Challenger RoGator 635B User manual

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Printing Batch Number
© AGCO Corporation, 2013 All rights reserved.
Part Number 639782-1 (English)
Printed in the Netherlands
December 2012
Challenger®
RoGator 635B - 645B - 655B
Chassis and System
SERVICE MANUAL
639782-1
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© AGCO Corporation, 2013 All rights reserved.
Part Number 639782-1 (English)
Printed in the Netherlands
December 2012
Challenger®
RoGator 635B - 645B - 655B
Chassis and System
SERVICE MANUAL
639782-1
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
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639782-1 1-i
Contents
Challenger®
RoGator 635B - 645B - 655B
Chassis and System
SERVICE MANUAL
639782-1
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
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1-ii 639782-1
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
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639782-1 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.
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Safety
1-2 639782-1
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
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639782-1 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 your 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.
FIG. 2
0037
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Safety
1-4 639782-1
SAFETY AND MAINTENANCE 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 & Maintenance Sign Locations
Left Side
FIG. 3
2
6
3
7
9
5
7
13
14
17
16
15
9
1
4
8
5
10
12
11
6
18 19
S000119
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639782-1 1-5
Safety
FIG. 4:
1. Warning - External hydraulic system filled with
Hydraulic Oil ISO VG 46.
Sign is located on hydraulic tank.
FIG. 5:
2. High Pressure Fluid Hazard - Risk of Scalding or
Burns.
Safety sign is located on top of the engine coolant
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:
3. Check temperature and level of engine coolant.
Maintenance sign is located on front of the
expansion tank.
FIG. 7:
4. Danger - Do not enter the product tank, great risk
of serious injury or death.
Safety sign is located on product tank cover.
The manhole on the product tank is only for visible
inspection, never enter the product tank.
FIG. 4
P625052-A
FIG. 5
P511134D1
FIG. 6
R000251
FIG. 7
Q519660D1

Safety
1-6 639782-1
FIG. 8:
5. Danger - Chemical and Confined space hazard.
Safety sign is located on product tank cover and on
eductor lid.
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.
Because residue of chemicals can spread toxic
gases or vapor. Do not ingest chemical -
Chemicals can be toxic. Read and follow
manufacturers instructions. Do not breathe vapor,
wear proper respirator when working around
chemicals.
FIG. 9:
6. Retorque wheel nut with 630 Nm - See the
Lubrication & Maintenance section.
Decal is located on every rim.
Follow the instructions given in the Lubrication &
Maintenance section.
FIG. 10:
7. Check oil level wheel motor - Read the operator’s
manual, see the Lubrication & Maintenance
section.
Maintenance sign is located on each wheel motor.
FIG. 11:
8. Use protective gear when handling chemicals and
operating the machine.
Decals are located near the eductor and operator
control station.
a. Goggels;
b. Gloves;
c. Safety boots;
d. Clothing;
e. Breathing protection;
f. Hearing protection.
FIG. 8
N511210D1
FIG. 9
S000122
FIG. 10
R000236
FIG. 11
abc
def

639782-1 1-7
Safety
FIG. 12:
9. Warning - Read Manual - 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. 13:
10. No standing.
Decal is located on the eductor cover.
Don’t use location where decal is shown for
standing or step.
FIG. 14:
11. Two way ball valve ON / OFF.
Decal located on cover of the chemical eductor. By
using the valve the rinse nozzle on the cover inside
the eductor will activated.
FIG. 15:
12. Hand wash tank - Use only for washing hands
after.
Decal is located on the hand wash water tank
under the ladder.
Use the hand wash tank to wash your hands after
working with chemicals on or near the machine.
FIG. 12
M511088D1
FIG. 13
S000087
FIG. 14
S000016
FIG. 15
M619716-A

Safety
1-8 639782-1
FIG. 16:
13. Warning - Impact hazard warning.
Safety signs are located on ladder to platform and
on the boom center frame.
Use caution to avoid injury from impact with spray
booms.
FIG. 17:
14. Warning - Falling off - 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. 18:
15. Warning - Tire pressure - 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. 19:
16. Warning - Parking Brake.
Located inside cab on left-hand bar on door.
Make sure that parking brake is applied 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.
NOTE: Parking brake will automatically apply after 5
sec. when machine has been stopped moving.
FIG. 16
P514263D1
FIG. 17
M511416D1
FIG. 18
M511418D1
FIG. 19
Q519662D1

639782-1 1-9
Safety
FIG. 20:
17. Warning - Salt.
Make sure the machine is washed and clean of all
dirt and salt after the machine is delivered.
Located on front wind screen and will be removed
by your dealer.
FIG. 21:
18. Hazard - Danger poisonous substances.
Carefully read operator's manual before handling
the machine. Observe instructions and safety rules
when operating. Refer to the cautions specified by
the pesticide's supplier.
Located inside left storage compartment cover.
Follow the instructions given in the Controls
section.
FIG. 22:
19. Best Engine RPM for Max Pump RPM.
Set the engine RPM to 1250 to get the maximum
Pump RPM to fill the product tank.
Decal located near the eductor and operator
control station.
FIG. 20
S000015
FIG. 21
S000077
FIG. 22
S000083

Safety
1-10 639782-1
Safety & Maintenance Sign Locations
Left Side
FIG. 24:
1. Warning - Hydraulic accumulator under pressure -
Accumulators under high pressure can explode,
causing serious injury or death.
Safety sign is located on several places on the
machine on hydraulic components.
Hydraulic accumulator contains gas and oil under
pressure. For removal and repair instructions in
technical manual must be followed.
FIG. 23
1
2
3
64
5
1
2
3
87
9
10
S000092
S000120
FIG. 24
R000253

639782-1 1-11
Safety
FIG. 25:
2. Warning - Never spray - 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 malfunction
of the component or system.
FIG. 26:
3. Warning - High Pressurized fluid - 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. 27:
4. Mesh size 12.
Decal (black) is located on suction filter housing.
Replace filters always by original filters.
FIG. 28:
5. 5 way ball valve.
Decal is located by the 5-way ball valve.
FIG. 29:
6. Fill and transfer valve spray tank.
Decal located on the left side by the coupling.
FIG. 25
P620378-A
FIG. 26
M511144D1
FIG. 27
R000254
FIG. 28
S000017
FIG. 29
S000018

Safety
1-12 639782-1
FIG. 30:
7. Mesh size 80.
Decal (blue) is located on suction filter housing.
Replace filters always by original filters.
FIG. 31:
8. Eductor valve.
Decal located on left side by ball valve.
FIG. 32:
9. Tie down.
Decal is located on front side under cab near
towing eye’s 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. 33:
10. Pressures Hydraulic System.
Decal is located on left side of chassis behind
eductor.
The maximum pressure in the Hydraulic LS system
is 220 bar.
The maximum pressure in the Hydraulic HP
system is 420 bar.
FIG. 30
R000255
FIG. 31
S000019
FIG. 32
M500372D1-01
FIG. 33
S000085

639782-1 1-13
Safety
Safety & Maintenance Sign Locations
Right Side
FIG. 35:
1. Shearing Hazard - Engine Fan.
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. 34
3
1
2
4
17
18
6
7
5
8
9
10
13
14
15
16
19
20
21
22
23
24
13
14
12 11 S000117
FIG. 35
M511140D1

Safety
1-14 639782-1
FIG. 36:
2. Warning - Burn Hazard - 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 cause severe burns.
FIG. 37:
3. Fall off Hazard - Use seat belt.
Safety sign is located inside cab on left front cab
post.
Always fasten seat belt before machine operation.
Failure to use seat belts can result in serious injury
or death.
FIG. 38:
4. Danger - Electrocution.
Located inside cab on left-hand post.
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
or death.
See the Operator Chassis section for further
information.
FIG. 39:
5. Emergency Exit.
Located inside cab on right-hand rear cab post.
Use the right side window as emergency exit when
cab door is blocked. Remove pins and push
window out.
FIG. 36
N511128D1
FIG. 37
M511200D1
FIG. 38
M511202D1
FIG. 39
P625172-B