Challenger TG9300C User manual

Operator's Manual
Flotation Chassis
TG9300C
AGCC9300xKxxx1001-
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 2020
Original Operator's Manual
September 2020
591373D1E
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.
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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
1.1.6 California emission control warranty statement .......................... 18
1.2 Prepare for operation ................................................ 22
1.2.1 Mount and dismount the machine ....................................22
1.2.2 Before you start the engine .........................................22
1.2.3 Start the engine ................................................. 23
1.2.4 Before operating the machine ....................................... 23
1.2.5 Operate the machine ............................................. 23
1.2.6 Operator station ................................................. 24
1.2.7 Park the machine ................................................ 24
1.2.8 Exit the cab in an emergency ....................................... 25
1.2.9 Safety lamps and marking devices use ................................ 25
1.2.10 Roading on public roads ........................................... 26
1.2.11 Operate on a slope .............................................. 26
1.2.12 Electrical storm injury prevention .....................................26
1.3 Maintenance and service ............................................ 27
1.3.1 Maintenance safety .............................................. 27
1.3.2 Wear protective clothing ........................................... 31
1.3.3 Fire prevention and first aid .........................................31
1.3.4 Proper disposal of waste .......................................... 32
1.3.5 Shield and guards ................................................32
1.3.6 Support the machine correctly ...................................... 33
1.3.7 Asbestos information ............................................. 33
1.3.8 Pressurized air .................................................. 33
1.3.9 Cut and crush prevention .......................................... 33
1.3.10 Boom safety ................................................... 34
1.3.11 Fuel safety ..................................................... 34
1.3.12 Hydraulic safety ................................................. 34
1.3.13 High pressure leaks .............................................. 35
1.3.14 Chemical safety ................................................. 35
1.3.15 Engine safety ................................................... 37
1.3.16 Battery safety .................................................. 39
1.3.17 Tire safety ..................................................... 40
1.3.18 Avoid eye contact with radar ........................................ 40
1.3.19 Exhaust fumes .................................................. 41
1.3.20 Electrical power lines overhead ...................................... 41
1.3.21 Towing ....................................................... 41
1.3.22 Modifications ................................................... 41
1.3.23 Mobile radio installation ........................................... 42
1.3.24 Safety signs .................................................... 42
1.4 Chassis safety signs ................................................. 43
1.4.1 Electrocution hazard .............................................. 44
1.4.2 Hot pressurized coolant ........................................... 44
1.4.3 Burn hazard .................................................... 44
1.4.4 Rotating blades ................................................. 44
1.4.5 Starter bypass .................................................. 45
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Flotation Chassis
591373D1E
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1.4.6 Electrical hazard ................................................. 45
1.4.7 Crush and falling hazard ........................................... 45
1.4.8 Radar / high pressure hazard ........................................ 46
1.4.9 High pressure / ether / belt entanglement .............................. 47
1.5 Cab safety signs .................................................... 48
1.5.1 Runover hazard ................................................. 49
1.5.2 Sound horn / electrical hazard / read manual ............................ 49
1.5.3 Rollover-seatbelt / runover-no riders ................................... 49
1.6 Informational signs ................................................. 50
1.6.1 Informational - Manufacturer plate ....................................51
1.6.2 Informational - Tiedown ........................................... 51
1.6.3 Ultra low sulfur diesel fuel ......................................... 51
1.6.4 Informational - Hydraulic oil level ..................................... 51
1.6.5 Informational - Alternate exit ........................................ 52
1.6.6 Informational - Hand wash ......................................... 52
1.6.7 Informational - Cab filter #2 and washer bottle ........................... 52
1.6.8 Informational - Cab filter #3 ......................................... 52
1.6.9 Informational - Cab filter #1 ......................................... 53
1.6.10 Informational - Battery terminals ..................................... 53
1.7 Informational electrical signs ........................................ 54
1.7.1 Informational - Battery box fuse / relay .................................54
1.7.2 Informational - Cab fuse / relay ...................................... 54
2 Introduction .............................................................. 55
2.1 Information ......................................................... 57
2.1.1 Intended use ................................................... 57
2.1.2 Proper disposal of waste .......................................... 57
2.1.3 Emissions reduction - selective catalyst reduction — SCR — technology ........ 57
2.1.4 DEF Storage and Shelf Life ......................................... 58
2.2 Machine identification ...............................................60
2.2.1 Product identification information .................................... 60
2.2.2 Serial number definition ........................................... 60
2.2.3 Engine serial number plate .........................................61
2.2.4 Transmission serial number plate .................................... 61
2.3 Break-in period ..................................................... 62
2.3.1 General break-in information ........................................ 62
2.3.2 Break-in maintenance schedule ......................................62
2.3.3 Operate the engine-first 200 hours ................................... 62
2.3.4 Initial interval for inline fuel strainer ................................... 62
2.3.5 Break-in the transmission .......................................... 62
2.3.6 Break-in the rear axle ............................................. 62
2.3.7 Do a check of the rear axle mounting bolts ............................. 63
2.3.8 Do a check of the wheel mounting hardware ............................ 63
2.3.9 Hydraulic filter .................................................. 63
2.3.10 Initial pressure washer pump ....................................... 63
2.4 Machine transport .................................................. 64
2.4.1 Operate the machine in limp-home mode .............................. 64
2.4.2 Transport the machine on a truck or trailer .............................. 67
2.4.3 Towing information ...............................................68
2.4.3.1 Prepare for towing - engine operation ........................ 68
2.4.3.2 Prepare for towing - engine not operating ..................... 71
2.4.3.3 Tow the machine ....................................... 71
2.5 Park brake information .............................................. 73
2.5.1 Release the manual park brake ...................................... 73
2.5.2 Release the park brake using air ..................................... 73
2.5.3 Release the park brake by manually releasing the spring ................... 73
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Flotation Chassis
591373D1E
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2.6 Major components .................................................. 76
2.6.1 Component location (front/rear view) ..................................76
2.6.2 Component location (side view) ..................................... 77
2.6.3 Component location (top view) ...................................... 78
2.7 Emissions warranty ................................................. 79
2.7.1 United States and Canada emission control warranty statement ............. 79
2.7.2 California emission control warranty statement .......................... 82
3 Operation ................................................................ 87
3.1 Instruments and controls ............................................ 91
3.1.1 Dash panel .................................................... 91
3.1.2 Operating status displays .......................................... 92
3.1.3 Multiple display screens ........................................... 92
3.1.4 Console keypad ................................................. 94
3.1.5 Ignition switch .................................................. 94
3.1.6 Multifunction lever ............................................... 95
3.1.7 Set the windshield wiper delay ...................................... 96
3.1.8 Tilt - telescoping lever .............................................97
3.1.9 Foot pedals .................................................... 97
3.1.10 Park brake ..................................................... 98
3.1.11 Drive lever controls .............................................. 98
3.1.12 Armrest controls ................................................ 99
3.1.13 Armrest adjustment .............................................. 99
3.1.14 Automatic heated mirrors .......................................... 99
3.1.15 Power mirror adjustment ..........................................100
3.1.16 Interior lamps .................................................. 101
3.1.17 Radio (if equipped) .............................................. 101
3.1.18 Sun Visor ..................................................... 101
3.1.19 Cup holders ................................................... 101
3.1.20 Storage compartments ........................................... 102
3.1.21 Power strip ....................................................102
3.1.22 Power ports ................................................... 102
3.1.23 Cargo net ..................................................... 103
3.1.24 Lamp switches .................................................104
3.1.25 Bluetooth microphone ........................................... 105
3.1.26 Objects in the cab .............................................. 105
3.1.27 Automatic battery disconnect ...................................... 105
3.2 Cab temperature control ............................................ 107
3.2.1 Automatic temperature control ..................................... 107
3.2.2 Heater operation ................................................108
3.2.3 Defroster operation ............................................. 108
3.2.4 Air conditioner operation .......................................... 108
3.2.5 Automatic fan speed control ....................................... 109
3.2.6 Manual fan speed control (HI/LO) ................................... 109
3.2.7 Air conditioning compressor clutch control ............................. 109
3.2.8 Heater water valve .............................................. 109
3.2.9 Cab air temperature sensor ........................................ 109
3.2.10 Evaporator probe ............................................... 110
3.2.11 Temperature control troubleshooting ................................. 110
3.3 Seats .............................................................. 112
3.3.1 Seatbelt operation ...............................................112
3.3.2 Basic operator seat .............................................. 113
3.3.3 Deluxe operator seat .............................................114
3.3.4 Deluxe vented operator seat ....................................... 116
3.3.5 Instructor seat ................................................. 117
3.4 General inspection ................................................. 119
3.4.1 Check fluids ................................................... 119
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Flotation Chassis
591373D1E
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3.4.2 Check for Condition and Cleanliness ................................. 119
3.4.3 Do a check of the hydraulics ....................................... 119
3.4.4 Check fuel system .............................................. 120
3.4.5 Do a check of the cab ............................................ 120
3.4.6 Check mirrors ..................................................120
3.4.7 Check the Hoses ............................................... 120
3.4.8 Check the Safety Signs ........................................... 120
3.5 Terminal ........................................................... 122
3.5.1 Terminal introduction ............................................ 122
3.5.2 Audible alarms and indicators ...................................... 123
3.5.3 Display the chassis software information .............................. 123
3.5.4 Set the language ............................................... 124
3.5.5 Set the date and time ............................................ 125
3.5.6 Set the audio level .............................................. 126
3.5.7 Set the screen brightness ......................................... 127
3.5.8 Switch between day and night mode ................................. 129
3.5.9 Call up the USB Data screen ....................................... 129
3.5.10 Select and transfer individual data to the USB stick .......................130
3.5.11 Select and transfer all data to the USB stick ............................ 131
3.5.12 Transfer data from the USB stick to the terminal .........................132
3.5.13 Task data ..................................................... 133
3.5.14 Field data ..................................................... 134
3.5.15 Take a screenshot from the AccuTerminal ............................. 135
3.5.16 Download a screenshot from the AccuTerminal ......................... 135
3.5.17 Clean the terminal screen ......................................... 136
3.5.18 Calibrate the touch screen ........................................ 137
3.5.19 Do a touch test ................................................ 138
3.5.20 Set up the camera application - if equipped ............................ 139
3.5.21 View the service interval screens ....................................140
3.5.22 Program the user-defined service intervals ............................. 140
3.5.23 Calibrate the radar .............................................. 142
3.5.24 Calibrate the wheel speed .........................................142
3.5.25 Calibrate the wheel speed and radar ................................. 143
3.5.26 Calibrate the steering angle sensor .................................. 144
3.5.27 Calibrate the steering valve ........................................ 145
3.5.28 Calibrate the lever ...............................................146
3.5.29 Calibrate the transmission range .................................... 146
3.5.30 Calibrate the CVT transmission ..................................... 147
3.5.31 Calibrate the turbo clutch ......................................... 147
3.5.32 View the diagnostic screens ....................................... 148
3.5.33 View the active errors screen ...................................... 149
3.5.34 Set the power management values .................................. 149
3.5.35 View the fuel consumption screen ...................................150
3.5.36 Call up the ISOBUS Information screen ............................... 151
3.5.37 View the Auto-Guide™ map ....................................... 152
3.5.38 View the worked area settings ..................................... 153
3.5.39 Make a wayline from the map ...................................... 154
3.5.39.1 AB wayline .......................................... 155
3.5.39.2 Contour wayline ...................................... 155
3.5.39.3 A+ angle wayline ...................................... 156
3.5.39.4 Pivot wayline ......................................... 157
3.5.39.5 AB coordinates wayline .................................157
3.5.40 Make a boundary from the map .....................................157
3.5.41 Make an obstacle from the map .................................... 159
3.5.42 Adjust the Auto-Guide™ steering settings ............................. 161
3.5.43 Update the terminal software ...................................... 163
3.6 Raven Viper 4 values ............................................... 164
3.7 Camera settings ................................................... 166
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Flotation Chassis
591373D1E
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3.7.1 Camera options and connections ....................................166
3.7.2 Position the camera image ........................................ 167
3.7.3 Change cameras ............................................... 167
3.7.4 Display the camera image while reversing ............................. 168
3.7.5 Change the camera to and from full-screen ............................ 169
3.7.6 Adjust the brightness ............................................ 169
3.7.7 Adjust the contrast .............................................. 170
3.7.8 Adjust the color saturation .........................................171
3.8 Start the engine ....................................................172
3.8.1 Cold weather start procedure ...................................... 173
3.8.2 Diesel exhaust fluid (DEF) cold start ..................................174
3.8.3 Restart a stalled engine ...........................................174
3.8.4 Engine power limitations .......................................... 174
3.8.5 Low diesel exhaust fluid (DEF) level .................................. 175
3.8.6 Stop the engine and afterrun ....................................... 176
3.9 Tag axle operation ..................................................177
3.9.1 Tag axle ...................................................... 177
3.9.2 Operate the tag axle ............................................. 177
3.10 Operate on a public road ............................................178
3.10.1 Machine operation on a public road .................................. 178
3.11 Transmission function .............................................. 179
3.11.1 Transmission - general ........................................... 179
3.11.2 High and low speed range .........................................179
3.11.3 Drive the machine .............................................. 180
3.11.4 Drive modes .................................................. 180
3.11.5 Increase the drive speed .......................................... 181
3.11.6 Decrease the drive speed ......................................... 182
3.11.7 Change the drive direction ........................................ 183
3.11.8 Stop the machine ............................................... 184
3.11.9 Set the cruise control speeds ...................................... 185
3.11.10 Set the drive handle aggressiveness ................................. 186
3.11.11 Transmission management system (TMS) ............................. 186
3.11.12 Set the power management values .................................. 187
3.11.13 Joystick mode ................................................. 187
3.11.14 Foot pedal throttle mode ..........................................188
3.12 AccuField Command ............................................... 190
3.12.1 Manual configuration ............................................ 190
3.12.2 General function - AccuField Command ............................... 191
3.12.3 Functions and dependencies ....................................... 191
3.12.4 Call up and activate AccuField Command .............................. 193
3.12.5 Joystick assignment ............................................. 194
3.12.6 Record an operational sequence .................................... 195
3.12.7 Start an operational sequence ...................................... 197
3.12.8 Configure an operational sequence manually ........................... 197
3.12.9 Step mode .................................................... 199
3.13 Cold weather considerations ........................................ 201
3.13.1 Minimize the eect of cold weather ..................................201
3.13.2 Using grade No. 1-D fuel .......................................... 201
3.13.3 Fuel filters .................................................... 201
3.13.4 Coolant heater ................................................. 201
3.13.5 Seasonal viscosity oil and proper coolant concentration ................... 201
3.13.6 Winterfronts .................................................. 202
3.13.7 Idling the engine ............................................... 202
3.13.8 Engine coolant specifications ...................................... 202
3.13.9 Cooling system water quality ...................................... 202
3.13.10 Antifreeze .................................................... 202
3.13.11 Grease .......................................................203
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Flotation Chassis
591373D1E
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3.13.12 Diesel fuel .................................................... 203
3.13.13 Lubricity of diesel fuels ........................................... 203
3.13.14 Diesel fuel storage .............................................. 204
3.14 Storage ........................................................... 205
3.14.1 Prepare for long term storage ...................................... 205
3.14.2 Remove the machine from long term storage .......................... 205
3.15 Optional accessories ............................................... 207
3.15.1 Weather station - if equipped ...................................... 207
3.15.2 Install the mini SIM card for Global System for Mobile communication (GSM) ... 208
3.16 SmartConnect™ ................................................... 210
3.16.1 SmartConnect™ app .............................................210
3.16.2 Wi-Fi connection (SmartConnect ™) ................................. 211
3.16.3 SmartConnect ™ icons ........................................... 211
3.16.4 Quick start .................................................... 213
3.16.5 Homepage .................................................... 216
3.16.6 Dashboard .................................................... 218
3.16.7 History .......................................................219
3.16.8 First steps .................................................... 219
3.16.9 Map page .................................................... 220
3.16.10 Configuration page .............................................. 221
3.16.11 The task data in SmartConnect™ ................................... 222
4 Engine Operation ........................................................ 225
4.1 Safety instructions ................................................. 227
4.2 To the user ........................................................ 228
4.2.1 Engine type designations ......................................... 228
4.2.2 Location of the engine serial number ................................. 229
4.2.3 Type plate of the electronic control unit ............................... 230
4.3 Technical data ..................................................... 231
4.3.1 Principal dimensions and data ...................................... 231
4.3.2 Fuel system ................................................... 231
4.3.3 Lubrication system .............................................. 231
4.3.4 Cooling system ................................................ 231
4.3.5 Selective Catalytic Reduction (SCR) system technical data ................. 232
4.4 Air control system ................................................. 234
4.4.1 2 stage turbocharging ............................................ 235
4.4.2 Interstage charge air cooling ....................................... 235
4.4.3 Throttle valve .................................................. 235
4.5 Fuel system ........................................................236
4.6 Engine control system .............................................. 238
4.7 Lubrication system ................................................. 239
4.7.1 Oil pressure regulating valve ....................................... 240
4.7.2 Oil filter and oil cooler ............................................ 240
4.8 Cooling system .................................................... 241
4.8.1 Engine heater ..................................................241
4.9 Electrical system ................................................... 242
4.10 SCR system ....................................................... 243
4.10.1 Selective Catalytic Reduction (SCR) system overview ..................... 243
4.10.2 Selective Catalytic Reduction (SCR) system components and their functions .... 244
4.11 Operation and driving .............................................. 246
4.12 Daily pre-start check ............................................... 247
4.13 Starting the engine ................................................ 248
4.13.1 Break in the engine ............................................. 248
4.14 Starting the engine in cold conditions ............................... 250
4.14.1 Warming up the engine .......................................... 250
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Flotation Chassis
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4.15 Start the engine with an auxiliary battery ............................ 251
4.16 Attention during operation ......................................... 252
4.17 Stopping the engine ............................................... 253
5 Maintenance ............................................................ 255
5.1 Maintenance intervals .............................................. 259
5.1.1 Maintenance introduction ......................................... 259
5.1.2 Maintenance symbols ........................................... 259
5.1.3 Lubricant filling reminders .........................................260
5.1.4 Maintenance schedule ........................................... 261
5.1.4.1 Maintenance chart .....................................261
5.1.4.2 Daily maintenance schedule ..............................262
5.1.4.3 Maintenance schedule 10 to 1000 hours ..................... 262
5.1.4.4 Maintenance Schedule 2000 to 4000 hours .................. 264
5.1.5 Lubricants and fluids .............................................265
5.2 Air dryer and compressed air system ................................ 266
5.2.1 Air reservoir and air dryer ......................................... 266
5.2.2 Replace the air dryer filter ......................................... 266
5.3 Air conditioner system ............................................. 268
5.3.1 Air conditioner ................................................. 268
5.3.2 Condenser .................................................... 268
5.4 Engine ............................................................ 269
5.4.1 Do a check of the engine oil ....................................... 269
5.4.2 Change the oil and oil filter ........................................ 269
5.4.3 Engine belts and tensioner ........................................ 270
5.4.3.1 Replace the serpentine belt ..............................270
5.4.3.2 Replace the water pump belt ............................. 271
5.4.4 Fuel system ................................................... 273
5.4.5 Fuel tank ..................................................... 273
5.4.6 In-line fuel strainer .............................................. 274
5.4.7 Replace the fuel filters ........................................... 274
5.4.8 Prime the fuel system ........................................... 275
5.4.9 Engine coolant ................................................. 276
5.5 Air cleaner maintenance ............................................ 278
5.5.1 Engine air cleaner indicator ........................................ 278
5.5.2 Replace the air filter element ...................................... 278
5.5.3 Secondary air filter element ....................................... 279
5.6 Hydraulic system ...................................................280
5.6.1 Do a check of the hydraulic oil-level check ............................. 280
5.6.2 Replace the hydraulic system oil and filter ............................. 280
5.7 Continuously variable transmission ................................. 282
5.7.1 Transmission operating temperatures ................................ 282
5.7.2 Do a check of the transmission oil ................................... 282
5.7.3 Change the transmission oil ....................................... 283
5.8 Driveline lubrication and U-joint inspection .......................... 285
5.8.1 Inspect and lubricate the engine to transmission driveline ..................285
5.8.2 Lubricate the transmission to rear axle driveline ........................ 286
5.9 Intercoolers ........................................................ 288
5.9.1 Heat exchangers ............................................... 288
5.9.2 Clean the heat exchangers ........................................ 288
5.10 Wheel and axle bearings ............................................ 290
5.10.1 Lubricate the front wheel bearing ................................... 290
5.10.2 Tag axle bearing bolts and lubricate the tag axle fittings — if equipped ........ 290
5.11 Tag axle ........................................................... 291
5.11.1 Tag axle bearing bolts and lubricating the tag axle fittings — if equipped ....... 291
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591373D1E
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5.12 Steering ........................................................... 292
5.12.1 Steering cylinder ............................................... 292
5.13 Rear axle .......................................................... 293
5.13.1 Clean the rear axle breather ....................................... 293
5.13.2 Do a check of the rear axle oil ...................................... 293
5.13.3 Change the rear axle oil .......................................... 294
5.14 Brake Maintenance ................................................. 296
5.14.1 Lubricate the brake slack adjuster ................................... 296
5.14.2 Brake air lines ................................................. 296
5.14.3 Parking brake .................................................. 296
5.14.4 Do a check of the service brake system ...............................296
5.14.5 Adjust the manual slack adjusters ................................... 297
5.14.5.1 Brake adjustment procedure ............................. 298
5.15 Wheels ............................................................ 299
5.15.1 Remove the front wheel .......................................... 299
5.15.2 Install the front wheel ............................................ 301
5.15.3 Remove the rear wheel .......................................... 302
5.15.4 Remove the rear wheel .......................................... 303
5.15.5 Install the rear wheel ............................................ 304
5.15.6 Tighten the wheel mounting hardware ............................... 304
5.16 Tires .............................................................. 305
5.16.1 Inflate the tire ................................................. 305
5.16.2 Replace the tire ................................................ 305
5.16.3 Tire chart ..................................................... 305
5.17 Cab maintenance .................................................. 307
5.17.1 Do a check of the cab mount bolts .................................. 307
5.17.2 Cab air filters .................................................. 308
5.17.3 Change the primary fresh air filter ................................... 309
5.17.4 Change the secondary clean air filter ................................. 310
5.17.5 Change the recirculation air filter ................................... 312
5.17.6 Clean the cab air filter element ..................................... 313
5.17.7 Do a check of the windshield washer reservoir ..........................313
5.17.8 Windshield wiper blade ...........................................314
5.18 Electrical system ................................................... 315
5.18.1 Batteries ..................................................... 315
5.18.1.1 Remove the battery terminal connection ..................... 315
5.18.2 Battery box components .......................................... 316
5.18.3 Remove the battery terminal connection .............................. 317
5.18.4 Jump start the battery ........................................... 318
5.18.5 Change a fuse/relay ............................................. 319
5.18.6 Fuse/relay location .............................................. 320
5.19 Paint and decals ................................................... 324
5.19.1 Safety treads .................................................. 324
5.20 Hand rinse tank .................................................... 325
5.20.1 Fill the hand rinse tank ........................................... 325
5.20.2 Rinse hands and equipment ....................................... 326
5.20.3 Winterize the hand rinse tank ...................................... 326
5.21 Pressure washer ................................................... 327
5.21.1 Pressure washer input water supply ................................. 327
5.21.2 Before starting the pressure washer ................................. 327
5.21.3 Prime the pressure washer pump ................................... 327
5.21.4 General care of the pressure washer pump ............................ 327
5.21.5 Pressure washer pump storage in freezing conditions .................... 327
5.21.6 Operate the pressure washer ...................................... 327
5.21.7 Change the pressure washer pump motor oil ........................... 328
5.21.8 Change the pressure washer strainer ................................ 329
Table of contents
Flotation Chassis
591373D1E
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