Challenger TG8400C User manual

Operator's Manual
Flotation Chassis
TG8400C
AGCC8400xKxxx1001-
North America
4205 River Green Parkway, Duluth GA 30096 USA
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
© AGCO 2019
Original Operator's Manual
November 2019
591367D1F
NA
English

CALIFORNIA
Proposition 65 Warning
WARNING: Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, or other reproductive harm.
WARNING: Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer, birth defects, or other reproductive
harm. Wash hands after handling.
Congratulations on your selection of an AGCO®Product. We believe you
have exercised excellent judgment in the purchase of your AGCO®
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 correct 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 machine. Also, time spent in becoming fully acquainted
with its 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 AGCO®Dealer at time of purchase.
AGCO®reserves the right to make changes or add improvements to its products at any time
without incurring any obligation to make such changes to products manufactured previously. AGCO
®, or its dealers, accept no responsibility for variations which may be evident in the actual
specifications of its products and the statements and descriptions contained in this publication.
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Flotation Chassis
1 Safety ....................................................................13
1.1 A word to the operator .............................................. 15
1.1.1 Important safety information ........................................ 15
1.1.2 Safety symbol .................................................. 16
1.1.3 Safety messages ................................................ 17
1.1.4 Information messages ............................................ 17
1.1.5 General hazard information ......................................... 17
1.2 Prepare for operation ................................................ 19
1.2.1 Mount and dismount the machine .................................... 19
1.2.2 Before you start the engine ......................................... 19
1.2.3 Start the engine ................................................. 20
1.2.4 Before operating the machine ....................................... 20
1.2.5 Operate the machine ............................................. 20
1.2.6 Operator station ................................................. 21
1.2.7 Park the machine ................................................ 21
1.2.8 Exit the cab in an emergency ....................................... 22
1.2.9 Safety lamps and marking devices use ................................ 22
1.2.10 Roading on public roads ........................................... 23
1.2.11 Operate on a slope .............................................. 23
1.2.12 Electrical storm injury prevention .....................................23
1.3 Maintenance and service ............................................ 24
1.3.1 Maintenance safety .............................................. 24
1.3.2 Wear protective clothing ........................................... 28
1.3.3 Fire prevention and first aid .........................................28
1.3.4 Proper disposal of waste .......................................... 29
1.3.5 Shield and guards ................................................29
1.3.6 Support the machine correctly ...................................... 30
1.3.7 Asbestos information ............................................. 30
1.3.8 Pressurized air .................................................. 30
1.3.9 Cut and crush prevention .......................................... 30
1.3.10 Boom safety ................................................... 31
1.3.11 Fuel safety ..................................................... 31
1.3.12 Hydraulic safety ................................................. 31
1.3.13 High pressure leaks .............................................. 32
1.3.14 Chemical safety ................................................. 32
1.3.15 Engine safety ................................................... 34
1.3.16 Battery safety .................................................. 36
1.3.17 Tire safety ..................................................... 37
1.3.18 Avoid eye contact with radar ........................................ 37
1.3.19 Exhaust fumes .................................................. 38
1.3.20 Electrical power lines overhead ...................................... 38
1.3.21 Towing ....................................................... 38
1.3.22 Modifications ................................................... 38
1.3.23 Mobile radio installation ........................................... 39
1.3.24 Safety signs .................................................... 39
1.4 Cab signs ...........................................................40
1.4.1 Break glass - exit ................................................ 41
1.4.2 Runover hazard ................................................. 41
1.4.3 Cab filter number 2 .............................................. 41
1.4.4 Cab filter number 3 .............................................. 41
1.4.5 Cab filter number 1 .............................................. 42
1.4.6 Sound horn / electrical hazard / read manual ............................ 42
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Flotation Chassis
591367D1F
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1.4.7 Rollover-seatbelt / runover-no riders ................................... 42
1.5 Electrical signs ...................................................... 43
1.5.1 Radar hazard ................................................... 44
1.5.2 Electrocution hazard .............................................. 44
1.5.3 Electrical hazard ................................................. 44
1.5.4 Radar / high pressure hazard ........................................ 45
1.5.5 Informational - Cab fuse / relay ...................................... 45
1.5.6 Informational - Battery box fuse / relay .................................45
1.6 Chassis signs ....................................................... 46
1.6.1 Informational - Do not alter ......................................... 47
1.6.2 Informational - Hand wash ......................................... 47
1.6.3 Tie down ...................................................... 47
1.6.4 Informational - Manufacturer plate ....................................47
1.6.5 Crush and falling hazard ........................................... 48
1.6.6 Ultra low sulfur diesel fuel ......................................... 48
1.6.7 Informational - Hydraulic oil level ..................................... 48
1.7 Engine signs ........................................................ 49
1.7.1 Hot pressurized coolant ........................................... 50
1.7.2 Rotating blades hazard ............................................ 50
1.7.3 High pressure hazard ............................................. 50
1.7.4 Run over hazard ................................................. 50
1.7.5 Ether, belt, and fan entanglement hazard ............................... 51
2 Introduction .............................................................. 53
2.1 Information ......................................................... 55
2.1.1 Intended use ................................................... 55
2.1.2 Proper disposal of waste .......................................... 55
2.1.3 Emissions reduction - selective catalyst reduction — SCR — technology ........ 55
2.1.4 DEF Storage and Shelf Life ......................................... 56
2.2 Machine identification ...............................................58
2.2.1 Product identification information .................................... 58
2.2.2 Serial number definition ........................................... 58
2.2.3 Engine serial number plate .........................................59
2.2.4 Transmission serial number plate .................................... 59
2.3 Break-in period ..................................................... 60
2.3.1 General break-in information ........................................ 60
2.3.2 Break-in maintenance schedule ......................................60
2.3.3 Operate the engine-first 200 hours ................................... 60
2.3.4 Initial interval for inline fuel strainer ................................... 60
2.3.5 Break-in the transmission .......................................... 60
2.3.6 Break-in the rear axle ............................................. 60
2.3.7 Do a check of the wheel mounting hardware ............................ 60
2.3.8 Hydraulic filter .................................................. 61
2.3.9 Initial pressure washer pump ....................................... 61
2.4 Machine transport .................................................. 62
2.4.1 Operate the machine in limp-home mode .............................. 62
2.4.2 Transport the machine on a truck or trailer .............................. 65
2.4.3 Information for towing the machine ...................................66
2.4.3.1 Prepare for towing - engine operation ........................ 66
2.4.3.2 Prepare for towing - engine not operating ..................... 69
2.4.3.3 Tow the machine ....................................... 69
2.5 Park brake information .............................................. 71
2.5.1 Release the manual park brake ...................................... 71
2.5.2 Release the park brake using air ..................................... 71
2.5.3 Release the park brake with the manual release (MGM Brake Chambers) ....... 71
2.5.3.1 Return the release bolt to the storage/run position. ............. 72
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Flotation Chassis
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2.6 Major components .................................................. 74
2.6.1 Component location (front/rear view) .................................. 74
2.6.2 Component location (side view) ..................................... 75
2.6.3 Component location (top view) ...................................... 76
2.7 Emissions warranty ................................................. 77
2.7.1 United States and Canada emission control warranty statement ............. 77
2.7.2 California emission control warranty statement .......................... 80
3 Operation ................................................................ 85
3.1 Instruments and controls ............................................ 89
3.1.1 Dash panel .................................................... 89
3.1.2 Operating status displays .......................................... 90
3.1.3 Multiple display screens ........................................... 90
3.1.4 Console keypad ................................................. 92
3.1.5 Ignition switch .................................................. 92
3.1.6 Multifunction lever ............................................... 93
3.1.7 Set the windshield wiper delay ...................................... 94
3.1.8 Tilt - telescoping lever .............................................95
3.1.9 Foot pedals .................................................... 95
3.1.10 Park brake ..................................................... 96
3.1.11 Drive lever controls .............................................. 96
3.1.12 Armrest controls ................................................ 97
3.1.13 Armrest adjustment .............................................. 97
3.1.14 Automatic heated mirrors .......................................... 97
3.1.15 Power mirror adjustment .......................................... 98
3.1.16 Interior lamps ...................................................99
3.1.17 Radio (if equipped) ............................................... 99
3.1.18 Sun Visor ...................................................... 99
3.1.19 Cup holders .................................................... 99
3.1.20 Storage compartments ........................................... 100
3.1.21 Power strip ....................................................100
3.1.22 Power ports ................................................... 100
3.1.23 Cargo net ..................................................... 101
3.1.24 Lamp switches .................................................102
3.1.25 Bluetooth microphone ........................................... 103
3.1.26 Objects in the cab .............................................. 103
3.1.27 Automatic battery disconnect ...................................... 103
3.2 Cab temperature control ............................................ 105
3.2.1 Automatic temperature control ..................................... 105
3.2.2 Heater operation ................................................106
3.2.3 Defroster operation ............................................. 106
3.2.4 Air conditioner operation .......................................... 106
3.2.5 Automatic fan speed control ....................................... 107
3.2.6 Manual fan speed control (HI/LO) ................................... 107
3.2.7 Air conditioning compressor clutch control ............................. 107
3.2.8 Heater water valve .............................................. 107
3.2.9 Cab air temperature sensor ........................................ 107
3.2.10 Evaporator probe ............................................... 108
3.2.11 Temperature control troubleshooting ................................. 108
3.3 Seats .............................................................. 110
3.3.1 Seatbelt operation ...............................................110
3.3.2 Basic operator seat .............................................. 111
3.3.3 Deluxe operator seat .............................................112
3.3.4 Deluxe vented operator seat ....................................... 114
3.3.5 Instructor seat ................................................. 115
3.4 General inspection ................................................. 117
3.4.1 Check fluids ................................................... 117
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Flotation Chassis
591367D1F
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3.4.2 Check for Condition and Cleanliness ................................. 117
3.4.3 Do a check of the hydraulics ....................................... 117
3.4.4 Check fuel system .............................................. 118
3.4.5 Do a check of the cab ............................................ 118
3.4.6 Check mirrors .................................................. 118
3.4.7 Check the Hoses ............................................... 118
3.4.8 Check the Safety Signs ........................................... 118
3.5 Terminal ........................................................... 120
3.5.1 Terminal introduction ............................................ 120
3.5.2 Audible alarms and indicators ...................................... 121
3.5.3 Display the chassis software information .............................. 121
3.5.4 Set the language ............................................... 122
3.5.5 Set the date and time ............................................ 123
3.5.6 Set the audio level .............................................. 124
3.5.7 Set the screen brightness ......................................... 125
3.5.8 Switch between day and night mode ................................. 127
3.5.9 Call up the USB Data screen ....................................... 127
3.5.10 Select and transfer individual data to the USB stick .......................128
3.5.11 Select and transfer all data to the USB stick ............................ 129
3.5.12 Transfer data from the USB stick to the terminal .........................130
3.5.13 Task data ..................................................... 131
3.5.14 Field data ..................................................... 132
3.5.15 Take a screenshot from the AccuTerminal ............................. 133
3.5.16 Download a screenshot from the AccuTerminal ......................... 133
3.5.17 Clean the terminal screen ......................................... 134
3.5.18 Calibrate the touch screen ........................................ 135
3.5.19 Do a touch test ................................................ 136
3.5.20 Set up the camera application - if equipped ............................ 137
3.5.21 View the service interval screens ....................................138
3.5.22 Program the user-defined service intervals ............................. 138
3.5.23 Calibrate the radar .............................................. 140
3.5.24 Calibrate the wheel speed .........................................140
3.5.25 Calibrate the wheel speed and radar ................................. 141
3.5.26 Calibrate the steering angle sensor .................................. 142
3.5.27 Calibrate the steering valve ........................................ 143
3.5.28 Calibrate the lever ...............................................144
3.5.29 Calibrate the transmission range .................................... 144
3.5.30 Calibrate the CVT transmission ..................................... 145
3.5.31 Calibrate the turbo clutch ......................................... 145
3.5.32 View the diagnostic screens ....................................... 146
3.5.33 View the active errors screen ...................................... 147
3.5.34 Set the power management values .................................. 147
3.5.35 View the fuel consumption screen ...................................148
3.5.36 Call up the ISOBUS Information screen ............................... 149
3.5.37 View the Auto-Guide™ map ....................................... 150
3.5.38 View the worked area settings ..................................... 151
3.5.39 Make a wayline from the map ...................................... 152
3.5.39.1 AB wayline .......................................... 153
3.5.39.2 Contour wayline ...................................... 153
3.5.39.3 A+ angle wayline ...................................... 154
3.5.39.4 Pivot wayline ......................................... 155
3.5.39.5 AB coordinates wayline ................................. 155
3.5.40 Make a boundary from the map .....................................155
3.5.41 Make an obstacle from the map .................................... 157
3.5.42 Adjust the Auto-Guide™ steering settings ............................. 159
3.5.43 Update the terminal software ...................................... 161
3.6 Raven Viper 4 values ............................................... 162
3.7 Camera settings ................................................... 164
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Flotation Chassis
591367D1F
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3.7.1 Camera options and connections ....................................164
3.7.2 Position the camera image ........................................ 164
3.7.3 Change cameras ............................................... 165
3.7.4 Display the camera image while reversing ............................. 165
3.7.5 Change the camera to and from full-screen ............................ 166
3.7.6 Adjust the brightness ............................................ 167
3.7.7 Adjust the contrast .............................................. 167
3.7.8 Adjust the color saturation ........................................ 168
3.8 Start the engine ....................................................169
3.8.1 Cold weather start procedure ...................................... 170
3.8.2 Diesel exhaust fluid (DEF) cold start ..................................171
3.8.3 Restart a stalled engine ...........................................171
3.8.4 Engine power limitations .......................................... 171
3.8.5 Low diesel exhaust fluid (DEF) level .................................. 172
3.8.6 Stop the engine and afterrun ....................................... 173
3.9 Tag axle operation ..................................................174
3.9.1 Tag axle ...................................................... 174
3.9.2 Operate the tag axle ............................................. 174
3.10 Operating on a public road ..........................................175
3.10.1 Machine operation on a public road .................................. 175
3.11 Transmission function .............................................. 176
3.11.1 Transmission - general ........................................... 176
3.11.2 High and low speed range .........................................176
3.11.3 Drive the machine .............................................. 177
3.11.4 Drive modes .................................................. 177
3.11.5 Increase the drive speed .......................................... 178
3.11.6 Decrease the drive speed ......................................... 179
3.11.7 Change the drive direction ........................................ 180
3.11.8 Stop the machine ............................................... 181
3.11.9 Set the cruise control speeds ...................................... 182
3.11.10 Set the drive handle aggressiveness ................................. 183
3.11.11 Transmission management system (TMS) ............................. 183
3.11.12 Set the power management values .................................. 184
3.11.13 Joystick mode ................................................. 184
3.11.14 Foot pedal throttle mode ..........................................185
3.12 AccuField Command ............................................... 187
3.12.1 Manual configuration ............................................ 187
3.12.2 General function - AccuField Command ............................... 188
3.12.3 Functions and dependencies ....................................... 188
3.12.4 Call up and activate AccuField Command .............................. 190
3.12.5 Joystick assignment ............................................. 191
3.12.6 Record an operational sequence .................................... 192
3.12.7 Start an operational sequence ...................................... 194
3.12.8 Configure an operational sequence manually ........................... 194
3.12.9 Step mode .................................................... 196
3.13 Cold weather considerations ........................................ 198
3.13.1 Minimize the eect of cold weather ..................................198
3.13.2 Using grade No. 1-D fuel .......................................... 198
3.13.3 Fuel filters .................................................... 198
3.13.4 Coolant heater ................................................. 198
3.13.5 Seasonal viscosity oil and proper coolant concentration ................... 198
3.13.6 Winterfronts .................................................. 199
3.13.7 Idling the engine ................................................199
3.13.8 Engine coolant specifications ...................................... 199
3.13.9 Cooling system water quality ...................................... 199
3.13.10 Antifreeze .................................................... 199
3.13.11 Grease ...................................................... 200
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3.13.12 Diesel fuel .................................................... 200
3.13.13 Lubricity of diesel fuels ........................................... 200
3.13.14 Diesel fuel storage .............................................. 201
3.14 Storage ........................................................... 202
3.14.1 Prepare for long term storage ...................................... 202
3.14.2 Remove the machine from long term storage .......................... 202
3.15 Optional accessories ............................................... 204
3.15.1 Weather station - if equipped ...................................... 204
3.15.2 Install the mini SIM card for Global System for Mobile communication (GSM) ... 205
3.16 SmartConnect™ ................................................... 207
3.16.1 SmartConnect™ app ............................................ 207
3.16.2 Wi-Fi connection (SmartConnect ™) ................................. 208
3.16.3 SmartConnect ™ icons ........................................... 208
3.16.4 Quick start .................................................... 210
3.16.5 Homepage .................................................... 213
3.16.6 Dashboard .................................................... 215
3.16.7 History .......................................................216
3.16.8 First steps .................................................... 216
3.16.9 Map page .................................................... 217
3.16.10 Configuration page .............................................. 218
3.16.11 The task data in SmartConnect™ ....................................219
4 Engine Operation ........................................................ 221
4.1 Safety instructions ................................................. 223
4.2 To the user ........................................................ 224
4.2.1 Engine type designations ......................................... 224
4.2.2 Location of the engine serial number ................................. 225
4.2.3 Type plate of the electronic control unit ............................... 226
4.3 Technical data ..................................................... 227
4.3.1 Principal dimensions and data ...................................... 227
4.3.2 Fuel system ................................................... 227
4.3.3 Lubrication system .............................................. 227
4.3.4 Cooling system ................................................ 227
4.3.5 Selective Catalyst Reduction (SCR) system technical data ..................228
4.4 Air control system ................................................. 230
4.4.1 2 stage turbocharging ............................................ 231
4.4.2 Interstage charge air cooling ....................................... 231
4.4.3 Throttle valve .................................................. 231
4.5 Fuel system ........................................................232
4.6 Engine control system .............................................. 234
4.7 Lubrication system ................................................. 235
4.7.1 Oil pressure regulating valve ....................................... 236
4.7.2 Oil filter and oil cooler ............................................ 236
4.8 Cooling system .................................................... 237
4.8.1 Engine heater ..................................................237
4.9 Electrical system ................................................... 238
4.10 SCR system ....................................................... 239
4.10.1 Selective Catalyst Reduction (SCR) system overview ..................... 239
4.10.2 Selective Catalyst Reduction (SCR) system components and their functions .... 240
4.11 Operation and driving .............................................. 242
4.12 Daily pre-start check ............................................... 243
4.13 Starting the engine ................................................ 244
4.13.1 Break in the engine ............................................. 244
4.14 Starting the engine in cold conditions ............................... 246
4.14.1 Warming up the engine .......................................... 246
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4.15 Start the engine with an auxiliary battery ............................ 247
4.16 Attention during operation ......................................... 248
4.17 Stopping the engine ............................................... 249
5 Maintenance ............................................................ 251
5.1 Maintenance intervals .............................................. 255
5.1.1 Maintenance introduction ......................................... 255
5.1.2 Maintenance symbols ........................................... 255
5.1.3 Lubricant filling reminders .........................................256
5.1.4 Maintenance schedule ........................................... 257
5.1.4.1 Maintenance chart .....................................257
5.1.4.2 Daily maintenance schedule ..............................258
5.1.4.3 Maintenance schedule 10 to 1000 hours ..................... 258
5.1.4.4 Maintenance Schedule 2000 to 4000 hours .................. 261
5.1.5 Lubricants and fluids .............................................261
5.2 Air reservoir and air dryer ...........................................263
5.2.1 Air dryer ......................................................263
5.3 Air conditioner system ............................................. 265
5.3.1 Air conditioner ................................................. 265
5.3.2 Condenser .................................................... 265
5.4 Engine ............................................................ 267
5.4.1 Do a check of the engine oil level ................................... 267
5.4.2 Change the engine oil and filter ..................................... 268
5.4.3 Engine belts and tensioner ........................................ 268
5.4.3.1 Replace the serpentine belt .............................. 268
5.4.3.2 Replace the water pump belt ............................. 269
5.4.4 Fuel system ................................................... 271
5.4.5 Fuel tank ..................................................... 271
5.4.6 In-line fuel strainer .............................................. 272
5.4.7 Replace the fuel filters ........................................... 272
5.4.8 Prime the fuel system ........................................... 273
5.4.9 Engine coolant ................................................. 274
5.5 Maintaining the air cleaner ......................................... 276
5.5.1 Engine air cleaner indicator ........................................ 276
5.5.2 Replace the air filter element ...................................... 276
5.5.3 Secondary air filter element ....................................... 277
5.6 Hydraulic system ...................................................278
5.6.1 Do a check of the hydraulic oil-level check ............................. 278
5.6.2 Replace the hydraulic system oil and filter ............................. 278
5.7 Continuously variable transmission ................................. 280
5.7.1 Transmission operating temperatures ................................ 280
5.7.2 Do a check of the transmission oil ................................... 280
5.7.3 Change the transmission oil ....................................... 281
5.8 Transfer case .......................................................283
5.8.1 Do a check of the transfer case oil ...................................283
5.8.2 Change the transfer case oil ....................................... 283
5.8.3 Clean the transfer case breather .................................... 284
5.9 Lubricate and inspect driveline and components ..................... 285
5.9.1 Inspect and lubricate the engine to transmission driveline ..................285
5.9.2 Lubricate the transmission to the transfer case driveline ................... 285
5.9.3 Lubricate the transfer case to rear axle driveline ......................... 286
5.9.4 Lubricate the front axle kingpins .................................... 286
5.9.5 Lubricate the front axle springs ..................................... 288
5.9.6 Do a check of the front axle mounting nuts ............................ 288
5.9.7 Lubricate the rear axle springs ..................................... 288
5.9.8 Do a check of the rear axle mounting nuts ............................. 289
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Flotation Chassis
591367D1F
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5.10 Intercoolers ........................................................290
5.10.1 Heat exchangers ............................................... 290
5.10.2 Clean the heat exchangers ........................................ 290
5.11 Front wheel bearings ............................................... 291
5.11.1 Do a check of the front wheel bearing oil ............................. 291
5.11.2 Change the front wheel bearing oil .................................. 291
5.11.3 Wheel end oil change intervals and specifications ....................... 292
5.12 Tag axle ........................................................... 293
5.12.1 Tag axle bearing bolts and lubricating the tag axle fittings — if equipped ....... 293
5.13 Steering ........................................................... 294
5.13.1 Steering cylinders ...............................................294
5.13.2 Do a check of the front wheel toe-in ................................. 294
5.13.2.1 Measure the front wheel toe-in ........................... 294
5.13.2.2 Adjust the front wheel toe-in ............................. 295
5.14 Rear axle .......................................................... 296
5.14.1 Clean the breather for the rear axle .................................. 296
5.14.2 Do a check of the rear axle oil ...................................... 296
5.14.3 Break-in the rear axle ............................................ 297
5.14.4 Change the rear axle oil .......................................... 297
5.15 Brake maintenance ................................................. 299
5.15.1 Lubricate the front brake slack adjuster ............................... 299
5.15.2 Lubricate the rear brake slack adjuster ................................ 299
5.15.3 Brake air lines ................................................. 299
5.15.4 Parking brake .................................................. 299
5.15.5 Do a check of the service brake system ...............................300
5.15.6 Do a check of the automatic slack adjusters ............................300
5.15.7 Manually adjusting the automatic slack adjusters ........................ 301
5.16 Wheels ............................................................ 303
5.16.1 Remove the wheels ............................................. 303
5.16.2 Install the wheels ............................................... 303
5.16.3 Tighten the wheel mounting hardware ............................... 304
5.17 Tires .............................................................. 305
5.17.1 Inflate the tire ................................................. 305
5.17.2 Replace the tire ................................................ 305
5.17.3 Tire charts .................................................... 305
5.18 Cab maintenance .................................................. 312
5.18.1 Do a check of the cab mount bolts .................................. 312
5.18.2 Cab air filters .................................................. 313
5.18.3 Change the primary fresh air filter ................................... 314
5.18.4 Change the secondary clean air filter ................................. 315
5.18.5 Change the recirculation air filter ................................... 317
5.18.6 Clean the cab air filter element ..................................... 318
5.18.7 Do a check of the windshield washer reservoir ..........................318
5.18.8 Windshield wiper blade ...........................................319
5.19 Electrical system ................................................... 320
5.19.1 Batteries ..................................................... 320
5.19.2 Battery box components ..........................................320
5.19.3 Remove the battery terminal connection .............................. 322
5.19.4 Jump start the battery ........................................... 322
5.19.5 Change a fuse/relay ............................................. 323
5.19.6 Fuse/relay location .............................................. 324
5.20 Paint and decals ................................................... 328
5.20.1 Safety treads .................................................. 328
5.21 Hand rinse tank .................................................... 329
5.21.1 Fill the hand rinse tank ........................................... 329
5.21.2 Rinse hands and equipment ....................................... 330
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5.21.3 Winterize the hand rinse tank ...................................... 330
5.22 Pressure washer ................................................... 331
5.22.1 Pressure washer input water supply ................................. 331
5.22.2 Before starting the pressure washer ................................. 331
5.22.3 Prime the pressure washer pump ................................... 331
5.22.4 General care of the pressure washer pump ............................ 331
5.22.5 Pressure washer pump storage in freezing conditions .................... 331
5.22.6 Operate the pressure washer ...................................... 331
5.22.7 Change the pressure washer pump motor oil ........................... 332
5.22.8 Change the pressure washer strainer ................................ 333
5.22.9 Winterize the pressure washer system ............................... 333
6 Troubleshooting ......................................................... 335
6.1 Engine ............................................................ 337
6.1.1 Low diesel exhaust fluid (DEF) level ..................................341
6.2 Transmission ...................................................... 342
6.3 Electrical system ................................................... 344
6.4 Hydraulic system ...................................................345
6.5 Parking brake troubleshooting ...................................... 346
6.6 Operation ......................................................... 347
6.7 Cab ............................................................... 348
6.8 TG7300C/TG8300C/TG8400C/TG9300C fault code reference ........... 349
6.8.1 Accuterminal module fault code reference ............................. 349
6.8.2 Armrest module fault code reference ................................ 350
6.8.3 Automatic steering module fault code reference ........................ 350
6.8.4 Electrical controller module fault code reference ........................ 353
6.8.5 Error management module fault code reference .........................353
6.8.6 Machine information module fault code reference ....................... 354
6.8.7 Machine module fault code reference ................................ 354
6.8.8 Transmission module fault code reference ............................. 355
7 Specifications ........................................................... 359
7.1 Machine specifications ............................................. 361
7.2 Machine dimensions ............................................... 364
8 Index ................................................................... 367
Table of contents
Flotation Chassis
591367D1F

Table of contents
Flotation Chassis
591367D1F

1 Safety
1.1 A word to the operator .................................................. 15
1.1.1 Important safety information ............................................15
1.1.2 Safety symbol ...................................................... 16
1.1.3 Safety messages .................................................... 17
1.1.4 Information messages ................................................ 17
1.1.5 General hazard information ............................................. 17
1.2 Prepare for operation ....................................................19
1.2.1 Mount and dismount the machine ....................................... 19
1.2.2 Before you start the engine ............................................ 19
1.2.3 Start the engine ..................................................... 20
1.2.4 Before operating the machine ...........................................20
1.2.5 Operate the machine ................................................. 20
1.2.6 Operator station .................................................... 21
1.2.7 Park the machine .................................................... 21
1.2.8 Exit the cab in an emergency ........................................... 22
1.2.9 Safety lamps and marking devices use .................................... 22
1.2.10 Roading on public roads ............................................... 23
1.2.11 Operate on a slope .................................................. 23
1.2.12 Electrical storm injury prevention ........................................ 23
1.3 Maintenance and service ................................................ 24
1.3.1 Maintenance safety .................................................. 24
1.3.2 Wear protective clothing .............................................. 28
1.3.3 Fire prevention and first aid ............................................ 28
1.3.4 Proper disposal of waste .............................................. 29
1.3.5 Shield and guards ................................................... 29
1.3.6 Support the machine correctly .......................................... 30
1.3.7 Asbestos information ................................................. 30
1.3.8 Pressurized air ...................................................... 30
1.3.9 Cut and crush prevention .............................................. 30
1.3.10 Boom safety ....................................................... 31
1.3.11 Fuel safety .........................................................31
1.3.12 Hydraulic safety ..................................................... 31
1.3.13 High pressure leaks .................................................. 32
1.3.14 Chemical safety ..................................................... 32
1.3.15 Engine safety ...................................................... 34
1.3.16 Battery safety ...................................................... 36
1.3.17 Tire safety ......................................................... 37
1.3.18 Avoid eye contact with radar ............................................37
1.3.19 Exhaust fumes ..................................................... 38
1.3.20 Electrical power lines overhead ..........................................38
1.3.21 Towing ........................................................... 38
1.3.22 Modifications .......................................................38
1.3.23 Mobile radio installation ............................................... 39
1.3.24 Safety signs ....................................................... 39
1.4 Cab signs .............................................................. 40
1.4.1 Break glass - exit ................................................... 41
1.4.2 Runover hazard ..................................................... 41
1.4.3 Cab filter number 2 .................................................. 41
1.4.4 Cab filter number 3 .................................................. 41
1.4.5 Cab filter number 1 .................................................. 42
Table of contents
Flotation Chassis 13
591367D1F

1.4.6 Sound horn / electrical hazard / read manual ................................ 42
1.4.7 Rollover-seatbelt / runover-no riders ....................................... 42
1.5 Electrical signs ......................................................... 43
1.5.1 Radar hazard .......................................................44
1.5.2 Electrocution hazard ................................................. 44
1.5.3 Electrical hazard .....................................................44
1.5.4 Radar / high pressure hazard ........................................... 45
1.5.5 Informational - Cab fuse / relay .......................................... 45
1.5.6 Informational - Battery box fuse / relay .................................... 45
1.6 Chassis signs ........................................................... 46
1.6.1 Informational - Do not alter ............................................. 47
1.6.2 Informational - Hand wash ............................................. 47
1.6.3 Tie down .......................................................... 47
1.6.4 Informational - Manufacturer plate ....................................... 47
1.6.5 Crush and falling hazard ............................................... 48
1.6.6 Ultra low sulfur diesel fuel ............................................. 48
1.6.7 Informational - Hydraulic oil level ......................................... 48
1.7 Engine signs ........................................................... 49
1.7.1 Hot pressurized coolant ............................................... 50
1.7.2 Rotating blades hazard ................................................ 50
1.7.3 High pressure hazard ................................................. 50
1.7.4 Run over hazard ..................................................... 50
1.7.5 Ether, belt, and fan entanglement hazard ...................................51
Table of contents
14 Flotation Chassis
591367D1F

1.1 A word to the operator
It is your responsibility to read and understand the
safety section in this manual and the manual for all
implements before you operate this machine. You
are responsible for your safety. Good safety
procedures prevent injury to you and the persons
around you.
Make the information in the safety section of this
manual a part of your safety procedure. This safety
section is written only for this type of machine.
Safety is your responsibility. You can prevent injury
and death.
This safety section gives basic safety examples
that can occur during the operation and
maintenance of your machine. This safety section
is not a replacement for safety instruction in other
sections of this manual.
Injury or death can occur if the safety instruction is
not obeyed.
Learn how to operate the machine and how to use
the controls correctly.
Do not operate the machine if you do not know
how to operate the machine. Do not let persons
operate the machine that do not know how to
operate the machine.
Follow all safety instructions in the manuals and on
the safety signs on the machine, the implements,
and the attachments.
Use only approved attachments and implements.
Make sure that your machine has the correct
equipment that is necessary by the local
regulations.
WARNING:
Do not use alcohol or drugs that can
have an eect on alertness or
coordination. If you use prescription
or 'over the counter' drugs, get
medical advice about the safe
operation of machines.
CAUTION:
If attachments or implements used
with this machine have a dierent
operator manual, see that operator
manual for other important safety
instructions.
GUID-AC91CCF6-1FF8-4A85-97A1-2D1562806825-high.jpg [High]
Fig. 1
1.1.1 Important safety information
Most personal injuries which occur during machine operation, maintenance or repair are caused by failure
to obey basic safety rules and precautions. Usually, an injury can be avoided by recognizing dangerous
situations before an injury occurs.
GUID-F38BCC9A-5A98-41F3-BA3C-2C5AB224EDFB [V6]
GUID-C5A0147C-1966-4D7E-8EFB-5A9A1913F996 [V1]
1. Safety
Flotation Chassis 15
591367D1F

The operator must be alert to possible hazards and have the necessary training, skills, and tools to do these
functions correctly.
WARNING:
Incorrect operation, lubrication, maintenance or repair of the machine can be dangerous
and can cause injury or death.
Do not operate or do any lubrication, maintenance or repair on the machine, until reading and
understanding the operation, lubrication, maintenance and repair information.
WARNING:
Safety precautions and warnings are provided in this manual and on machine. If these
hazard warnings are not heeded, bodily injury or death can occur to the operator or
others.
Not every possible circumstance involving a potential hazard can be anticipated. Warnings in this
publication and on the machine are not all-inclusive. If a tool, procedure, work method, or operating
method not specifically recommended is used, make sure it is safe for the operator and others.
Make sure the machine will not be damaged or made dangerous by lubrication, maintenance or repair
procedures selected. Information, specifications, and illustrations in this publication are on the basis of
information available at the time publication was written.
Specifications, torques, pressures, measurements, adjustments, illustrations and other items can change
at any time. These changes can change the service given to the machine. Get the complete and most
current information before starting any job. Local dealer has most current information available.
WARNING:
When replacement parts are required for this machine, use only AGCO replacement parts
or parts with equivalent specifications including, but not limited to, dimensions, type,
strength and material. Failure to heed this warning can cause early failures, product
damage, personal injury or death.
1.1.2 Safety symbol
The safety symbol tells you about a potentially
hazardous area!
Look for the safety symbol in this manual and on
the machine. The safety symbols tell you that
there is important safety instructions in the
manual.
GUID-4C201302-DBD2-4BFB-8D98-1DDED263BD6E-high.jpg [High]
Fig. 2
GUID-5D9F270E-D748-4741-82B1-BE49B78685F2 [V5]
1. Safety
16 Flotation Chassis
591367D1F

1.1.3 Safety messages
The words DANGER, WARNING or CAUTION are
used with the safety symbol. Learn these safety
messages and obey the recommended
precautions and safety instructions.
DANGER:
If you do not obey the recommended
precautions and safety instructions,
DEATH OR INJURY will occur.
WARNING:
If you do not obey the recommended
precautions and safety instructions,
DEATH OR INJURY can occur.
CAUTION:
If you do not obey the recommended
precautions and safety instructions,
INJURY can possibly occur.
GUID-73F05026-C37B-415A-8140-AD939A283378-high.jpg [High]
Fig. 3
1.1.4 Information messages
The words important and note are not related to personal safety, and are used to give information about
the operation and servicing of the machine.
IMPORTANT: Identifies special instructions or procedures which, if not followed, can cause damage to the
machine, the process, or the area around the machine.
NOTE: Information to make procedures easier.
1.1.5 General hazard information
CAUTION:
Carefully read the operator's manual
before operating the machine. See all
instructions and safety rules when
operating or doing maintenance.
GUID-FE6A41D4-536F-4C0D-BE60-FA0CCDEEB171-high.jpg [High]
Fig. 4
GUID-E54F7740-C021-42A8-8784-4287BE4356C8 [V4]
GUID-9A909F52-D57E-4C30-8CC7-6FDB6D7E9982 [V3]
GUID-45723AC0-5E25-4FA2-BB74-FF22568B117F [V3]
1. Safety
Flotation Chassis 17
591367D1F

Do not start the engine until the area is free of
personnel. Honk the horn two times to alert
others. This will help in avoiding personal injury
because machine movement can occur.
Know the width of the equipment to keep correct
clearance when operating the machine near
fences or near boundary obstacles.
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can
catch on controls or on other parts of the machine.
Make sure that all protective guards and all covers
are attached in position on the machine.
GUID-6CB742A7-222E-47ED-9806-1887BFD0CF24-high.jpg [High]
Fig. 5
Keep the machine free from unwanted material. Remove debris, oil, tools, and other items from the deck,
from walkways, and from steps.
Secure lunch boxes, tools, and other loose items that are not a part of the machine.
Know the appropriate work location hand signals and the personnel that are authorized to give the hand
signals. Get hand signals from one person only.
Never put maintenance fluids into glass containers. Drain all liquids into an approved container.
Discard any drained fluids and discard any filter elements according to local regulations.
Use all cleaning solutions with precaution.
Report all necessary repairs.
Do not let untrained or not approved personnel on the machine.
Do not smoke when servicing an air conditioner. Also, do not smoke if refrigerant gas can be present.
Inhaling the fumes that are released from a flame that contacts air conditioner refrigerant can cause bodily
harm or death.
Inhaling gas from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death.
Unless being instructed dierently, complete the maintenance under the following conditions:
• Turn the battery disconnect switch to "o" position.
• The machine is parked on level ground.
• Implements are lowered to the ground.
• Transmission control lever is in the park position.
• The engine is stopped.
• The engine start switch is turned o and the switch key is removed.
• The machine has cooled down.
Any additional precautions must be observed based on the conditions and environment where the machine
is being used.
1. Safety
18 Flotation Chassis
591367D1F

1.2 Prepare for operation
Read and understand all operation instructions and precautions in this manual before you operate the
machine or do the servicing.
Make sure that you know and understand the positions and operations of all controls. Make sure that all
controls are in neutral and that the parking brake is applied before you start the machine.
Make sure that all persons are away from your area of work before you start and operate the machine.
Examine and learn the controls in an area that is clear of persons and obstacles before you start work.
Know the machine dimensions and make sure that you have sucient space available to operate the
machine. Do not operate the machine at high speeds in crowded areas.
It is important to know and use the correct procedures when you do work around and operate the
machine. Do not let children or unqualified persons operate the machine. Keep others, especially children,
away from your area of work. Do not let others ride on the machine.
Make sure that the machine is in good condition for operation. Refer to the operator manual. Make sure
that the machine has the correct equipment required by local regulations.
1.2.1 Mount and dismount the machine
Mount the machine and dismount the machine only at locations that have steps and/or hand holds. Before
mounting the machine, clean the steps and the hand holds. Inspect the stairs and hand holds. Make any
necessary repairs.
When dismounting the machine, descend the steps backwards, and maintain a three-point contact with
the steps and hand holds. Three-point contact is two feet and one hand or one foot and two hands.
Never mount a moving machine. Never dismount a moving machine. Never jump o the machine except in
an emergency.
Do not carry tools or supplies when you try to mount the machine or when you try to dismount the
machine. Use a hand line to pull equipment onto the platform.
Do not use any controls as hand holds when you enter the operator compartment or when you exit the
operator compartment.
1.2.2 Before you start the engine
Start the engine only from the operator
compartment. Never short across the starter
terminals or batteries. Shorting can damage
electrical system or cause unexpected machine
movement.
Adjust the seat so full pedal travel can be achieved
with operator's back against seat back.
Make sure the machine is equipped with a lighting
system sucient for job conditions. Make sure all
machine lights are working properly.
Before starting the engine or moving the machine,
make sure no one is under, around or on machine.
Make sure area is free of personnel.
To honk horn the key must be turned to “run” to
enable the horn. As a warning honk horn twice, to
alert others.
GUID-6CB742A7-222E-47ED-9806-1887BFD0CF24-high.jpg [High]
Fig. 6
GUID-A25B667B-D7CF-4C75-8AED-C10113104322 [V6]
GUID-0C2DDCD0-EBC4-429D-9582-2E6B1E2DC763 [V2]
GUID-344A454E-7D26-49D5-9AB4-3FEEFA88AFD5 [V3]
1. Safety
Flotation Chassis 19
591367D1F

1.2.3 Start the engine
Diesel engine exhaust contains products of combustion which can be dangerous to your health. Always
start and operate the engine in a well ventilated area. If operating the engine in an closed area, vent the
exhaust to the outside.
When turning the steering wheel when the engine is operating, the machine will not turn with the
transmission control lever in the NEUTRAL position. The wheels will change direction but not rotate.
Do not start the engine until the area is free of personnel.
1.2.4 Before operating the machine
Clear all personnel from the machine and from the area.
Clear all obstacles from the machine's path. Be aware of hazards (wires, ditches, and so on).
Make sure that all the windows are clean.
Secure the door in the closed position.
Adjust the rear view mirrors for the best visibility near the machine. Make sure that the horn, the backup
alarm (if equipped), and all other warning devices are working correctly.
Fasten the seat belt securely, low around the operator's hips.
1.2.5 Operate the machine
Only operate the machine from the operator's seat. Wear the seat belt while operating the machine. Only
operate the controls while the engine is operating.
Check for correct operation of all controls and protective devices while operating the machine slowly in an
open area.
Make sure that no one will be endangered before moving the machine.
Report damage that was observed during operation of the machine. Make necessary repairs.
Do not operate the machine near an overhang, near the edge of a cli, or near the edge of an excavation.
Be careful to avoid any ground condition which can cause the machine to tilt.
A rollover of the machine can occur when operating on hills, on banks, or on slopes. A rollover of the
machine can also occur when moving across ditches, ridges, or other obstacles.
When possible, operate the machine up slopes and down slopes. Avoid operating the machine across the
slope.
Keep the machine under control. Do not overload the machine more than capacity.
Never straddle a wire cable. Never let other personnel straddle a wire cable.
Know the maximum dimensions of the machine.
When you operate on icy roads, decrease travel speed.
After you operate in muddy conditions, let sucient time for the tires to eject debris and moisture before
making high speed maneuvers. Tires that are wet and muddy can impede the machine's steering.
If stability of the machine is noticeably reduced, decrease travel speed.
GUID-404F2B41-5D2C-43EF-9AF6-E3F166487050 [V3]
GUID-E66151F8-AF87-4E6C-BCD5-6CE1A7A2699C [V1]
GUID-F987F244-EAFA-406C-9FFA-D879E94E4138 [V4]
1. Safety
20 Flotation Chassis
591367D1F