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Challenger TG8400B Workshop Service Manual

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Workshop Service Manual
TG8300B
North America
May 2017
4205 River Green Parkway, Duluth GA 30096 USA
79035613B
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
EAME
© AGCO 2017
English

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Summary of Contents for Challenger TG8400B

  • Page 1 Workshop Service Manual TG8300B North America May 2017 4205 River Green Parkway, Duluth GA 30096 USA 79035613B Challenger is a registered trademark of Caterpillar Inc. and is used under license by AGCO. EAME © AGCO 2017 English...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 TABLE OF CONTENT General Engine Powertrain Cab and platform Wheels and tires Frame and axles Electrical Steering and hydraulic system Pneumatics HVAC Appearance 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 1.3.35 Support the machine correctly ......... . 1-31 1.3.36 Maintenance safety .

  • Page 6: 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 7: Machine Serial Number Information

    GUID-2369DE17-F3A2-40BB-988B-36559CC24520-high.jpg [High] Fig. 3 Beginning symbol World manufacturer code Brand code: • A - AG-Chem • C - Challenger • S - SpraCoupe • W - Willmar • M - Massey Ferguson Model identifier (model number) Check letter Model Year Code: •...
  • Page 8 1. General Engine serial number: Engine type: GUID-9419F7AE-A47B-436C-9EFD-640C22FE0E42-high.jpg [High] Fig. 4 79035613B Find manuals at https://best-manuals.com...

  • Page 9: Lubrication And Maintenance

    1. General 1.2 Lubrication and maintenance GUID-CF71A599-B8E9-47DF-B285-A40F5BBE34F3 [V2] 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.

  • Page 10: Maintenance Chart For Jackson

    1. General Maintenance symbols Drain or empty Fuel filter Engine oil Air filter Engine oil level Tire pressure GUID-5E0F3DBC-3967-4D86-85E3-6F1FA54D7819 [V3] 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.

  • Page 11: Daily Maintenance Schedule

    1. General 84 AWF and 98 AWF Maintenance work Service interval / running hours 4000 Check the engine oil level Check the coolant level Check for oil, fuel or coolant leakages Clean the cooling system (from outside) Check the condition of the belt Change the engine oil and the oil filter Change the fuel filters Update engine software...

  • Page 12: Maintenance Schedule 10 To 1000 Hours

    1. General Daily Service Item Check tire air pressures and inflate tire as necessary (refer to tire charts in this manual) Check battery cables Check the hand rinse tank level Check the fuel water separator (if equipped); drain if water is present Drain the water from air storage tanks Inspect all decals and replace, if necessary GUID-85144157-3C0E-4637-AC74-8AFA3AE57D14 [V6]...
  • Page 13 1. General 10 hours 50 hours 1000 Service Item hours hours hours hours hours or annually Check torque on the rear wheel nuts Lubricate the steering cylinder ends Drain the water and sediment out of the fuel tank Check the differential and planetary oil level Replace the differential and planetary oil...

  • Page 14: Maintenance Schedule 2000 To 4000 Hours

    1. General 10 hours 50 hours 1000 Service Item hours hours hours hours hours or annually Replace the receiver-dryer (A/ C system) Replace the primary engine air filter Every third primary filter replacement Replace the safety (secondary) engine air filter Replace the hydraulic oil and filter Replace the CVT high...

  • Page 15: Lubricant Filling Reminders

    1. General 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 AGCO permatran 821XL Plus 57 L (15 gal) plus 15W-40 STOU 15W-40 STOU...
  • Page 16 1. General 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.

  • Page 17: Important Safety Information

    1. General GUID-C5A0147C-1966-4D7E-8EFB-5A9A1913F996 [V1] 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.

  • Page 18: Fire Prevention And First Aid

    1. General GUID-9D716526-CF1A-4CD9-89A6-FD350D1B1E7A [V5] 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.

  • Page 19: Safety Symbol

    1. General GUID-5D9F270E-D748-4741-82B1-BE49B78685F2 [V4] 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.

  • Page 20: General Hazard Information

    1. General GUID-45723AC0-5E25-4FA2-BB74-FF22568B117F [V3] 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.

  • Page 21: 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 22: Engine Starting

    1. General GUID-404F2B41-5D2C-43EF-9AF6-E3F166487050 [V2] 1.3.12 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 23: Parking The Machine

    1. General Wear a seat belt always. GUID-5BA328EA-7732-4CE8-97B2-6511151E943C-high.jpg [High] Fig. 12 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 24: Operator Station

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

  • Page 25: Fuel Safety

    1. General GUID-70E88E0B-A1B2-4AA8-ABB1-E0D40FDF2DD6 [V1] 1.3.19 Fuel safety Handle fuel with care: it is highly flammable. Clean up any spilled fuel immediately. Never use diesel fuel, kerosene, gasoline or any flammable solvents for cleaning the machine or parts. 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.
  • Page 26 1. General 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. Wear approved hearing protection such as earmuffs or earplugs to protect against loud noises.

  • Page 27: Exiting The Cab In An Emergency

    1. General The chemical manufacturer Material Safety Data Sheet (MSDS) provides specific instructions on dangerous chemical products: health hazards, safety procedures, and emergency response techniques. Check the MSDS before starting any job using a dangerous chemical. Know exactly what the risks are and how to do the job safely.

  • Page 28: Engine Safety

    1. General Procedure Grab the tab and pull. Remove the rope and push out the glass. Exit the cab through the window. GUID-BD11A1C4-681F-44D8-B4E5-A6A6780C3D06-high.jpg [High] Fig. 21 GUID-33011E96-B9C6-4289-B6C3-5254E0584EBD [V3] 1.3.23 Engine safety Make sure all shields, guards and access doors are in position and are closed before you start the engine.

  • Page 29: Safety Lamps And Marking Devices Use

    1. General Keep out of the engine compartment while the engine is in operation. Before you open the engine cover, stop the engine and take the key with you. Look and Listen! Make sure that all parts that move are stopped. GUID-E8A0C04D-128F-4E5C-8BE1-DF408AD9FB5A-high.jpg [High] Fig.

  • Page 30: Operating On Slopes

    1. General GUID-89E7B8D8-E388-4DFC-A3C1-63CE30390E60 [V1] 1.3.25 Operating on slopes Keep machine in a lower gear when going down slopes. Avoid holes, ditches and obstructions, causing roll-over, especially on hillsides. Avoid sharp turns on hills. Never drive near edge of a gully or steep embankment.

  • Page 31: Exhaust Fumes

    1. General GUID-7F41C7C3-DACC-46D2-ADC7-531D148964D3 [V2] 1.3.28 Exhaust fumes Always work in a correct ventilated area. Engine exhaust fumes can cause sickness or death. If necessary to run engine in a closed area, use correct equipment to safely remove exhaust fumes from area. Always open the doors and get outside air into area.

  • Page 32: Towing

    1. General Do not operate the machine with the drive shaft shields open or removed. Entanglement in drive shafts that turn can cause injury or death. Keep away from the components that turn. Make sure guards that turn are free. GUID-CEB32148-1F4C-457C-ADF7-595DFC51AC25-high.jpg [High] Fig.

  • Page 33: A Word To The Operator

    1. General GUID-F38BCC9A-5A98-41F3-BA3C-2C5AB224EDFB [V5] 1.3.33 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 operating this machine. You are responsible for your safety. Good safety procedures not only prevent injury to you, but also the persons around you.

  • Page 34: Work In A Clean Area

    1. General GUID-40735280-B065-4FB8-899D-6974B5AE4F77 [V3] 1.3.34 Work in a clean area Thoroughly clean work area, machine, systems, and components before starting work. Dirty and greasy areas can create work hazards. NOTE: Let the work lights cool for ten minutes after operation before washing. GUID-1626A83C-366E-48E2-AB46-07E33EF408C9-high.jpg [High] Fig.
  • Page 35 1. General Illuminate the working area correctly, adequately and safely. Use correct safety lamps with wire safety cages. Exposed bulbs can ignite fluids. Drain fluids in correct containers. Never use beverage containers that can mislead and result in personnel drinking from them. GUID-1CB771F0-5306-493B-90A0-BD90985761AD-high.jpg [High] Fig.
  • Page 36 1. General Lifting incorrectly can cause injury or machine damage. Follow the procedures recommended in the proper manual for removal and installation of components of this machine, systems or components. GUID-17FA5F34-A0AA-472E-8E8A-EEA91C7DC826-high.jpg [High] Fig. 41 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.
  • Page 37 1. General Never heat by welding, soldering or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area from torch cutting or arch welding. Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to personnel and bystanders.
  • Page 38 1. General Never weld on a wheel or rim that has a tire on it. Never try to mount or remove a tire unless using the correct equipment. A tire safety cage, instructions, and training are necessary to do the work safely.
  • Page 39 1. General Use a piece of cardboard or wood to look for possible leaks. Do not use your bare hand. Wear leather gloves for hand protection and safety goggles for eye protection. Remove all pressure before you loosen hydraulic lines. Lower equipment in the up position, close the accumulator valve, and stop the engine.
  • Page 40 Table of contents 2. Engine 2.1 Serpentine belt removal and installation ........2-9 2.1.1 Removing the serpentine belt .
  • Page 41 Table of contents 2.16.1 Removing the engine ..........2-93 2.16.2 Installing the engine .
  • Page 42 Table of contents 2.25.6 Camshaft ............2-143 2.25.7 Crankshaft .
  • Page 43 Table of contents 2.33.6 Assembling the valve mechanism with the hydraulic lash adjusters ....2-186 2.33.7 Pre-adjusting the hydraulic lash adjusters ....... . . 2-187 2.33.8 Changing camshaft or camshaft gear .
  • Page 44 Table of contents 2.39.6 Remove the coolant pump and the thermostat housing ..... . . 2-217 2.39.7 Install the coolant pump and the thermostat housing ......2-217 2.39.8 Reconditioning coolant pump .
  • Page 45 Table of contents 2.42.8.1 Solve the DEF pressure build-up failure ......2-261 2.42.8.2 Supply module lifting capacity test ....... . 2-263 2.42.8.3 Solve the failure when the SM lifting capacity test is not OK .
  • Page 46 Table of contents 2.49.3 Changing crankshaft rear oil seal ........2-297 2.49.4 Install the suction pipe of the oil pump .
  • Page 47 Table of contents 79035613B...
  • Page 48 2. Engine 2.1 Serpentine belt removal and installation GUID-43A21744-97B6-439E-848F-A40A4D90645C [V1] 2.1.1 Removing the serpentine belt WARNING: Hot components can burn. Severe personal injury can result. Let the engine and components cool before doing maintenance. Procedure Rotate the battery disconnect key (1) on rear of the battery box (2) counterclockwise to the disconnected position.
  • Page 49 2. Engine Procedure Check for free, smooth rotation of the tensioner roller. Tension roller surface must be smooth and free of any defects. During inspection, if finding any deficiencies, replace the tension roller. Check the torque on the pulley bolt (3) to 48 Put the new serpentine belt (1) onto the pulleys as shown.
  • Page 50 2. Engine Procedure Rotate the battery disconnect key (1) on rear of the battery box (2) counterclockwise to the disconnected position. GUID-D7D206A1-E250-422C-BDE1-235AF4D1B33B-high.jpg [High] Fig. 5 Remove the tensioner bolt (1) from the tensioner (2). Tensioner bolt Tensioner GUID-2D84D730-1903-4007-8EBA-1D21F7B2B5F7-high.jpg [High] Fig. 6 Install the tensioner compression tool to the tensioner.
  • Page 51 2. Engine Compress the tensioner (2) and install the holding strap (1). Holding strap Tensioner GUID-0017FEE2-DF63-4A3A-9ECC-BFF49225601C-high.jpg [High] Fig. 8 Remove the tensioner compression tool from the tensioner (1). Remove the second bolt (1) and remove the tensioner. Remove the water pump belt (3). GUID-5A87A31C-5016-4243-ADEC-293CCF56688E-high.jpg [High] Fig.
  • Page 52 2. Engine Pull on the water pump belt to compress tensioner (2) and remove the holding strap (1). Holding strap Tensioner Put the holding strap (1) in the cab. Install the serpentine belt: see chapter 2.1.2 Installing the serpentine belt, page 2-9 .
  • Page 53 2. Engine 2.2 Alternator removal and installation GUID-F2673D3A-4D5C-41BD-8035-EE2E523214EF [V1] 2.2.1 Removing the alternator WARNING: Hot components can burn. Severe personal injury can result. Let the engine and components cool before doing maintenance. Before starting the procedure Remove the serpentine belt, see chapter 2.1.1 Removing the serpentine belt, page 2-9 .
  • Page 54 2. Engine Remove two mounting bolts (1) to remove the bottom alternator (2). The alternator may be most easily removed from below. The alternator weighs approximately 8 kg. GUID-B5509FB1-0677-4A24-9021-1342C0D3E3C4-high.jpg [High] Fig. 16 GUID-AFF76621-EE10-4CE7-A8DE-F29F58C0982C [V1] 2.2.2 Installing the alternator Procedure Install the bottom alternator (1) with two bolts (2).
  • Page 55 2. Engine Connect positive (1) and negative (2) cables to the alternators. Install the belts and the belt guards, see chapter 2.1.2 Installing the serpentine belt, page 2-9 . GUID-31C6A28C-D842-449F-9576-EC1D3E6AC553-high.jpg [High] Fig. 19 Rotate the battery disconnect key (1) on rear of the battery box (2) clockwise to the connected position.
  • Page 56 2. Engine 2.3 Cooling package removal and installation GUID-7DFC433B-AD70-4580-B8DD-3283B807800E [V1] 2.3.1 Removing the cooling package WARNING: Machine movement hazard. Personal injury or machine damage can occur. Park the machine on a solid level surface. Lower all implements to the ground. Stop the engine, apply the park brake, and take the key with you.
  • Page 57 2. Engine Procedure Put a clean container under the radiator and turn the valve (1) counterclockwise to drain coolant for storage or disposal. Turn the valve clockwise to close after coolant finishes draining. GUID-07BF25CE-6F65-4ED3-89B0-1C3079990627-high.jpg [High] Fig. 21 Remove three bolts and washers (1) and remove the left-hand side fan guard (2).
  • Page 58 2. Engine Loosen clamp (1) and disconnect the radiator expansion tank hose (2) from the radiator hose (3). Loosen two clamps (4) and remove the radiator hose. NOTE: Prevent contamination by installing plugs to openings. GUID-0736E1A4-71D3-4950-918B-256070F3A2E9-high.jpg [High] Fig. 24 Remove the upper radiator seal (1). GUID-A245005D-45D0-4D83-93DD-1A61C0522D84-high.jpg [High] Fig.
  • Page 59 2. Engine Remove three bolts and washers (1) and remove the right-hand side fan guard (2). GUID-5BA59C38-5411-478E-814E-F14261D7E793-high.jpg [High] Fig. 28 Clean any dirt off the charge air cooler tube (1) and connections to prevent contamination. Loosen four clamps (2) and remove the right-hand side charge air cooler tube.
  • Page 60 2. Engine Remove the right-hand side radiator seal (1). GUID-8B91A36A-F778-469C-89AC-2FF02A40D69A-high.jpg [High] Fig. 31 Remove five bolts and washers (1) and move the fan shroud (2) as far rearward as possible. GUID-CF15BE9B-C393-42A6-AA78-CEB356AD0B64-high.jpg [High] Fig. 32 From the front of the machine, remove four bolts (1) and two hydraulic cooler and transmission cooler brackets (2).
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