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Challenger RoGator 635B Service Manual

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NOTE TO THE RECIPIENT - This packet is one component of two or more components
required to comprise a complete publication. The following items, shipped under separate part
number, are used with this publication:
•
Expandable storage binder (Binder label provided in printed material packets.)
Printing Batch Number
Challenger
RoGator 635B - 645B - 655B
Chassis and System
SERVICE MANUAL
639782-1
®
© AGCO Corporation, 2013 All rights reserved.
Part Number 639782-1 (English)
Printed in the Netherlands
December 2012

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Summary of Contents for Challenger RoGator 635B

  • Page 1 Challenger ® RoGator 635B - 645B - 655B Chassis and System SERVICE MANUAL 639782-1 NOTE TO THE RECIPIENT - This packet is one component of two or more components required to comprise a complete publication. The following items, shipped under separate part number, are used with this publication: •...
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  • Page 3 ® 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 ..............................
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  • Page 5: Table Of Contents

    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 ..........................
  • Page 6 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 ........................

  • Page 7: Safety

    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.

  • Page 8: Safety Alert Symbol

    Safety 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.

  • Page 9: Follow Safety Instructions

    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.
  • Page 10 Safety SAFETY AND MAINTENANCE SIGNS WARNING: Do not remove or obscure Danger, Warning 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.
  • Page 11 Safety FIG. 4: 1. Warning - External hydraulic system filled with Hydraulic Oil ISO VG 46. Sign is located on hydraulic tank. P625052-A FIG. 4 FIG. 5: 2. High Pressure Fluid Hazard - Risk of Scalding or Burns. Safety sign is located on top of the engine coolant expansion tank.
  • Page 12 Safety 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.
  • Page 13 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. M511088D1 FIG. 12 FIG.

  • Page 14: Safety Signs

    Safety 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. P514263D1 FIG. 16 FIG. 17: 14. Warning - Falling off - Do not ride or stand in this area when machine or booms are in motion.
  • Page 15 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. S000015 FIG. 20 FIG.
  • Page 16 Safety Safety & Maintenance Sign Locations Left Side S000120 S000092 FIG. 23 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.
  • Page 17 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.
  • Page 18 Safety FIG. 30: 7. Mesh size 80. Decal (blue) is located on suction filter housing. Replace filters always by original filters. R000255 FIG. 30 FIG. 31: 8. Eductor valve. Decal located on left side by ball valve. S000019 FIG. 31 FIG.

  • Page 19: Safety Sign Locations Right Side

    Safety Safety & Maintenance Sign Locations Right Side 12 11 S000117 FIG. 34 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.
  • Page 20 Safety 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.
  • Page 21 Safety FIG. 40: 6. Cab category according EN15695. Located inside cab on right-hand rear post. This cab complies EN15695-1 category 4 and protects against dust, areosols and vapour. S000088 FIG. 40 FIG. 41: 7. Danger - Chemical and Confined space hazard. Safety sign is located on product tank cover and on eductor lid.
  • Page 22 Safety FIG. 44: Only applicable for RG635 10. Use only Diesel fuel - Read the operator’s manual, see the Lubrication & Maintenance section. Located on the fuel tank. P511414D1-01 FIG. 44 FIG. 45: Only applicable for RG645B & RG655B 11. Use only Diesel fuel with ultra low sulfur, use only AdBlue or DEF - Read the operator’s manual, see the Lubrication &...
  • Page 23 Safety FIG. 48: 14. 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. S000122 FIG. 48 FIG. 49: 15. Water separator Diesel fuel - Read the operator’s manual, see the Lubrication &...
  • Page 24 Safety FIG. 52: 18. Fuel filter - See the Lubrication & Maintenance section. Located on chassis frame near fuel filter. R000232 FIG. 52 FIG. 53: 19. Do not open or remove safety shields while engine is running. Located on the engine cover. WARNING: Never reach into area’s with rotating parts such as belts and pulley’s.
  • Page 25 Safety FIG. 56: 22. 12 volt - see the Lubrication & Maintenance section. Located on chassis frame near main power key. This machine is equipped with a 12 volt electrical system. WARNING: Never jump start a 12 volt system with a 24 volt power supply. R000256 Explosion hazard can occur causing serious injury or death.
  • Page 26 Safety Safety & Maintenance Sign Locations Right Side S000118 FIG. 59 FIG. 60: 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.
  • Page 27 Safety FIG. 62: 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.
  • Page 28 Safety FIG. 66: 7. Warning - Only drive the maximum allowed speed, when tire and tire pressure are in accordance with tire pressure table. WARNING: Never exceed the tire load according the tire pressure table. NOTE: Decal only applicable for UK and Netherlands. S000029 FIG.

  • Page 29: Prepare For Emergencies

    Safety PREPARE FOR EMERGENCIES FIG. 69: Keep a first aid kit and fire extinguisher handy. Dial 112 or your national emergency number in cases of emergency. Keep emergency numbers for doctors, ambulance service, hospital and fire department readily available at all times.

  • Page 30: Operating Machine

    Safety OPERATING MACHINE FIG. 71: Wear the seat belt at all times. 0052 FIG. 71 FIG. 72: Make sure operator and ladder areas are clean and dry to prevent personal injuries. • Make sure all wheel bolts are torqued to proper specifications before operation.

  • Page 31: Prevent Machine Runaway

    Safety PREVENT MACHINE RUNAWAY FIG. 74: Never by-pass start the engine by making a connection across starter terminals. Engine will start and machine will move if normal circuitry is bypassed. WARNING: Possible injury or death can result from machine runaway. Never start engine while standing on ground.

  • Page 32: Stopping And Parking

    Safety To increase visibility, use lights and devices provided. Amber flashing warning lights and/or turn signals are recommended whenever driving on public roads unless prohibited by law. Keep all lights and markers clean and in proper working order. Replace any missing or damaged components immediately.

  • Page 33: Overhead Electrical Power Lines

    Safety OVERHEAD ELECTRICAL POWER LINES FIG. 78: Never allow machine to contact overhead power lines. To avoid contact, bend radio antenna down and secure during operation or transport. Do not park, service or repair machine under overhead power lines. See the Operation Spray System section for the safe working distances table.

  • Page 34: Handle Fuel Properly - Avoid Fires

    Safety • Awkward positions; • Handling of heavy goods; • Life style as overweight smoking; • Vibrations; • Shocks from jumping, hitting obstacles Therefore not only the machinebut also the driving behaviour / handling / other tasks, prehistory of the operator and the environment will play a role.

  • Page 35: Stay Clear Of Rotating Drive Lines And Moving Parts

    Safety STAY CLEAR OF ROTATING DRIVE LINES AND MOVING PARTS FIG. 81: Entanglement in rotating drive lines or moving components cause serious injury or death. 0043 FIG. 81 FIG. 82: Keep all guards and shields in place at all times during operation. Turn key off.

  • Page 36: Maintenance And Service

    Safety MAINTENANCE AND SERVICE FIG. 84: Read and understand maintenance and safety instructions before performing any maintenance procedures. Only trained and qualified personnel should perform any maintenance procedures or repairs. Never modify any equipment or add attachments not approved by AGCO. 0027 FIG.
  • Page 37 Safety • The cab door is closed; • 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. 88: Operators must also avoid entering or exiting cab in treated areas.
  • Page 38 Safety FIG. 91: Hazard - Danger poisonous substances. WARNING: Never used contaminated personal protective equipment with new or clean personal protective equipment in one storage compartment. If hazardous chemicals come in contact with body, wash immediately according chemical manufacturer's recommendations. Select a proper area to fill, flush, calibrate and decontaminate machine.

  • Page 39: Wear Protective Clothing

    Safety Activated Carbon Filter Information FIG. 94: Decal, Danger - Chemical and Confined space hazard. WARNING: Due risk contaminants entering the cab when the door is opened to enter or exit, use of a carbon filter is intended to supplement but not necessarily replace the use of personal protective equipment when operating in an environment containing...

  • Page 40: Understand Correct Service

    Safety UNDERSTAND CORRECT SERVICE FIG. 97: Light working area properly and adequately. Use proper safety lights with wire safety cages. Exposed bulbs can ignite fluids. Catch draining fluids in proper containers. Never use beverage containers to store chemicals that could mislead personnel to drink from them. 0025 FIG.
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This manual is also suitable for:

Rogator 645bRogator 655b

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