Challenger MT755E Workshop Service Manual Download

Page: 4 / 61

1. General

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1.1.1 A word to the technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.1.2 Service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.1.3 Safety symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.1.4 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.1.5 Information messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.1.6 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.1.7 Important safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.1.8 General hazard information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.1.9 Pressurized air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.1.10 Asbestos information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.1.11 Electrical storm injury prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.1.12 Mount and dismount the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.1.13 Before you start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.1.14 Start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.1.15 Before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.1.16 Procedures for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.1.17 Park the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.1.18 Operator station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.1.19 Cut and crush prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.1.20 Rollover protective structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.1.21 Burn prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.1.22 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.1.23 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.1.24 High pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.1.25 Fluid penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.1.26 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.1.27 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.1.28 Noise prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.1.29 Fire and explosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.1.30 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.1.31 Public road transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.2 Machine identification information

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1-16

1.3 Serial number definition

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1-18

1.4 Proper disposal of waste

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1-20

1.5 Lubricant viscosities and refill capacities

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1-21

1.5.1 Lubricant viscosities for ambient temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

1.5.2 Lubricant viscosities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

1.5.3 Refill capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

1.6 Service intervals

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1-24

1.6.1 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1.6.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

1.7 Fuel system

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1-27

1.7.1 Fuel tank water and sediment drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

1.7.2 Fuel water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

1.7.3 Prime the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

1.7.4 Fuel cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

1.7.5 Drain the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

1.7.6 Change the prefilter and the fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

1.8 Main fuse panel

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1-31

Table of contents

Rubber Track Tractor

1-1

79036614D

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

Summary of Contents for MT755E

Page 1: ...er Track Tractor MT755E MT765E MT775E North America 4205 River Green Parkway Duluth GA 30096 USA Challenger is a registered trademark of Caterpillar Inc and is used under license by AGCO AGCO 2018 Jun...

Page 2: ...alifornia to cause cancer birth defects or other reproductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to...

Page 3: ...in system 5 Brake system 6 Compressed air system 7 Hydraulic system 8 Electrical system 9 Cab 10 Air conditioning and heating system 11 Chassis 12 Track belt system 13 Implement drive system 14 Implem...

Page 4: ...essure lines 1 11 1 1 25 Fluid penetration 1 12 1 1 26 Batteries 1 12 1 1 27 Exhaust fumes 1 13 1 1 28 Noise prevention 1 14 1 1 29 Fire and explosion prevention 1 14 1 1 30 Fire extinguisher 1 15 1 1...

Page 5: ...ercarriage inspection 1 38 1 10 Selective catalytic reduction SCR System 1 40 1 10 1 Supply module 1 40 1 10 2 Diesel exhaust fluid DEF tank 1 41 1 10 3 DEF heater circuit fuse 1 42 1 10 4 DEF storage...

Page 6: ...with these situations The safety section does not replace safety practices in other parts of this service manual Practice good safety to help prevent injury or death Learn how to operate the machine a...

Page 7: ...rtant safety instructions in the manual GUID 4C201302 DBD2 4BFB 8D98 1DDED263BD6E high jpg High Fig 2 1 1 4 Safety messages The words DANGER WARNING or CAUTION are used with the safety symbol Learn th...

Page 8: ...an injury occurs A person must be alert to possible dangers This person must also have the necessary training skills and tools to do these operations correctly Incorrect operation lubrication mainten...

Page 9: ...h boxes tools and other loose items that are not a part of the machine Know the appropriate work location hand signals and the personnel that are authorized to give the hand signals Get hand signals f...

Page 10: ...e ground during an electrical storm stay away from the machine 1 1 12 Mount and dismount the machine Mount the machine and dismount the machine only at locations that have steps and or hand holds Befo...

Page 11: ...and the engine is idling WARNING Do not use ether at any time Use will cause engine damage and or personal injury Do not start the engine until the area is free of personnel to prevent personal injury...

Page 12: ...rating in muddy conditions permit sufficient time for tracks to reject debris and moisture before making high speed maneuvers Belts that are wet and belts that are muddy can impede machine s steering...

Page 13: ...er pin can fly out causing personal injury Make sure that there are no people in the area when hitting a retainer pin To prevent eye injury wear protective glasses when hitting a retainer pin Chips or...

Page 14: ...h a bare hand Remove the filler cap slowly to relieve the pressure The cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact skin eyes or mouth GUI...

Page 15: ...has a kink Outer coverings have embedded armoring The end fittings are displaced IMPORTANT Take care to contain fluids during the performance of the inspection the maintenance the testing the adjustin...

Page 16: ...arks away from the top of the battery Do not smoke in the battery charging areas Incorrect jumper cable connections can cause an explosion causing an injury To prevent an explosion never charge a froz...

Page 17: ...to accumulate on machine Store fuels and lubricants in correctly identified containers away from not approved persons Store rags with oil and any flammable materials in protective containers Do not s...

Page 18: ...operation 1 1 31 Public road transportation Always walk around and visually examine the machine before moving on a public road As a warning to others in the area honk the horn two times before startin...

Page 19: ...ts not designed for an operator are identified by serial numbers For reference record identification numbers in spaces provided in the table below GUID 5823ABA4 9A30 4AC3 9108 74D6BC83C7AD high jpg Hi...

Page 20: ...r 1 Emissions Control Information N A 2 Machine PIN Plate 3 Engine Serial Number 4 Cab Serial number 5 Operator Seat Serial Number 6 Right Track Belt Number Left Track Belt Number 7 Differential Seria...

Page 21: ...number will start over at the beginning of each model year The first machine of each model year will start with sequence 1001 11 Ending Symbol NOTE For serial number breaks in this manual only the in...

Page 22: ...2014 L 2020 F 2015 M 2021 G 2016 N 2022 Model year code definition Code Definition 0 No code Position 8 option code definition Code Definition 0 No code Position 9 option code definition 1 General Ru...

Page 23: ...as food or beverage container s may mislead someone into drinking from them Do not pour or spill waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping into...

Page 24: ...additional information is needed 1 5 2 Lubricant viscosities AGCO Genuine Lubricants are the recommended products for this machine Using other lubricants may not provide the same level of required pe...

Page 25: ...auge 227 liter 60 gal Wide gauge 235 liter 62 gal Ultra wide gauge 265 liter 70 gal Front idler hub AGCO Synthetic Final Drive and Axle Oil SAE 50 0 49 liter 0 13 gal Midwheel hub AGCO Synthetic Final...

Page 26: ...1 gal Refrigerant R134A 1 46 kg 3 2 lb Hydraulic System AGCO Permatran 821XL Standard gauge 227 liter 60 gal Wide gauge 235 liter 62 gal Ultra wide gauge 265 liter 70 gal Front idler hub AGCO Synthet...

Page 27: ...stem water separator drain Window washer reservoir fill Window wipers inspect replace Windows clean 1 6 1 Maintenance chart Maintenance chart for engine models 84 AWF and 98 AWF used in RoGator TerraG...

Page 28: ...8000 running hours Valve adjustment intervals 1 2 1st 2nd 3rd 4th 5th 400 2000 4000 6000 8000 1 The 98 engines have hydraulic lash adjusters from the engine serial number B52904 Do not adjust the val...

Page 29: ...filter x Replace the case drain filter x Examine the ROPS x Examine the seat belt x 3 Lubricate the front idler swing link pin 1200 hours or annually that which occurs first Replace the DEF pump main...

Page 30: ...1 from the drain valve 2 Open the drain valve 2 located at the rear of the main tank Let water and sediment drain into an applicable container 3 Close the drain valve when clean fuel shows GUID 791C0...

Page 31: ...supply valve 1 is open Loosen the plug 2 to let air release from the fuel lines Make sure the plug is open enough or priming the pump will not work GUID AA245A32 1AD9 4191 8644 0A81521AAD5E high jpg H...

Page 32: ...immediately CAUTION Escaping fluid under pressure can penetrate skin causing serious injury Release pressure before disconnecting fuel or other lines Tighten all connections before applying pressure K...

Page 33: ...move the main filter 4 in a similar way 8 Fasten the water detector 3 to the new prefilter bottom end 9 Lubricate the filter element o ring seal 6 with clean fuel 10 Fill the outer shell of the filter...

Page 34: ...rcuit 2 Power train resistor 120 OHM 3 Light Auxiliary resistor 120 OHM 4 Guidance RS232 5 ET Electronic service connector 6 EDT Electronic diagnostic service connector 7 ISO Service connector 8 Fuse...

Page 35: ...p Cigar lighter 2 10 Amp Rear washer 3 15 Amp Brakes 4 30 Amp Light module top 5 30 Amp Light module top 6 7 8 30 Amp Light module top 9 15 Amp Trailer lights 10 10 Amp Telemetry Item Rating Descripti...

Page 36: ...iler auxiliary 4 30 Amp Bottom Module 5 10 Amp Decel sensor air sensor belt tension 6 15 Amp Mirror power heat front washer intermittent wiper 7 20 Amp Rear wiper 8 15 Amp Front wiper 9 30 Amp Bottom...

Page 37: ...Amp High wiper relay 4 Not used 5 35 Amp Trailer work light relay Fuse relay block one battery Item Fuse Description 6 Not used 7 15 Amp Front wiper high 8 Not used 9 Not used 10 25 Amp UREA Heater U...

Page 38: ...0 Amp Bottom light module 14 20 Amp Bottom light module 15 20 Amp Top light module GUID DF07ED36 70A1 4182 B3B4 FA2D54DD9891 high jpg High Fig 30 1 8 6 Main fuse The two main fuses for the cab power a...

Page 39: ...the transmission ECM is in the cab in the fuse panel area 1 The circuit breaker is 20 Amps GUID 2D704C06 94B8 4332 B100 6EE991426658 high jpg High Fig 32 GUID CB0218BA A154 4A2F A6C1 F2C7D9AA6C9A V2...

Page 40: ...apacities Install and tighten the magnetic plug GUID DA4E7181 5B06 4C15 B68A 9900C7413D9D high jpg High Fig 33 1 9 2 Change the drive wheel hub oil 1 Put the machine on a hard level surface 2 Drive fo...

Page 41: ...o locate fill drain plug 2 at six o clock position 2 Place the chocks at the front and the rear of the tracks 3 Clean the area around the fill drain plug 4 Remove the plug 2 and allow the oil to drain...

Page 42: ...4210 A5FC 9AA397434AC3 high jpg High Fig 39 Portions of individual tread bars 4 that become separated from track carcass are not expected to significantly change traction Replace a track when the tre...

Page 43: ...shutdown the remaining diesel exhaust fluid DEF in system is automatically emptied back to the diesel exhaust fluid DEF tank During the emptying process continuous power supply must be provided for E...

Page 44: ...tank may damage gaskets of the SCR system IMPORTANT Diluting the DEF or mixing with other substances is not allowed it may damage the catalyst 1 The DEF tank fill cap is blue displaying DEF and symbol...

Page 45: ...F Note 2 NOTE Main factors taken into account to define shelf life in this table are ambient storage temperature and initial alkalinity of DEF The difference in evaporation between vented and non vent...

Page 46: ...l warning signal will start flashing at 1 Hz and inducements will begin After one hour the engine has been derated to final level The after treatment system ATS malfunction indicator will start flashi...

Page 47: ...RPM 1st to 15th gear Forward Neutral Reverse and Park 2300 RPM in 16th gear Forward MT775E 2200 RPM 1st to 15th gear Forward Neutral Reverse and Park 2300 RPM in 16th gear Forward governed engine spe...

Page 48: ...ollowing conditions Screw tip 1 extends 6 35 mm 25 in A beyond housing Belleville springs are collapsed nearly flat after screw 2 is tightened to a torque of 11 Nm 8 1 lbf ft GUID 8A45BF90 64A6 4B49 A...

Page 49: ...studs Thread Size Pound Feet lbf ft Newton Meters Nm 1 4 6 8 5 16 13 17 3 8 26 35 7 16 33 45 1 2 48 65 5 8 80 110 3 4 125 170 7 8 190 260 1 300 400 1 1 8 390 525 1 1 4 550 750 1 3 8 700 950 1 1 2 880...

Page 50: ...ng the fitting Tighten after initial tightening as in service work Tighten both the tube and the hose connections finger tight and wrench 1 4 turn O ring fittings must be tightened as for initial asse...

Page 51: ...sembly torque values for metric fasteners Standard High Low Thread Size Pound Feet lbf ft Newton Meters Nm Pound Feet lbf ft Newton Meters Nm Pound Feet lbf ft Newton Meters Nm M6 x 1 8 to 10 9 to 15...

Page 52: ...ft Newton Meters Nm M6 6 8 M8 13 17 M10 26 35 M12 48 65 M16 80 110 M20 125 170 M24 300 400 M30 550 750 M36 880 1200 Metric bolt and cap screws GUID 7AF08829 E556 40A7 B8C7 61E951B65C34 high jpg High F...

Page 53: ...5 in K 1765 mm 69 5 in C 1812 6 mm 71 4 in L 2438 mm 96 in D 1280 mm 50 4 in M 1104 6 mm 43 5 in E 3662 5 mm 144 2 in N 1068 mm 42 in F 3483 6 mm 137 1 in O 68 5 mm 2 7 in G 1387 3 mm 54 6 in P 488 6...

Page 54: ...1 13 1 Rear view dimensions GUID 723962C0 2BC7 4BD4 91CD 5EA016AE13BD high jpg High Fig 50 GUID F1000C11 AF93 4FDF 8756 8BB3AB344DA6 V2 1 General Rubber Track Tractor 1 51 79036614D...

Page 55: ...s A Overall width 2933 2 mm 115 5 in B Cab roof 2069 mm 81 5 in C Beacon 1376 mm 54 2 in D Ground clearance 368 mm 14 5 in E Belt 635 mm 25 in F Axle to axle 2464 mm 98 5 in 1 General 1 52 Rubber Trac...

Page 56: ...eme application 760 kg 1675 lb 16 inch Diagonal general ag 739 kg 1630 lb 16 inch Diagonal low profile 750 kg 1653 lb 16 inch Diagonal extreme application 850 kg 1874 lb 18 inch Chevron general ag 685...

Page 57: ...rd gauge 943 2 liter 249 gal for the wide and ultra wide gauge Weight does not include the creeper option or operator Total vehicle weight not to exceed 17360 kg 39000 lb 1000 lb idler weights 2000 lb...

Page 58: ...hine uses oil cooled multi disc brakes activated by the service brake pedal Located on each side of machine is one multiple disc brake Park brake is an oil cooled multi disc brake Park brake works on...

Page 59: ...d shaft Fuel tank Additional tank 282 0 liter 74 5 gal Standard fuel tank capacity 657 1 liter 173 6 gal Additional tank is standard on wide and ultra wide gauge machines Debris deflector compatabilit...

Page 60: ...V drawbar capacity Drawbar position Distance from the PTO shaft to the hold for the drawbar pin Maximum downward short 413 mm 16 3 in 5443 kg 12 000 lb standard 508 mm 20 in 4536 kg 10 000 lb Drawbar...

Page 61: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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