AGCO Challenger RG635C Workshop Service Manual Download Page 2 | Manualshive

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Summary of Contents for Challenger RG635C

Page 1: ...RG645C AGCC0645 FW001001 RG655C AGCC0655 FW001001 Grubbenvorst AGCO Netherlands BV Horsterweg 66a 5971 NG Grubbenvorst Netherlands Challenger is a registered trademark of Caterpillar Inc and is used u...

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Page 3: ...1 2 7 Noise 1 11 1 2 8 Vibrations 1 11 1 2 9 Handle fuel correctly Avoid fire 1 12 1 2 10 Rotating and moving parts 1 12 1 2 11 Towing 1 13 1 2 12 Exhaust fumes 1 13 1 3 Maintenance and service 1 14...

Page 4: ...2 wheel steer 1 47 1 11 Component location 1 48 1 11 1 Chassis 1 48 1 11 2 Component location system 1 51 1 12 Service panel location 1 53 1 12 1 Main fuse panel 1 53 1 12 2 Automatic fuses and relay...

Page 5: ...ply module 2 50 2 4 7 Removing the DEF filter 2 51 2 4 8 Installing the DEF filter 2 52 2 4 9 Removing the dosing module 2 54 2 4 10 Installing the Dosing module 2 54 2 4 11 Trouble shooting DEF syste...

Page 6: ...ank 8 6 8 2 1 Removing air tank 8 6 8 2 2 Installing air tank 8 6 8 3 Air compressor 8 8 8 3 1 Removing air compressor 8 8 8 3 2 Installing air compressor 8 8 8 4 Air dryer 8 10 8 4 1 Removing air dry...

Page 7: ...panel locations 10 35 10 3 1 Fuse panel 10 35 10 3 2 Main fuse panel 10 35 10 3 3 Fuse panel descriptions 10 35 10 3 4 Fuse block CP03 10 36 10 3 5 Fuse block CP04 10 37 10 3 6 Fuse block CP05 10 38...

Page 8: ...04 0 28 10 115 10 8 34 Error code 04 0 29 10 117 10 8 35 Error code 04 0 30 10 119 10 8 36 Error code 04 0 31 10 121 10 8 37 Error code 04 0 34 10 123 10 8 38 Error code 04 0 35 10 125 10 8 39 Error c...

Page 9: ...91 Error code 53 1 03 10 203 10 8 92 Error code 53 1 04 10 204 10 8 93 Error code 53 1 05 10 206 10 8 94 Error code 53 1 06 10 208 10 8 95 Error code 53 1 07 10 210 10 8 96 Error code 54 1 01 10 210...

Page 10: ...r code 50 1 45 10 289 10 9 53 Error code 50 1 46 10 290 10 9 54 Error code 50 1 47 10 291 10 9 55 Error code 50 1 48 10 293 10 9 56 Error code 50 1 49 10 297 10 9 57 Error code 51 1 01 10 298 10 9 58...

Page 11: ...10 11 24 Error code 18 0 45 10 373 10 11 25 Error code 18 0 46 10 376 10 11 26 Error code 18 0 47 10 379 10 11 27 Error code 18 0 48 10 381 10 12 Error codes Lighting 10 385 10 12 1 Error code 19 1 01...

Page 12: ...11 38 11 10 2 Installing the door 11 38 11 10 3 Setting door striker location 11 39 11 10 3 1 Verify cab pressurization 11 39 11 10 4 Removing the door handle 11 39 11 10 5 Installing the door handle...

Page 13: ...accumulator 12 32 12 13 Heater system overview 12 33 12 14 Actuator motor water valve 12 35 12 14 1 Schematic for testing the water valve 12 35 12 15 Air flow 12 36 12 15 1 Air flow components 12 36 1...

Page 14: ...5 Troubleshooting 12 76 12 25 1 Troubleshooting preparation 12 76 12 25 2 General troubleshooting 12 76 12 25 3 Visual inspection 12 77 12 25 4 Troubleshooting faults with service codes active 12 77 1...

Page 15: ...Hydraulic system 18 73 18 2 1 Hydraulic System Legend 18 73 18 2 2 Hydraulic System Schematic 18 75 18 3 Air system 18 85 18 3 1 Air System Schematic 18 87 18 4 Spray system 18 89 18 4 1 Schematic sp...

Page 16: ...Table of contents RoGator 600C 644410 1...

Page 17: ...ines 1 11 1 2 7 Noise 1 11 1 2 8 Vibrations 1 11 1 2 9 Handle fuel correctly Avoid fire 1 12 1 2 10 Rotating and moving parts 1 12 1 2 11 Towing 1 13 1 2 12 Exhaust fumes 1 13 1 3 Maintenance and serv...

Page 18: ...L SPRAYBIB VF 1 37 1 7 5 480 80 R50 166D TL AGRIFLEX 354 1 38 1 7 6 520 85 R46 173A8 TL AGRIFLEX 385 1 39 1 7 7 620 70 R42 160D TL OMNIBIB 1 40 1 7 8 620 75 R34 170A8 170B TL MEGAXBIB 1 41 1 7 9 710 7...

Page 19: ...ers Service manual is separated into divisions Refer to master table of contents Each division has an identifying part number with an revision level indicator Each division has a table of contents and...

Page 20: ...hassis near the fuel tank Use these numbers when referring to machine Serial number Product Model number Year of construction Nominal power Mass standard Pressure spraying system Max draw bar pull Max...

Page 21: ...onents and repair parts include current safety signs See your local dealer for replacement safety signs Never operate machine and or equipment without correct instruction and a complete understanding...

Page 22: ...y hazardous situation that if not avoided could result in DEATH OR SERIOUS INJURY CAUTION Indicates a potentially hazardous situation that if not avoided may result in MINOR INJURY Informational messa...

Page 23: ...r in cases of emergency Keep emergency numbers for doctors ambulance service hospital and fire department readily available at all times Fig 8 1 1 14 Emergency exit from cab Understand procedure to us...

Page 24: ...rants damage the atmosphere Government regulations require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Also refer to the Dismantling section 1...

Page 25: ...immediately in a practical way if there is any failure Do not turn off the key until the machine is stopped and shutdown correctly The operator must not exceed speeds loads or tire inflation listed o...

Page 26: ...and away from the tire while adding air to prevent possible personal injury from blow outs etc IMPORTANT Air temperature can have a large effect on tire pressure 1 2 3 Prevent machine runaway Never by...

Page 27: ...8 1 2 8 Vibrations The typical hand arm vibrations exposure is 0 6 m s2 so does not exceed 2 5 m s2 Measuring method following NF EN ISO 5349 1 2002 The typical whole body vibration exposure is 0 26 m...

Page 28: ...in a safe place away from open flame or sparks Fill fuel tank outdoors Never completely fill fuel tank Clean up any spilled fuel immediately Never use diesel fuel kerosene gasoline or any flammable so...

Page 29: ...ine must be approved by AGCO CAUTION Using machine for towing creates a hazard and can void machine or system warranty Fig 22 1 2 12 Exhaust fumes Always work in a well ventilated area Engine exhaust...

Page 30: ...To avoid potentially toxic fumes CAUTION To prevent damage to the wiring and hoses never drill into the cab especially any vertical tube NOTE Do not tamper with or modify the engine in any way This pr...

Page 31: ...Cab ventilation is running on maximum Air filter is clean and is serviced under maintenance interval See Lubrication Maintenance Section of this manual Check the Cab pressure indicator Fig 27 Operato...

Page 32: ...k MSDS before using any hazardous chemical Know risks and how to perform project safely Follow procedures and equipment recommendations See chemical manufacturer for SDS s on chemical products used wi...

Page 33: ...store chemicals that could mislead personnel to drink from them Fig 35 1 3 8 Use correct tools Use the correct equipment and procedures Make shift tools and procedures create safety hazards Use power...

Page 34: ...ng fluid under pressure can penetrate skin causing serious injury WARNING Machine must be stopped and cooled before checking fluids Use caution when removing radiator caps plugs grease fittings or pre...

Page 35: ...lammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to personnel and bystanders Fig 42 1 3 14 Welding or heating Welding and heating can generate potentia...

Page 36: ...ath Never weld on a wheel or rim with a tire on it Never attempt to mount or remove a tire unless using correct equipment tire safety cage and instructions Tire repair procedures must be performed by...

Page 37: ...eter as a guide for maintenance intervals The maintenance intervals can be shown in both operating hours and time Example 10 Hours or Every Day Use the interval operating hours or time that comes firs...

Page 38: ...X X 33 Change air cleaner elements X 34 Change cab air recirculation filter X 35 Change hydraulic oil and filters X X 36 Check hoses and clamps of CAC X 37 Check ground connections X 38 Change SCR sup...

Page 39: ...Valve adjustments intervals Valve adjustment intervals hours 1st 2nd 3rd 4th 5th 500 2000 4000 6000 8000 1 General RoGator 600C 1 23 644410 1...

Page 40: ...Maintenance component overview Fig 46 1 4 3 Lubricants and fluids IMPORTANT Capacities listed are approximate Check fluid levels after filling 1 General 1 24 RoGator 600C 644410 1...

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