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Challenger MT755E Workshop Service Manual

Rubber track tractor
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Workshop Service Manual
Rubber Track Tractor
MT755E
MT765E
MT775E
North America
June 2018
4205 River Green Parkway, Duluth GA 30096 USA
79036614D
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
NA
© AGCO 2018
English

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Summary of Contents for Challenger MT755E

  • Page 1 Workshop Service Manual Rubber Track Tractor MT755E MT765E MT775E North America June 2018 4205 River Green Parkway, Duluth GA 30096 USA 79036614D Challenger is a registered trademark of Caterpillar Inc. and is used under license by AGCO. © AGCO 2018 English...
  • Page 2 CALIFORNIA Proposition 65 Warning WARNING: Diesel engine exhaust and some of its constituents are known to the State of California 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 cause cancer, birth defects, or other reproductive harm.
  • Page 3 TABLE OF CONTENT General Engine, fuel, and exhaust system Frame and suspension Steering system Drive train system Brake system Compressed air system Hydraulic system Electrical system Air conditioning and heating system Chassis Track belt system Implement drive system Implement lift system Attachments Diagrams Special tools...

  • Page 4: Table Of Contents

    Table of contents 1. General ............1-3 1.1 Safety signs 1.1.1 A word to the technician .
  • Page 5 Table of contents 1.8.1 Fuse panel ............1-32 1.8.2 Fuse block one .

  • Page 6: Safety Signs

    1. General 1.1 Safety signs GUID-3C35D58D-1F5D-4B85-A915-C7BB48F47262 [V1] 1.1.1 A word to the technician Read and understand the safety section in this service manual before operating or servicing the machine. Read and understand the safety sections in the manuals for all attachments before operating or servicing attachments.

  • Page 7: Service Manual

    1. General GUID-96F0DBC2-FDAB-4BE2-A442-8D57B94A81B4 [V1] 1.1.2 Service manual WARNING: Some pictures in the manual show the shields removed to permit a clearer view. Never operate the machine with any shields removed. This service manual has been prepared with the latest service information available at publication. Read and understand the service manual carefully before doing any service on the machine.

  • Page 8: Safety Signs

    1. General IMPORTANT: Identifies special instructions or procedures which, if not followed, can cause damage to the machine, the process, or the area around the machine. NOTE: Information to make procedures easier. GUID-2FB17168-6A01-47C5-B298-234AF171520B [V6] 1.1.6 Safety signs WARNING: Do not remove the safety signs. Replace safety signs that you cannot read, are damaged, or are missing.

  • Page 9: General Hazard Information

    1. General GUID-45723AC0-5E25-4FA2-BB74-FF22568B117F [V3] 1.1.8 General hazard information CAUTION: Carefully read the operator's manual before operating the machine. See all instructions and safety rules when operating or doing maintenance. GUID-FE6A41D4-536F-4C0D-BE60-FA0CCDEEB171-high.jpg [High] Fig. 4 Do not start the engine until the area is free of personnel.

  • Page 10: Pressurized Air

    1. General • Transmission control lever is in the park position. • The engine is stopped. • The engine start switch is turned off and the switch key is removed. • The machine has cooled down. Any additional precautions must be observed based on the conditions and environment where the machine is being used.

  • Page 11: Before You Start The Engine

    1. General GUID-344A454E-7D26-49D5-9AB4-3FEEFA88AFD5 [V3] 1.1.13 Before you start the engine Start the engine only from the operator compartment. Never short across the starter terminals or batteries. Shorting can damage electrical system or cause unexpected machine movement. Adjust the seat so full pedal travel can be achieved with operator's back against seat back.

  • Page 12: Park The Machine

    1. General Check for the correct operation of all the controls and the protective devices. As a warning honk the horn twice to alert others in the area to prevent personal injury because of machine movement. During operation of the machine, report any damage recorded. Make any necessary repairs. A rollover of machine can occur when working on hills, banks, or slopes.

  • Page 13: Cut And Crush Prevention

    1. General Any item brought into the cab must not extend into defined operator space. Secure loose items. Objects must not pose an impact hazard in rough terrain or if there is a rollover. GUID-C5B3B243-B184-48C6-9CF2-F4FF44F55F30 [V4] 1.1.19 Cut and crush prevention Support the equipment correctly when performing work below the equipment.

  • Page 14: Burn Prevention

    1. General GUID-1527F9B5-890D-4E6F-AA25-C4A364C27BA9 [V2] 1.1.21 Burn prevention Do not touch any part of an operating engine. Other components such as the transmission, the axles and the oil reservoir can also be hot. Let the engine cool before performing any maintenance on the engine.

  • Page 15: Fluid Penetration

    1. General DANGER: Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes. This can cause serious personal injury, blindness, or death. GUID-E76BB0CD-67F0-40CD-A4CC-D6B27E9CDCCE [V2] 1.1.25 Fluid penetration Always use a board or cardboard when checking for a leak. Leaking fluid under pressure can penetrate the body tissue.

  • Page 16: Exhaust Fumes

    1. General Wash hands after touching batteries and connectors. WARNING: WARNING: Batteries contain electrolyte which is an acid that can cause personal injury. Do not let the electrolyte contact the skin or eyes. Always wear protective glasses for servicing batteries. GUID-6942F6BB-021E-47D8-8B36-8FB6CB6088DB-high.jpg [High] Fig.

  • Page 17: Noise Prevention

    1. General GUID-99732186-65C2-4EC3-8EDB-760F7ABE29B7 [V1] 1.1.28 Noise prevention Wear proper hearing protective devices such as earmuffs or earplugs to prevent loss of hearing due to high noise levels. GUID-48B1B90D-20EB-42DB-A016-3CA0AB8AC168-high.jpg [High] Fig. 15 GUID-43C214E0-CE68-4B1B-9480-B36317FC1602 [V3] 1.1.29 Fire and explosion prevention Use caution when refueling a machine. Do not smoke while refueling and do not refuel near open flames or sparks.

  • Page 18: Fire Extinguisher

    1. General explosive. Repair such components in a well ventilated area away from open flames or sparks. Inspect all lines and hoses for wear or for deterioration and replace if necessary. Route hoses correctly. Lines and hoses must have sufficient support and secure clamps. Tighten all connections to recommended torque.

  • Page 19: Machine Identification Information

    1. General GUID-656A4902-1346-4A17-BE88-42FC715A7506 [V1] 1.2 Machine identification information Components such as engines, transmissions, and primary attachments 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 [High] Fig.
  • Page 20 1. General Machine identification Callout Description Serial Number Emissions Control Information Machine PIN Plate Engine Serial Number Cab Serial number Operator Seat Serial Number Right Track Belt Number Left Track Belt Number Differential Serial Number Rubber Track Tractor 1-17 79036614D...

  • Page 21: Serial Number Definition

    Location Built Code Ending Symbol NOTE: For serial number breaks in this manual, only the information from the model year code and following will be given. Code Definition Ag-Chem Challenger Spra-Coupe Willmar Massey Ferguson Brand code definitions Code Definition Code...
  • Page 22 1. General Code Definition Code Definition 2014 2020 2015 2021 2016 2022 Model year code definition Code Definition No code Position 8 option code definition Code Definition No code Position 9 option code definition Rubber Track Tractor 1-19 79036614D...

  • Page 23: Proper Disposal Of Waste

    1. General GUID-D27C9EFF-D3E3-4F5E-93ED-A6E5560C23DF [V3] 1.4 Proper disposal of waste Improper disposal of waste can pollute the environment and ecology. A few examples of potentially harmful equipment waste can include, but not limited to, items such as oil, fuel, coolant, brake fluid, filters, battery chemicals, tires, etc.

  • Page 24: Lubricant Viscosities And Refill Capacities

    1. General 1.5 Lubricant viscosities and refill capacities GUID-E8D816FA-6438-4587-B33A-299C7258D0EB [V1] 1.5.1 Lubricant viscosities for ambient temperatures Proper oil viscosity grade is determined by the minimum outside temperature while the machine is started and while operated. To determine the proper oil viscosity grade, refer to the minimum column in the following table. This information reflects the coldest ambient temperature condition for starting and for operating a cold machine.
  • Page 25 1. General Approximate refill capacities Compartment or Liter (gal) system Engine coolant system AGCO® Antifreeze and coolant or equivalent that meets 40 liter (10.6 gal) the following requirements. 50/50 Water and Ethylene/ propylene- glycol without stop leak additive, ASTM D3306 - See Engine operation and maintenance manual Diesel fuel Meets EN590-2009 or ASTM D975 Grade No.
  • Page 26 1. General Approximate refill capacities Compartment or Liter (gal) system Fuel tank extra with 113.5 liter (30.0 gal) standard gauge Fuel tank extra 284 liter (75 gal) Engine crankcase and AGCO® Multiguard® SAE15W-40 API grade CJ-4 or 34.8 liter (9.2 gal) filter ACEA E9 DEF tank (Diesel...

  • Page 27: Service Intervals

    1. General GUID-EA0FBA0F-7172-4901-9612-36F8DE6176FA [V4] 1.6 Service intervals IMPORTANT: Always stop the engine before starting service work When required: • Cab recirculation filter - clean/inspect/replace • Cab air filter - clean/replace • Check the HVAC drain lines and clean as needed •...

  • Page 28: Maintenance Schedule

    1. General Maintenance work Service interval / running hours 4500 [7 , 8] Change the SCR supply module main filter Once a year. [7] [8] Change the SCR supply module inlet filter Once a year. Change the coolant Every two years. Change the vibration damper (98 engines) Every five years.
  • Page 29 1. General Every 10 Every Service Item Every 50 Every 250 Every 400 hours or 1000 Other hours hours hours daily hours Get a sample of the power train system oil for analysis Every Replace the power train system 1500 oil and filters hours Clean or replace the hydraulic...

  • Page 30: Fuel System

    1. General GUID-98D413A8-22F7-4500-AACB-A19CC773EF17 [V3] 1.7 Fuel system WARNING: Add fuel only in an area that has a free movement of fresh air and no open flames or sparks. Never smoke when adding fuel. IMPORTANT: When servicing the fuel system, the work area and all parts must be completely clean. IMPORTANT: Even small amounts of DEF in diesel fuel will cause serious fuel system failure.

  • Page 31: Prime The Fuel System

    1. General GUID-C2013F9F-CC6C-4030-BE59-8D541DC5C696 [V3] 1.7.3 Prime the fuel system Before starting the procedure IMPORTANT: Do not turn the engine for more than 30 seconds. Let the starter motor cool for two minutes before starting again. Turbocharger damage can result if the engine rpm is not kept low until the oil gauge display verifies oil pressure is sufficient.

  • Page 32: Fuel Cap

    1. General GUID-708F36EC-6B2D-4413-AD5D-F021DEE323FB [V3] 1.7.4 Fuel cap WARNING: Personal injury or death can result from a fire. Fuel leaked or spilled on hot surfaces or electrical components can cause a fire. Cleanup all leaked or spilled fuel. Do not smoke while working on fuel system.
  • Page 33 1. General Procedure Clean the fuel filters and adjacent area. Close the fuel valve (5). Drain prefilter (2). Disconnect prefilter water detector connector (1). Turn filter element (2) counterclockwise and remove element from mounting bracket. Collect fuel into a applicable container. Remove the water detector (3) from the prefilter bottom end.

  • Page 34: Main Fuse Panel

    1. General GUID-559BFC75-36BF-4417-8AF7-EFDB99FDE9B6 [V3] 1.8 Main fuse panel GUID-C88DE612-1945-4CBE-B340-68A20D3521F8-high.jpg [High] Fig. 25 The main fuse panel is located inside of the cab. 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...

  • Page 35: Fuse Panel

    1. General GUID-69DD0110-EDC9-4B7C-9268-1156BA14005C [V2] 1.8.1 Fuse panel The main fuse panel is located on the right-hand side of cab seat near floor of the cab. To get access to the fuses, two spring loaded fasteners (1) need to be loosened. GUID-BBFB41B4-B50B-4731-9010-EF25DDCCAD55-high.jpg [High] Fig.

  • Page 36: Fuse Block Two

    1. General Fuse block one 30 Amp Roof light module 30 Amp Roof light module 30 Amp Roof light module 30 Amp Power port GUID-17BDDCCD-D1F1-4D65-9BFF-7403F7334B9A [V4] 1.8.3 Fuse block two Fuse block two Item Rating Description Switch battery 20 Amp Implement valve / hitch valve...

  • Page 37: Fuse Relay Block One

    1. General Fuse block two 10 Amp Tractor management center (TMC) 15 Amp Fan control / DEF quality sensor 15 Amp Product link 15 Amp Horn 10 Amp Cell phone port / power port 10 Amp Light switch GUID-3CC7DD6C-524C-47B8-ADE2-F12EFF0FFF3E [V2] 1.8.4 Fuse relay block one Fuse / relay block one Item...

  • Page 38: Fuse Relay Block Two

    1. General GUID-676FEAA6-B2A0-4E2F-B598-A275D350B6E5 [V1] 1.8.5 Fuse relay block two Fuse / relay block two 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 Fuse / relay block two - ECU relay power Item Fuse...

  • Page 39: Circuit Breaker

    1. General GUID-CB0218BA-A154-4A2F-A6C1-F2C7D9AA6C9A [V2] 1.8.7 Circuit breaker The circuit breaker for 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 1-36 Rubber Track Tractor 79036614D...

  • Page 40: Undercarriage (Mobil Trac) System

    1. General 1.9 Undercarriage (Mobil trac) system GUID-C15CFF67-0F2F-4BC5-BA65-60E56FC7E488 [V2] 1.9.1 Do a check of the oil level for the drive wheel hubs NOTE: Inspect the oil level frequently for machines operating in extremely wet or muddy conditions. Change the oil every 400 hours under these conditions. NOTE: There are two plugs in the drive wheel hub.

  • Page 41: Do A Check Of The Oil Level For The Idler Wheel And The Mid Roller Wheel Hubs

    1. General Replace the chocks at the front and rear of the tracks. Add the correct oil to the threaded hole (1) in the outer hub until the oil level reaches bottom of the threaded hole. Approximately 1.4 L Install plugs in both the inner and the outer hubs. GUID-ACBFA2E4-4929-411A-8DA1-BEF4D8B94A92 [V3] 1.9.3 Do a check of the oil level for the idler wheel and the mid roller wheel hubs NOTE: Inspect the oil level frequently if the machine is operated in extremely wet or muddy conditions.
  • Page 42 1. General The cables can deteriorate, by rusting, if moisture reaches the cables through cuts or gouges exposing cables. Cuts or gouges exposing cable, must be repaired. GUID-3567A918-FC16-4391-9799-CEEDC8640C29-high.jpg [High] Fig. 38 Any damaged zero degree cables above the surface of the track carcass must be cut or ground down to below the surface of the track to prevent additional damage due to unraveling.

  • Page 43: Selective Catalytic Reduction (Scr) System

    1. General GUID-93890D3C-C199-45A9-AA14-454D326DE326 [V2] 1.10 Selective catalytic reduction (SCR) System These general instructions need to be followed: • The selective catalytic reduction (SCR) system must not be contaminated by diesel fuel, oil, or other hydrocarbons. Damage to the system will result. If any part of the system has been in touch with such substances, the part must be cleaned very carefully.

  • Page 44: Diesel Exhaust Fluid (Def) Tank

    1. General Move the bracket to make room to remove the two bolts (4), and pivot module to loosen filter and remove. GUID-32ABDD24-58E3-4005-A606-FBF234725197-high.jpg [High] Fig. 41 GUID-5687B041-3B37-45D3-AEA3-73F8866D616E [V1] 1.10.2 Diesel exhaust fluid (DEF) tank NOTE: Always monitor cleanliness, to prevent other fluids or contaminants from entering the tank. IMPORTANT: Even small amounts of diesel fuel in DEF tank may damage gaskets of the SCR system.

  • Page 45: Def Heater Circuit Fuse

    1. General GUID-E943B4DC-1A3E-4CCA-ABC9-CD949AE9F2D9 [V4] 1.10.3 DEF heater circuit fuse The DEF heater circuit fuses, each fuse 20 AMPS. GUID-44F2A38C-42D3-4832-844C-C6535DA70213-high.jpg [High] Fig. 43 GUID-519D05AB-26F6-4F28-9B05-8D34AC9AE0A0 [V5] 1.10.4 DEF storage and shelf life The following table provides information for the DEF shelf life as a function of temperature: Constant ambient temperature Minimum shelf life - months less than or equal to 10°C (50°...

  • Page 46: Low Diesel Exhaust Fluid (Def) Level

    1. General GUID-67BFE79B-B8DD-49A0-AE83-08C52C46C7F0 [V5] 1.10.5 Low diesel exhaust fluid (DEF) level GUID-E4D419C7-FDC1-433E-945E-79C6C04909CC-high.jpg [High] Fig. 44 AGCO Power warning strategy activates for the first time at 15% diesel exhaust fluid (DEF) tank level. This warning is temporary (10 seconds) and it repeats at every engine startup, until the next warning level is reached.

  • Page 47: Engine Specifications

    1808 Nm (1334 lbf ft) @ 1500 1921 Nm (1417 lbf ft) @ 1500 high idle MT755E - 2160 RPM - 1st to 15th MT765E - 2160 RPM - 1st to 15th MT775E: 2200 RPM - 1st to 15th gear - Forward, Neutral, Reverse,...

  • Page 48: Torque Specifications

    1. General GUID-0BAF2E7B-A615-4A36-871A-E23E5E1880B6 [V1] 1.12 Torque specifications WARNING: Mismatched or incorrect fasteners can cause damage or malfunction, or personal injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torques are in the service manual, if necessary. Before installation of any hardware, make sure the components are in near new condition.
  • Page 49 1. General Standard High Thread Size Pound Feet Newton Pound Feet Newton Pound Feet Newton lbf ft Meters Nm lbf ft Meters Nm lbf ft Meters Nm 1 1/8 - 7 860 to 1060 1150 to 1450 965 to 1175 1300 to 1600 465 to 565 610 to 790 1 1/4 - 7...
  • Page 50 1. General GUID-03108AC9-D116-472B-8878-816A93A7CD2D-high.jpg [High] Fig. 47 Straight thread fittings The straight thread hydraulic fittings require accurate tightening. Overtightening of the hydraulic fittings will damage the sealing surfaces and will require the replacement of the damaged parts. Correct initial tightening depends on the mating parts to be connected. Continue as follows: An adapter fitting (37°...

  • Page 51: Metric Fasteners

    1. General DASH SIZE TUBE O. D. (REF) TORQUE MAX lbf in lbf ft 3600 2 1/2 4800 6000 O-ring face seal (ORFS) fittings ORFS Connectors, ORFS Hose Couplings, ORFS Plugs, and ORFS Tube Assembly Nut Torques Ref Nominal Tube OD Standard Torque High Pressure Drive Torque Dynamic...
  • Page 52 1. General Standard taperlock studs Thread Size Pound Feet lbf ft Newton Meters Nm 1200 Metric bolt and cap screws GUID-7AF08829-E556-40A7-B8C7-61E951B65C34-high.jpg [High] Fig. 48 Rubber Track Tractor 1-49 79036614D...

  • Page 53: General Dimensions

    1. General GUID-457CA639-1D58-4EA4-B39E-26C20396A0D9 [V2] 1.13 General dimensions GUID-14DA3D5B-1227-49C9-9289-E7A2429789E0-high.jpg [High] Fig. 49 General dimensions for standard gauge 5993 mm (235.9 in) 480 mm (18.9 in) 4888.4 mm (192.5 in) 1765 mm (69.5 in) 1812.6 mm (71.4 in) 2438 mm (96 in) 1280 mm (50.4 in) 1104.6 mm (43.5 in) 3662.5 mm (144.2 in)

  • Page 54: Rear View Dimensions

    1. General GUID-F1000C11-AF93-4FDF-8756-8BB3AB344DA6 [V2] 1.13.1 Rear view dimensions GUID-723962C0-2BC7-4BD4-91CD-5EA016AE13BD-high.jpg [High] Fig. 50 Rubber Track Tractor 1-51 79036614D...
  • Page 55 1. General Rear view dimensions 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) 1-52...

  • Page 56: Shipping Weights

    1. General GUID-A50E9FE7-6092-4202-9B89-56A39478B88C [V3] 1.14 Shipping weights Standard gauge weight Shipping Operating Standard 13667 kg (30131 lb) 14203 kg (31312 lb) With front counter weights 15190 kg (33488 lb) 15726 kg (34670 lb) With front and idler weights 16822 kg (37086 lb) 17358 kg (38268 lb) Wide gauge weight Shipping...
  • Page 57 1. General Operating weight includes 658.9 liter (174 gal) fuel for standard 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) . ¹...

  • Page 58: Machine Specifications - Mt700E

    1. General GUID-A2FB1161-C2CA-4236-B229-52027F3695C6 [V2] 1.15 Machine specifications - MT700E Title Description Transmission Electronically controlled direct drive power shift. Sixteen forward gears, and four reverse gears. Three methods of shifting. Creeper option has 14 forward and 3 reverse. Electrical system 12 volt. Two alternators - 150 A each = total 300 A charging system.
  • Page 59 1. General Title Description Steering system Machine has a differential steering system. Steering system controls difference in speed between two belts during turns. Steering system consists of the following components: three planet gear sets, A bidirectional hydraulic steering motor. Three point hitch 3-Point linkage is electronically controlled.
  • Page 60 1. General Category III drawbar capacity Drawbar position Distance from the Maximum downward Maximum downward force PTO shaft to the hold force with heavy duty drawbar for the drawbar pin support short 413 mm (16.3 in) 4536 kg (10 000 lb) 5443 kg (12 000 lb) standard 508 mm (20 in)
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