Table of Contents
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Challenger
MT745C / MT755C / MT765C
Rubber Track Tractor
SERVICE MANUAL
79033093 D Rev.
Volume 1
CONTENTS
Volume 1
INTRODUCTION.....................................................................................................................................................01
ENGINE ..................................................................................................................................................................02
POWERTRAIN........................................................................................................................................................03
FRAME ...................................................................................................................................................................04
STEERING AND BRAKE SYSTEM .......................................................................................................................05
IMPLEMENT AND THREE-POINT HITCH HYDRAULIC SYSTEMS.....................................................................06
ELECTRICAL SCHEMATICS.................................................................................................................................07
AIR SYSTEM ..........................................................................................................................................................08
VIRTUAL TERMINAL .............................................................................................................................................09
CAB ........................................................................................................................................................................10
Volume 2
HEATING VENTILATION AND AIR CONDITIONING......................................................................................................11
BALLASTING .....................................................................................................................................................................12
APPEARANCE GROUP.....................................................................................................................................................13
ELECTRONICS...................................................................................................................................................................14
© AGCO Corporation, 2013 All rights reserved.
Part Number 79033093 D Rev. (English)
Printed in U.S.A.
March, 2013
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Summary of Contents for Challenger MT745C
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Page 1: Table Of Contents
® Challenger MT745C / MT755C / MT765C Rubber Track Tractor SERVICE MANUAL 79033093 D Rev. Volume 1 CONTENTS Volume 1 INTRODUCTION..............................01 ENGINE ..................................02 POWERTRAIN................................03 FRAME ...................................04 STEERING AND BRAKE SYSTEM ........................05 IMPLEMENT AND THREE-POINT HITCH HYDRAULIC SYSTEMS..............06 ELECTRICAL SCHEMATICS..........................07 AIR SYSTEM ................................08 VIRTUAL TERMINAL .............................09... - Page 2 Contents ® Challenger MT745C / MT755C / MT765C Rubber Track Tractor SERVICE MANUAL 79033093 D Rev. 01 - Introduction Contents INTRODUCTION Service Manual .............................. 01-1 Divisions and Page Numbers ........................01-1 Units of Measurement ............................ 01-1 Replacement Parts ............................01-1 Important Safety Information .........................
- Page 3 Contents Lubricant Viscosities And Refill Capacities ....................01-22 Lubricant Viscosities ..........................01-22 Refill Capacities ............................. 01-22 Service Intervals ............................01-23 When Required ............................. 01-23 Maintenance Access ............................ 01-26 Engine Compartment ..........................01-26 Location of Guards ..........................01-26 Engine Screen Cover ..........................01-27 Electrical System ............................
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Page 4: Introduction
Introduction INTRODUCTION SERVICE MANUAL This service manual has been prepared with the latest service information available at publication. Read and understand service manual carefully before doing any service on machine. Right-hand and left-hand, as used in manual, are determined by facing direction machine travels when in use. -
Page 5: Important Safety Information
Introduction IMPORTANT SAFETY INFORMATION FIG. 1: Most personal injuries occurring during product operation, maintenance or repair are caused by failure to observe basic safety rules and precautions. In most cases, an injury can be avoided by recognizing hazardous situations before an injury occurs. Be alert to potential hazards and have the necessary training, skills and tools to perform these functions properly. -
Page 6: Safety Alert Symbol
Introduction Safety Alert Symbol FIG. 2: This is the safety alert symbol. It means ATTENTION! BECOME ALERT! SAFETY IS INVOLVED! Look for it, both in this manual and on safety decals on machine. It directs attention to information involving operator safety and safety of others. FIG. -
Page 7: General Hazard Information
Introduction IMPORTANT: Used to identify special instructions or procedures which, if not strictly observed, could result in damage to or destruction of machine, process or its surroundings. NOTE: Used to indicate points of particular interest for more efficient and convenient repair or operation. Right-hand and left-hand, as used in this manual, are determined by facing direction machine travels when in use. - Page 8 Introduction Hydraulic oil or diesel fuel leaking under pressure can penetrate skin and cause infection or other injury. To prevent personal injury relieve all pressure before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition.
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Page 9: Protective Clothing
Introduction Protective Clothing FIG. 7: Wear a hard hat, protective glasses and other protective equipment as required. N020903007 FIG. 7 Mounting and Dismounting FIG. 8: Mount and dismount machine only where there are steps and/or handholds. Face machine whenever mounting or dismounting. Maintain three-point contact with steps and handrails. -
Page 10: Exhaust Dangers
Introduction Wear gloves to handle wire cable and do not use kinked or frayed wire cable. Retainer pins can fly when struck, ensure there are no personnel in area before striking. Wear protective glasses to protect eyes. When striking objects, chips or other debris may fly off. -
Page 11: Operation
Introduction Operation Only operate machine from operator's seat. Seat belt must be fastened during machine operation. Only operate controls while engine is running. Check for proper operation of all controls and protective devices while operating machine slowly in an open area. Make sure area is free of personnel before moving machine. -
Page 12: Engine
Introduction Engine Starting FIG. 10: Only start engine from operator’s seat. Never short across starter terminals or batteries. Move all hydraulic controls to HOLD position and transmission control lever to PARK before starting engine. WARNING: Machine will turn if steering wheel is moved and engine is starting or running. -
Page 13: Fluid Precautions
Introduction Fluid Precautions FIG. 13: Drain all fluids into suitable container and never put maintenance fluid into glass containers. Discard drained fluids and fluid-saturated materials according to local regulations. Use all cleaning solution with care. N020903013 FIG. 13 FIG. 14: Do not smoke when serving an air conditioner. Inhaling gas from air conditioner refrigerant through a lit cigarette can cause bodily harm or death. -
Page 14: Burn Hazards
Introduction Burn Hazards FIG. 16: Do not touch any part of an operating engine. Other components such as transmission, axles and oil reservoir may be hot. Allow engine to cool before any maintenance is performed. Relieve all pressure in air, oil, lubrication, fuel system or cooling system before any line, fittings or related items are disconnected. -
Page 15: Batteries
Introduction FIG. 19: Use a piece of cardboard or wood to search for possible leaks, never use hands. IMPORTANT: Ensure fluids contained during performance of inspection, maintenance, testing, adjusting and repair of machine. Be prepared to collect fluid with suitable containers before opening any compartment or disassembling any component containing fluids. -
Page 16: Lights, Reflector And Signs
Introduction Lights, Reflector and Signs FIG. 22: Ensure all machine lights, reflectors and slow moving vehicle (SMV) are installed, in good condition and wiped clean. Consult local law enforcement agency for local regulations regarding movement of equipment on public roads. N020903022 FIG. -
Page 17: Fire Extinguisher
Introduction FIG. 24: Use caution and do not smoke while refueling a machine. Do not refuel a machine near open flames or sparks and always stop engine before refueling. Always refuel outdoors. N021603002 FIG. 24 Fire Extinguisher FIG. 25: Ensure a fire extinguisher is available. Be familiar with operation of fire extinguisher. -
Page 18: Machine Identification
Introduction MACHINE IDENTIFICATION Product Identification Information Plate Locations Product identification number (PIN) will be used to identify a machine designed for an operator to ride. Components such as engines, transmissions and major attachments that are not designed for an operator to ride, are identified by serial numbers. - Page 19 Introduction FIG. 29: Cab Serial Number. Plate is located inside cab, below inching clutch control. Cab Serial Number: ____________________________ 00804942 FIG. 29 FIG. 30: Operators Seat Serial Number. Tag (1) is located on rear of operator’s seat. Seat Serial Number: ___________________________ KA15322 FIG.
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Page 20: Torque Specifications
Introduction TORQUE SPECIFICATIONS WARNING: Mismatched incorrect fasteners can result in damage, malfunction or personal injury. Avoid mixing metric and inch dimensioned fasteners. Exceptions to torques are listed in Service Manual, if necessary. Prior to installation of any hardware, ensure components are in near new condition. -
Page 21: Fasteners Information
Introduction FASTENERS INFORMATION Metric Fasteners Assembly Torque for Metric Fasteners Standard High Thread Size Torque Torque Torque Torque Torque Torque Pound Feet Newton Pound Feet Newton Pound Feet Newton lbf ft Meters lbf ft Meters lbf ft Meters M6 x 1 8 to 10 9 to 15 9 to 11... -
Page 22: Inch Fasteners
Introduction Inch Fasteners Assembly Torque for Inch Fasteners Standard High Thread Size Torque Torque Torque Torque Torque Torque Pound Feet Newton Pound Feet Newton Pound Feet Newton lbf ft Meters lbf ft Meters lbf ft Meters 1/4 - 20 8 to 10 9 to 15 9 to 11 10 to 16... -
Page 23: Tightening Straight Thread Fittings
Introduction TIGHTENING STRAIGHT THREAD FITTINGS Straight thread hydraulic fittings require precise tightening. Overtightening ruins sealing surfaces and require replacement of damaged parts. Proper initial tightening depends on mating parts to be connected. Proceed as follows: An adapter fitting (37 degree flare) connected to a double flare tube assembly, fitting must be tightened finger tight and wrenched 1/2 turn (for single flare, 1/4 turn). -
Page 24: Metric Information
Introduction METRIC INFORMATION MULTIPLY: To Get: MULTIPLY To Get: LINEAR inches x 25.4 millimeters (mm) x 0.03937 = inches feet x 0.3048 meters (m) x 3.281 = feet yards x 0.9144 meters (m) x 1.0936 = yards miles x 1.6093 kilometers (km) x 0.6214 = miles... -
Page 25: Lubricant Viscosities And Refill Capacities
Introduction LUBRICANT VISCOSITIES AND REFILL CAPACITIES Lubricant Viscosities Proper oil viscosity grade is determined by minimum outside temperature while machine is started and while operated. To determine proper oil viscosity grade, refer to minimum column in following table. This information reflects coldest ambient temperature condition for starting and for operating a cold machine. -
Page 26: Service Intervals
Introduction SERVICE INTERVALS When Required • Cab Recirculation Filter - Clean/Inspect/Replace • Cab Air Filter - Clean/Replace • Primary Engine Air Filter - Clean • Batteries - Replace • Air Conditioner and Alternator belt - Replace • Fan Belt - Replace •... - Page 27 Introduction Every Every Initial Every Initial Every Every Every Every 1000 2000 3000 hours hours Hours hours hours hours hours hours hours Daily Initially: Check all hose clamps on engine at 10 hrs and again at 50 hrs, tighten and retorque as required, repeat when a hose is replaced Cooling System Level - Check...
- Page 28 Introduction Every Every Initial Every Initial Every Every Every Every 1000 2000 3000 hours hours Hours hours hours hours hours hours hours Daily Secondary Engine Air Filter - Replace Case Drain Filter - Replace Hydraulic System Oil - Change Hydraulic System Oil Filters - Replace ROPS - Inspect Seat Belt - Inspect...
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Page 29: Maintenance Access
Introduction MAINTENANCE ACCESS Engine Compartment FIG. 34: Raise hood pull slowly outward on plastic latch (1). This will allow you to release rubber strap (2) from hood. Release plastic latches and rubber straps on other side of machine. Use handle (3) to raise hood. P112011005 FIG. -
Page 30: Engine Screen Cover
Introduction Bottom Guards FIG. 37: Support guard (1) with proper lifting device before removing. Remove seven bolts and washers from shield (1) to lower shield (1). Remove two bolts from guard (2). Install guards in reverse order they were removed. P111111005 FIG. - Page 31 Introduction Right Hand Side FIG. 39: Remove bolts securing engine screen (1). P112011008 FIG. 39 01-28 79033093 D Rev. Find manuals at http://best-manuals.com/search?&s=CHAL-79033093...
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Page 32: Electrical System
Introduction ELECTRICAL SYSTEM Main Fuse Panel P092511001 FIG. 40 FIG. 40: Main fuse panel is located near floor of cab on right side. 79033093 D Rev. 01-29 Find manuals at http://best-manuals.com/search?&s=CHAL-79033093... -
Page 33: Powertrain
Introduction R060811001 FIG. 41 FIG. 41: Fuse Panel Descriptions Item Description ISO - TBC (Terminating Bias Circuit) Power Train Resistor 120 OHM Light/Auxiliary Resistor 120 OHM Guidance RS232 ET - Electronic Service Connector EDT- Electronic Diagnostic Service Connector ISO - Service Connector 40 Amp - A/C Fuse 01-30 79033093 D Rev. - Page 34 Introduction FIG. 42: Fuse Block 1 Fuse Block 1 Item Rating Description Switched Battery 10 Amp Cigar Lighter 10 Amp Not used 15 Amp Brakes 30 Amp Light Module Front 30 Amp Light Module Front 30 Amp Light Module Rear 30 Amp Light Module Rear 30 Amp...
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Page 35: Virtual Terminal
Introduction FIG. 43: Fuse Block 2 Fuse Block 2 Item Rating Description Switched Battery 20 Amp Implement Valve/Hitch Valve 10 Amp Inch Sensor/Steer Sensor/Rockshaft Sensor 15 Amp Trailer Auxiliary 30 Amp Not used 10 Amp Decel Sensor/Air Sensor/Belt Tension Sensor 10 Amp Mirror Power/Heat 10 Amp... - Page 36 Introduction FIG. 44: Fuse/ Relay Block 1 Fuse/Relay Block 1 Item Relay Description 35 Amp Not used 35 Amp Not used 35 Amp Not used 35 Amp Italian Trailer Brakes 35 Amp Trailer Work Lights P101411014 FIG. 44 FIG. 45: Fuse/ Relay Block 1 Fuse/Relay Block 1 - Battery + Item Fuse...
- Page 37 Introduction FIG. 46: Fuse/Relay Block 2 Fuse/Relay Block 2 Item Relay Description 35 Amp Neutral Start Relay 35 Amp Horn Relay 35 Amp ISO Power Relay 35 Amp ISO ECU Relay 35 Amp ECU Relay P101411015 FIG. 46 FIG. 47: Fuse/Relay Block 2 Fuse/Relay Block 2 - ECU Relay Power Item Fuse...
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Page 38: Cab
Introduction Main Fuse FIG. 48: Two main fuses are located on left side of machine on inside of frame rail, as shown. Fuse (1) is rated at 175 Amps and is main fuse for cab power. Fuse (2) is rated at 200 Amps and is main fuse for alternator. - Page 39 Introduction NOTES 01-36 79033093 D Rev. Find manuals at http://best-manuals.com/search?&s=CHAL-79033093...
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Page 40: Index
Index INDEX Asbestos Information ......... 01-14 Hood ..............01-26 Assembly Torque for Inch Fasteners ....01-19 Hydraulic System Assembly Torque for Metric Fasteners ....01-18 Fluid Capacity ..........01-22 Auto-Guide Precautions ........01-14 Hydraulic System Fluid Capacity ......01-22 Batteries ............. 01-12 Inch Fasteners ............ - Page 41 Index When Required ..........01-23 Shield Removal ............ 01-9 Signal Words ............01-3 Special Tooling ..........01-35 Tightening Straight Thread Fittings ....01-20 Torque Specifications ........01-17 Undercarriage (Mobil Trac) System Fluid Capacity ..........01-22 Units of Measurement .......... 01-1 Windshield Washer reservoir ......
- Page 42 Contents ® Challenger MT745C / MT755C / MT765C Rubber Track Tractor SERVICE MANUAL 79033093 D Rev. 02 - Engine Contents ENGINE COMPONENTS Introduction ..............................02-1 Specifications and Standards Concerning Fuel, Oil and Coolant ..............02-1 Fuel Quality ............................. 02-1 Oil Quality ..............................02-1 Coolant Quality ............................
- Page 43 Contents Fan Installation Procedure ........................02-135 Air Conditioning Compressor Removal and Installation ................02-138 Air Conditioning Compressor Removal ....................02-138 Air Conditioning Compressor Installation .................... 02-142 Air Conditioning Accumulator Removal and Installation ................02-146 Air Conditioning Accumulator Removal ....................02-146 Air Conditioning Accumulator Installation ....................
- Page 44 Engine Components ENGINE COMPONENTS INTRODUCTION The machine utilizes a diesel engine manufactured by CAT for AGCO. Many of the components are mounted and operate directly with the CAT engine. This section describes the proper procedures to remove and install the components. If an internal engine problem arises that warrants engine removal from the frame of the machine this section will describe the proper procedure for removal and...
- Page 45 Engine Components SERPENTINE BELT REPLACEMENT WARNING: Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Serpentine Belt Removal WARNING: Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
- Page 46 Engine Components FIG. 4: Use handle (1) to lift hood (2) completely open. P012306001 FIG. 4 FIG. 5: Remove right-hand guard. NOTE: Right-hand side guard does not need to be removed replacing just alternator serpentine belt. Remove bolts (1) and remove guard (2). P020106001 FIG.
- Page 47 Engine Components FIG. 6: Remove left-hand guard. Remove loop clip bolts (1) and remove loop clips. Remove mounting bolts (2) and remove guard (3). P012906001 FIG. 6 FIG. 7: Air conditioning compressor serpentine belt removal. WARNING: Equipment parts under spring tension can cause bodily injury. Use caution in releasing belt tension.
- Page 48 Engine Components FIG. 8: Alternator serpentine belt removal. NOTE: Skip this step if the alternator serpentine belt does not need to be replaced. NOTE: Air conditioning compressor serpentine belt must be removed to replace alternator serpentine belt. WARNING: Equipment parts under spring tension can cause bodily injury.
- Page 49 Engine Components Serpentine Belt Installation FIG. 9: Alternator serpentine belt install. NOTE: Skip this step if the alternator serpentine belt was not removed. WARNING: Equipment parts under spring tension can cause bodily injury. Use caution in applying pressure to belt tensioner.
- Page 50 Engine Components FIG. 11: Remove left-hand guard. Install guard (3) and install bolts and washers (2) and tighten. Tighten to 28 Nm (20 lbf ft). Install loop clips, bolts and washers (1) and tighten. Tighten to 12 Nm (9 lbf ft). P012906001 FIG.
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