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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