Challenger EU Applicators TerraGator TG8400B Flotation Chassis Operator’s Manual – PDF DOWNLOAD
DESCRIPTION:
Challenger EU Applicators TerraGator TG8400B Flotation Chassis Operator’s Manual – PDF DOWNLOAD
TG8400B
AGCC8400xGxxx1001-
A word to the operator:
It is your responsibility to read and understand the safety section in this manual and the manual for all implements before you operate this machine. You are responsible for your safety. Good safety procedures prevent injury to you and the persons around you. Make the information in the safety section of this manual a part of your safety procedure. This safety section is written only for this type of machine. Safety is your responsibility. You can prevent injury and death.
- This safety section gives basic safety examples that can occur during the operation and maintenance of your machine. This safety section is not a replacement for safety instruction in other sections of this manual.
- Injury or death can occur if the safety instruction is not obeyed. Learn how to operate the machine and how to use the controls correctly. Do not operate the machine if you do not know how to operate the machine.
- Do not let persons operate the machine that do not know how to operate the machine. Follow all safety instructions in the manuals and on the safety signs on the machine, the implements, and the attachments. Use only approved attachments and implements. Make sure that your machine has the correct equipment that is necessary by the local regulations.
Prepare for operation:
Read and understand all operation instructions and precautions in this manual before you operate the machine or do the servicing. Make sure that you know and understand the positions and operations of all controls. Make sure that all controls are in neutral and that the parking brake is applied before you start the machine. Make sure that all persons are away from your area of work before you start and operate the machine.
- Examine and learn the controls in an area that is clear of persons and obstacles before you start work. Know the machine dimensions and make sure that you have sufficient space available to operate the machine.
- Do not operate the machine at high speeds in crowded areas. It is important to know and use the correct procedures when you do work around and operate the machine. Do not let children or unqualified persons operate the machine.
- Keep others, especially children, away from your area of work. Do not let others ride on the machine. Make sure that the machine is in good condition for operation. Refer to the operator manual. Make sure that the machine has the correct equipment required by local regulations.
TABLE OF CONTENTS:
Challenger EU Applicators TerraGator TG8400B Flotation Chassis Operator’s Manual – PDF DOWNLOAD
1 Safety 11
1 1 A word to the operator 13
1 1 1 Important safety information 1 3
1 1 2 Safety symbol 1 4
1 1 3 Safety messages 1 5
1 1 4 Information messages 1 5
1 1 5 General hazard information 1 5
1 2 Prepare for operation 17
1 2 1 Mount and dismount the machine 17
1 2 2 Before you start the engine 17
1 2 3 Start the engine 1 8
1 2 4 Before operating the machine 1 8
1 2 5 Operate the machine 1 8
1 2 6 Operator station 1 9
1 2 7 Park the machine 1 9
1 2 8 Exit the cab in an emergency 20
1 2 9 Safety lamps and marking devices use 20
1 2 10 Reading on public roads 20
1 2 1 1 Operate on a slope 2 1
1 2 1 2 Electrical storm injury prevention 2 1
1 3 Maintenance and service 22
1 3 1 Maintenance safety 2 2
1 3 2 Wear protective clothing 26
1 3 2 1 Prepare for long term storage 26
1 3 3 Fire prevention and first aid 27
1 3 4 Proper disposal of waste 28
1 3 5 Shield and guards 28
1 3 6 Support the machine correctly 29
1 3 7 Asbestos information 29
1 3 8 Pressurized air 29
1 3 9 Cut and crush prevention 29
1 3 10 Boom safety 30
1 3 1 1 Fuel safety 30
1 3 1 2 Hydraulic safety 30
1 3 1 3 High pressure leaks 3 1
1 3 1 4 Chemical safety 3 1
1 3 15 Engine safety 3 3
1 3 16 Battery safety 35
1 3 17 T ire safety 36
1 3 1 8 Avoid eye contact with radar 36
1 3 19 Exhaust fumes 37
1 3 20 Electrical power lines overhead 37
1 3 2 1 Towing 37
1 3 2 2 Modifications 37
1 3 2 3 Mobile radio installation 38
1 3 2 4 Safety signs 38
1 4 Safety signs 39
1 4 1 Overhead electrical power lines 40
1 4 2 Starter bypass 40
1 5 Cab safety signs 41
1 5 1 Operator’s manual 4 2
Flotation Chassis
591105O1F
Table of contents
1 5 2 Park brake 4 2
1 5 3 Bystander alert 4 2
1 5 4 Crushing hazard 4 2
1 5 5 Fall off hazard 4 3
1 5 6 Seatbelt 4 3
1 5 7 No passengers 4 3
1 6 Chassis safety signs 44
1 6 1 Hot pressurized coolant 4 5
1 6 2 Rotating blades 4 5
1 6 3 High pressurized fluid 46
1 6 4 Ether 46
1 6 5 Belt entanglement 4 7
1 6 6 Electrocution hazard 4 7
1 6 7 Radar 4 7
1 6 8 Crushing hazard 4 8
1 7 Informational signs 49
1 7 1 Informational – T iedown 50
1 7 2 Ultra low sulfur diesel fuel 50
1 7 3 Informational – Cab filter # 1 50
1 7 4 Informational – Hand wash 50
1 7 5 Informational – Battery shut off 5 1
1 7 6 Informational – Battery terminals 5 1
1 7 7 Informational – Cab filter # 3 5 1
1 7 8 Informational – Cab filter # 2 and washer bottle 5 1
1 7 9 Informational – Manufacturer plate 5 2
1 7 10 Informational – Alternate exit 5 2
1 7 1 1 Informational – Outlet voltage and maximum amperage 5 2
1 7 1 2 Informational – Hydraulic oil level 5 2
1 7 1 3 Informational – Do not alter 5 3
1 8 Informational electrical signs 54
1 8 1 Informational – Power distribution module 5 4
1 8 2 Informational – Upper electrical panel 55
1 8 3 Informational – Lower electrical panel 56
1 8 4 Informational – Chassis electrical panel 57
2 Introduction 59
2 1 Information 6 1
2 1 1 Intended use 6 1
2 1 2 Proper disposal of waste 6 1
2 1 3 Emissions reduction – selective catalyst reduction – SCR – technology 6 1
2 1 4 DEF Storage and Shelf Life 6 2
2 2 Machine identification 64
2 2 1 Product identification information 6 4
2 2 2 Serial number definition 6 4
2 2 3 Engine serial number plate 6 5
2 2 4 Transmission serial number plate 6 5
2 3 Break-in period 66
2 3 1 General break-in information 6 6
2 3 2 Break-in maintenance schedule 6 6
2 3 3 Operate the engine-first 200 hours 6 6
2 3 4 Initial interval for inline fuel strainer 6 6
2 3 5 Break-in the transmission 6 6
2 3 6 Break-in the rear axle 6 6
2 3 7 Axle mounting bolts 6 6
2 3 8 Do a check of the wheel mounting hardware 6 7
2 3 9 Hydraulic filter 6 7
2 3 10 Initial pressure washer pump 6 7
Flotation Chassis
591105O1F
Table of contents
2 3 11 Initial engine valve adjustment 6 7
2 4 Machine transport 68
2 4 1 Operate the machine in limp-home mode 6 8
2 4 2 Transport the machine on a truck or trailer 71
2 4 3 Towing information 72
2 4 3 1 Prepare for towing – engine operation 72
2 4 3 2 Preparing for towing – engine not operating 75
2 4 3 3 Tow the machine 75
2 5 Park brake information 77
2 5 1 Release the manual park brake 77
2 5 2 Release the park brake using air 77
2 5 3 Release the park brake by manually releasing the spring 77
2 6 Major components 80
2 6 1 Component location (front/rear view) 80
2 6 2 Component location (side view) 81
2 6 3 Component location (top view) 82
2 7 Emissions warranty 83
2 7 1 United States and Canada emission control warranty statement 83
2 7 2 California emission control warranty statement 86
3 Operation 91
3 1 Cab temperature control 93
3 1 1 Automatic temperature control 93
3 1 2 Heater operation 94
3 1 3 Defroster operation 94
3 1 4 Air conditioner operation 94
3 1 5 Automatic fan speed control 95
3 1 6 Manual fan speed control (HI/LO) 95
3 1 7 Air conditioning compressor clutch control 95
3 1 8 Heater water valve 95
3 1 9 Cab air temperature sensor 95
3 1 10 Temperature control troubleshooting 96
3 2 Controls and instruments 98
3 2 1 Inside cab components 98
3 2 2 Light switches for machine lights 100
3 2 3 Seatbelt operation 101
3 2 4 Basic operator seat 102
3 2 5 Deluxe operator seat 103
3 2 6 Deluxe vented operator seat 104
3 2 7 Instructor seat 105
3 2 8 Armrest controls 106
3 2 9 Shield and guards 107
3 2 10 Joystick controls 108
3 2 11 Instrument cluster 108
3 2 12 Steering wheel controls 113
3 2 13
3 2 14
3 2 15
3 2 16
3 2 17
3 2 18
3 2 19
3 2 2 0
3 2 2 1
3 2 2 2
Flotation Chassis
591105O1F
3 2 12 1 Power shuttle and shuttle lock 114
3 2 12 2 Shuttle shifting 115
Park brake 115
Foot pedals 115
Telemetry (if equipped) 116
Monitor/Camera (if equipped) 117
Battery disconnect switch 117
DOT matrix display screens 11 8
DOT matrix display screen operation 12 1
Changing speed readout units 12 6
Reset the maintenance indicator lamp and the service hourmeter 12 7
Application rate controller options 12 7
Table of contents
3 2 2 3 Slingshot ready – if equipped 1 27
3 3 Tag axle operation 128
3 3 1 Tag axle 1 28
3 3 2 Operate the tag axle 1 28
3 4 Preparing to start the engine 129
3 4 1 Do a check of the engine before starting 1 29
3 4 2 Engine power limitations 1 29
3 4 3 Low DEF level 1 3 0
3 4 4 SCR system malfunction 1 3 1
3 4 5 Start the engine 1 3 2
3 4 6 Cold temperature starting 1 3 4
3 4 7 Stalled engine – restart 1 3 4
3 4 8 Stop the engine and afterrun 1 3 5
3 4 9 Using the engine throttle control switches 1 3 5
3 4 9 1 Remote throttle preset 1 3 5
3 4 9 2 Location of the remote throttle control 1 3 5
3 4 9 3 Remote throttle controls 1 3 5
3 5 Operating on a public road 137
3 5 1 Machine operation on a public road 1 3 7
3 6 Transmission function 138
3 6 1 Transmission – general 1 3 8
3 6 2 High and low speed range 1 3 8
3 6 3 Set the preset start up speeds 1 4 0
3 6 4 Engine underspeed supervisor 1 4 1
3 6 5 Joystick mode 1 4 1
3 6 6 Foot pedal throttle mode 1 4 2
3 6 7 Machine management system 1 4 3
3 7 Calibration 145
3 7 1 Machine calibration 1 4 5
3 7 2 Inputting at level 1 – Cal 2 1 4 5
3 7 3 Clear the DCC 3 dash cluster error code 1 46
3 7 4 Calibrate the joystick handle 1 4 7
3 7 5 Calibrate the clutch 1 4 7
3 7 6 Calibrate the foot pedal throttle 1 4 8
3 7 7 Clear the Auto 4 transmission controller error code 1 49
3 7 8 Inputting at level 1 – Cal 1 1 50
3 7 9 Calibrate the hare and tortoise range 1 50
3 7 10 Calibrate the transmission 1 5 1
3 7 1 1 Calibrate the coupler function 1 5 2
3 7 1 2 Calibrate the radar 1 5 3
3 7 1 3 Calibrate the speed 1 5 4
3 8 Cold weather considerations 155
3 8 1 Minimize the effect of cold weather 1 55
3 8 2 Using grade No 1-D fuel 1 55
3 8 3 Fuel filters 1 55
3 8 4 Coolant heater 1 55
3 8 5 Seasonal viscosity oil and proper coolant concentration 1 55
3 8 6 Winterfronts 1 56
3 8 7 Idling the engine 1 56
3 8 8 Engine coolant specifications 1 56
3 8 9 Cooling system water quality 1 56
3 8 10 Antifreeze 1 56
3 8 1 1 Grease 1 57
3 8 1 2 Diesel fuel 1 57
3 8 1 3 Lubricity of diesel fuels 1 57
3 8 1 4 Diesel fuel storage 1 58
3 8 1 5 Fuel tank information 1 58
Flotation Chassis
591105O1F
Table of contents
3 9 Storage 160
3 9 1 Prepare for long term storage 16 0
3 9 2 Remove the machine from long term storage 16 0
4 Maintenance 163
4 1 Maintenance intervals 167
4 1 1 Maintenance introduction 16 7
4 1 2 Maintenance symbols 16 7
4 1 3 Lubricant filling reminders 16 8
4 1 4 Maintenance schedule 16 9
4 1 4 1 Maintenance chart 16 9
4 1 4 2 Daily maintenance schedule 17 0
4 1 4 3 Maintenance schedule 10 to 1000 hours 17 0
4 1 4 4 Maintenance Schedule 2000 to 4 000 hours 17 3
4 1 5 Lubricants and fluids 17 3
4 2 Air dryer and conpressed air system 175
4 2 1 Air reservoir and air dryer 17 5
4 2 2 Air dryer 17 5
4 3 Air conditioner system 17 7
4 3 1 Air conditioner 17 7
4 3 2 Condenser 17 7
4 4 Engine 17 9
4 4 1 Do a check of the engine oil level 17 9
4 4 2 Change the engine oil and filter 1 8 0
4 4 3 Engine belts and tensioner 1 8 0
4 4 3 1 Replace the serpentine belt 1 8 0
4 4 3 2 Replace the water pump belt 1 8 1
4 4 4 Fuel system 1 8 3
4 4 5 Fuel tank 1 8 3
4 4 6 In-line fuel strainer 1 8 4
4 4 7 Replace the fuel filters 1 8 4
4 4 8 Prime the fuel system 1 8 5
4 4 9 Engine coolant 1 8 6
4 4 10 How to recognize an engine with hydraulic lash adjusters 1 8 7
4 5 Maintaining the air cleaner 189
4 5 1 Engine air cleaner indicator 1 8 9
4 5 2 Replace the air filter element 1 8 9
4 5 3 Secondary air filter element 19 0
4 6 Hydraulic system 19 1
4 6 1 Do a check of the hydraulic oil-level check 19 1
4 6 2 Replace the hydraulic system oil and filter 19 1
4 7 Continuously variable transmission 193
4 7 1 Transmission operating temperatures 19 3
4 7 2 Do a check of the transmission oil 19 3
4 7 3 Change the transmission oil 19 4
4 8 Transfer case assembly 196
4 8 1 Do a check of the transfer case oil 19 6
4 8 2 Change the transfer case oil 19 6
4 8 3 Clean the transfer case breather 19 7
4 9 Lubricating and inspecting driveline and components 198
4 9 1 Inspect and lubricate the engine to transmission driveline 19 8
4 9 2 Lubricate the transmission to the transfer case driveline 19 9
4 9 3 Lubricate the transfer case to rear axle driveline 19 9
4 9 4 Lubricate the front axle kingpins 200
4 9 5 Lubricate the front axle springs 20 1
4 9 6 Check the front axle mounting bolts 20 1
Flotation Chassis
591105O1F
Table of contents
4 9 7 Lubricate rear axle springs 20 1
4 9 8 Check the rear axle mounting bolts 20 2
4 10 lntercoolers 203
4 10 1 Heat exchangers 20 3
4 10 2 Clean the heat exchangers 20 3
4 11 Front wheel and tag axle bearings 205
4 1 1 1 Front wheel bearing 20 5
4 1 1 1 1 Do a check of the front wheel bearing oil 20 5
4 1 1 1 2 Change the front wheel bearing oil 20 5
4 1 1 1 3 Wheel end oil change intervals and specifications 206
4 1 1 2 Tag axle bearing bolts and lubricating the tag axle fittings – if equipped 206
4 12 Steering 20a
4 1 2 1 Steering cylinders 208
4 1 2 2 Do a check of the front wheel toe-in 208
4 1 2 2 1 Measure the front wheel toe-in 208
4 1 2 2 2 Adjust the front wheel toe-in 209
4 13 Rear axle 210
4 1 3 1 Clean the breather for the rear axle 2 10
4 1 3 2 Do a check of the rear axle oil 2 10
4 1 3 3 Break-in the rear axle 2 1 1
4 1 3 4 Change the rear axle oil 2 1 1
4 14 Brake maintenance 213
4 1 4 1 Lubricate the front brake slack adjuster 2 1 3
4 1 4 2 Lubricate the rear brake slack adjuster 2 1 3
4 1 4 3 Brake air lines 2 1 3
4 1 4 4 Parking brake 2 1 3
4 1 4 5 Do a check of the service brake system 2 1 4
4 1 4 6 Do a check of the automatic slack adjusters 2 1 4
4 1 4 7 Manually adjusting the automatic slack adjusters 2 1 5
4 15 Wheels 2 17
4 1 5 1 Remove the wheels 2 17
4 1 5 2 Install the wheels 2 17
4 1 5 3 Tighten the wheel mounting hardware 2 1 8
4 16 Tires 219
4 16 1 Inflate the tire 2 19
4 16 2 Replace the tire 2 19
4 16 3 T ire charts 2 19
4 17 Cabin filters and windscreen wipers 227
4 17 1 Cab air filters and the windscreen washer reservoir 2 27
4 1 7 2 Maintain the cab air filter 2 27
4 1 7 2 1 Maintain the primary fresh air filter 2 27
4 1 7 2 2 Maintain the secondary fresh air filter 2 27
4 1 7 2 3 Maintain the recirculation air filter 2 28
4 1 7 2 4 Clean the cab filter element 2 28
4 1 7 3 Cab air filters 2 28
4 1 7 3 1 Remove the primary fresh air filter 2 28
4 1 7 3 2 Install the primary fresh air filter 2 29
4 1 7 3 3 Remove the secondary fresh air filter 2 29
4 1 7 3 4 Install the secondary fresh air filter 2 3 1
4 1 7 3 5 Remove the recirculation air filter 2 3 1
4 1 7 3 6 Install the recirculation air filter 2 3 3
4 1 7 4 Windshield wiper blade 2 3 3
4 1 7 5 Fill the windscreen washer reservoir 2 3 3
4 18 Cab mounts 234
4 1 8 1 Do a check of the cab mounting bolts, rubber mounts, and air ride suspension 2 3 4
4 1 8 2 Do a check of the cab mounting bolts and rubber mounts 2 3 4
Flotation Chassis
591105O1F
Table of contents
4 19 Electrical system 235
4 19 1 Batteries 2 3 5
4 19 1 1 Battery box components 2 3 5
4 19 1 2 Battery disconnect switch lever 2 3 6
4 19 1 3 Remove the battery terminal connection 2 3 6
4 19 2 Jump start the battery 2 3 7
4 19 3 Locate the fuse panel 2 3 8
4 19 4 Fuse locations 2 39
4 20 Cab seat preventative maintenance 2 42
4 20 1 Lubricate seat adjusters 2 4 2
4 20 2 Armrest mechanism 2 4 2
4 21 Paint and decals 2 43
4 2 1 1 Safety treads 2 4 3
4 22 Hand rinse tank and pressure washer 2 4 4
4 2 2 1 Remove the hand rinse tank 2 4 4
4 2 2 2 Install the hand rinse tank 2 4 4
4 2 2 3 Pressure washer 2 4 5
4 2 2 3 1 Pressure washer input water supply 2 4 5
4 2 2 3 2 Before starting the pressure washer 2 4 5
4 2 2 3 3 Prime the pressure washer pump 2 4 5
4 2 2 3 4 General care of the pressure washer pump 2 4 5
4 2 2 3 5 Pressure washer pump storage in freezing conditions 2 4 5
4 2 2 3 6 Operate the pressure washer 2 4 5
4 2 2 3 7 Change the pressure washer pump motor oil 2 4 6
4 2 2 3 8 Change the pressure washer strainer 2 4 7
4 2 2 3 9 Winterize the pressure washer system 2 4 7
4 2 2 3 10 During system changeovers 2 4 8
4 23 Application system 2 49
4 2 3 1 Application system installation 2 49
5 Troubleshooting 251
5 1 Engine 253
5 1 1 Low diesel exhaust fluid ( DEF) level 257
5 2 Transmission 258
5 3 Electrical system 260
5 4 Hydraulic system 261
5 5 Parking brake troubleshooting 262
5 6 Operation 263
5 7 Cab 26 4
5 8 Fault codes 265
5 8 1 Engine control system error and fault codes 26 5
5 8 2 Transmission error and fault codes 28 1
5 8 3 D CC 3 error and fault codes 28 3
5 8 4 Chassis error and fault codes 28 5
6 Specifications 291
6 1 Machine specifications 293
6 2 Machine dimensions 296
7 Index 299
FILE DETAILS:
Challenger EU Applicators TerraGator TG8400B Flotation Chassis Operator’s Manual – PDF DOWNLOAD
Size: 48.6 MB
Format: PDF
Language: English
Brand: Challenger
Type of Machine: Applicators
Type of document: Operator’s Manual
Model: Challenger EU Applicators TerraGator TG8400B Flotation Chassis
Serial Number: AGCC8400xGxxx1001-
Number of Pages: 304 pages
Date Modified: 08/2019
Part Number: 591105D1F
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Challenger EU Applicators TerraGator TG8400B Flotation Chassis Operator’s Manual – PDF DOWNLOAD
Challenger EU Applicators TerraGator TG8400B Flotation Chassis Operator’s Manual – PDF DOWNLOAD
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