speed.

2. Air conditioning system turns on.

a. Clutch for refrigerant compressor engages.

b. Temperature of supply line at evaporator coil

decreases.

Push Button for Temperature

1. Set temperature to equal temperature of cab.

2. Set control for blower fan in auto position.

Test Result

1. Speed of blower fan should change to a low speed.

2. Air conditioning system will turn on.

Control for Mode of Airflow

1. Change control for mode of airflow.

Test Result

1. Airflow from vents should change to match control

for airflow.

Control for Mode of Airflow (Defrost)

1. Change control for mode of airflow to defrost.

Test Result

1. Clutch for refrigerant compressor should engage.

2. Airflow should be directed to vents for defrost.

627333-A  

6-i

Contents

Challenger

®

Terra Gator 3244

Chassis

SERVICE MANUAL

627333-A

06 - Electrical

Contents

GENERAL INFORMATION

Introduction ................................................................................................................................................ 6-1

Basic Troubleshooting Procedures ............................................................................................................ 6-1

Tools .......................................................................................................................................................... 6-2

General Testing Procedures ...................................................................................................................... 6-3

Visual Inspection  ................................................................................................................................. 6-3

Continuity Check  ................................................................................................................................. 6-3

Voltage Check  ..................................................................................................................................... 6-3

Testing for Open Circuits ..................................................................................................................... 6-3

Finding a Break in an Open Circuit  ..................................................................................................... 6-3

Testing for Short Circuits ..................................................................................................................... 6-4

Testing for High Resistance  ................................................................................................................ 6-4

Finding a High Resistance Circuit  ....................................................................................................... 6-4

Fuse Testing ........................................................................................................................................ 6-4

Relay Testing  ...................................................................................................................................... 6-4

Diode Testing  ...................................................................................................................................... 6-4

Wire Colors  ................................................................................................................................................ 6-5

ELECTRICAL SYSEM

Description ................................................................................................................................................. 6-7

Requirements ............................................................................................................................................ 6-7

Definition .................................................................................................................................................... 6-7

Component Location .................................................................................................................................. 6-8

Primary CAN Bus Components  ................................................................................................................. 6-9

PDM ......................................................................................................................................................... 6-16

PDM1 ................................................................................................................................................ 6-17

PDM2 ................................................................................................................................................ 6-17

PDM3 ................................................................................................................................................ 6-18

2-Pack Relay Modules  ...................................................................................................................... 6-18

4-Pack Relay Module  ........................................................................................................................ 6-19

Flasher Module .................................................................................................................................. 6-19

Power Supply Block  .......................................................................................................................... 6-21

INDEX ......................................................................................................................................................... 6-23

 

 

 

 

 

 

 

Content   ..  112  113  114  115   ..