Challenger TG8400B User manual
Workshop Service Manual
TG8300B
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 2017
May 2017
79035613B
EAME
English
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 Product identification information ..........................................1-3
1.1.4 Transmission serial number plate ..........................................1-3
1.1.5 Machine serial number information ........................................1-4
1.1.6 Engine serial number plate ..............................................1-4
1.2 Lubrication and maintenance ............................................1-6
1.2.1 Maintenance introduction ...............................................1-6
1.2.2 Maintenance symbols ..................................................1-6
1.2.3 Maintenance chart for Jackson ...........................................1-7
1.2.4 Daily maintenance schedule .............................................1-8
1.2.5 Maintenance schedule 10 to 1000 hours ....................................1-9
1.2.6 Maintenance Schedule 2000 to 4000 hours .................................1-11
1.2.7 Lubricants and fluids ..................................................1-11
1.2.8 Lubricant filling reminders ..............................................1-12
1.3 Important safety information ...........................................1-14
1.3.1 Prepare for operation ..................................................1-14
1.3.2 Fire prevention and first aid .............................................1-15
1.3.3 Safety symbol .......................................................1-16
1.3.4 Safety messages .....................................................1-16
1.3.5 Information messages .................................................1-16
1.3.6 General hazard information .............................................1-17
1.3.7 Pressurized air ...................................................... 1-18
1.3.8 Asbestos information ................................................. 1-18
1.3.9 Electrical storm injury prevention .........................................1-18
1.3.10 Mounting and dismounting the machine ...................................1-18
1.3.11 Before starting the engine .............................................1-18
1.3.12 Engine starting .....................................................1-19
1.3.13 Before operating the machine ..........................................1-19
1.3.14 Operating the machine ...............................................1-19
1.3.15 Parking the machine .................................................1-20
1.3.16 Operator station ....................................................1-21
1.3.17 Cut and crushing prevention ............................................1-21
1.3.18 Boom safety .......................................................1-21
1.3.19 Fuel safety ........................................................1-22
1.3.20 Hydraulic safety .....................................................1-22
1.3.21 Chemical safety .....................................................1-22
1.3.22 Exiting the cab in an emergency .........................................1-24
1.3.23 Engine safety ......................................................1-25
1.3.24 Safety lamps and marking devices use ....................................1-26
1.3.25 Operating on slopes ................................................. 1-27
1.3.26 Roading on public roads ...............................................1-27
1.3.27 Avoid eye contact with radar ...........................................1-27
1.3.28 Exhaust fumes .....................................................1-28
1.3.29 Electrical power lines overhead .........................................1-28
1.3.30 Shield and guards ...................................................1-28
1.3.31 Towing ...........................................................1-29
1.3.32 Modifications ......................................................1-29
1.3.33 A word to the operator ............................................... 1-30
1.3.34 Work in a clean area .................................................1-31
Table of contents
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1.3.35 Support the machine correctly ..........................................1-31
1.3.36 Maintenance safety ..................................................1-31
1.3.37 High pressure leaks ..................................................1-35
Table of contents
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1.1 Service manual
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 your parts quickly, have the following information:
Correct part description and part number
Model number of the machine
Serial number of the machine
1.1.3 Product identification information
Each machine has an identification plate with the model number and the serial number.
The product identification number (PIN) is used to
identify a machine.
The manufacturer's plate contains the PIN.
The serial numbers identify the engines,
transmissions, and attachments.
For reference, record the PIN on the line below:
The manufacturer's plate (1) is on the right-hand
side of the frame weldment.
Machine PIN:
GUID-DACEE2D9-FA24-4D37-9DB3-7BE1BF3D8154-high.jpg [High]
Fig. 1
1.1.4 Transmission serial number plate
The transmission serial number plate (1) is on the
side of the transmission.
Transmission serial number:
GUID-B6840A2E-61AD-4DC5-9FC0-3E0F123483DE-high.jpg [High]
Fig. 2
[V]
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GUID-41CD5D9C-8ECA-42A2-A8B1-9E3D92A75311 [V2]
GUID-3EE0239F-796B-455A-AEF8-7BF5029534AB [V2]
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1.1.5 Machine serial number information
GUID-2369DE17-F3A2-40BB-988B-36559CC24520-high.jpg [High]
Fig. 3
(1) Beginning symbol
(2) World manufacturer code
(3) Brand code:
•A - AG-Chem
• C - Challenger
• S - SpraCoupe
• W - Willmar
• M - Massey Ferguson
(4) Model identifier (model number)
(5) Check letter
(6) Model Year Code:
• W - 2011
• C - 2012
• D - 2013
• E - 2014
• F - 2015
(7) Location built code
(8) Option code
(9) Option code
(10) Machine sequence number - sequence number will start over at the beginning of each model year.
The first machine of each model year will be sequenced 1001.
(11) Ending symbol
1.1.6 Engine serial number plate
The engine serial number plate (1) is on the left-hand side of the cylinder block.
Record the engine serial number and the engine type below.
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1.2 Lubrication and maintenance
1.2.1 Maintenance introduction
IMPORTANT:
Do the maintenance procedures at regularly scheduled intervals. Failure to do regularly scheduled
maintenance results in damage to components or engine. Maintenance schedule is a recommended guide
for correct maintenance.
Do not change schedule unless increasing frequency of service when operating in very hot, cold, dusty or
corrosive conditions.
Use the hourmeter as a guide for maintenance intervals.
Maintenance intervals can show in both operating hours and time.
Example:
10 Hours or Every Day. Use the interval: operating hours or time — that comes first.
1.2.2 Maintenance symbols
Maintenance symbols
Inspect or check Engine oil filter
Elapsed operating hours Engine coolant level
Grease lubrication Hydraulic oil
Oil lubrication Hydraulic oil level
Service indicator Hydraulic oil filter
Pressurized Battery
[V]
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GUID-BBD6DDAB-C59C-47B1-B077-507CBFD8B839 [V1]
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Maintenance symbols
Drain or empty Fuel filter
Engine oil Air filter
Engine oil level Tire pressure
1.2.3 Maintenance chart for Jackson
Maintenance chart for engine models 49 AWF and 74 AWF used in RoGator. Maintenance chart for engine
models 84 AWF and 98 AWF used in RoGator, TerraGator and MT700E series tractors.
49 AWF and 74 AWF
Maintenance work Service interval / running hours
10 100 500 1000 4000
Check the engine oil level x[1]
Check the coolant level x[1]
Check for oil, fuel or coolant leakages x[1]
Clean the cooling system (from outside) x
Check the condition of the belt x
Change the engine oil and the oil filter x[2]
Change the fuel filters x[3]
Update engine software x
Adjust valves See the valve adjustment intervals table.
Turbocharger and intercooler inspection in an
authorized workshop
x
Change SCR supply module main filter Once a year. [4]
Change the coolant Every two years.
[1] or once a day.
[2] or once a year (at the end of the season).
[3] or once a year (at the end of the season) or earlier if the engine control system notifies by specific service code.
[4] or after 1200 running hours.
Valve adjustment intervals
1st 2nd 3rd 4th 5th
500 2000 4000 6000 8000
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84 AWF and 98 AWF
Maintenance work Service interval / running hours
10 100 400 800 4000
Check the engine oil level x[1]
Check the coolant level x[1]
Check for oil, fuel or coolant leakages x[1]
Clean the cooling system (from outside) x
Check the condition of the belt x
Change the engine oil and the oil filter x[2]
Change the fuel filters x[3]
Update engine software x
Adjust the valves[4, 5] See the valve adjustment intervals table.
Turbocharger and intercooler inspection in an
authorized workshop
x
Change SCR supply module main filter Once a year. [6]
Change the coolant Every two years.
Change the vibration damper (98 engines) Every five years. [7]
[1] or once a day.
[2] or once a year (at the end of the season).
[3] or once a year (at the end of the season) or earlier if the engine control system notifies by specific service code.
[4] The 98 engines have hydraulic lash adjusters from the engine serial number B52904. Do not adjust the valves.
[5] In the spring 2016, AGCO Power started to install hydraulic lash adjusters gradually to different 84 AWF engines.
See for information, how to recognize an engine with hydraulic lash adjusters. Do not adjust the valves of an
engine, which has hydraulic lash adjusters!
[6] or after 1200 running hours.
[7] or after 8000 running hours.
Valve adjustment intervals[1, 2]
1st 2nd 3rd 4th 5th
400 2000 4000 6000 8000
[1] The 98 engines have hydraulic lash adjusters from the engine serial number B52904. Do not adjust the valves.
[2] In the spring 2016, AGCO Power started to install hydraulic lash adjusters gradually to different 84 AWF engines.
See for information, how to recognize an engine with hydraulic lash adjusters. Do not adjust the valves of an
engine, which has hydraulic lash adjusters!
1.2.4 Daily maintenance schedule
Daily Service Item
XCheck the transmission oil level
XCheck the hydraulic tank oil level
XCheck hydraulic hoses and lines
XCheck the air cleaner service indicator
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Daily Service Item
XCheck tire air pressures and inflate tire as necessary (refer to tire charts in this
manual)
XCheck battery cables
XCheck the hand rinse tank level
XCheck the fuel water separator (if equipped); drain if water is present
XDrain the water from air storage tanks
XInspect all decals and replace, if necessary
1.2.5 Maintenance schedule 10 to 1000 hours
Follow the maintenance procedures at regularly scheduled intervals. Use the hourmeter as a guide for
maintenance intervals.
Initially: Do a check of all clamps on the engine at 10 hours and again at 50 hours, tighten and torque as
necessary. Do the process again when a hose is replaced.
10 hours 50 hours 100
hours
250
hours
400
hours
500
hours
1000[5]
hours or
annually
Service Item
X[1] Check the torque on rear
wheel nuts
X[2] Check the torque on the hose
clamps on the charge air hose
from the turbo to the charge-
air cooler (CAC)
X[3] Replace the inline fuel
strainer
X Lubricate the tag axle fittings
(if equipped)
X Lubricate front wheel
bearings
X[2] Check the rear axle mounting
bolts tighten to a torque of
575 Nm (424 lbf ft)
X Check brake air lines
X[2] Replace the hydraulic oil filter
X[2] Replace the CVT high
pressure filter
X[2] Replace the pressure washer
pump oil
X Check the front wheel bolt
and nut torque
X Check front and rear cab
mounts
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10 hours 50 hours 100
hours
250
hours
400
hours
500
hours
1000[5]
hours or
annually
Service Item
X Check torque on the rear
wheel nuts
X Lubricate the steering
cylinder ends
X Drain the water and sediment
out of the fuel tank
X Check the differential and
planetary oil level
X[2] Replace the differential and
planetary oil
X Clean the differential breather
X Check the tag axle bearing
bolt torque (if equipped)
X Check the rear axle mounting
bolts tighten to a torque of
575 Nm (424 lbf ft)
X[5] Check brakes manual slack
adjusters (if equipped)
X Inspect and clean the cab air
filters; replace, if required
X Lubricate grease fittings on
driveline
X Check the clutch master
cylinder fluid; check for
correct operation
X Replace the air dryer filter
X Lubricate the brake slack
adjuster on the rear axle
X Check the engine-to-frame
ground connections
X[4] Replace the pressure washer
pump oil
X Check driveline U-joints
X Replace the inline fuel
strainer
X Change the fuel water
separator filter - if equipped
X Check the charge air cooler
hose and charge air cooler
hose clamps
1. General
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10 hours 50 hours 100
hours
250
hours
400
hours
500
hours
1000[5]
hours or
annually
Service Item
X Replace the receiver-dryer (A/
C system)
X[5] Replace the primary engine
air filter
Every third primary filter replacement Replace the safety
(secondary) engine air filter
X Replace the hydraulic oil and
filter
X Replace the CVT high
pressure filter
X Replace the differential and
planetary oil
X Replace the pressure washer
strainer
Every 1500 hours or annually Replace the cab air filters
[1] Every 10 hours for first 50 hours, then at given intervals
[2] Intial schedule, at 50 hours, then every 1000 hours
[3] Initial schedule, then at given intervals
[4] Or annually (at the end of the season)
[5] Or as necessary
1.2.6 Maintenance Schedule 2000 to 4000 hours
Follow maintenance procedures at regularly schedule intervals. Use the hourmeter as a guide for
maintenance intervals.
2000 hours 3000 hours 4000 hours Service Item
X[1] Change the CVT clutch oil
X[2] Replace the water pump belt
X[1] X[3] X Replace the CVT transmission filtration strainer
X[1] X[3] X Drain and replace the CVT transmission oil
[1] Initial occurrence, then at given intervals.
[2] Every 3000 running hours or when the belt has been removed.
[3] After initial occurrence, CVT oil change interval and CVT filtration strainer replacement interval will vary with type
of oil used.
NOTE:
Replace the CVT filtration strainer at the same interval as the oil change interval.
Use AGCO Permatran 821XL Plus 15W-40 STOU, at the 2000 hour service interval or every two years (whichever
occurs first).
Use AGCO Permatran 821XL 10W-30, at the 1000 hour service interval or annually (whichever occurs first).
1.2.7 Lubricants and fluids
IMPORTANT:
Capacities listed are approximate. Check fluid levels after filling.
GUID-65AFA107-765C-42EE-A07E-9C5D492B1A5E [V2]
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79035613B
Identification Initial fill Recommended Capacity
Rear axle Multi-purpose gear lube SAE 80/90, API class GL-5 24.6 L (6.5 gal)
Hydraulic system AGCO permatran 821XL oil or equivalent 51 L (13.4 gal)
Transmission AGCO permatran 821XL
plus 15W-40 STOU
AGCO permatran 821XL Plus
15W-40 STOU
NOTE: The CVT oil change
interval is 2000 hours or every
two years, whichever come first.
57 L (15 gal)
Engine oil API CJ-4. AGCO powerlube multiguard
SAE 10W30
Ambient temp -17 to 40 °C (0 to
104 °F).
AGCO powerlube multiguard
SAE 15W40
Ambient Temp -9 to 50 °C (15 to
122 °F).
23 L (6 gal)
Grease fittings High temperature moly-
lithium base grease
As required
Pressure washer pump SAE 30W non detergent
oil
354 ml (11.97 fl
oz)
Engine coolant 50/50 water & ethylene
glycol without stop leak
additive with SCA
31 L (8 gal)
Diesel fuel Grade No. 1-D or 2-D S15,B5 624 L (165 gal)
Air conditioning system HFC-R134A HFC-R134A 1.15 kg (2.53 lb)
CVT clutch oil Pentosin CHF 11S Initial fill 150 ml
(5 fl oz )
Diesel exhaust fluid
(DEF)
BRENNTAG 56.8 L (15 gal)
Grease fittings on
driveline
High temperature NLGI #2 multi-purpose moly-free lithium
grease
As required
1.2.8 Lubricant filling reminders
Use only high-quality lubricants as specified. Do
not use a different lubricant.
Low quality lubricants reduce machine service life
and can cause component failures.
Do not add a lubricant unless the lubricant is the
same type and the same grade as the original
lubricant. If the grade is unknown or not available,
replace the lubricant with new lubricant.
Keep lubricants in a clean container and in an area
that has protection from dust, dirt, water, or other
contamination.
Incorrect disposal of potentially dangerous
materials can threaten the environment and the
GUID-2348C479-0553-4BA9-8AF1-A1BBF421896C-high.jpg [High]
Fig. 5 Correct disposal of dangerous chemicals
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1. General
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ecology. Potentially dangerous materials used with
AGCO machines include such items as oil, fuel,
fluids, and batteries.
Use leak-proof nonglass containers when draining
fluids. Never use a food container or beverage
container for fluids. Use of these containers can
mislead a person to drink from the containers.
Never pour dangerous materials on the ground,
down a drain, or into any water source.
Released air conditioning refrigerants damage the
air. Government regulations require a certified air
conditioning service center to collect and recycle
used air conditioning refrigerants.
1. General
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1.3 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.
1.3.1 Prepare for operation
Read and understand all operating instructions and precautions in this manual before operating or servicing
the machine.
Make sure you know and understand the positions and operations of all controls. Make certain all controls
are in neutral and the park brake is applied before starting the machine.
Make certain all people are well away from your area of work before starting and operating the machine.
Check and learn all controls in an area clear of people and obstacles before starting your work. Be aware of
the machine size and have enough space available to allow for operation. Never operate the machine at
high speeds in crowded places.
Emphasize the importance of using correct procedures when working around and operating the machine.
Do not let children or unqualified persons operate the machine. Keep others, especially children, away
from your area of work. Do not permit others to ride on the machine.
Make sure the machine is in the proper operating condition as stated in the Operator Manual. Make sure
the machine has the correct equipment required by local regulations.
GUID-C5A0147C-1966-4D7E-8EFB-5A9A1913F996 [V1]
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1.3.2 Fire prevention and first aid
Be prepared for emergencies.
Keep a first aid kit available for use on small cuts
and scratches.
Keep one or more fire extinguishers of the correct
type. Check fire extinguishers regularly as stated
by the manufacturer. Make sure that the fire
extinguishers are charged and in operating
condition.
Crop material is flammable, there is a risk of fire.
Use a water type fire extinguisher or other water
source for a fire in crop.
For fires in any other than crop, such as oil or
electrical components, use a dry chemical fire
extinguisher with an ABC rating.
Keep fire extinguishers easy to access where fires
can occur.
Frequently remove crop material from the machine
and check for components that are too hot. Do
checks on the machine daily for noises that are not
usual. Such noises can indicate a worn out
component that can cause too much heat.
If flame cutting, welding, arc welding, or grinding
is to be done on the machine or attachments, clear
crop material and unwanted material from around
the area. Make sure that the area below the work
area is clear of flammable material because falling
molten metal and sparks can cause ignition in the
material.
GUID-FF34ACC9-D080-4CD5-9528-F426605803FF-high.jpg [High]
Fig. 6
If fire occurs, move upwind and away from smoke
from the fire.
GUID-8FDCA67C-244A-40BA-967B-3FA4E7667A7E-high.jpg [High]
Fig. 7
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1.3.3 Safety symbol
The safety symbol tells you about a dangerous
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. 8
1.3.4 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. 9
1.3.5 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.
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1.3.6 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. 10
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. 11
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 differently, complete the maintenance under the following conditions:
•Turn the battery disconnect switch to "off" position.
• The machine is parked on level ground.
• Implements are lowered to the ground.
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Table of contents
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