AGCO Challenger RoGator 635 Service Manual Download Page 3

Page: 3 / 41

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

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Summary of Contents for Challenger RoGator 635

Page 1: ...ped 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 Chal...

Page 2: ...Find manuals at https best manuals com...

Page 3: ...lands 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 ELECTR...

Page 4: ...Find manuals at https best manuals com...

Page 5: ...Label Only Master No 632154 1 Service Manual ROGATOR 635 645 655 CHASSIS AND SYSTEM Volume Find manuals at https best manuals com...

Page 6: ...Find manuals at https best manuals com...

Page 7: ...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...

Page 8: ...e 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 Specificatio...

Page 9: ...re 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 m WARNING An operat...

Page 10: ...not avoided will result in DEATH OR VERY SERIOUS INJURY m WARNING Indicates a potentially hazardous situation that if not avoided could result in DEATH OR SERIOUS INJURY m CAUTION Indicates a potenti...

Page 11: ...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 mach...

Page 12: ...aler 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...

Page 13: ...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 absorbe...

Page 14: ...ctric 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...

Page 15: ...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...

Page 16: ...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...

Page 17: ...nd 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...

Page 18: ...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 locate...

Page 19: ...achine 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...

Page 20: ...ays 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...

Page 21: ...ocution A lead acid battery generates flammable and explosive gases Keep sparks and flames away from battery Injury or death could occur FIG 32 Warning Electrocution Safety sign is located in the fron...

Page 22: ...ear post of the right had cab window Remove lift and remove the window and exit OPERATING MACHINE FIG 35 Wear a seat belt at all times FIG 36 Make sure operator and stairs areas are clean and dry to p...

Page 23: ...e key and take it with you PREVENT MACHINE RUNAWAY FIG 38 Never by pass start the engine by making a connection across starter terminals Engine will start and machine will move if normal circuitry is...

Page 24: ...PES FIG 39 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 gull...

Page 25: ...hts parking brake horn windshield wiper and washer and rear view mirrors Repair or replace any component not in proper working order Never drive at a speed causing machine to bounce or lose control Ob...

Page 26: ...ensors emit a low intensity microwave signal Microwave signal cause no ill effects during normal use To avoid eye damage never look directly into sensor while in operation EXHAUST FUMES FIG 42 Always...

Page 27: ...PROPERLY AVOID FIRES FIG 45 Fuel is highly flammable Handle with care Always stop engine before refueling Never refuel while smoking Add fuel in a safe place away from open flame or sparks Fill fuel t...

Page 28: ...ents or performing any type of service on engine or machine TOWING FIG 48 Towing a trailer under the following circumstances is approved by AGCO The tow hook and trailer brake installation on the RoGa...

Page 29: ...a necktie necklace scarf or loose clothing when working near machine tools or moving parts Tie long hair behind head and wear a hair net Remove all jewellery to prevent electrical shorts or other pers...

Page 30: ...r allow chemicals to contact skin or eyes FIG 54 Always wear approved protective equipment and clothing Before leaving cab wear personal protective equipment as required by pesticide use instructions...

Page 31: ...e using any hazardous chemical Know risks and how to perform project safely Follow procedures and equipment recommendations See chemical manufacturer for MSDS s on chemical products used with AGCO equ...

Page 32: ...hem USE PROPER TOOLS FIG 60 Use only proper equipment and procedures Make shift tools and procedures create safety hazards Use power tools only to loosen threaded parts and fasteners Use only SAE tool...

Page 33: ...l pressure before doing maintenance or repairs on any pressurized system Tighten all connections before applying pressure FIG 64 Search for leaks with a piece of wood or cardboard Protect hands and bo...

Page 34: ...cool enough to touch with bare hands Slowly loosen filler cap to first stop to relieve any pressure before removing cap completely REMOVE PAINT BEFORE WELDING OR HEATING FIG 67 Avoid potentially toxi...

Page 35: ...proper disposal of potentially harmful waste can threaten environment and ecology Potentially harmful waste used with AGCO machines includes such items as oil fuel fluids and batteries Use leak proof...

Page 36: ...Safety 1 28 632154 1 NOTES...

Page 37: ...s in manual show machine with shields removed for a better view of subject matter Never operate machine with any shields removed Divisions and Page Numbers Service manual is separated into divisions R...

Page 38: ...___________________________________ Model number _______________________________ Year of construction __________________________ Nominal power ___________________________ kW Mass standard ____________...

Page 39: ...632154 1 1 31 General Operator s Seat Serial Number FIG 4 Operator s Seat Serial Number Tag 1 is located on rear of operator s seat Seat Serial Number _________________________ FIG 4 1 KA15322...

Page 40: ...l of the drum so it is important to follow the manufacturer s cleaning instructions when changing to use of different chemical agent The use of different chemicals can leads to situations in which phy...

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