AGCO Challenger RoGator 635 User manual

NOTE TO THE RECIPIENT - This packet is one component of two or more components
required to comprise a complete publication. The following items, shipped under separate part
number, are used with this publication:
Printing Batch Number
© AGCO Corporation, 2010 All rights reserved.
Part Number 632154-1 (English)
Printed in the Netherlands
December 2010
Challenger®
RoGator 635 - 645 - 655
Chassis and System
SERVICE MANUAL
632154-1
• Expandable storage binder (Binder label provided in printed material packets.)

Find manuals at https://best-manuals.com

© AGCO Corporation, 2010 All rights reserved.
Part Number 632154-1 (English)
Printed in the Netherlands
December 2010
Challenger®
RoGator 635 - 645 - 655
Chassis and System
SERVICE MANUAL
632154-1
CONTENTS
INTRODUCTION..............................................................................................................................................01
ENGINE ...........................................................................................................................................................02
POWERTRAIN.................................................................................................................................................03
CHASSIS.........................................................................................................................................................04
CAB .................................................................................................................................................................05
PLUMBING......................................................................................................................................................06
BOOM / CENTER FRAME ..............................................................................................................................07
ELECTRICAL ..................................................................................................................................................08
HYDRAULIC....................................................................................................................................................09
AIR SYSTEM...................................................................................................................................................10
TROUBLESHOOTING.....................................................................................................................................11
Find manuals at https://best-manuals.com

Find manuals at https://best-manuals.com

Label Only
Master No. 632154-1
Service
Manual
ROGATOR 635 - 645 - 655
CHASSIS AND SYSTEM
Volume
Find manuals at https://best-manuals.com

Find manuals at https://best-manuals.com

632154-1 1-i
Contents
Challenger®
RoGator 635 - 645 - 655
Chassis and System
SERVICE MANUAL
632154-1
01 - Introduction
Contents
SAFETY
Introduction ................................................................................................................................................ 1-1
Prepare for Operation ................................................................................................................................ 1-1
Understanding Safety ................................................................................................................................ 1-1
Safety Alert Symbol ................................................................................................................................... 1-2
Safety Messages ................................................................................................................................. 1-2
Informational Messages ............................................................................................................................. 1-2
Follow Safety Instructions .......................................................................................................................... 1-3
Safety Signs ............................................................................................................................................... 1-4
Safety Sign Locations Right Side ........................................................................................................ 1-4
Safety Sign Locations Right Side ........................................................................................................ 1-9
Safety Sign Locations Left Side ........................................................................................................ 1-10
Safety Sign Locations Left Side ........................................................................................................ 1-12
Safety Signs Locations Battery ......................................................................................................... 1-13
Prepare for Emergencies ......................................................................................................................... 1-14
Emergency Exit from Cab ........................................................................................................................ 1-14
Operating Machine .................................................................................................................................. 1-14
Prevent Machine Runaway ...................................................................................................................... 1-15
Use Proper Lighting and Marking ............................................................................................................ 1-15
Operating on Slopes ................................................................................................................................ 1-16
Travelling on Public Roads ...................................................................................................................... 1-17
Stopping and Parking .............................................................................................................................. 1-17
System Boom Operation .......................................................................................................................... 1-18
Avoid Eye Contact with Radar ................................................................................................................. 1-18
Exhaust Fumes ........................................................................................................................................ 1-18
Overhead Electrical Power Lines ............................................................................................................. 1-19
Noise ........................................................................................................................................................ 1-19
Handle Fuel Properly - Avoid Fires .......................................................................................................... 1-19
Stay Clear of Rotating Drive Lines and Moving Parts .............................................................................. 1-20
Towing ..................................................................................................................................................... 1-20
Modifications ............................................................................................................................................ 1-20
Maintenance and Service ........................................................................................................................ 1-21
Practice Correct Maintenance ................................................................................................................. 1-21
Chemical Safety ....................................................................................................................................... 1-22
Operator Cabs ................................................................................................................................... 1-22
Wear Protective Clothing ......................................................................................................................... 1-23
Work in a Clean Area ............................................................................................................................... 1-23
Understand Correct Service .................................................................................................................... 1-24
Use Proper Tools ..................................................................................................................................... 1-24
Support Machine Properly ....................................................................................................................... 1-24
Proper Lifting Equipment ......................................................................................................................... 1-25
High-Pressure Fluids ............................................................................................................................... 1-25
Avoid Heating Near Pressurized Fluid Lines ........................................................................................... 1-26
Service Cooling System Properly ............................................................................................................ 1-26
Remove Paint Before Welding or Heating ............................................................................................... 1-26
Batteries ................................................................................................................................................... 1-27
Tires and Wheels ..................................................................................................................................... 1-27
Find manuals at https://best-manuals.com

1-ii 632154-1
Contents
Dispose of Waste Properly ...................................................................................................................... 1-27
Mobile Radio Installations ........................................................................................................................ 1-27
GENERAL
Service Manual ........................................................................................................................................ 1-29
Divisions and Page Numbers ............................................................................................................ 1-29
Unit of Measurement ......................................................................................................................... 1-29
Replacement Parts .................................................................................................................................. 1-29
Serial Number Identification Plate ........................................................................................................... 1-30
Serial Number Identification Plates ................................................................................................... 1-30
Engine Serial Number ....................................................................................................................... 1-30
Cab Serial Number ............................................................................................................................ 1-30
Operator’s Seat Serial Number ......................................................................................................... 1-31
Important Safety Instructions ................................................................................................................... 1-32
Maintenance Introduction ........................................................................................................................ 1-34
Maintenance Chassis .............................................................................................................................. 1-34
Maintenance Schedule ...................................................................................................................... 1-34
Lubricants and Fluids ........................................................................................................................ 1-37
Lubricant Filling Reminders ............................................................................................................... 1-37
Maintenance System ............................................................................................................................... 1-38
Maintenance Schedule ...................................................................................................................... 1-38
Lubricants and Fluids ........................................................................................................................ 1-40
Lubricant Filling Reminders ............................................................................................................... 1-40
DIMENSIONS
Vehicle Dimensions ................................................................................................................................. 1-41
Turning Radius ........................................................................................................................................ 1-43
BEFORE ASSEMBLY / DISASSEMBLY
TORQUE SPECIFICATIONS
Torque Specifications .............................................................................................................................. 1-47
Constant Torque Hose Clamps ............................................................................................................... 1-47
Fastener Information ................................................................................................................................ 1-48
Metric Fasteners ................................................................................................................................ 1-48
SAE Fasteners .................................................................................................................................. 1-49
Tightening Straight Thread Fittings .......................................................................................................... 1-53
Metric Thread .................................................................................................................................... 1-53
JIC Swivel Nuts ................................................................................................................................. 1-55
Conversion Information ............................................................................................................................ 1-56
JACK UP THE MACHINE
Chassis .................................................................................................................................................... 1-59
Place Jack ......................................................................................................................................... 1-60
Place Support .................................................................................................................................... 1-63
TOOLING LIST
Tooling List .............................................................................................................................................. 1-65
Measuring Hoses .............................................................................................................................. 1-65
Pressure Gauge ................................................................................................................................ 1-65
Fitting ................................................................................................................................................. 1-66
EDT tool ............................................................................................................................................ 1-67
EXT Measure Box ............................................................................................................................. 1-67
EDT Kit .................................................................................................................................................... 1-68
General Information EDT Tool .......................................................................................................... 1-68
Annual Subscription .......................................................................................................................... 1-68
EDT Diagnostic Terminal .................................................................................................................. 1-69
EDT Use ............................................................................................................................................ 1-69
INDEX ......................................................................................................................................................... 1-71
Find manuals at https://best-manuals.com

632154-1 1-1
Safety
SAFETY
INTRODUCTION
The Safety section of this manual is intended to point
out some basic safety situations which may be
encountered during normal operation. This section also
suggests possible ways of dealing with those
situations. This section is not a replacement for other
safety practices featured in other sections of this
manual.
Additional precautions may be necessary, depending
on attachments used and conditions at the work site or
in the service area. AGCO has no direct control over
machine application, operation, inspection, lubrication
or maintenance. Therefore, it is your responsibility to
use good safety practices in those areas.
PREPARE FOR OPERATION
Read this manual completely and know the positions
and operations of all controls before operation. Check
all controls in an area clear of people and obstacles
before starting work.
All equipment has a limit. Make sure to understand the
speed, brakes, steering, stability and load
characteristics of this machine before operation.
Make sure machine has correct equipment required by
local regulations.
mWARNING: An operator should not use
alcohol or drugs which can affect
alertness or coordination. An operator
taking prescription or over the counter
medication should seek medical advice
on whether or not they can properly
operate machinery.
UNDERSTANDING SAFETY
It is your responsibility to read and understand entire
operation manual before operating machine. Safety
instructions must be read and followed.
Remember that you are the key to safety. Good safety
practices not only protect you but also those people
around you. Study the features in this manual and
make them a working part of your safety program.
Keep in mind that this Safety section is written
specifically for this type of machinery.
mWARNING: Pictures in this manual may
show protective shields and guards
opened or removed for illustration
purposes. Be sure all shields and guards
are in place during operation.
Find manuals at https://best-manuals.com

Safety
1-2 632154-1
SAFETY ALERT SYMBOL
FIG. 1: The safety alert symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
Look for safety alert symbols both in this manual and
on safety signs on this machine. The safety alert
symbol will direct your attention to information that
involves your safety and the safety of others.
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.
mDANGER: Indicates an imminently
hazardous situation that, if not avoided,
will result in DEATH OR VERY SERIOUS
INJURY.
mWARNING: Indicates a potentially
hazardous situation that, if not avoided,
could result in DEATH OR SERIOUS
INJURY.
mCAUTION: Indicates a potentially
hazardous situation that, if not avoided,
may result in MINOR INJURY.
INFORMATIONAL MESSAGES
The words IMPORTANT and NOTE are not related to
personal safety, but are used to give additional
information and tips for operating or servicing this
equipment.
IMPORTANT: Identifies special instructions or
procedures which, if not strictly observed,
could result in damage to or destruction of the
machine, process or its surroundings.
NOTE: Identifies points of particular interest for more
efficient and convenient repair or operation.
FIG. 1
0001
Find manuals at https://best-manuals.com

632154-1 1-3
Safety
FOLLOW SAFETY INSTRUCTIONS
FIG. 2: Carefully read, learn and understand all safety
messages and information in this manual and on
machine's safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs.
Make sure new equipment components and repair
parts include current safety signs. See local dealer for
replacement safety signs.
Never operate machine and/or equipment without
proper instruction and a complete understanding of
control operation.
Learn to operate machine and how to use all controls
properly before operation. Do not let anyone operate
machine, systems or perform service and maintenance
procedures without proper instruction.
Keep machine, all components and systems in proper
working condition. Modifications unauthorized by
AGCO may impair function, affect machine life and void
machine warranty.
IMPORTANT: Any modifications to machine or
systems not authorized by AGCO void the
AGCO warranty. Including, but not limited to
hitches.
FIG. 2
0037

Safety
1-4 632154-1
SAFETY SIGNS
mWARNING: Do not remove or obscure
Danger, Warning or Caution signs.
Replace any Danger, Warning or Caution
signs that are not readable or are
missing. Replacement signs are available
from your dealer in the event of loss or
damage. The actual location of the safety
signs is illustrated in this section of the
manual.
If a used machine has been purchased, make sure all
safety signs are in correct location and can be read.
Safety Sign Locations Right Side
FIG. 4: Warning - External hydraulic system (1) filled
with ISO VG 46.
Sign is located on hydraulic tank.
FIG. 3
2
5
3
6
8
5
4
9
10
11
12
13
14
6
14
7r00160s
FIG. 4
P625052-A

632154-1 1-5
Safety
FIG. 5: High Pressure Fluid Hazard (2)- Risk of
Scalding or Burns.
Safety sign is located near expansion tank.
Pressurized coolant can cause serious burns. To open
cooling system filler cap, stop engine and wait until
cooling system components are cool. Loosen cooling
system pressure cap slowly to relieve pressure.
FIG. 6: Danger-Do not enter the product tank (3), great
risk of serious injury or death.
Safety sign is located near entrance product tank.
The manhole on the product tank is only for visible
inspection, never enter the product tank.
FIG. 7: Danger - Chemical and Confined space
hazard. (4)
Safety sign is located on product tank and near eductor.
Do not allow chemical solution to come in contact with
skin or eyes. Some chemicals can be absorbed into
body through skin. Wear rubber gloves, safety glasses
and protective clothing at all times. Cover on tank must
be open while servicing tank. Ventilate tank before and
during servicing. Do not ingest chemical - Chemicals
can be toxic. Read and follow manufacturer’s
instructions. Do not breathe vapour, wear proper
respirator when working around chemicals.
FIG. 8: Retorque wheel nut with 500 Nm (5).
Decal is located on every rim.
Follow the instructions given in the Lubrication &
Maintenance section.
FIG. 5
Q000126S
FIG. 6
R519660D1S
FIG. 7
FIG. 8
Q630168-A
R511210D1S

Safety
1-6 632154-1
FIG. 9: Warning - Read Manual (6) - Read and
Understand Operator’s Manual before operating
machine.
Safety sign is located on several places on the
machine.
Decal is also shown on the machine as horizontal
decal.
FIG. 10: Warning - Never spray (7) - On hydraulic and
electric equipment near this decal.
Safety sign is located on several places on the machine
near electric and hydraulic components.
Spraying with a high pressure washer on electric and
hydraulic components can cause mal function of the
component or system.
FIG. 11: Use protective gear (8) when handling
chemicals and operating the machine.
Decals are located near the eductor and operator
control station.
1. Goggles;
2. Gloves;
3. Safety boots;
4. Clothing;
5. Breathing protection.
FIG. 12: Hand wash tank (9) - Use only for washing
hands.
Decal is located on the hand wash water tank under the
stairs.
Use the hand wash tank to wash your hands after
working with chemicals on or near the machine.
NOTE: Use the hand wash tank when there could
have been contact with chemicals.
FIG. 9
Q000118S
FIG. 10
Q000127S
FIG. 11
123
45
FIG. 12
Q000128S

632154-1 1-7
Safety
FIG. 13: Microwave Radiation Hazard (10).
Safety sign is located on outside underneath cab on
both sides.
Do not look directly into face of the ground speed
sensor while in operation. Eye injury may occur from
low intensity microwave signal emitted
FIG. 14: Tie down (11).
Decal is located on front side under cab near towing
eyes and on rear of machine next to towing hook.
Use the eyes in the chassis for towing the machine or
tie down during transport on truck. Never use other
points, holes or hooks.
FIG. 15: Warning - Impact hazard warning (12).
Safety signs are located on ladder to platform and on
the boom centre frame.
Use caution to avoid injury from impact with spray
booms.
FIG. 16: Warning - Tire pressure (13) - Check the tire
pressure according the tire pressure table regularly.
Safety sign is located on the cab door.
Check the tire pressure according the tire pressure
table from the Lubrication & Maintenance section.
FIG. 13
Q000120S
FIG. 14
M500372D1-01
FIG. 15
R514263D1S
FIG. 16
Q000121S

Safety
1-8 632154-1
FIG. 17: Warning - Falling Off (14) - Do not ride or
stand in this area when machine or booms are in
motion.
Safety sign is located on the cab door.
It is not allowed to carry passengers on the machine
when machine is in motion.
FIG. 17
Q000132S

632154-1 1-9
Safety
Safety Sign Locations Right Side
FIG. 19: Warning - High Pressurized fluid (1) - Oil leak
may produce high pressure fluid stream which can
penetrate skin.
Safety sign is located near high pressurized fluid tubes
and hoses.
Do not touch stream or use hands to locate leak. If
spray penetrates skin, seek immediate medical
treatment.
FIG. 20: Warning - Secure lifting cylinder (1) - Failure
of cylinder can cause serious injury or death.
Safety sign is located on the spray boom centre frame.
Always secure lifting cylinders when working or doing
maintenance under or near the spray boom centre
frame.
FIG. 18
1
2
r00161s
FIG. 19
Q000119S
FIG. 20
RE720565S

Safety
1-10 632154-1
Safety Sign Locations Left Side
FIG. 22: Shearing Hazard - Engine Fan (1)
Safety sign is located on both sides of fan shroud.
Shut off engine and remove key before performing
maintenance or repair work. Failure to do so may result
in personal injury due to inadvertent machine operation.
Do not start engine or move any controls if “Do not
operate” or similar warning tag is attached to start
switch or controls.
FIG. 23: Warning - Burn Hazard (2) - Avoidance: Stay
clear. Do not touch parts.
Safety sign is located near muffler on right side of
machine and near fan.
Avoid contact with hot surfaces. Exhaust piping and
engine components become hot during engine
operation and cool slowly after engine shutdown. Any
contact with hot surfaces causes severe burns.
FIG. 21
3
12
4
7
2
8
5
6
r00162s
FIG. 22
Q000123S
FIG. 23
R511128D1S

632154-1 1-11
Safety
FIG. 24: Fall Off Hazard (3) -
Safety sign is located inside cab on the left front cab
post.
Always fasten seat belt before machine operation.
Failure to use seat belts can result in serious injury or
death. Read and understand Operator Manual.
FIG. 25: Danger - Electrocution (4)
Location: left hand post inside of the cab.
Always take care and be aware of what’s around the
machine, especially overhead electrical power lines.
Failure to comply may result in serious injury.
FIG. 26: Warning - Parking Brake (5)
Location: left hand post inside of the cab.
Always apply parking brake and remove ignition key
when you leave the cab. To prevent unauthorised
moving or starting the machine. Failure to comply may
result in serious injury.
FIG. 27: Emergency Exit (6)
Location: right hand post inside of the cab.
Use the right side window as emergency exit when cab
door is blocked. Pull straps and push the window.
FIG. 24
Q000131S
FIG. 25
Q000130S
FIG. 26
R519662D1S
FIG. 27
Q000129S

Safety
1-12 632154-1
FIG. 28: Run over Hazard (7)
Location: on the right engine cover.
mWARNING: Do not short across starter
terminals from the ground to start
machine. Always start machine from the
operator seat. Personal injury or risk of
machine run over could occur.
FIG. 29: Danger - Explosion Hazard - Disconnect
Battery (8)
Safety sign is located on battery hold down bracket.
Improper jumper cable connections can cause
explosion resulting in personal injury.
Safety Sign Locations Left Side
FIG. 28
R511132D1S
FIG. 29
Q000122S
FIG. 30
r00163s