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Challenger RG900C Workshop Service Manual

Applicator chassis
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Workshop Service Manual
Applicator Chassis
RG900C
RG1100C
RG1300C
North America
August 2019
4205 River Green Parkway, Duluth GA 30096 USA
79037219C
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
NA
© AGCO 2019
English

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Summary of Contents for Challenger RG900C

  • Page 1 Workshop Service Manual Applicator Chassis RG900C RG1100C RG1300C North America August 2019 4205 River Green Parkway, Duluth GA 30096 USA 79037219C Challenger is a registered trademark of Caterpillar Inc. and is used under license by AGCO. © AGCO 2019 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 Contents

    Table of contents Applicator Chassis 1 General ..............1-1 .
  • Page 4 Table of contents 1.4.26 Safety and informational signs ........1-31 Tightening specifications .
  • Page 5 Table of contents 2.5.4 Valve mechanism ..........2-108 2.5.5 Cylinder head .
  • Page 6 Table of contents 2.10 Terminal diagram ..........2-160 .
  • Page 7 Table of contents 2.18 Timing gear assembly ..........2-196 2.18.1 Removing timing gear casing .
  • Page 8 Table of contents 2.21.12 Remove the intake manifold ........2-230 2.21.13 Install the intake manifold .
  • Page 9 Table of contents 2.24.5 Replace the electronic control unit ....... . . 2-280 2.24.6 Replace an empty electronic control unit (ECU) .
  • Page 10 Table of contents 2.30.11 Installing the closed crankcase ventilation system components ... . 2-313 2.30.12 Install the fuel filters ......... . . 2-314 2.30.12.1 Install the injector overflow pipe .
  • Page 11 Table of contents 2.35.10 Install the dosing module ........2-393 2.35.11 Remove an exhaust gas temperature sensor .
  • Page 12 Table of contents 5.2.10 Disassemble a cylinder ......... . 5-14 5.2.11 Assemble a cylinder .
  • Page 13 Table of contents 8.2.4 Install the air dryer ..........8-12 8.2.5 Remove the air reservoir .
  • Page 14 Table of contents 9.3.13 Remove the hydrostatic drive pump ....... . . 9-42 9.3.14 Replace the bearing and shaft .
  • Page 15 Table of contents 10.2.1 Code 1.1.00 ..........10-14 10.2.2 Code 1.1.01 .
  • Page 16 Table of contents 10.2.59 Code 4.1.0C ..........10-19 10.2.60 Code 4.1.0D .
  • Page 17 Table of contents 10.2.117 Code 4.1.46 ..........10-26 10.2.118 Code 4.1.47 .
  • Page 18 Table of contents 10.2.175 Code 18.1.10 ..........10-31 10.2.176 Code 18.1.11 .
  • Page 19 Table of contents 10.2.233 Code 19.1.24 ..........10-36 10.2.234 Code 19.1.25 .
  • Page 20 Table of contents 10.2.291 Code 19.1.5F ..........10-42 10.2.292 Code 19.1.60 .
  • Page 21 Table of contents 10.2.349 Code 1B.1.05 ..........10-46 10.2.350 Code 1B.1.06 .
  • Page 22 Table of contents 10.2.407 Code 4.1.5D ..........10-53 10.2.408 Code 4.1.5E .
  • Page 23 Table of contents 10.5 Fuses and relays ..........10-161 10.5.1 Fuse/relay panel .
  • Page 24 Table of contents 10.7 .48 Phoenix 200 schematic ........10-239 10.7 .49 Radar schematic .
  • Page 25 Table of contents 11.1.24 Remove the windshield washer tank ....... . 11-37 11.1.25 Install the windshield washer tank .
  • Page 26 Table of contents 12.5.10 Recovery ........... . 12-33 12.5.11 Moisture in a refrigerant system .
  • Page 27 Table of contents 15.2.1 Remove the crop deflector ........15-5 15.2.2 Install the crop deflector .
  • Page 28 Table of contents Applicator Chassis 79037219C...

  • Page 29: General

    Table of contents 1 General Service manual ............1-3 1.1.1 Units of measurement .
  • Page 30 Table of contents 1.4.25 Safety signs ............1-31 1.4.26 Safety and informational signs .

  • Page 31: Service Manual

    1. General GUID-96F0DBC2-FDAB-4BE2-A442-8D57B94A81B4 [V1] 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 32 1. General Engine serial number Plate (1) is located on engine. Engine serial number:______________________________ GUID-C7D1527B-69B0-4D00-B1C9-8D56F7C0BAC6-high.jpg [High] 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 [High] Fig. 3 Cab serial number Plate is located inside cab, below rear window, behind operator’s seat.

  • Page 33: 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 [High] Fig. 5 GUID-77EA0176-1F24-4287-A496-44B9570B6D7E [V2] 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 34: A Word To The Operator

    1. General GUID-F38BCC9A-5A98-41F3-BA3C-2C5AB224EDFB [V6] 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 implements before you operate this machine. You are responsible for your safety. Good safety procedures prevent injury to you and the persons around you.

  • Page 35: Safety Symbol

    1. General 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.

  • Page 36: Safety Messages

    1. General GUID-E54F7740-C021-42A8-8784-4287BE4356C8 [V4] 1.2.3 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.
  • Page 37 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 38: Protective Equipment

    1. General GUID-7AC94187-E268-4840-A392-13B874621BCA [V2] 1.2.6 Protective equipment Always wear approved protective equipment and clothing. 1. Goggles 2. Gloves 3. Safety boots 4. Clothing 5. Breathing protection 6. Hearing protection GUID-51136DDD-819F-4C00-9966-14CE084951C2-high.jpg [High] Fig. 12 WARNING: Before leaving cab, wear personal protective equipment as required by pesticide use instructions and chemical manufacturer recommendations.

  • Page 39: Prepare For Operation

    1. General GUID-A25B667B-D7CF-4C75-8AED-C10113104322 [V6] 1.3 Prepare for operation Read and understand all operation instructions and precautions in this manual before you operate the machine or do the servicing. Make sure that you know and understand the positions and operations of all controls. Make sure that all controls are in neutral and that the parking brake is applied before you start the machine.

  • Page 40: Start The Engine

    1. General GUID-404F2B41-5D2C-43EF-9AF6-E3F166487050 [V3] 1.3.3 Start the engine 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 41: Operator Station

    1. General Wear a seat belt always. GUID-5BA328EA-7732-4CE8-97B2-6511151E943C-high.jpg [High] Fig. 15 GUID-4585DBB4-5925-4C8B-9903-1E9BA678327B-high.jpg [High] Fig. 16 Do not turn the key switch to the OFF position until the machine is stopped and the machine is shutdown correctly. Do not use the machine for transporting applicator product along public roads.

  • Page 42: Safety Lamps And Marking Devices Use

    1. General IMPORTANT: If parking on a grade, chock the tires and make sure the park brake is always applied. Press the Park brake switch (1). Before you stop the engine, move the throttle control lever to the LOW IDLE position.

  • Page 43: Maintenance And Service

    1. General GUID-A68922CA-C2A0-4800-8263-852A6064FF48 [V2] 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.

  • Page 44: Maintenance Safety

    1. General GUID-E7753612-F7C1-4458-A489-C73E0434BE9F [V2] 1.4.2 Maintenance safety Fully clean the work area, the machine, systems, and components before starting a job. Dirty and greasy areas can create work hazards. GUID-46310DE1-3B25-4081-953A-1433A08E2F58-high.jpg [High] Fig. 22 Illuminate the working area correctly, adequately and safely. Use correct safety lamps with wire safety cages.
  • Page 45 1. General Never support the machine on cinder blocks, hollow tiles or supports that can crumble. Never work under a machine that is only supported by a jack. Always use wheel chocks. GUID-9025066F-C689-430E-BEE2-1B59E9059E45-high.jpg [High] Fig. 25 Lifting incorrectly can cause injury or machine damage.
  • Page 46 1. General When searching for leaks, use a piece of wood or cardboard. Protect hands and body from high pressure fluids. Do not use your hands. Never open hydraulic lines or fuel lines when they are under pressure. Hydraulic fluid or diesel fuel under pressure can cut the skin, cause bad burns, eye injury, skin irritation, or gangrene.
  • Page 47 1. General Electrical storage batteries give off highly flammable hydrogen gas. Keep sparks and flames away from the battery. Do not lay tools or other conductive materials on a battery. Be careful when connecting booster cables to the machine. Electrical component damage or battery explosion can result if booster cables are not installed correctly.

  • Page 48: Wear Protective Clothing

    1. General Related Links page 1-29 Tire safety GUID-AD7F3282-F5C8-4F7C-9240-D622E50C1D75 [V2] 1.4.3 Wear protective clothing Wear close fitting clothing and the proper safety equipment required. Wear suitable hearing protection such as ear muffs or ear plugs to protect against loud noises. Prolonged exposure to high noise levels can cause hearing impairment.

  • Page 49: Proper Disposal Of Waste

    1. General If fire occurs, move upwind and away from the smoke from the fire. GUID-8FDCA67C-244A-40BA-967B-3FA4E7667A7E-high.jpg [High] Fig. 36 GUID-D27C9EFF-D3E3-4F5E-93ED-A6E5560C23DF [V3] 1.4.5 Proper disposal of waste Improper disposal of waste can pollute the environment and ecology. A few examples of potentially harmful equipment waste can include, but not limited to, items such as oil, fuel, coolant, brake fluid, filters, battery chemicals, tires, etc.

  • Page 50: Support The Machine Correctly

    1. General DANGER: Entanglement hazard. Rotating components. Severe personal injury or death can occur. Do not make adjustments or repairs to components while they are moving. Stop the machine before doing service to the machine. Do not operate the machine with the drive shaft shields open or removed.
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This manual is also suitable for:

Rg1100cRg1300c

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