Challenger RG900B Workshop Service Manual
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Challenger RG900B Workshop Service Manual

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Workshop Service Manual
Applicator Chassis
RG900B
RG1100B
RG1300B
North America
November 2015
4205 River Green Parkway, Duluth GA 30096 USA
79035871B
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
NA
© AGCO 2015
English

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Summary of Contents for Challenger RG900B

  • Page 1 Workshop Service Manual Applicator Chassis RG900B RG1100B RG1300B North America November 2015 4205 River Green Parkway, Duluth GA 30096 USA 79035871B Challenger is a registered trademark of Caterpillar Inc. and is used under license by AGCO. © AGCO 2015 English...
  • Page 2 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.
  • Page 3 TABLE OF CONTENT General Engine, fuel, and exhaust system Axles Frame and suspension Steering system Drive train system Brake system Air system Hydraulic system Electrical troubleshooting Air conditioning and heating system Chassis Wheels Attachments Accessories Diagrams Find manuals at https://best-manuals.com...

  • Page 4: Table Of Contents

    Table of contents 1. General ............1-3 1.1 Service manual 1.1.1 Units of measurement .
  • Page 5 Table of contents 1.5 Tightening specifications ..........1-32 1.5.1 Constant torque hose clamp .

  • Page 6: Service Manual

    1. General GUID-96F0DBC2-FDAB-4BE2-A442-8D57B94A81B4 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.
  • Page 7 1. General Engine serial number Plate (1) is located on engine. Engine serial number:______________________________ GUID-C7D1527B-69B0-4D00-B1C9-8D56F7C0BAC6-high.jpg Fig. 2 Hydrostatic pump identification Plate is located on top of hydrostatic pump. Hydrostatic pump serial number:______________________________ GUID-1C6DBAFD-D151-41CB-BD5F-7BFE666F7C06-high.jpg Fig. 3 Cab serial number Plate is located inside cab, below rear window, behind operator’s seat.

  • Page 8: Engine Identification

    1. General Operator seat serial number Tag (1) is located on rear of operators seat. Seat serial number:_______________________________ GUID-5C28A823-B154-4BDE-88F1-2C2198B33AD6-high.jpg Fig. 5 GUID-77EA0176-1F24-4287-A496-44B9570B6D7E 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.

  • Page 9: A Word To The Operator

    1. General GUID-F38BCC9A-5A98-41F3-BA3C-2C5AB224EDFB 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.

  • Page 10: Important Safety Information

    1. General GUID-C5A0147C-1966-4D7E-8EFB-5A9A1913F996 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.

  • Page 11: Safety Messages

    1. General GUID-E54F7740-C021-42A8-8784-4287BE4356C8 1.2.3 Safety messages The words DANGER, WARNING or CAUTION are used with the safety alert symbol. Learn to recognize these safety alerts and follow the recommended precautions and safety practices. DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in DEATH OR VERY SERIOUS INJURY.
  • Page 12 1. General 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.

  • Page 13: Prepare For Operation

    1. General GUID-A25B667B-D7CF-4C75-8AED-C10113104322 1.3 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.

  • Page 14: Engine Starting

    1. General GUID-404F2B41-5D2C-43EF-9AF6-E3F166487050 1.3.3 Engine starting Diesel engine exhaust contains products of combustion which can be dangerous to your health. Always start and operate the engine in a well ventilated area. If operating the engine in an closed area, vent the exhaust to the outside.

  • Page 15: Operator Station

    1. General Wear a seat belt always. GUID-5BA328EA-7732-4CE8-97B2-6511151E943C-high.jpg Fig. 13 Make sure the operator station and the steps areas are clean and dry to help prevent personal injuries. Tighten all wheel bolts to correct specifications before operating the machine. Never let passengers on, or in the machine when the machine is in operation.

  • Page 16: Parking The Machine

    1. General GUID-C9F9F774-F326-4D74-A7F6-EF97DE8473EC 1.3.7 Parking the machine Procedure Park the machine on a level surface. NOTE: If parking on a grade, chock the machine's tires and apply the park brake. Depress the Safety Hydraulic over Electric Lock-out (SHEL) switch or roading lockout switch.

  • Page 17: Roading On Public Roads

    1. General GUID-B42C9A0C-6A9B-4889-A4E3-A7466784F6F0 1.3.10 Roading on public roads WARNING: The machine was built for applying chemicals and fertilizers in off-road use. Do not use the machine for transporting application product on public roads. Chemical spills result in environmental damage. A loaded machine driven on public roads has high risk of tire failure.

  • Page 18: Maintenance And Service

    1. General GUID-A68922CA-C2A0-4800-8263-852A6064FF48 1.4 Maintenance and service Read and understand maintenance and safety instructions before performing any maintenance procedures. Any maintenance procedures and or repairs must only be done by trained personnel. Never change any equipment or add attachments not approved by AGCO. GUID-7A2043D6-4BF0-4103-A043-7EAC2FF8C2D7-high.jpg Fig.
  • Page 19 1. General Make-shift tools and procedures can create safety hazards. Use only the correct equipment and procedures. Use power tools only to loosen threaded parts and fasteners. Use only SAE tools with SAE fasteners and metric tools with metric fasteners. GUID-DEE49459-BB74-4B2E-8888-B708F25FD8C5-high.jpg Fig.
  • Page 20 1. General Avoid High-Pressure Fluids Releasing fluid or fluid leaking from the hydraulic system or the fuel injection system under high pressure can be very hard to see. The fluid can go into the skin causing serious injury. Fluid injected into the skin must be surgically removed within a few hours.
  • Page 21 1. General Rapid release of fluids from pressurized cooling systems can cause serious burns. Shut off the engine. Remove the filler cap only when the filler cap is cool enough to touch with bare hands. Slowly, loosen the filler cap to the first stop to relieve any pressure before removing the cap completely.

  • Page 22: Wear Protective Clothing

    1. General Stay away from potentially toxic fumes and dust. Dangerous fumes can be generated when paint is heated by welding, soldering or using a torch. Always work outside or in a well ventilated area. Discard paint and solvent correctly. Always remove paint before welding or heating.

  • Page 23: Proper Disposal Of Waste

    1. General noises that are not normal. Such noises could indicate a failed component that can cause excess heat. If any flame cutting, welding, or arc welding is to be done on the machine or attachments, make sure to clear any crop material or debris from around the area.

  • Page 24: Support The Machine Correctly

    1. General Do not operate the machine with the drive shaft shields open or removed. Entanglement in rotating drive shafts can cause serious injury or death. Stay clear of rotating components. Make sure rotating guards turn freely. GUID-CEB32148-1F4C-457C-ADF7-595DFC51AC25-high.jpg Fig. 35 GUID-33C891CB-037C-470E-97E2-487B71EF7F53 1.4.6 Support the machine correctly Never support the machine on cinder blocks,...

  • Page 25: Boom Safety

    1. General Keep objects away from moving fan blades. The fan blades will throw objects and the fan blades can cut. Do not use a wire tow cable that is kinked or frayed. Wear gloves when touching wire cable. When hitting a retainer pin, the retainer pin can fly out causing personal injury. Make sure that there are no people in the area when hitting a retainer pin.

  • Page 26: High Pressure Leaks

    1. General GUID-68111A90-0641-4B8F-9AB9-A5B05A044C46 1.4.13 High pressure leaks Fluid leaking from the hydraulic system or the fuel injection system under high pressure can be very hard to see. The fluid can go into the skin causing serious injury. Fluid injected into the skin must be surgically removed within a few hours.
  • Page 27 1. General If dangerous chemicals come in contact with the body, wash immediately according to the chemical manufacturer's recommendations. Never put nozzles, tips or other parts to lips to blow out trash or debris. Have spare tips available for replacement. Wear close fitting clothing and correct safety equipment required.

  • Page 28: Engine Safety

    1. General If contact is made with chemicals or fertilizers, follow the correct treatment on the container. Always wash hands before touching your face or mouth. Get medical aid immediately if signs of illness, such as drowsiness or constant fatigue, occur during or recently after the use of dry or liquid agricultural chemicals or fertilizers.
  • Page 29 1. General Do not use aerosol starting fluid as a starting aid. The heaters in the intake manifold can cause the starting fluid to ignite resulting in an explosion. This explosion can cause death or very serious injury and damage to the engine. GUID-E707838B-F5D5-48F0-BF75-34B264F6453D-high.jpg Fig.

  • Page 30: Battery Safety

    1. General Never remove the cap from a hot radiator. Escaping steam and hot fluids can cause personal injury. Always permit the radiator to cool to the touch before removing the cap. GUID-4202FBD9-E970-40A6-A525-8762838BEBD0-high.jpg Fig. 48 GUID-F032CF5D-CE06-454C-A6F7-775BBA12CD64 1.4.16 Battery safety Electrical storage batteries give off highly flammable hydrogen gas.

  • Page 31: Tire Safety

    1. General GUID-E28CEEE8-E160-49B0-8080-8D193B1B4E86 1.4.17 Tire safety Check tires for cuts, bulges, and correct pressure. Replace worn or damaged tires. When tire service is needed, have a qualified tire mechanic service the tire. Tire changing can be very hazardous and must be done by qualified tire mechanic using proper tools and equipment.

  • Page 32: Avoid Eye Contact With Radar

    1. General GUID-3BCD51B8-9171-4A55-BA5F-BA93C63D9F30 1.4.18 Avoid eye contact with radar Radar ground speed sensors emit a low intensity microwave signal. The signal causes no ill effects during normal use. To prevent eye damage, never look directly into an operating sensor. GUID-B711134F-913D-43A0-88CA-FAC022CCC893-high.jpg Fig.

  • Page 33: Towing

    1. General GUID-2DB2321D-BA05-4E5C-88D7-1F2DF98936D0 1.4.21 Towing Towing is not approved by AGCO. Using the machine for towing can create a safety hazard and can void the machine or system warranty. GUID-062233BB-726B-4EDA-A20C-802459E560D5-high.jpg Fig. 55 GUID-DBB358D7-0FCA-4675-A8BA-016508F1C366 1.4.22 Modifications Welding or altering chassis in any way such as adding implement towing hitches can cause damage or failure of components.
  • Page 34 1. General GUID-2FD78C2A-913B-44E7-9791-7F4D6B2938C5-high.jpg Fig. 56 The signal word panel (1) shows the level or severity of the hazard. The signal words are DANGER, WARNING, and CAUTION. The hazard panel (2) shows the consequence of encountering the hazard. The avoidance panel (3) shows the procedure required to prevent the hazard. Applicator Chassis 1-31 79035871B...

  • Page 35: Tightening Specifications

    1. General GUID-560092D3-0E1C-41B4-9982-DE66EE9895E5 1.5 Tightening specifications IMPORTANT: Mismatched or incorrect fasteners can result in damage, malfunction, or personal injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torque values are given in the Service Manual if necessary. Prior to the installation of any hardware, make sure the components are in near new condition.
  • Page 36 1. General Standard High M24 x 3 530 to 650 700 to 900 600 to 730 800 to 1000 285 to 345 375 to 475 M30 x 3.5 1060 to 1400 to 1800 1200 to 1460 1600 to 2000 565 to 685 750 to 950 13000 M36 x 4...

  • Page 37: Metric Fasteners

    1. General Standard High Thread size Torque lbf ft Torque Nm Torque lbf ft Torque Nm Torque lbf ft Torque Nm 1 1/4 - 7 1190 to 1450 1600 to 2000 1395 to 1705 1850 to 2350 880 to 1070 875 to 1125 1 3/8 - 6 1600 to 1960 2100 to 2700 1790 to 2190 2400 to 3000 1185 to 1445 850 to 1150...

  • Page 38: Inch Fasteners

    1. General Standard High Thread Size Pound Feet Newton Pound Feet Newton Pound Feet Newton lbf ft Meters Nm lbf ft Meters Nm lbf ft Meters Nm M24 x 3 530 to 640 700 to 900 600 to 730 800 to 1000 285 to 345 375 to 475 M30 x 3.5...
  • Page 39 1. General Standard High Thread Size Pound Feet Newton Pound Feet Newton Pound Feet Newton lbf ft Meters Nm lbf ft Meters Nm lbf ft Meters Nm 1/4 - 20 8 to 10 9 to 15 9 to 11 10 to 16 3.5 to 4.5 5 to 7 5/16 - 18...
  • Page 40 1. General Four-bolt split flange Make sure the sealing surfaces are free of burrs, damage, and scratches or any unwanted particles. Lubricate the O-ring. Set the flanges and the half clamps. Put the lock washers on the bolts and put the bolts through the half clamps.
  • Page 41 1. General DASH SIZE TUBE O. D. (REF) TORQUE MAX lbf in lbf ft 5/16 1080 1 1/4 1440 1 1/2 1575 3600 2 1/2 4800 6000 O-ring face seal (ORFS) fittings ORFS Connectors, ORFS Hose Couplings, ORFS Plugs, and ORFS Tube Assembly Nut Torques Ref Nominal Tube OD Standard Torque High Pressure Drive...

  • Page 42: Conversion Table

    1. General GUID-F9D11390-9AB1-40A0-928B-0053242C4F01 1.5.5 Conversion table GUID-431973BE-8D8B-4448-AC64-D9F14769DE29-high.jpg Fig. 61 Applicator Chassis 1-39 79035871B...

  • Page 43: Lubrication And Maintenance

    1. General 1.6 Lubrication and maintenance GUID-A5043855-D7BD-4349-820B-96475F0FC4B1 1.6.1 Maintenance introduction IMPORTANT: Do maintenance procedures at regularly scheduled intervals. Failure to do regularly scheduled maintenance will cause damage to machine components or the engine. The maintenance schedule is a recommended guide for correct machine maintenance. IMPORTANT: When operating in normal conditions, do not change the schedule.
  • Page 44 1. General Service intervals Service item Daily Every Every Every Every Every Every Every Every Every 1000 1200 4000 hours hours hours hours hours hours hours hours hours rods, and anti- roll bar Remove water from air reservoir(s) Check for oil, fuel or coolant leakages Inspect/clean...
  • Page 45 1. General Service intervals Service item Daily Every Every Every Every Every Every Every Every Every 1000 1200 4000 hours hours hours hours hours hours hours hours hours engine control system code X(1) Change additional fuel water separator filter (if necessary) See Valve adjustment intervals table Adjust the manual valve...
  • Page 46 1. General Service intervals Service item Daily Every Every Every Every Every Every Every Every Every 1000 1200 4000 hours hours hours hours hours hours hours hours hours X(2) Replace hydraulic oil X(5) Replace pressure washer pump seal kit (if equipped) X(2) Drain water...

  • Page 47: Lubricant Filling Reminders

    1. General Manual valve lash adjustment intervals¹ Engine 7.4L 1200 2400 3600 4800 8.4L 1800 3600 5400 7200 ¹ - If the engine is equipped with hydraulic lift adjusters, do not adjust the valves. GUID-F5D8EEDA-2B1F-469B-804B-D447609660B5 1.6.3 Lubricant filling reminders Use only high-quality lubricants. Low quality lubricants reduce the service life of the machine and can cause component failures.
  • Page 48 Table of contents 2. Engine, fuel, and exhaust system 2.1 Engine system ............2-7 2.1.1 Disassembling the cooling package .
  • Page 49 Table of contents 2.3 Exhaust system ............2-222 2.3.1 Removing the exhaust system without diesel exhaust fluid .
  • Page 50 Table of contents 2.7.9 Timing gears ............2-273 2.7.10 Connecting rod .
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

Rg1100bRg1300b

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