Challenger RG900B User manual

Workshop Service Manual
Applicator Chassis
RG900B
RG1100B
RG1300B
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 2015
November 2015
79035871B
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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TABLE OF CONTENT
General 1
Engine, fuel, and exhaust system 2
Axles 3
Frame and suspension 4
Steering system 5
Drive train system 6
Brake system 7
Air system 8
Hydraulic system 9
Electrical troubleshooting 10
Cab 11
Air conditioning and heating system 12
Chassis 13
Wheels 14
Attachments 15
Accessories 16
Diagrams 17
.
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1. General
1.1 Service manual .........................................................1-3
1.1.1 Units of measurement ..................................................1-3
1.1.2 Replacement parts ....................................................1-3
1.1.3 Identification plates ....................................................1-3
1.1.4 Engine identification ...................................................1-5
1.2 A word to the operator ..................................................1-6
1.2.1 Important safety information .............................................1-7
1.2.2 Safety alert symbol ....................................................1-7
1.2.3 Safety messages .....................................................1-8
1.2.4 Informational messages ................................................1-8
1.2.5 General hazard information ..............................................1-8
1.3 Prepare for operation ...................................................1-10
1.3.1 Mounting and dismounting the machine ....................................1-10
1.3.2 Before starting the engine ..............................................1-10
1.3.3 Engine starting ......................................................1-11
1.3.4 Before operating the machine ...........................................1-11
1.3.5 Operating the machine ................................................1-11
1.3.6 Operator station .....................................................1-12
1.3.7 Parking the machine ..................................................1-13
1.3.8 Exiting the cab in an emergency ..........................................1-13
1.3.9 Safety lamps and marking devices use .....................................1-13
1.3.10 Roading on public roads ...............................................1-14
1.3.11 Operating on a slope .................................................1-14
1.3.12 Electrical storm injury prevention ........................................1-14
1.4 Maintenance and service ...............................................1-15
1.4.1 Maintenance safety ...................................................1-15
1.4.2 Wear protective clothing ...............................................1-19
1.4.3 Fire prevention and first aid .............................................1-19
1.4.4 Proper disposal of waste ...............................................1-20
1.4.5 Shield and guards ....................................................1-20
1.4.6 Support the machine correctly ...........................................1-21
1.4.7 Asbestos information ................................................. 1-21
1.4.8 Pressurized air ...................................................... 1-21
1.4.9 Cut and crushing prevention ............................................ 1-21
1.4.10 Boom safety .......................................................1-22
1.4.11 Fuel safety ........................................................1-22
1.4.12 Hydraulic safety .....................................................1-22
1.4.13 High pressure leaks ..................................................1-23
1.4.14 Chemical safety .....................................................1-23
1.4.15 Engine safety ......................................................1-25
1.4.16 Battery safety ......................................................1-27
1.4.17 Tire safety .........................................................1-28
1.4.18 Avoid eye contact with radar ...........................................1-29
1.4.19 Exhaust fumes .....................................................1-29
1.4.20 Electrical power lines overhead .........................................1-29
1.4.21 Towing ...........................................................1-30
1.4.22 Modifications ......................................................1-30
1.4.23 Mobile radio installation ...............................................1-30
1.4.24 Safety signs .......................................................1-30
1.4.25 Safety and informational signs ..........................................1-30
Table of contents
Applicator Chassis 1-1
79035871B
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1.5 Tightening specifications ...............................................1-32
1.5.1 Constant torque hose clamp ............................................1-32
1.5.2 Fastener tightening specifications ........................................1-32
1.5.3 Metric fasteners .....................................................1-34
1.5.4 Inch fasteners .......................................................1-35
1.5.5 Conversion table .....................................................1-39
1.6 Lubrication and maintenance ...........................................1-40
1.6.1 Maintenance introduction ..............................................1-40
1.6.2 Maintenance schedule .................................................1-40
1.6.3 Lubricant filling reminders ..............................................1-44
1.6.4 Lubricants and fluids ..................................................1-44
Table of contents
1-2 Applicator Chassis
79035871B
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1.1 Service manual
WARNING:
Some pictures in the manual show the shields removed to permit a clearer view. Never
operate the machine with any shields removed.
This service manual has been prepared with the latest service information available at publication. Read
and understand the service manual carefully before doing any service on the machine.
Right-hand and left-hand, as used in this manual, are determined by facing the direction of machine travel
when in use.
Photos, illustrations, and data used were current at the time of printing, due to possible production
changes, the machine can vary slightly. The manufacturer reserves the right to redesign and change the
machine as necessary without notification.
1.1.1 Units of measurement
Measurements are given in metric units followed by the equivalent in US units. Hardware sizes are given
in millimeters for metric hardware and inches for US hardware.
1.1.2 Replacement parts
To receive prompt efficient service, remember to have the following information:
Correct part description and part number
Model number of the machine
Serial number of the machine
1.1.3 Identification plates
The product identification number (PIN) will be used to identify a machine.
Components such as engines, transmissions and major attachments are identified by serial numbers.
For quick reference, record the identification numbers in the spaces provided.
Machine PIN
Machine PIN. Plate (1) is located on right-hand side
frame rail in front of fuel tank.
Machine PIN:______________________________
Fig. 1 GUID-498D8289-0BFB-4E62-83C7-2541C21D4A8E-high.jpg
GUID-96F0DBC2-FDAB-4BE2-A442-8D57B94A81B4
GUID-EBB3FCAE-8712-43A9-BB65-1DB48189C57C
GUID-0DCC2166-0585-4D9F-9842-E9E5A15E5873
GUID-6022486A-3D3A-4156-9055-EFF66300E12F
1. General
Applicator Chassis 1-3
79035871B
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Engine serial number
Plate (1) is located on engine.
Engine serial
number:______________________________
Fig. 2 GUID-C7D1527B-69B0-4D00-B1C9-8D56F7C0BAC6-high.jpg
Hydrostatic pump identification
Plate is located on top of hydrostatic pump.
Hydrostatic pump serial
number:______________________________
Fig. 3 GUID-1C6DBAFD-D151-41CB-BD5F-7BFE666F7C06-high.jpg
Cab serial number
Plate is located inside cab, below rear window,
behind operator’s seat.
Cab serial
number:______________________________
Fig. 4 GUID-268F56FE-96A3-4A07-8FBB-69AF38F82994-high.jpg
1. General
1-4 Applicator Chassis
79035871B
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Operator seat serial number
Tag (1) is located on rear of operators seat.
Seat serial
number:_______________________________
Fig. 5 GUID-5C28A823-B154-4BDE-88F1-2C2198B33AD6-high.jpg
1.1.4 Engine identification
The engine model number (1) is cast on the right-
hand side of the engine block, below the injection
pump.
The engine serial number (2) is stamped into the
cylinder block, below the engine model number.
Engine model
number:
Engine serial
number:
Fig. 6 GUID-21BF420B-5724-429A-B629-B619F88A16AE-high.jpg
GUID-77EA0176-1F24-4287-A496-44B9570B6D7E
1. General
Applicator Chassis 1-5
79035871B
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1.2 A word to the operator
It is your responsibility to read and understand the
safety section in this manual and the manual for all
attachments before operating this machine.
Remember you are the key to safety. Good safety
practices not only protect you, but also the people
around you.
Study the content in this manual and make the
content a working part of your safety program.
Keep in mind that this safety section is written
only for this type of machine. Practice all other
usual and customary safe working precautions,
and above all remember - safety is your
responsibility. You can prevent serious injury or
death.
This safety section is intended to point out some
of the basic safety situations that may be
encountered during the normal operation and
maintenance of your machine. This section also
suggests possible ways of dealing with these
situations. This section is not a replacement for
other safety practices featured in other sections of
this manual.
Personal injury or death may result if these
precautions are not followed.
Learn how to operate the machine and how to use
the controls properly.
Do not let anyone operate the machine without
instruction and training.
For your personal safety and the personal safety of
others, follow all safety precautions and
instructions found in the manuals and on safety
signs affixed to the machine and all attachments.
Use only approved attachments and equipment.
Make sure your machine has the correct
equipment needed by the local regulations.
WARNING:
An operator should not use alcohol or
drugs which can affect their alertness
or coordination. An operator on
prescription or 'over the counter'
drugs needs medical advice on
whether or not they can properly
operate machines.
CAUTION:
If any attachments used on this
equipment have a separate Operator
Manual, see that manual for other
important safety information.
Fig. 7 GUID-AC91CCF6-1FF8-4A85-97A1-2D1562806825-high.jpg
GUID-F38BCC9A-5A98-41F3-BA3C-2C5AB224EDFB
1. General
1-6 Applicator Chassis
79035871B
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1.2.1 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.
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.
1.2.2 Safety alert symbol
The safety alert symbol means Attention! Become
Alert! Your Safety Is Involved!
Look for the safety alert symbol both in this
manual and on safety signs on this machine. The
safety alert symbol will direct your attention to
information that involves your safety and the
safety of others.
Fig. 8 GUID-4C201302-DBD2-4BFB-8D98-1DDED263BD6E-high.jpg
GUID-C5A0147C-1966-4D7E-8EFB-5A9A1913F996
GUID-5D9F270E-D748-4741-82B1-BE49B78685F2
1. General
Applicator Chassis 1-7
79035871B
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