Challenger TERRA-GATOR 3244 User manual

AG617715
January 2011
Operator Manual
TERRA-GATOR 3244
Chassis
S/N: MY 2011

TO OUR CUSTOMER:
Congratulations on your selection of a Challenger
®
Product. We
believe you have exercised excellent judgment in the purchase of
your Challenger
®
machine. We are most appreciative of your patronage.
Your Dealer has performed the pre-delivery service on your new
machine.
He will discuss with you the operating and maintenance instructions
given in this manual, and instruct you in the proper and varied
applications of this machine. Call on him at any time when you have a
question or need equipment related to the use of your machine.
We recommend that you carefully read this entire manual before
operating the unit. Also, time spent in becoming fully acquainted with it’s
performance features, adjustments, and maintenance schedules will be
repaid in a long and satisfactory life of the product.
This equipment is covered by a written warranty which will be
provided to you by your Challenger
®
Dealer at time of purchase.
AGCO®reservesthe right to make changesor add improvementsto itsproductsat any time without incurring any
obligation to make such changesto productsmanufactured previously. AGCO®, or itsdealers, accept no
responsibility for variationswhich may be evident in the actual specificationsof itsproductsand the statements
and descriptionscontained in thispublication.
Challenger
®
is a worldwide brand of AGCO Corporation, Duluth, Georgia USA
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AG617715 1-i
CONTENTS
CHALLENGER®
TERRA-GATOR 3244
AG617715
CONTENTS
SAFETY ........................................................................................................................................................ 1-1
Follow Safety Instructions .......................................................................................................................... 1-1
Prepare for Emergencies ........................................................................................................................... 1-1
Emergency Exit From Cab ......................................................................................................................... 1-1
Operating the Vehicle Safely ..................................................................................................................... 1-2
Prevent Vehicle Runaway .......................................................................................................................... 1-3
Use Safety Lights and Devices .................................................................................................................. 1-3
Operating on Slopes .................................................................................................................................. 1-3
Traveling on Public Roads ......................................................................................................................... 1-4
Stopping and Parking the Vehicle .............................................................................................................. 1-4
System Boom Safety ................................................................................................................................. 1-5
Overhead Electrical Power Lines ............................................................................................................... 1-5
Avoid Eye Contact with Radar ................................................................................................................... 1-5
Exhaust Fumes .......................................................................................................................................... 1-6
Noise .......................................................................................................................................................... 1-6
Handle Fuel Safely - Avoid Fires ............................................................................................................... 1-6
Stay Clear of Rotating Drive Lines and Moving Parts ................................................................................ 1-7
Towing other Vehicles / Trailers / Equipment ............................................................................................ 1-7
Modifications .............................................................................................................................................. 1-7
Maintenance and Service Safety ............................................................................................................... 1-8
Practice Safe Maintenance ........................................................................................................................ 1-8
Chemical Safety ......................................................................................................................................... 1-9
Operator Cabs ..................................................................................................................................... 1-9
Wear Protective Clothing ......................................................................................................................... 1-10
Work in a Clean Area ............................................................................................................................... 1-10
Understand Correct Service .................................................................................................................... 1-11
Use Proper Tools ..................................................................................................................................... 1-11
Support Machine Properly ....................................................................................................................... 1-11
Proper Lifting Equipment ......................................................................................................................... 1-11
High-Pressure Fluids ............................................................................................................................... 1-12
Hydraulic Hoses ....................................................................................................................................... 1-12
Avoid Heating near Pressurized Fluid Lines ............................................................................................ 1-12
Service Cooling System Safely ................................................................................................................ 1-13
Remove Paint before Welding or Heating ................................................................................................ 1-13
Safety Tread and Grip Material ................................................................................................................ 1-13
Batteries ................................................................................................................................................... 1-13
Tires and Wheels ..................................................................................................................................... 1-14
Dispose of Waste Properly ...................................................................................................................... 1-14
Mobile Radio Installations ........................................................................................................................ 1-14
Maintenance in the Articulation Joint (Hinge) Area .................................................................................. 1-15
Safety Tread and Grip Material ................................................................................................................ 1-15
Safety and Service Decal Locations Chassis .......................................................................................... 1-16
Safety Sign Locations Left View ........................................................................................................ 1-16
Safety Sign Locations Left View ........................................................................................................ 1-21
Safety Sign Locations Top View ........................................................................................................ 1-25
Safety Sign Locations Front and Rear View ...................................................................................... 1-26
INTRODUCTION ........................................................................................................................................... 2-1
Terra Gator 3244, Chassis ........................................................................................................................ 2-1
Identification ............................................................................................................................................... 2-2
Serial Number Identification Plate ....................................................................................................... 2-2
Engine Serial Number and Information Plate ...................................................................................... 2-2
Break-in Period .......................................................................................................................................... 2-3
First 250 Hours of Engine Operation ................................................................................................... 2-3
Transmission ....................................................................................................................................... 2-3
Axles .................................................................................................................................................... 2-3
Wheel Bolts ......................................................................................................................................... 2-3
Maintenance Schedule ........................................................................................................................ 2-3
Hydraulic Filter .................................................................................................................................... 2-3
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1-ii AG617715
CONTENTS
Fuel In-line Strainer ............................................................................................................................. 2-3
Chassis / Cab Modification ........................................................................................................................ 2-3
Towing ....................................................................................................................................................... 2-4
Parking Brake Information ......................................................................................................................... 2-4
Parking Brake Emergency Release ........................................................................................................... 2-4
Transporting ............................................................................................................................................... 2-5
Component Locations ................................................................................................................................ 2-6
Left View and Right View .................................................................................................................... 2-6
Front View, Rear View and Top View ................................................................................................. 2-8
CONTROLS .................................................................................................................................................. 3-1
Controls And Instruments .......................................................................................................................... 3-1
Instrument Panel ................................................................................................................................. 3-1
Front Console ...................................................................................................................................... 3-2
Multi Function Gear Handle ................................................................................................................. 3-3
Transmission Display .......................................................................................................................... 3-5
Upper Switch Panel Armrest ............................................................................................................... 3-6
Lower Switch Panel Armrest ............................................................................................................... 3-7
Roof Switch Panel ............................................................................................................................... 3-8
Accessory Panel .................................................................................................................................. 3-9
Map Dome Light .................................................................................................................................. 3-9
Radio/CD Player ................................................................................................................................ 3-10
Sun Visor ........................................................................................................................................... 3-10
Cup Holder ........................................................................................................................................ 3-10
Hidden Compartment ........................................................................................................................ 3-11
Power Outlet Station ......................................................................................................................... 3-11
Cargo Net .......................................................................................................................................... 3-11
Foot Pedals .............................................................................................................................................. 3-12
Steering Wheel ........................................................................................................................................ 3-13
Automatic Temperature Control ............................................................................................................... 3-14
Description ........................................................................................................................................ 3-14
Special Functions .............................................................................................................................. 3-14
Troubleshooting ................................................................................................................................. 3-15
Key Switch And System Power Switch .................................................................................................... 3-16
Operator Seat .......................................................................................................................................... 3-17
Seat Belts ................................................................................................................................................ 3-19
OPERATION ................................................................................................................................................. 4-1
Before Starting the Vehicle Engine ............................................................................................................ 4-1
Starting the Engine .................................................................................................................................... 4-1
Cold Temperature Starting .................................................................................................................. 4-1
Starting a Warm Engine ...................................................................................................................... 4-1
Stopping the Engine ............................................................................................................................ 4-1
Cruise Control ............................................................................................................................................ 4-2
Traveling on Public Roads ......................................................................................................................... 4-2
Transmission Function Description ............................................................................................................ 4-2
Inching ................................................................................................................................................. 4-2
Shuttle Shifts ....................................................................................................................................... 4-2
Speed Matching .................................................................................................................................. 4-2
Roading Auto Shift .............................................................................................................................. 4-3
Headland Auto Shift ............................................................................................................................ 4-4
High/Low Gear Setting ........................................................................................................................ 4-4
Manual Shift Mode .............................................................................................................................. 4-5
Display Sections .................................................................................................................................. 4-6
Roading Speed Limit ........................................................................................................................... 4-6
Downshift Inhibit for Engine Overspeed Protection ............................................................................. 4-6
Error Codes ......................................................................................................................................... 4-6
Calibration ........................................................................................................................................... 4-6
2 / 4 Wheel Drive ....................................................................................................................................... 4-7
Dog Walk (Optional) .................................................................................................................................. 4-7
Emergency Steering (Optional) ................................................................................................................. 4-8
Controller ................................................................................................................................................... 4-8
Engine Hood .............................................................................................................................................. 4-9
Opening the Engine Hood ................................................................................................................... 4-9
Closing the Engine Hood ..................................................................................................................... 4-9
Cab Tipping Over ..................................................................................................................................... 4-10
Tipping Over ...................................................................................................................................... 4-10
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AG617715 1-iii
CONTENTS
Lower the Cabin ................................................................................................................................ 4-11
Fuel .......................................................................................................................................................... 4-13
Fuel Tank .......................................................................................................................................... 4-13
Extra Fuel Tank ................................................................................................................................. 4-13
LUBRICATION AND MAINTENANCE .......................................................................................................... 5-1
Maintenance Introduction .......................................................................................................................... 5-1
Maintenance Schedule .............................................................................................................................. 5-1
Lubricants and Fluids ................................................................................................................................. 5-5
Lubricant Filling Reminders ....................................................................................................................... 5-5
Daily maintenance or every 8 - 10 hours ................................................................................................... 5-6
1. Check Air Pressure Tires - Tires ..................................................................................................... 5-6
2. Check All Decals ............................................................................................................................. 5-7
3. Remove Water From Air Reservoirs ............................................................................................... 5-7
4. Check Coolant ................................................................................................................................. 5-8
5. Check Fuel Water Separator ........................................................................................................... 5-8
6. Check Engine Oil ............................................................................................................................. 5-8
7. Check Battery Cables ...................................................................................................................... 5-9
8. Check Hydraulic Oil ......................................................................................................................... 5-9
9. Check Transmission Oil ................................................................................................................ 5-10
10. Check Hand Rinse Tank ............................................................................................................. 5-11
11. Articulation Joint (Hinge) Pivot Bearings ..................................................................................... 5-12
12. Check Air Cleaner Indicator ........................................................................................................ 5-12
13. Check Wheel Bolts ...................................................................................................................... 5-13
14. Lubricate the Dog Walk Rotating Bearing ................................................................................... 5-13
15. Grease Steering Cylinders (2) Bases & Rod Ends (2x) .............................................................. 5-14
16. Grease Steering Cylinders Dog Walk (2) Bases & Rod Ends (2x) .............................................. 5-14
17. Grease Dog Walk Locking Pin .................................................................................................... 5-15
18. Check Play Dog Walk Tunnel ...................................................................................................... 5-15
19. Check Play Steering Rod Dog Walk Tunnel ................................................................................ 5-15
Maintenance Every 50 Hours .................................................................................................................. 5-16
20. Grease Cross Bearings from Drive Shaft Articulation and Drive Shaft to Rear Axle ................... 5-16
21. Clean Battery Cables .................................................................................................................. 5-16
22. Check Hydraulic Hoses and Lines .............................................................................................. 5-16
23. Check Air Hoses .......................................................................................................................... 5-17
24. Engine Belts and Tensioner ........................................................................................................ 5-17
25. Check Rotating Bearing .............................................................................................................. 5-17
Maintenance Every 100 Hours ................................................................................................................ 5-18
26. Remove Plug Bottom of Fuel Tank Remove Sediment ............................................................... 5-18
27. Check Cab Mounts ...................................................................................................................... 5-18
28. Clean Heat Exchangers .............................................................................................................. 5-19
29. Check Axle Oil ............................................................................................................................. 5-19
Maintenance Every 250 Hours ................................................................................................................ 5-20
30. Grease Drive Shaft Hanger Bearing ............................................................................................ 5-20
31. Replace Engine Oil and Filter ...................................................................................................... 5-20
32. Clean or Replace Cab Air Filters ................................................................................................. 5-21
33. Check Service Brake System Operation ..................................................................................... 5-22
34. Replace Fuel Filter ...................................................................................................................... 5-23
35. Tighten Wheel Bolts .................................................................................................................... 5-24
Maintenance 500 Hours ........................................................................................................................... 5-25
36. Retorque Axle Bolts ..................................................................................................................... 5-25
37. Replace Air Dryer Filter ............................................................................................................... 5-25
38. Retorque Articulation Pin Bolts and Steering Cylinder Bolts ....................................................... 5-25
39. Lubricate Back Seat Adjusters and Armrest Mechanism ............................................................ 5-26
Maintenance Every 1000 Hours Or Annual ............................................................................................. 5-27
40. Calibrate Transmission ................................................................................................................ 5-27
41. Replace Axle Oil .......................................................................................................................... 5-27
42. Replace Transmission Oil and Filter ........................................................................................... 5-28
43. Replace Interne Oil Filter Gearbox .............................................................................................. 5-29
44. Replace Air Cleaner Elements .................................................................................................... 5-30
45. Replace Cab Air Filters ............................................................................................................... 5-31
46. Flush and Replace Coolant ......................................................................................................... 5-32
47. Replace Hydraulic Filter .............................................................................................................. 5-33
48. Replace Hydraulic Oil .................................................................................................................. 5-34
49. Clean Axle Breather .................................................................................................................... 5-35
50. Check Drive Shaft Hanger Bearings ........................................................................................... 5-35
51. Check Cross Bearings of Drive Shaft .......................................................................................... 5-35
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1-iv AG617715
CONTENTS
52. Replace Fuel In-line Strainer ....................................................................................................... 5-35
Air Conditioner ......................................................................................................................................... 5-36
Fuel Storage ............................................................................................................................................ 5-36
Brake Adjustment and Maintenance ........................................................................................................ 5-36
Parking Brake .................................................................................................................................... 5-36
Parking Brake Emergency Release .................................................................................................. 5-37
Removing the Wheels .............................................................................................................................. 5-37
Cab Roof Removal .................................................................................................................................. 5-38
Windshield Wiper Blade ........................................................................................................................... 5-38
Windshield Washer Reservoir .................................................................................................................. 5-38
Electrical System ..................................................................................................................................... 5-39
Fuse Panel ........................................................................................................................................ 5-40
Automatic Fuses ................................................................................................................................ 5-41
Jump Starting ........................................................................................................................................... 5-41
Exterior Storage Compartments .............................................................................................................. 5-42
Safety Treads .......................................................................................................................................... 5-42
Paint and Decals ...................................................................................................................................... 5-42
COLD WEATHER OPERATION ................................................................................................................... 6-1
Starting Fluid .............................................................................................................................................. 6-1
Minimizing the Effect of Cold Weather ....................................................................................................... 6-1
Fuel Filters ........................................................................................................................................... 6-1
Coolant Heaters .................................................................................................................................. 6-1
Seasonal Viscosity Oil and Proper Coolant Concentration ................................................................. 6-1
Winterfronts ......................................................................................................................................... 6-1
Idling Engine ........................................................................................................................................ 6-2
Engine Coolant Specifications ............................................................................................................. 6-2
Water Quality ....................................................................................................................................... 6-2
Antifreeze/Summer Coolant Concentrate ............................................................................................ 6-2
Ethylene Glycol Concentrate (Antifreeze) ........................................................................................... 6-2
Grease ................................................................................................................................................. 6-3
Diesel Fuel .......................................................................................................................................... 6-4
Sulfur Content of Diesel Fuel .............................................................................................................. 6-4
Lubricity of Diesel Fuels ...................................................................................................................... 6-4
Diesel Fuel Storage ............................................................................................................................. 6-4
Bleed the Fuel System ........................................................................................................................ 6-4
LONG TERM STORAGE .............................................................................................................................. 7-1
Long Term Storage Preparation ................................................................................................................ 7-1
Long Term Storage Removal ..................................................................................................................... 7-1
TROUBLESHOOTING .................................................................................................................................. 8-1
SPECIFICATIONS........................................................................................................................................ 9-1
Specifications ............................................................................................................................................. 9-1
Options ...................................................................................................................................................... 9-3
Vehicle Speeds .......................................................................................................................................... 9-3
Dimensions ................................................................................................................................................ 9-4
Turning Radius .......................................................................................................................................... 9-6
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AG617715 1-v
CONTENTS
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1-vi AG617715
CONTENTS
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AG617715 1-1
SAFETY
SAFETY
IMPORTANT: Any Modifications to the vehicle or
systems not authorized by Challenger will void the
Challenger Warranty. This includes, but is not limited to
hitches.
FOLLOW SAFETY INSTRUCTIONS
FIG. 1: Carefully read, learn and understand all safety
messages and information in this manual and on the
vehicle's safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs.
Make sure new equipment components and repair
parts include the current safety signs. Replacement
safety signs are available from your Challenger dealer.
Never operate the vehicle and/or equipment without
proper instruction and/or a complete understanding of
control operation!
Learn how to operate the vehicle and how to use all
controls properly BEFORE OPERATION. Do not let
anyone operate the vehicle, systems or perform service
and maintenance procedures without the proper
instruction.
Keep the vehicle, all components and systems in the
proper working condition. Modifications unauthorized
by Challenger to the vehicle may impair the function
and/or safety, affect vehicle life, and will void the vehicle
warranty.
PREPARE FOR EMERGENCIES
FIG. 2: Be prepared if a fire starts. Keep a first aid kit
and fire extinguisher handy.
Dial 112 or your national emergency number in cases
of emergency.
Keep emergency numbers for doctors, ambulance
service, hospital and fire department readily available at
all times.
EMERGENCY EXIT FROM CAB
FIG. 3: Understand the procedure to use the
emergency exit from the Right Hand side of the cab
before operating the vehicle.
1. Pull green tab located at the rear of the Right Hand
Cab Window. This removes the glass seal.
2. Push out the Right Hand Cab Window and exit the
vehicle.
FIG. 1
FIG. 2
FIG. 3
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SAFETY
1-2 AG617715
OPERATING THE VEHICLE SAFELY
FIG. 4: Wear a seat belt at all times.
FIG. 5: Make sure the operator and ladder areas are
clean and dry to help prevent personal injuries.
• Make sure all wheel bolts are torqued to the proper
specifications before operating the vehicle.
• Never permit any passengers on, or in the vehicle
when it is in operation.
• Engage the Parking Brake and place the Drive
Lever in the NEUTRAL position before starting the
vehicle's engine.
• Stop the vehicle, turn off the engine and set the
Parking Brake before inspecting any damage if an
accident occurs.
• Stop the vehicle immediately if there is a failure in
the engine, hydraulic system, or any vehicle
system. Do not turn the key switch to the OFF
position until the vehicle is stopped and the vehicle
is shutdown properly.
• The operator must not exceed the speeds and
loads listed on the tire load and inflation table in the
Maintenance section.
• Tire inflation pressure must be maintained per the
tire load and inflation table in the Maintenance
section.
• Never get off a moving vehicle.
FIG. 6: When leaving the vehicle unattended, engage
the Parking Brake and remove the key.
FIG. 4
FIG. 5
FIG. 6
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AG617715 1-3
SAFETY
PREVENT VEHICLE RUNAWAY
FIG. 7: Avoid possible injury or death from vehicle
runaway.
Never start the engine by shorting across the starter
terminals. The engine will start, and the vehicle will
move if normal circuitry is bypassed.
Never start the vehicle's engine while standing on the
ground. Start the engine only from the operator's seat
with the seat belt on, Drive Lever in the NEUTRAL
position and the Parking Brake engaged.
USE SAFETY LIGHTS AND DEVICES
To increase visibility, use the safety lights and devices
provided with the vehicle. Whenever driving on public
roads use Amber flashing Warning Lights and turn
signals, unless prohibited by law. Keep safety items and
features in the proper working order. Replace any
missing or damaged components immediately.
OPERATING ON SLOPES
FIG. 8: Keep the vehicle in a safe lower gear when
going down slopes. Avoid holes, ditches and
obstructions that may cause vehicle roll-over, especially
on hillsides. Avoid sharp turns on hills.
When driving parralel on steep slopes be aware that
vehicle doesn’t roll over.
Never drive near the edge of a gully or steep
embankment.
FIG. 7
FIG. 8

SAFETY
1-4 AG617715
TRAVELING ON PUBLIC ROADS
mCAUTION: This vehicle was designed for
applyingchemicals and fertilizers in
off-road use. Do not use the vehicle for
transportingproduct over public roads.
Chemical spills may occur resultingin
environmental damage. A loaded vehicle
driven on public roads also runs the high
risk of tire failure. Personal Injury could
result.
ALWAYS walk around and visually inspect the vehicle
before traveling on public roads. Check for damage
and/or faulty components that can fail and create a
hazard or unsafe condition. Make sure ALL vehicle
systems operate properly including, but not limited to:
Front Road Lights, Tail and Brake Lights, Hazard
Warning Lights, Safety Lights, Parking Brake, Horn,
Windshield Wiper and Washer, and Rear View Mirrors.
Repair or replace any component that is not in proper
working order.
Never drive at a speed that causes the vehicle to
bounce or cause the loss of control.
Obey all traffic safety rules. Operate the vehicle with
hazard warning lights ON, unless prohibited by law. It is
the operator's responsibility to activate and use the
road lights while traveling on public roads.
STOPPING AND PARKING THE VEHICLE
Vehicle roll-over, collisions, runaway vehicles, and
people being crushed under vehicles can occur when
the vehicle's operator ignores operation safety
procedures.
Signal before stopping, turning or slowing down on
public roads, or anywhere it will cause a potential safety
hazard.
Pull over to the side of the road before stopping the
vehicle.
Be extremely careful when stopping the vehicle on
slippery surfaces.
Be extremely careful when stopping with heavy loads.
Always engage the Parking Brake when the vehicle is
stopped.
Remove the key to prevent any unauthorized personnel
from operating the vehicle.

AG617715 1-5
SAFETY
SYSTEM BOOM SAFETY
FIG. 9: If you have a system with booms, make sure
no personnel or objects are ever in the path of the
booms before operating them. Especially, when
retracting or extending the booms.
Be aware of the location of the booms at all times.
Before driving on public roads, retract and lock the
booms if applicable.
OVERHEAD ELECTRICAL POWER
LINES
FIG. 10: Never let the vehicle come into contact with
overhead power lines. All antennas must be bent over
and secured in place any time overhead electrical
power lines are near the vehicle. This can decrease the
possibility that the vehicle may come into contact with
an overhead power line when in operation or when the
vehicle is transported.
AVOID EYE CONTACT WITH RADAR
FIG. 11: Radar ground sensors emit a low intensity
microwave signal. The microwave signal will not cause
any ill effects during normal use. Although the intensity
is low, to avoid eye damage, never look directly into the
sensor while the sensor is in operation.
FIG. 9
FIG. 10
FIG. 11

SAFETY
1-6 AG617715
EXHAUST FUMES
FIG. 12: Always work in a Properly Ventilated Area.
Engine exhaust fumes can cause sickness or death. If it
is necessary to run an engine in an enclosed area, use
the proper equipment to safely remove the exhaust
fumes from the working area.
Always open the doors and get fresh outside air into the
working area.
Never operate the vehicle's engine inside a building
unless adequate ventilation is provided to safely and
properly remove the exhaust fumes.
NOISE
FIG. 13: Long periods of exposure to high decibels or
loud noise can cause hearing impairment or loss.
Wear proper hearing protection during periods of
exposure to high decibels or loud noise.
Wear a proper hearing protective device such as
earmuffs or earplugs to protect against high decibels
and/or uncomfortable loud noises.
HANDLE FUEL SAFELY - AVOID
FIRES
FIG. 14: Handle fuel with care: it is highly flammable.
Always stop the engine before refueling the vehicle.
Never refuel the vehicle while smoking.
Add fuel in a safe place, away from open flame or
sparks.
Fill the fuel tank outdoors.
Never fill the fuel tank completely to the top of the fuel
tank.
Clean up any spilled fuel immediately.
Never use diesel fuel, kerosene, gasoline or any
flammable solvents for cleaning. Never use any
flammable solvents for cleaning anything, EVER!
Prevent fire hazards by keeping the vehicle clean of any
accumulated trash, grease and debris.
Always have a multipurpose dry chemical fire
extinguisher filled and available during vehicle
operation and adding fuel. Know how to use it.
FIG. 12
FIG. 13
FIG. 14

AG617715 1-7
SAFETY
STAY CLEAR OF ROTATING DRIVE
LINES AND MOVING PARTS
FIG. 15: Entanglement in rotating drive lines or
moving components will cause serious injury or death.
FIG. 16: Keep all safety guards and shields in place at
all times when operating the vehicle.
Turn the key switch to the OFF position. Remove the
key from the switch to prevent unauthorized operation
of the vehicle before removing any safety guards and
shields.
Wear close fitting clothing. Stop the engine and make
sure the drive lines are stopped before making any
adjustments or performing any type of service on the
engine or vehicle.
TOWING OTHER VEHICLES /
TRAILERS / EQUIPMENT
FIG. 17: Towing of other vehicles without brakes is
NOT approved by Challenger.
Using the vehicle for towing can create a safety hazard
and can void the vehicle or system warranty.
MODIFICATIONS
Welding or altering the chassis in any way (such as
adding implement towing hitches) can cause damage
or failure of components and create a safety hazard.
Modifications not approved by Challenger can also void
the vehicle or system warranty.
FIG. 15
FIG. 16
FIG. 17

SAFETY
1-8 AG617715
MAINTENANCE AND SERVICE SAFETY
FIG. 18: Read the maintenance and safety
instructions and understand them before performing
any maintenance procedures.
Never perform any maintenance procedures or repairs
if the instructions and safety procedures are not fully
understood. Only trained and qualified personnel
should perform any maintenance procedures or
repairs.
Never modify any equipment or add attachments not
approved by Challenger.
PRACTICE SAFE MAINTENANCE
FIG. 19: Never lubricate, service, or adjust the vehicle,
any of its systems or components while they are
moving.
Never wear a necktie, necklace, scarf or loose clothing
when working near machine tools or moving parts.
Tie long hair behind the head and wear a hair net.
Remove rings and other jewelry to prevent electrical
shorts or other personal injury when in contact with
machine tools or moving parts.
FIG. 20: Stop the engine. Remove the key.
Allow the vehicle to cool.
Keep all parts in good condition and properly installed.
Fix any damaged vehicle, systems or component
immediately.
Replace worn, damaged or broken parts immediately.
Remove any buildup of grease, oil or debris.
Disconnect the electrical system before making
adjustments on electrical systems or welding on the
vehicle.
FIG. 18
FIG. 19
FIG. 20

AG617715 1-9
SAFETY
CHEMICAL SAFETY
Operator Cabs
FIG. 21: Some cabs use filters that MAY NOT filter out
dangerous chemicals.
Follow instructions given by the chemical manufacturer.
Cabs labeled as "Enclosed Cabs for Pesticide
Application IncorporatingRespiratory
Protection" or "ECPAR" comply with ASAE S525 and
EPA Worker Protection Standards for operating in a
pesticide environment. This does not include fumigants.
(Look for the ECPAR decal to check if the cab is an
ECPAR cab.) However, to remain in compliance,
ECPAR cabs MUST be operated with the door closed
and the fan on MAX setting when applying or driving in
a treated area. Operators must also avoid entering or
exiting the cab in treated areas. Cabs must be
equipped with the required filters and maintained
properly. (See the Maintenance Section of this manual.)
FIG. 22: Never spray hazardous chemicals when the
wind is in excess of the chemical manufacturer's
recommendation. NEVER allow chemicals to contact
the skin or eyes.
FIG. 23: Always wear APPROVED protective
equipment and clothing.
Before leaving the cab, wear personal protective
equipment as required by pesticide use instructions
and the chemical manufacturer recommendations.
Before re-entering the cab, remove protective
equipment and store; either outside the cab in a closed
box or another type of sealable container. Inside the
cab, use a pesticide resistant container such as a
plastic bag or approved container. Clean shoes or
boots to remove soil or other contaminant prior to
entering the cab.
Select a safe area to fill, flush, calibrate and
decontaminate the vehicle. Select an area where
hazardous chemicals will not drift or run off to
contaminate people, animals, vegetation, water supply,
etc.
If hazardous chemicals come in contact with the body,
wash immediately according to the chemical
manufacturer's recommendations.
Never place nozzles, tips or other parts to lips to blow
out trash or debris. Have spare tips available for
replacement.
FIG. 21
FIG. 22
FIG. 23

SAFETY
1-10 AG617715
FIG. 24: Clean the vehicle of hazardous chemicals
after use. Hazardous chemical residue can build up on
the inside and outside of the vehicle.
Direct exposure to hazardous chemicals can cause
serious injury or death. Potentially hazardous
chemicals used with Challenger equipment include
such items as fuel, lubricants, coolants, hydraulic fluid,
paints and adhesives.
FIG. 25: The Material Safety Data Sheet (MSDS)
provides specific details on hazardous chemical
products: physical and health hazards, safety
procedures and emergency response techniques.
Check the MSDS before starting any project using a
hazardous chemical. Know exactly what the risks are
and how to do the project safely. Follow procedures and
equipment recommendations.
(See the chemical manufacturer for MSDS's on
chemical products used with Challenger equipment.)
WEAR PROTECTIVE CLOTHING
FIG. 26: Wear close fitting clothes and the proper
safety equipment required for the job.
Wear a suitable hearing protection device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Prolonged exposure to high decibels or loud noise can
cause hearing impairment or loss of hearing.
Operating equipment safely requires the full attention of
the operator. Never wear radio or music headphones
while operating the vehicle.
WORK IN A CLEAN AREA
FIG. 27: Thoroughly clean the work area, the vehicle,
systems, and components before starting a job. Dirty
and greasy areas can create work hazards.
FIG. 24
FIG. 25
FIG. 26
FIG. 27

AG617715 1-11
SAFETY
UNDERSTAND CORRECT SERVICE
FIG. 28: Light your working area properly, adequately
and safely.
Use proper safety lights with wire safety cages.
Exposed bulbs can ignite fluids.
Catch draining fluids in proper containers.
Never use beverage containers that could mislead
personnel to drink from them.
USE PROPER TOOLS
FIG. 29: Make-shift tools and procedures can create
safety hazards. Use only the proper equipment and
procedures.
Use power tools only to loosen threaded parts and
fasteners.
Use only U.S. tools with U.S. fasteners and metric tools
with metric fasteners.
SUPPORT MACHINE PROPERLY
FIG. 30: Never support the vehicle on cinder blocks,
hollow tiles or supports that may crumble.
Never work under a vehicle that is only supported by a
jack. Use wheel chocks.
PROPER LIFTING EQUIPMENT
FIG. 31: Lifting incorrectly can cause severe injury or
vehicle damage.
Follow the procedures recommended in the proper
manual for removal and installation of components of
this vehicle, systems or components.
FIG. 28
FIG. 29
FIG. 30
FIG. 31

SAFETY
1-12 AG617715
HIGH-PRESSURE FLUIDS
FIG. 32: AVOID HIGH-PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the skin
causing serious injury.
The vehicle must be stopped and cooled before
checking fluids. Use caution when removing radiator
caps, plugs, grease fittings or pressure taps.
Never open pressure lines when they are under
pressure. Release all pressure before doing
maintenance or repairs on any pressure system.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
FIG. 33: Search for leaks with a piece of wood or
cardboard. Protect hands and body from high pressure
fluids. Do not use your hands!
Never open hydraulic lines or fuel lines when they are
under pressure. Hydraulic fluid or diesel fuel under
pressure can cut the skin, cause bad burns, eye injury
or skin irritation.
If an accident does occur, get medical help immediately
if any personnel are injured by hydraulic fluid or fuel.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may result.
Doctors unfamiliar with this type of injury should
reference a knowledgeable medical source.
HYDRAULIC HOSES
IMPORTANT: Hydraulic hoses have a limited working
live. By weather influences and use under
heavy conditions and normal aging the
working live reduce.
Therefore is checking of hydraulic hoses by damaging
and aging important for good functioning of your
machine and the safety of the user and the
environment.
Replace immediately damaged and leaking hydraulic
hoses.
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
FIG. 34: Never heat by welding, soldering or using a
torch near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area.
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
personnel and bystanders.
FIG. 32
FIG. 33
FIG. 34