Ag-Chem TG8400B Flotation Chassis Operators Manual (FXXX1001 and later)

Manuals: Operators Manual
Serial: FXXX1001 and later
1. Safety
1.1 A word to the operator
1.1.1 Important safety information
1.1.2 Safety symbol
1.1.3 Safety messages
1.1.4 Information messages
1.1.5 General hazard information
1.2 Prepare for operation
1.2.1 Mount and dismount the machine
1.2.2 Before you start the engine
1.2.3 Start the engine
1.2.4 Before operating the machine
1.2.5 Operate the machine
1.2.6 Operator station
1.2.7 Park the machine
1.2.8 Exit the cab in an emergency
1.2.9 Safety lamps and marking devices use
1.2.10 Roading on public roads
1.2.11 Operate on a slope
1.2.12 Electrical storm injury prevention
1.3 Maintenance and service
1.3.1 Maintenance safety
1.3.2 Wear protective clothing
1.3.3 Fire prevention and first aid
1.3.4 Proper disposal of waste
1.3.5 Shield and guards
1.3.6 Support the machine correctly
1.3.7 Asbestos information
1.3.8 Pressurized air
1.3.9 Cut and crush prevention
1.3.10 Boom safety
1.3.11 Fuel safety
1.3.12 Hydraulic safety
1.3.13 High pressure leaks
1.3.14 Chemical safety
1.3.15 Engine safety
1.3.16 Battery safety
1.3.17 Tire safety
1.3.18 Avoid eye contact with radar
1.3.19 Exhaust fumes
1.3.20 Electrical power lines overhead
1.3.21 Towing
1.3.22 Modifications
1.3.23 Mobile radio installation
1.3.24 Safety signs
1.4 Safety signs
1.4.1 Overhead electrical power lines
1.4.2 Starter bypass
1.5 Cab safety signs
1.5.1 Operator’s manual
1.5.2 Park brake
1.5.3 Bystander alert
1.5.4 Crushing hazard
1.5.5 Fall off hazard
1.5.6 Seatbelt
1.5.7 No passengers
1.6 Chassis safety signs
1.6.1 Hot pressurized coolant
1.6.2 Rotating blades
1.6.3 High pressurized fluid
1.6.4 Ether
1.6.5 Belt entanglement
1.6.6 Electrocution hazard
1.6.7 Radar
1.6.8 Crushing hazard
1.7 Informational signs
1.7.1 Informational – Tiedown
1.7.2 Ultra low sulfur diesel fuel
1.7.3 Informational – Cab filter #1
1.7.4 Informational – Hand wash
1.7.5 Informational – Battery shut off
1.7.6 Informational – Battery terminals
1.7.7 Informational – Cab filter #3
1.7.8 Informational – Cab filter #2 and washer bottle
1.7.9 Informational – Manufacturer plate
1.7.10 Informational – Alternate exit
1.7.11 Informational – Outlet voltage and maximum amperage
1.7.12 Informational – Hydraulic oil level
1.7.13 Informational – Do not alter
1.8 Informational electrical signs
1.8.1 Informational – Power distribution module
1.8.2 Informational – Upper electrical panel
1.8.3 Informational – Lower electrical panel
1.8.4 Informational – Chassis electrical panel
2. Introduction
2.1 Information
2.1.1 Intended use
2.1.2 Proper disposal of waste
2.1.3 Emissions reduction – selective catalyst reduction – SCR – technology
2.1.4 DEF Storage and Shelf Life
2.2 Machine identification
2.2.1 Product identification information
2.2.2 Serial number definition
2.2.3 Engine serial number plate
2.2.4 Transmission serial number plate
2.3 Break-in period
2.3.1 General break-in information
2.3.2 Break-in maintenance schedule
2.3.3 Operate the engine-first 200 hours
2.3.4 Initial interval for inline fuel strainer
2.3.5 Break-in the transmission
2.3.6 Break-in the rear axle
2.3.7 Do a check of the wheel mounting hardware
2.3.8 Hydraulic filter
2.3.9 Initial pressure washer pump
2.3.10 Initial engine valve adjustment
2.4 Machine transport
2.4.1 Operate the machine in limp-home mode
2.4.2 Transport the machine on a truck or trailer
2.4.3 Towing information
2.4.3.1 Prepare for towing – engine operation
2.4.3.2 Preparing for towing – engine not operating
2.4.3.3 Tow the machine
2.5 Park brake information
2.5.1 Release the manual park brake
2.5.2 Release the park brake using air
2.5.3 Release the park brake by manually releasing the spring
2.6 Major components
2.6.1 Component location (front/rear view)
2.6.2 Component location (side view)
2.6.3 Component location (top view)
2.7 Emissions warranty
3. Operation
3.1 Cab temperature control
3.1.1 Automatic temperature control
3.1.2 Heater operation
3.1.3 Defroster operation
3.1.4 Air conditioner operation
3.1.5 Automatic fan speed control
3.1.6 Manual fan speed control (HI/LO)
3.1.7 Air conditioning compressor clutch control
3.1.8 Heater water valve
3.1.9 Cab air temperature sensor
3.1.10 Evaporator probe
3.1.11 Temperature control troubleshooting
3.2 Controls and instruments
3.2.1 Inside cab components
3.2.2 Light switches for machine lights
3.2.3 Seatbelt operation
3.2.4 Basic operator seat
3.2.5 Deluxe operator seat
3.2.6 Deluxe vented operator seat
3.2.7 Instructor seat
3.2.8 Armrest controls
3.2.9 Joystick controls
3.2.10 Instrument cluster
3.2.11 Steering wheel controls
3.2.11.1 Power shuttle and shuttle lock
3.2.11.2 Shuttle shifting
3.2.12 Foot pedals
3.2.13 Telemetry (if equipped)
3.2.14 Monitor/Camera (if equipped)
3.2.15 Battery disconnect switch
3.2.16 DOT matrix display screens
3.2.17 DOT matrix display screen operation
3.2.18 Changing speed readout units
3.2.19 Reset the maintenance indicator lamp and the service hourmeter
3.2.20 Alarm – for future use
3.2.21 Application rate controller options
3.2.22 Slingshot ready – if equipped
3.3 Tag axle operation
3.3.1 Tag axle
3.3.2 Operate the tag axle
3.4 Prepare to start the engine
3.4.1 Do a check of the engine before starting
3.4.2 Engine power limitations
3.4.3 Low DEF level
3.4.4 SCR system malfunction
3.4.5 Start the engine
3.4.6 Cold temperature starting
3.4.7 Stalled engine – restart
3.4.8 Stop the engine and afterrun
3.4.9 Using the engine throttle control switches
3.4.9.1 Remote throttle preset
3.4.9.2 Location of the remote throttle control
3.4.9.3 Remote throttle controls
3.5 Operate on a public road
3.5.1 Machine operation on a public road
3.6 Transmission function
3.6.1 Transmission – general
3.6.2 Set the preset start up speeds
3.6.3 High and low speed range
3.6.4 Engine underspeed supervisor
3.6.5 Joystick mode
3.6.6 Foot pedal throttle mode
3.6.7 Machine management system
3.7 Calibration
3.7.1 Machine calibration
3.7.2 Inputting at level 1 – Cal 2
3.7.3 Calibrate the joystick handle
3.7.4 Calibrate the clutch
3.7.5 Calibrate the foot pedal throttle
3.7.6 Clear the DCC3 dash cluster error code
3.7.7 Clear the Auto4 transmission controller error code
3.7.8 Inputting at level 1 – Cal 1
3.7.9 Calibrate the hare and tortoise range
3.7.10 Calibrate the transmission
3.7.11 Calibrate the coupler function
3.7.12 Calibrate the radar
3.7.13 Calibrate the speed
3.8 Cold weather considerations
3.8.1 Minimize the effect of cold weather
3.8.2 Using grade No. 1-D fuel
3.8.3 Fuel filters
3.8.4 Coolant heater
3.8.5 Seasonal viscosity oil and proper coolant concentration
3.8.6 Winterfronts
3.8.7 Idling the engine
3.8.8 Engine coolant specifications
3.8.9 Cooling system water quality
3.8.10 Antifreeze
3.8.11 Grease
3.8.12 Diesel fuel
3.8.13 Lubricity of diesel fuels
3.8.14 Diesel fuel storage
3.8.15 Fuel tank information
3.9 Storage
3.9.1 Prepare for long term storage
3.9.2 Remove the machine from long term storage
4. Maintenance
4.1 Maintenance intervals
4.1.1 Maintenance introduction
4.1.2 Maintenance symbols
4.1.3 Lubricant filling reminders
4.1.4 Maintenance schedule
4.1.4.1 Daily maintenance schedule
4.1.4.2 Maintenance schedule 10 to 1000 hours
4.1.4.3 Maintenance Schedule 2000 to 4000 hours
4.1.5 Lubricants and fluids
4.2 Air dryer and conpressed air system
4.2.1 Air reservoir and air dryer
4.2.2 Air dryer
4.3 Air conditioner system
4.3.1 Air conditioner
4.3.2 Condenser
4.4 Engine
4.4.1 Do a check of the engine oil level
4.4.2 Change the engine oil and filter
4.4.3 Engine belts and tensioner
4.4.3.1 Replace the serpentine belt
4.4.3.2 Replace the water pump belt
4.4.4 Fuel system
4.4.5 Fuel tank
4.4.6 In-line fuel strainer
4.4.7 Replace the fuel filters
4.4.8 Prime the fuel system
4.4.9 Engine coolant
4.5 Maintaining the air cleaner
4.5.1 Engine air cleaner indicator
4.5.2 Replace the air filter element
4.5.3 Service the primary air filter
4.5.4 Secondary air filter element
4.6 Hydrailic system
4.6.1 Replace the hydraulic system oil and filter
4.7 Continouosly variable transmission
4.7.1 Transmission operating temperatures
4.7.2 Do a check of the transmission oil
4.7.3 Change the transmission oil
4.8 Transfer case assembly
4.8.1 Do a check of the transfer case oil
4.8.2 Change the transfer case oil
4.8.3 Clean the transfer case breather
4.9 Lubricate and inspect driveline and components
4.9.1 Lubricate the engine to the transmission driveline
4.9.2 Lubricate the transmission to the transfer case driveline
4.9.3 Lubricate the transfer case to rear axle driveline
4.9.4 Lubricate the front axle kingpins
4.9.5 Lubricate the front axle springs
4.9.6 Check the front axle mounting bolts
4.9.7 Lubricate rear axle springs
4.9.8 Check the rear axle mounting bolts
4.10 Intercoolers
4.10.1 Clean the heat exchangers
4.11 Front wheel and tag axle bearings
4.11.1 Front wheel bearing
4.11.1.1 Do a check of the front wheel bearing oil
4.11.1.2 Change the front wheel bearing oil
4.11.1.3 Wheel end oil change intervals and specifications
4.11.2 Tag axle bearing bolts and lubricating the tag axle fittings – if equipped
4.12 Steering
4.12.1 Steering cylinders
4.12.2 Do a check of the front wheel toe-in
4.12.2.1 Measure the front wheel toe-in
4.12.2.2 Adjust the front wheel toe-in
4.13 Rear axle
4.13.1 Clean the breather for the rear axle
4.13.2 Break-in the rear axle
4.13.3 Change the rear axle differential oil
4.13.4 Do a check of the rear axle oil
4.13.5 Change the rear axle planetary oil
4.14 Brake maintenance
4.14.1 Lubricate the front brake slack adjuster
4.14.2 Lubricate the rear brake slack adjuster
4.14.3 Brake air lines
4.14.4 Parking brake
4.14.5 Do a check of the service brake system
4.14.6 Do a check of the automatic slack adjusters
4.14.7 Manually adjusting the automatic slack adjusters
4.15 Wheels
4.15.1 Remove the wheels
4.15.2 Install the wheels
4.15.3 Tighten the wheel mounting hardware
4.16 Tires
4.16.1 Inflate the tire
4.16.2 Replace the tire
4.16.3 Tire charts
4.17 Cabin filters and windscreen wipers
4.17.1 Cab air filters and the windscreen washer reservoir
4.17.2 Cab air filters
4.17.2.1 Remove the primary fresh air filter
4.17.2.2 Install the primary fresh air filter
4.17.2.3 Remove the secondary fresh air filter
4.17.2.4 Install the secondary fresh air filter
4.17.2.5 Remove the recirculation air filter
4.17.2.6 Install the recirculation air filter
4.17.3 Maintain the cab air filter
4.17.3.1 Maintain the primary fresh air filter.
4.17.3.2 Maintain the secondary fresh air filter
4.17.3.3 Maintain the recirculation air filter
4.17.3.4 Clean the cab filter element
4.17.4 Windshield wiper blade
4.17.5 Fill the windscreen washer reservoir
4.18 Cab mounts
4.18.1 Do a check of the cab mounting bolts, rubber mounts, and air ride suspension
4.18.2 Do a check of the cab mounting bolts and rubber mounts
4.19 Electrical system
4.19.1 Batteries
4.19.1.1 Battery box components
4.19.1.2 Battery disconnect switch lever
4.19.1.3 Remove the battery terminal connection
4.19.2 Jump starting the battery
4.19.3 Locate the fuse panel
4.19.4 Fuse locations
4.20 Cab seat preventative maintenance
4.20.1 Lubricate seat adjusters
4.20.2 Armrest mechanism
4.21 Paint and decals
4.21.1 Safety treads
4.22 Application system
4.22.1 Application system installation
4.23 Hand rinse tank and pressure washer
4.23.1 Remove the hand rinse tank
4.23.2 Install the hand rinse tank
4.23.3 Pressure washer
4.23.3.1 Pressure washer input water supply
4.23.3.2 Before starting the pressure washer
4.23.3.3 Prime the pressure washer pump
4.23.3.4 General care of the pressure washer pump
4.23.3.5 Pressure washer pump storage in freezing conditions
4.23.3.6 Operate the pressure washer
4.23.3.7 Change the pressure washer pump motor oil
4.23.3.8 Change the pressure washer strainer
4.23.3.9 Winterize the pressure washer system
5. Troubleshooting
5.1 Engine
5.2 Transmission
5.3 Electrical system
5.4 Hydraulic system
5.5 Parking brake troubleshooting
5.6 Operation
5.7 Cab
5.8 Fault codes
5.8.1 Engine control system error and fault codes
5.8.2 Transmission error and fault codes
5.8.3 DCC3 error and fault codes
5.8.4 Chassis error and fault codes
6. Specifications
6.1 Machine specifications
6.2 Machine dimensions