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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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
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Flotation Chassis
591373D1E
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5.21.9 Winterize the pressure washer system ............................... 329
6 Troubleshooting ......................................................... 331
6.1 Engine ............................................................ 333
6.1.1 Low diesel exhaust fluid (DEF) level ..................................337
6.2 Transmission ...................................................... 338
6.3 Electrical system ................................................... 340
6.4 Hydraulic system ...................................................341
6.5 Parking brake troubleshooting ...................................... 342
6.6 Operation ......................................................... 343
6.7 Cab ............................................................... 344
6.8 TG7300C/TG8300C/TG8400C/TG9300C fault code reference ........... 345
6.8.1 Accuterminal module fault code reference ............................. 345
6.8.2 Armrest module fault code reference ................................ 346
6.8.3 Automatic steering module fault code reference ........................ 346
6.8.4 Electrical controller module fault code reference ........................ 349
6.8.5 Error management module fault code reference .........................349
6.8.6 Machine information module fault code reference ....................... 350
6.8.7 Machine module fault code reference ................................ 350
6.8.8 Transmission module fault code reference ............................. 351
7 Specifications ........................................................... 355
7.1 Machine specifications ............................................. 357
7.2 Machine dimensions ............................................... 360
8 Index ................................................................... 365
Table of contents
Flotation Chassis
591373D1E

Table of contents
Flotation Chassis
591373D1E

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
1.1.6 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
Table of contents
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1.4.5 Starter bypass ...................................................... 45
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
Table of contents
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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
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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
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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
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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.
1.1.6 California emission control warranty statement
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and AGCO Corporation ("AGCO") are pleased to explain the
emission control system warranty on Model Year 2016 and later o-road diesel engines. In California, new
heavy-duty o-road engines must be designed, built, and equipped to meet the State's stringent anti-smog
standards. AGCO must warrant the emission control system on your engine for the periods of time listed
below provided there has been no abuse, neglect or improper maintenance of your engine.
GUID-0C7C08FD-8529-4E64-A656-D3DA29A2D90F [V2]
1. Safety
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Your emission control system may include parts such as the fuel-injection system and the air induction
system. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, AGCO will repair your heavy-duty o-road engine at no cost to you
including diagnosis, parts, and labor.
MANUFACTURER'S WARRANTY COVERAGE:
The emission related devices on your Model Year 2016 and later heavy-duty o-road engines are warranted
for five (5) years or 3000 hours of operation for all engines 19KW or greater, whichever occurs first from
the date of delivery of the engine to the initial purchaser.
If any emission-related part on your engine is defective, the part will be repaired or replaced by AGCO
within the warranty period.
A) General Emissions Warranty Coverage
AGCO warrants to the ultimate purchaser and each subsequent purchaser of each o-road
compression-ignition engine that the engine is:
(1) Designed, built, and equipped so as to conform with all applicable regulations adopted by the Air
Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and
Safety Code; and
(2) Free from defects in materials and workmanship which cause the failure of a warranted part to be
identical in all material respects to the part as described in the engine manufacturer's application for
certification for a period of five years or 3,000 hours of operation, whichever occurs first, for all
engines rated at 19KW and greater, except as noted below. In the absence of a device to measure
hours of use, the engine shall be warranted for a period of five years.
B) Warranty on emissions-related parts shall be interpreted as follows:
(1) Any warranted part which is not scheduled for replacement as required maintenance shall be
warranted for the warranty period defined in Subsection (A)(2). If any such part fails during the period
of warranty coverage, it shall be repaired or replaced by the engine manufacturer according to
Subsection (4) below. Any such part repaired or replaced under the warranty shall be warranted for
the remaining warranty period.
(2) Any warranted part which is scheduled only for regular inspection shall be warranted for the
warranty period defined in Subsection (A)(2). A statement in such written instructions to the eect of
"repair or replace as necessary" shall not reduce the period of warranty coverage. Any such part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
(3) Any warranted part which is scheduled for replacement as required maintenance shall be
warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by the engine
manufacturer according to Subsection (4) below. Any such part repaired or replaced under warranty
shall be warranted for the remainder of the period prior to the first scheduled replacement point for
the part.
(4) Repair or replacement of any warranted part under the warranty provisions of this article shall be
performed at no charge to the owner at a warranty station.
(5) Notwithstanding the provisions of Subsection (4) above, warranty services or repairs shall be
provided at all manufacturer distribution centers that are AGCO dealers authorized to service the
subject engines.
(6) The owner shall not be charged for diagnostic labor that leads to the determination that a
warranted part is in fact defective, provided that such diagnostic work is performed at a warranty
station.
(7) The engine manufacturer shall be liable for damages to other engine components proximately
caused by a failure under warranty of any warranted part.
(8) Throughout the engine's warranty period defined in Subsection (A)(2), the engine manufacturer
shall maintain a supply of warranted parts sucient to meet the expected demand for such parts.
1. Safety
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(9) Any replacement part, as defined in Section 1900(b)(23), Title 13, may be used in the performance
of any maintenance or repairs and must be provided without charge to the owner. It is not necessary
for replacement parts to be the same brand or by the same manufacturer as the original part sold
with the engine. Such use shall not reduce the warranty obligations of the engine manufacturer.
(10) Add-on or modified parts, as defined in Section 1900(b)(1) and (b)(17), Title 13, that are not
exempted by the Air Resources Board may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty claim made in accordance with this article.
The engine manufacturer shall not be liable under this article to warrant failures of warranted parts
caused by the use of a non-exempted add-on or modified part.
(11) The Executive Ocer may request and, in such case, the engine manufacturer shall provide, any
documents which describe that manufacturer's warranty procedures or policies.
C) Each manufacturer shall include a copy of the following emission warranty parts list with each new
engine, using those portions of the list applicable to the engine.
(1) Fuel Metering System
(A) Fuel injection system
(B) Air/fuel ratio feedback and control system.
(C) Cold start enrichment system.
(2) Air Induction System
(A) Controlled hot air intake system.
(B) Intake manifold.
(C) Turbocharger/Supercharger Systems.
(D) Charge Air Cooling Systems.
(3) Catalyst or Thermal Reactor System
(A) Catalytic converter.
(B) Diesel Oxydation Catalyst (DOC)
(C) Exhaust manifold
(4) Particulate Controls
(A) Smoke Pu Limiters.
(5) Advanced Oxides of Nitrogen (NOx) Controls
(A) NOx Absorbers
(B) Selective Catalyst Reduction (SCR)
(C) Reluctant (urea/fuel) containers/dispensing systems
(D) Exhaust Gas Recirculation System (EGR)
(6) Positive Crankcase Ventilation (PCV) System.
(A) PCV Valve.
(B) Oil Filler Cap.
(7) Miscellaneous items Used in Above Systems
(A) Vacuum, temperature, and time sensitive valves and switches.
(B) Electronic control units, sensors, solenoids, and wiring harnesses.
(C) Hoses, belts, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices,
and mounting hardware.
(D) Pulleys, belts and idlers.
(E) Emission Control Information Labels
(F) Any other part with the primary purpose of reducing emissions or that can increase
emissions during failure without significantly degrading engine performance.
OWNER'S WARRANTY RESPONSIBILITIES:
As the heavy-duty o-road engine owner, you are responsible for the performance of the required
maintenance listed in your owner's manual .
1. Safety
20 Flotation Chassis
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