Challenger MT835C Service Manual
  1. Manuals
  2. Brands
  3. Challenger Manuals
  4. Tractor
  5. MT835C
  6. Service manual

Challenger MT835C Service Manual

Rubber track tractor
Hide thumbs
Table of Contents

Advertisement

Quick Links

Service Manual
MT835C / MT845C / MT855C /
MT865C / MT875C

Advertisement

Table of Contents
loading

Related Manuals for Challenger MT835C

Summary of Contents for Challenger MT835C

  • Page 1 Service Manual MT835C / MT845C / MT855C / MT865C / MT875C...
  • Page 2 ® Challenger MT835C / MT845C / MT855C / MT865C / MT875C Rubber Track Tractor SERVICE MANUAL 79033095 C Rev. Volume 1 CONTENTS Volume 1 INTRODUCTION..............................01 ENGINE ..................................02 POWERTRAIN................................03 FRAME ...................................04 STEERING AND BRAKE SYSTEM ........................05 IMPLEMENT HYDRAULIC AND THREE-POINT HITCH SYSTEMS..............06 ELECTRICAL SCHEMATICS..........................07...

  • Page 3: Table Of Contents

    Contents ® Challenger MT835C / MT845C / MT855C / MT865C / MT875C Rubber Track Tractor SERVICE MANUAL 79033095 C Rev. 01 - Introduction Contents INTRODUCTION Service Manual ..............................1-1 Divisions and Page Numbers ........................1-1 Units of Measurement ............................1-1 Replacement Parts ............................
  • Page 4 Contents Special Tooling .............................. 1-24 INDEX ................................01-25 01-ii 79033095 C Rev. Find manuals at http://best-manuals.com/search?&s=CHAL-79033095...

  • Page 5: Service Manual

    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 this manual, is determined by facing direction the machine travels when in use.

  • Page 6: Important Safety Information

    Introduction IMPORTANT SAFETY INFORMATION FIG. 1: Most personal injuries occurring during machine 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 7: 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 operator attention to information involving operator safety and safety of others. FIG.

  • Page 8: Informational Messages

    Introduction INFORMATIONAL MESSAGES FIG. 4: Do not operate or perform any lubrication, maintenance or repair on machine until reading and understanding operation, lubrication, maintenance and repair information. Read and understand this manual, operator’s manual and attachment manuals before operation. Learn how to operate machine and use controls properly. Do not allow anyone to operate machine without instruction and training.

  • Page 9: General Hazard Information

    Introduction GENERAL HAZARD INFORMATION FIG. 5: When engine is running and steering wheel is turned, machine will not turn with transmission control lever in PARK position. IMPORTANT: Ensure all personnel are a safe distance from machine before turning steering wheel. Do not start engine until area is free of personnel to avoid personal injury due to unexpected machine movement.

  • Page 10: Protective Clothing

    Introduction Never put maintenance fluids into glass containers, drain into a suitable container. Discard any drained fluids and discard any filter elements according to local regulations. Use all cleaning solutions with care. Report all necessary repairs. Some components of machine are very heavy. Use suitable lifting equipment or additional help.

  • Page 11: Mounting And Dismounting

    Introduction Mounting and Dismounting FIG. 8: Mount and dismount machine only where there are steps and/or hand holds. Face machine whenever mounting or dismounting. Maintain three-point contact with steps and hand holds. Three-point contact is two feet and one hand or one foot and two hands.

  • Page 12: Exhaust Dangers

    Introduction Exhaust Dangers FIG. 9: Diesel engine exhaust contains products of combustion, potentially harmful to health. Always run engine in a well-ventilated area. Never operate engine in a closed building unless exhaust is vented outside. Before Starting Engine Clear all personnel from machine and surrounding area. Make sure all obstacles are cleared from machine’s path.

  • Page 13: Operator Station

    Introduction When possible, operate machine up and down slopes. Avoid operating machine across slope, when possible. Keep machine under control. Do not overload machine beyond capacity. Make sure towing devices are adequate for application. Make sure components on three-point hitch are adequate for application.

  • Page 14: Engine Starting

    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 15: 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 solutions with care. N020903013 FIG. 13 FIG. 14: Do not smoke when servicing an air conditioner.

  • Page 16: Rollover Protective Structure (Rops)

    Introduction Rollover Protective Structure (ROPS) Do not make any modifications to ROPS as this affects protection provided. Do not alter structure by welding, cutting, adding weight or drilling holes into structure. Any alteration not specifically authorized by AGCO invalidates AGCO certification for ROPS. Protection offered by ROPS will be impaired if ROPS has structural damage.

  • Page 17: Escaping Fluid Dangers

    Introduction Escaping Fluid Dangers FIG. 18: Escaping fluid under high pressure can be almost invisible but can penetrate skin causing serous injury and possible death. A pinhole leak can cause severe injury. Consult a doctor immediately if an injury from escaping fluids is sustained.

  • Page 18: Batteries

    Introduction Batteries FIG. 20: Electrolyte is an acid and can cause personal injury. Do not allow electrolyte to contact skin or eyes. Always wear protective glasses when servicing batteries. Wash hands after touching batteries and connectors. N020903020 FIG. 20 FIG. 21: Battery gases can explode. Keep any open flames or sparks away from top of battery.

  • Page 19: Fire And Explosion Prevention

    Introduction Fire and Explosion Prevention FIG. 23: All fuels, most lubricants and some coolant mixtures are flammable. Flammable fluids leaking or spilled onto hot surfaces or electrical components can cause fire. Fire may cause personal injury and property damage. Remove all flammable materials such as fuel, oil and debris from machine.

  • Page 20: Fire Extinguisher

    Introduction Fire Extinguisher FIG. 25: Ensure a fire extinguisher is available. Be familiar with operation of fire extinguisher. Inspect and service extinguisher regularly and obey instructions on instruction plate. A mounting bracket can be installed on right front frame rail. Bracket is designed to hold a 4.5 kg (10 lb) extinguisher.

  • Page 21: Machine Identification

    Introduction MACHINE IDENTIFICATION Machine Identification Information Plate Locations Machine identification number (PIN) is used to identify a powered machine designed for an operator to ride. Components such as engines, transmissions and major attachments not designed for an operator to ride are identified by serial numbers.
  • Page 22 Introduction FIG. 29: Cab Serial Number. Plate is located on the outside front cab left. Cab Serial Number: ____________________________ P111103001 FIG. 29 FIG. 30: Operator’s Seat Serial Number. Tag (1) is located on rear of operator’s seat. Seat Serial Number: ___________________________ KA15322 FIG.

  • Page 23: Torque Specifications

    Introduction TORQUE SPECIFICATIONS WARNING: Mismatched incorrect fasteners can result in damage, malfunction or personal injury. Avoid mixing metric dimensioned fasteners inch dimensioned fasteners. Prior to installation of any hardware, ensure components are in near new condition. Bolts and threads must not be worn or damaged.

  • Page 24: 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 25: 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 26: Tightening Straight Thread Fittings

    Introduction TIGHTENING STRAIGHT THREAD FITTINGS Straight thread hydraulic fittings require precise tightening. Overtightening of hydraulic fittings ruin 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.

  • Page 27: 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 28 Introduction SPECIAL TOOLING Special tooling listed below may be required for removal, installation, disassembly or assembly of components of the machine. These parts can be ordered from AGCO. Part Number Description 516186D1 Hose AS. - Tensioner Charge 548008D1 Adapter GP - Communications 563181D1 Adapter GP (COM 3) 516201D1...
  • Page 29 Index INDEX Asbestos Information ........... 1-16 Machine Identification ........... 1-17 Assembly Torque for Inch Fasteners ....1-21 Metric Fasteners ........... 1-20 Assembly Torque for Metric Fasteners ....1-20 Metric Information ..........1-23 Auto-Guide Precautions ........1-16 Mounting and Dismounting ........1-7 Batteries ...............
  • Page 30 Index NOTES 01-26 79033095 C Rev. Find manuals at http://best-manuals.com/search?&s=CHAL-79033095...
  • Page 31 Contents ® Challenger MT835C / MT845C / MT855C / MT865C / MT875C Rubber Track Tractor SERVICE MANUAL 79033095 C Rev. 02 - Engine Contents ENGINE COMPONENT Introduction ..............................02-1 Specifications and Standards Concerning Fuel, Oil and Coolant ..............02-1 Fuel Quality ............................. 02-1 Oil Quality ..............................
  • Page 32 Contents Exhaust System Installation ........................ 02-107 Muffler Removal and Installation ....................... 02-109 Muffler Removal ..........................02-109 Muffler Installation ..........................02-111 Battery Removal and Installation ....................... 02-113 Battery Removal ..........................02-113 Battery Installation ..........................02-115 Fan Removal and Installation ........................02-117 Fan Removal ............................

  • Page 33: Engine Component

    Engine Component ENGINE COMPONENT 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 34: Serpentine Belt Replacement

    Engine Component 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 FIG. 1: Battery disconnect switch. IMPORTANT: Park the machine on a hard, level surface. Location of battery disconnect switch (1).
  • Page 35 Engine Component FIG. 3: Remove right guard. Remove bolts (1) and remove guard (2). N011906001 FIG. 3 FIG. 4: Remove left guard. NOTE: This guard does not need to be removed if replacing just the fan drive serpentine belt. Remove bolts (1) and remove guard (2). N012606004 FIG.
  • Page 36 Engine Component FIG. 5: Fan drive serpentine belt removal. Use a ratchet wrench in the square hole (1) on the belt tensioner (2) and turn counter clockwise to relieve belt tension. Remove serpentine belt (3). Slowly release the belt tensioner to relax into a neutral position. WARNING: Equipment parts under...

  • Page 37: Serpentine Belt Installation

    Engine Component Serpentine Belt Installation FIG. 7: Accessories serpentine belt install. NOTE: Skip this step if the accessories serpentine belt was not removed. Install serpentine belt (3) over pulleys on front of engine, leaving it off of alternator pulley. Ensure that belt ribs are properly seated in pulley valleys.
  • Page 38 Engine Component FIG. 9: Install right guard. Install guard (2) and install bolts and washers (1) and tighten. Tighten to 55 Nm (40 lbf ft). N011906001 FIG. 9 FIG. 10: Install left guard. NOTE: This step can be skipped if the left guard was not removed.
  • Page 39 Engine Component FIG. 11: Connect battery at battery disconnect switch. Install key (1) and rotate to connect the battery power. N012206002 FIG. 11 79033095 C Rev. 02-7 Find manuals at http://best-manuals.com/search?&s=CHAL-79033095...

  • Page 40: Alternator - Removal And Installation

    Engine Component ALTERNATOR - REMOVAL AND INSTALLATION Removal Procedure WARNING: Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. FIG. 12: Battery disconnect switch. IMPORTANT: Park the machine on a hard, level surface. Location of battery disconnect switch (1).
  • Page 41 Engine Component FIG. 14: Remove left guard. NOTE: This guard does not need to be removed if replacing just the fan drive serpentine belt. Remove bolts (1) and remove guard (2). N012606004 FIG. 14 FIG. 15: Remove wiring: Mark and remove wiring (1), (2), and (3) from alternator (4).
  • Page 42 Engine Component FIG. 16: Serpentine belt removal. Use a ratchet wrench in the square hole (1) on the belt tensioner (2) and turn clockwise to relieve belt tension. Remove serpentine belt (3). Slowly release the belt tensioner to relax into a neutral position. WARNING: Equipment parts under...

  • Page 43: Alternator Install

    Engine Component Alternator Install FIG. 18: Install pulley. Install pulley (1) onto alternator shaft (2) and tighten nut (3) to 102 Nm ± 7 Nm (75 lbf ft ± 5 lbf.ft). P100106058 FIG. 18 FIG. 19: Install alternator. Place alternator (3) and install the two top bolts (1) and bottom bolt (2).
  • Page 44 Engine Component FIG. 21: Install wiring. Mark and remove wiring (1), (2) and (3) from alternator (4). Connect electrical wires (1), (2) and (3) to posts on back of alternator (4). Position protective boot over power terminal (2). P100106057 FIG. 21 FIG.

  • Page 45: Cooling Assembly - Removal And Installation

    Engine Component COOLING ASSEMBLY - REMOVAL AND INSTALLATION Cooling Assembly Removal Procedure NOTE: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Any engine openings such as turbo charger, intake manifold ports and coolant ports should be plugged or capped while their respective tubes, hoses and any other connections are removed.
  • Page 46 Engine Component WARNING: Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
  • Page 47 Engine Component FIG. 25: Disconnect battery at battery disconnect switch. Rotate and remove key (1) to disconnect the battery power. N012206002 FIG. 25 FIG. 26: Remove fanblast guard. Remove four bolts (1) and remove fanblast guard (2). The weight of the fanblast guard is approximately 58 kg (128 lb).
  • Page 48 Engine Component FIG. 29: Remove air intake. Remove bolts (1). Slide air intake (2) forward. Carefully pull it out of its seal (3). N012606006 FIG. 29 FIG. 30: Remove right side charge air tube. Clean dirt off of charge air tube (1) and its connections to prevent dirt entering the system.
  • Page 49 Engine Component FIG. 32: Remove left guard. Remove bolts (1) and remove guard (2). N012606004 FIG. 32 FIG. 33: Remove right guard. Remove bolts (1) and remove guard (2). N011906001 FIG. 33 79033095 C Rev. 02-17 Find manuals at http://best-manuals.com/search?&s=CHAL-79033095...
  • Page 50 Engine Component FIG. 34: Fuel shut off. At the primary fuel filter / water separator (1) on the left side of the engine, turn shut off valve handle (2) 90 degrees clockwise. Shut off valve handle (2) should be perpendicular to the valve. N033006001 FIG.
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

Mt845cMt855cMt865cMt875c

Table of Contents