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Challenger TG8400C Workshop Service Manual

Applicator chassis
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Workshop Service Manual
Applicator Chassis
TG8400C
North America
September 2019
4205 River Green Parkway, Duluth GA 30096 USA
79037161C
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 TG8400C

  • Page 1 Workshop Service Manual Applicator Chassis TG8400C North America September 2019 4205 River Green Parkway, Duluth GA 30096 USA 79037161C 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 1.3.6 Maintenance Schedule 2000 to 4000 hours ......1-32 1.3.7 Lubricants and fluids ..........1-32 1.3.8 Lubricant filling reminders .
  • Page 5 Table of contents 2.4.10.3 Throttle valve ........2-84 2.4.11 Fuel system .
  • Page 6 Table of contents 2.11.1 Remove the flywheel housing ........2-135 2.11.2 Install the flywheel housing .
  • Page 7 Table of contents 2.18.7 .1 Install the oil sump gasket, metal gasket ....2-170 2.18.7 .2 Install the oil sump gasket, paper gasket ....2-170 2.18.7 .3 Install the oil sump gasket, cork gasket .
  • Page 8 Table of contents 2.21.9.3 Removing the pressure control valve ..... . 2-204 2.21.9.4 Fitting the pressure control valve ......2-205 2.21.9.5 Removing the pressure sensor .
  • Page 9 Table of contents 2.28 Disassemble the engine ......... . . 2-260 2.28.1 Remove the wiring harnesses .
  • Page 10 Table of contents 2.29.28 Install the wiring harnesses ........2-288 2.30 Lift the engine .
  • Page 11 Table of contents 3.1.6.1 Repair of the parts ........3-34 3.1.6.2 How to clean ground or polished parts .
  • Page 12 Table of contents 3.4.2.2 Remove the differential carrier from the axle housing ... 3-88 3.4.2.3 Remove the differential and ring gear from carrier ... . . 3-89 3.4.2.4 Do a check of the rotating resistance of the differential gears .
  • Page 13 Table of contents 3.5.3.4 Dry the cleaned planetary wheel end parts ....3-160 3.5.3.5 Prevent the corrosion on planetary wheel and parts ... 3-160 3.5.3.6 Inspect the planetary wheel end components .
  • Page 14 Table of contents 3.7 .8 Adjust the automatic slack adjusters ....... 3-211 3.7 .9 Commercial vehicle safety alliance (CVSA) guidelines .
  • Page 15 Table of contents 5.2.15 Install the head gland (retaining ring) ....... . . 5-42 5.2.16 Install a threaded piston .
  • Page 16 Table of contents 6.8.3.1 Remove the radar speed sensor ......6-88 6.8.3.2 Install the radar speed sensor ......6-89 Transmission testing and adjusting .
  • Page 17 Table of contents 7 .1.3 Air brake system description ........7-5 7 .1.4 Park brake system .
  • Page 18 Table of contents 7 .3.4 Air governor specifications ........7-67 7 .3.5 Air dryer specifications .
  • Page 19 Table of contents 9.2.3 Code 0D.1.02 ..........9-14 9.2.4 Code 0D.1.03 .
  • Page 20 Table of contents 9.4.30 Code 18.1.6D ..........9-19 9.4.31 Code 18.1.70 .
  • Page 21 Table of contents 9.6.12 Code 0F .1.10 ..........9-24 9.6.13 Code 0F .1.17 .
  • Page 22 Table of contents 9.7 .53 Code 19.1.30 ..........9-30 9.7 .54 Code 19.1.31 .
  • Page 23 Table of contents 9.7 .111 Code 19.1.6A ..........9-34 9.7 .112 Code 19.1.6B .
  • Page 24 Table of contents 9.9.5 Code 38.1.04 ..........9-39 9.9.6 Code 38.1.05 .
  • Page 25 Table of contents 9.11.39 Code 4.1.64 ........... 9-48 9.11.40 Code 4.1.65 .
  • Page 26 Table of contents 9.11.97 Code 4.2.BB ..........9-56 9.11.98 Code 4.2.BE .
  • Page 27 Table of contents 9.12.38 Lights- AFWL schematic ......... 9-116 9.12.39 Lightbar/smart yield schematic .
  • Page 28 Table of contents 10.2.4 Install the multifunction armrest ........10-27 10.2.5 Remove the AccuTerminal .
  • Page 29 Table of contents 11.3.3 Automatic temperature control panel test ......11-18 11.3.4 Troubleshoot with service codes ........11-19 11.3.5 Enter advanced diagnostics .
  • Page 30 Table of contents 13.1.10 Tire charts ........... . 13-9 14 Accessories .
  • Page 31 Table of contents 15.1 List of special tools ..........15-3 .
  • Page 32 Table of contents Applicator Chassis 79037161C...

  • Page 33: General

    Table of contents 1 General Service manual ............1-3 1.1.1 Units of measurement .
  • Page 34 Table of contents 1.3.6 Maintenance Schedule 2000 to 4000 hours ....... 1-32 1.3.7 Lubricants and fluids .

  • Page 35: Service Manual

    1. General 1.1 Service manual GUID-EBB3FCAE-8712-43A9-BB65-1DB48189C57C [V2] 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. GUID-0DCC2166-0585-4D9F-9842-E9E5A15E5873 [V3] 1.1.2 Replacement parts To receive your parts quickly, have the following information: Correct part description and part number...

  • Page 36: Serial Number Definition

    1. General GUID-F0DDF4A7-2860-4D6E-8682-15FC0457F092 [V3] 1.1.5 Serial number definition GUID-6A49518D-AF69-449D-9237-C047CCBF1E02-high.jpg [High] Fig. 3 Definition of the serial number Beginning Symbol Compliance Region Code World Manufacturer Code Option Code Brand Code Machine Sequence Number - sequence Model Identifier (Model Number) number will start over at the beginning of Check Letter each model year.

  • Page 37: Important Safety Information

    1. General GUID-C5A0147C-1966-4D7E-8EFB-5A9A1913F996 [V1] 1.2 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 38: Fire Prevention And First Aid

    1. General GUID-9D716526-CF1A-4CD9-89A6-FD350D1B1E7A [V7] 1.2.2 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. Examine fire extinguishers regularly as stated by the manufacturer.

  • Page 39: Safety Symbol

    1. General GUID-5D9F270E-D748-4741-82B1-BE49B78685F2 [V5] 1.2.3 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.

  • Page 40: General Hazard Information

    1. General GUID-45723AC0-5E25-4FA2-BB74-FF22568B117F [V3] 1.2.6 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. 9 Do not start the engine until the area is free of personnel.

  • Page 41: Pressurized Air

    1. General • Transmission control lever is in the park position. • The engine is stopped. • The engine start switch is turned off 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.

  • Page 42: Start The Engine

    1. General GUID-404F2B41-5D2C-43EF-9AF6-E3F166487050 [V3] 1.2.12 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 43: Park The Machine

    1. General Wear a seat belt always. GUID-5BA328EA-7732-4CE8-97B2-6511151E943C-high.jpg [High] Fig. 11 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 44: Operator Station

    1. General Depress the Safety Hydraulic over Electric Lock-out (SHEL) switch (1) or roading lockout switch. Before you stop the engine, move the throttle control lever to the LOW IDLE position. Run the engine at low idle speed for five minutes.

  • Page 45: Hydraulic Safety

    1. General Reduce fire hazards by cleaning any accumulated trash, grease and debris from the machine. Always have a multipurpose dry chemical fire extinguisher filled and available during machine operation and service, especially when adding fuel. Know how to use the fire extinguisher. GUID-4653B3AF-A55F-4989-99D9-C0AB44D4235E [V2] 1.2.20 Hydraulic safety The machine uses high-pressure fluids for operation.
  • Page 46 1. General Wear close fitting clothing and correct safety equipment required. Wear approved hearing protection such as earmuffs or earplugs to protect against loud noises. Long exposure to high noise levels can cause hearing impairment. Some cabs use filters that cannot remove dangerous chemicals.

  • Page 47: Exit The Cab In An Emergency

    1. General Never apply chemicals when the wind exceeds the chemical manufacturer's recommendation. NEVER let chemicals touch the skin or eyes. GUID-6942F6BB-021E-47D8-8B36-8FB6CB6088DB-high.jpg [High] Fig. 18 GUID-84374C1D-AD91-4281-A675-E6572267BBD0 [V1] 1.2.22 Exit the cab in an emergency Before starting the procedure Prior to machine operation, completely understand how to quickly exit the cab in an emergency. Procedure Remove the hammer (1) from the holder.
  • Page 48 1. General DANGER: Exposion hazard. Starting fluid. Personal injury, death, or machine damage can occur. Do not use starting fluid as a starting aid. Do not use aerosol starting fluid to start the engine. The heaters in the intake manifold can cause ignition and explosion of the starting fluid.

  • Page 49: Safety Lamps And Marking Devices Use

    1. General GUID-DC83B0FE-892B-404A-9FCE-D21E3D17639B [V1] 1.2.24 Safety lamps and marking devices use To increase visibility, use the safety lamps and marking devices provided with the machine. Use amber flashing warning lamps and turn signals whenever driving on public roads. Keep safety items and features in the correct working order.

  • Page 50: Avoid Eye Contact With Radar

    1. General GUID-3BCD51B8-9171-4A55-BA5F-BA93C63D9F30 [V1] 1.2.27 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 [High] Fig.
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