Usage:
1. Remove the hood. The weight of the hood for Challenger 65C and 70C Tractor is approximately 40 kg (88 lb). The weight of the hood for Challenger 75C and 85C Tractor is approximately 32 kg (70 lb).
2. Remove six screws (1) and panel (2).
3. Remove foam padding (3).
4. Remove four bolts and washers (4) and plate (5).
5. Disconnect wiring harness (6) below the cab floor.
6. Put identification marks on five cable assemblies (7). Disconnect the cable assemblies and pull them down thru the cab floor.
7. Remove two knob assemblies (8) and pull the two cable assemblies attached to them down thru the cab floor.
8. Remove bolt (9) and disconnect bracket (10) from the wiring harness.
9. Close heater valve (14). Loosen hose clamp (13). Disconnect and cap heater hose (12).
10. Remove two bolts (11) that hold heater hose (12) to the engine.
11. Close heater valve (15). Loosen hose clamp (16). Disconnect and cap heater hose (17).
12. Disconnect brake line (18).
13. Disconnect four lines (19) at the steering control unit (20).
14. Remove one bolt (21) and disconnect ground strap (22) from the frame.
15. Remove three bolts and washers (23) and cover plate (24).
16. Disconnect parking brake linkage located under cover plate (24).
17. Disconnect two electrical connections (25).
18. Remove one bolt (26) and disconnect wiring harness (27).
19. Remove two bolts and washers (28) and disconnect cable (29) from the transmission.
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Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (CCl2F2 Dichlorodifluoromethane) or refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning systems. INHALING REFRIGERANT R-12 OR REFRIGERANT R-134A THROUGH ANY SMOKING MATERIAL, ALTHOUGH NOT TOXIC OR FLAMMABLE, CAN GENERATE LETHAL PHOSGENE GAS AND CAUSE VIOLENT ILLNESS OR DEATH. ALSO, HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual, Form No. SENR3334 and SENR5664, for more information on removal and installation of lines and refrigerant from the system. |
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NOTE: Use a refrigerant reclaimer before loosening any lines.
20. Evacuate the air conditioning system.
21. Disconnect air conditioning line (30). Remove all bolts and clips (31) securing air conditioning line (30) to the machine.
22. Disconnect air conditioning line (32).
23. Install tooling (A) on top of the cab as shown. Fasten a hoist to cab (33).
24. Remove four cab mounting bolts (34) that hold the cab to the frame of the machine.
25. Slowly raise cab (33) enough to gain access to cable assembly (35).
26. Remove two bolts (36) and disconnect cable assembly (35).
27. Remove the cab. The weight of the cab is 975 kg (2150 lb).
Install Cab (2ZJ500-Up & 2YL227-Up & 4KK500-Up & 9TK231-Up)
1. Fasten tooling (A) and a hoist to the top of cab (33) as shown. Lower the cab to within 152 to 203 mm (6 to 8 in) from the frame of the machine. Connect cable assembly (35) and install bolts (36); then lower the cab onto the frame of the machine. Remove tool (A) from the cab.
2. Install four cab mounting bolts (34). Tighten the bolts to a torque of 400 ± 70 N·m (300 ± 50 lb ft).
3. Connect air conditioning line (32).
4. Connect air conditioning line (30) and install all bolts and clips (31) holding line (30) to the engine.
5. Connect cable (29) to the transmission. Install two bolts and washers (28).
6. Connect wiring harness (27) with bolt (26) to its original location.
7. Connect two electrical connections (25).
8. Connect parking brake linkage located under cover plate (24).
9. Reinstall three bolts and washers (23) and cover plate (24).
10. Connect ground strap (22) to the frame with bolt (21).
11. Connect four lines (19) to steering control unit (20) in their original locations.
12. Connect brake line (18).
13. Connect heater hose (17) to heater valve (15). Tighten hose clamp (16).
14. Open heater valve (15).
15. Connect heater hose (12) to heater valve (14). Tighten hose clamp (13).
16. Install two bolts (11) that hold heater hose (12) to the engine.
17. Open heater valve (14).
18. Connect bracket (10) to the wiring harness and install bolt (9).
19. Push the two cable assemblies that attach to knobs (8) through the bottom of the cab to their original location. Attach knobs (8) to the cable assemblies.
20. Push cable assemblies (7) and grommets in through the bottom of the cab. Route cables through the bracket in their original locations and connect the cables.
21. Reconnect wiring harness (6) below the cab floor.
22. Reinstall plate (5) and bolts (4).
23. Reinstall foam padding (3).
24. Reinstall panel (2) and bolts and washers (1) which hold it.
25. Reinstall the hood on the machine.
26. After the machine is made operable, charge the air conditioning system. See the Air Conditioning And Heating Service Manual, Form No. SENR3334.