Challenger MT745C, Service Manual

Page 1: ...r 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...

Page 2: ...01 8 Engine Starting 01 9 Seat Belts 01 9 Shield Removal 01 9 Fluid Precautions 01 10 Battery Disconnect 01 10 Rollover Protective Structure ROPS 01 10 Burn Hazards 01 11 Coolant Precautions 01 11 Esc...

Page 3: ...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 01 29 Main Fuse Panel 01 29 Main Fus...

Page 4: ...learer view Never operate machine with any shields removed Divisions and Page Numbers Service manual is separated into divisions Refer to Master Table of Contents Each division has an identifying part...

Page 5: ...ticipated Warnings in service manual and on product are therefore not all inclusive If a tool procedure work method or operating technique not specifically recommended by AGCO is used ensure it is saf...

Page 6: ...not avoided may result in MINOR INJURY Informational Messages FIG 4 Do not operate or perform any lubrication maintenance or repair on machine until reading and understanding operation lubrication ma...

Page 7: ...s stopped Engine start switch is turned off and switch key is removed Machine has cooled down Steering cylinder lock is in place m WARNING Do not start engine until area is free of personnel to avoid...

Page 8: ...rding to local regulations Report all necessary repairs Some components of machine are very heavy Use suitable lifting equipment or additional help as instructed in Service Manual Do not allow unautho...

Page 9: ...ng operator compartment Crushing Cutting Prevention Stay clear of center articulation joint area of machine when engine is running Connect articulation joint stop whenever servicing this area Support...

Page 10: ...e s path Operator must be familiar with hazards wires ditches fences etc Be sure all windows are clean Secure doors and windows in open or closed position Adjust rearview mirrors for best visibility c...

Page 11: ...ond capacity Make sure towing devices are adequate for application Connect trailing equipment only to drawbar or hitch Never straddle or allow any personnel to straddle a wire cable When maneuvering t...

Page 12: ...ontrols while engine is running Any rider in instructor s seat must fasten seat belt Never allow anyone on any part of machine or its attachments except in operator s and instructor s seat when engine...

Page 13: ...s shut off engine shift transmission to park remove ignition key and set battery disconnect switch 1 to OFF before permitting inspection cleaning lubrication adjustment or repair of any part of machin...

Page 14: ...lant level only after engine has been stopped Cooling system conditioner contains alkali that can cause personal injury Do not allow alkali to contact skin eyes or mouth Do not remove radiator cap if...

Page 15: ...s are kinked Outer covers have embedded armoring End fittings are displaced Batteries FIG 20 Electrolyte is an acid and can cause personal injury Do not allow electrolyte to contact skin or eyes Alway...

Page 16: ...storing flammable materials Do not operate machine near any flame Exhaust shields protect hot exhaust components from oil or fuel spray in case of a break in a line hose or seal Exhaust shields must...

Page 17: ...inst other parts and excessive heat Auto Guide Precautions Auto Guide can be momentarily disabled if satellite signal is lost It is imperative operator be alert to position and conditions in field at...

Page 18: ...r quick reference record identification numbers in spaces provided next to illustration FIG 26 Machine PIN Plate is located on left side of frame rail Machine PIN _________________________________ FIG...

Page 19: ..._______ FIG 31 Track Belt Serial Number The serial number is located on edge of each belt Left Belt Serial Number _________________________ Right Belt Serial Number ________________________ FIG 32 Ser...

Page 20: ...s except with rust preventative Rust preventative should be applied by supplier of component for purposes of shipping and storage Other applications for lubricating components may be specified in Serv...

Page 21: ...to 39 40 to 60 M14 x 2 108 to 132 130 to 190 120 to 140 145 to 205 55 to 65 65 to 95 M16 x 2 160 to 190 200 to 280 180 to 220 230 to 310 80 to 100 105 to 145 M20 x 2 5 305 to 375 400 to 520 350 to 43...

Page 22: ...0 to 280 75 to 95 95 to 135 3 4 10 245 to 305 320 to 420 290 to 350 370 to 490 135 to 165 160 to 240 7 8 9 410 to 510 540 to 700 470 to 570 610 to 790 215 to 265 285 to 365 1 8 590 to 730 800 to 1000...

Page 23: ...rvice work both tube and hose connnections should be tightened finger tight and wrenched 1 4 turn O ring fittings should be tightened as for initial assembly JIC SWIVEL NUTS 37 degree SEAT Following v...

Page 24: ...2366 liters x 4 227 cups bushel x 35 239 liters x 0 02838 bushels bushel x 0 03524 meters m x 28 378 bushels MASS ounces av x 28 35 grams g x 0 03527 ounces av pounds av x 0 4536 kilograms kg x 2 2046...

Page 25: ...Capacities Lubricant Viscosities for Ambient Temperatures Compartment or System Oil Type and Classification Oil Viscosities Celsius Fahrenheit Min Max Min Max Engine Crankcase CI 4 CH 4 SAE 0W20 40 1...

Page 26: ...Replace Drive Wheel Hub oil level Check Engine Air Precleaner Clean Ether Starting Aid Cylinder Replace Fuel Tank Water and Sediment Drain Fuses Circuit Breakers and Relays Replace Reset Idler Hubs oi...

Page 27: ...ater Separator Check x Air Tank Drain x Three Point Hitch Lubricate x Hydraulic System oil filters Replace x Batteries Inspect x Air Conditioner belt Inspect Replace x Fan belt Inspect Replace x Prima...

Page 28: ...S Inspect x Seat Belt Inspect x Air Dryer Cartridge Replace x Engine Valve Lash Check x Cooling System Coolant Change x Refrigerant Accumulator Replace x Every 10 hours or Daily Every 50 hours Initial...

Page 29: ...o modular fuel tanks Remove five bolts and washers to remove guard 1 Remove five bolts and washers to remove guard 2 Remove eight bolts and washers guard 3 Install guards in reverse order they were re...

Page 30: ...en bolts and washers from shield 1 to lower shield 1 Remove two bolts from guard 2 Install guards in reverse order they were removed Engine Screen Cover Left Hand Side FIG 38 Remove bolts securing eng...

Page 31: ...Introduction 01 28 79033093DRev Right Hand Side FIG 39 Remove bolts securing engine screen 1 FIG 39 P112011008 1 1 1 1 1 1 Find manuals at http best manuals com search s CHAL 79033093...

Page 32: ...93 D Rev 01 29 Introduction ELECTRICAL SYSTEM Main Fuse Panel FIG 40 Main fuse panel is located near floor of cab on right side FIG 40 P092511001 Find manuals at http best manuals com search s CHAL 79...

Page 33: ...iption 1 ISO TBC Terminating Bias Circuit 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 Conne...

Page 34: ...ght Module Front 6 30 Amp Light Module Rear 7 30 Amp Light Module Rear 8 30 Amp Light Module Front 9 15 Amp Trailer Lights 10 10 Amp Not used Item Rating Description Battery 11 15 Amp Not used 12 15 A...

Page 35: ...5 10 Amp Decel Sensor Air Sensor Belt Tension Sensor 6 10 Amp Mirror Power Heat 7 10 Amp Rear Wiper 8 10 Amp Front Wiper 9 20 Amp Not used 10 10 Amp Not used Item Rating Description Switched Battery 1...

Page 36: ...ler Brakes 5 35 Amp Trailer Work Lights FIG 45 P101411014 1 2 3 4 5 6 7 8 9 10 Fuse Relay Block 1 Battery Item Fuse Description 1 15 Amp Not used 2 15 Amp Not used 3 10 Amp Not used 4 10 Amp Not used...

Page 37: ...SO Power Relay 4 35 Amp ISO ECU Relay 5 35 Amp ECU Relay FIG 47 P101411015 1 2 3 4 5 6 7 8 9 10 Fuse Relay Block 2 ECU Relay Power Item Fuse Description 1 15 Amp Not used 2 15 Amp Not used 3 10 Amp No...

Page 38: ...in the fuse panel area Both circuit breakers are rated at 20 Amps SPECIAL TOOLING Special tooling listed below may be required for removal installation disassembly or assembly of components of the mac...

Page 39: ...Introduction 01 36 79033093DRev NOTES Find manuals at http best manuals com search s CHAL 79033093...

Page 40: ...Precautions 01 10 Fuel Tank Capacity 01 22 Fuses Main Fuse 01 35 Main Fuse Panel 01 29 G General Hazard Information 01 4 H Hood 01 26 Hydraulic System Fluid Capacity 01 22 Hydraulic System Fluid Capac...

Page 41: ...01 3 Special Tooling 01 35 T Tightening Straight Thread Fittings 01 20 Torque Specifications 01 17 U Undercarriage Mobil Trac System Fluid Capacity 01 22 Units of Measurement 01 1 W Windshield Washer...

Page 42: ...cedure 02 65 Hydraulic Oil Cooler Core Installation Procedure 02 73 Cooling Assembly Charge Air Cooler Removal and Installation 02 80 Charge Air Cooler Removal 02 80 Charge Air Cooler Removal 02 84 Co...

Page 43: ...e 02 170 Air Reservoir Removal and Installation 02 174 Air Reservoir Removal Procedure 02 174 Air Reservoir Installation Procedure 02 179 Air Dryer removal and Installation 02 182 Air Dryer Removal Pr...

Page 44: ...mpression Ignition Engines The quality of the fluids used in these engines as well as the servicing schedule must be respected in order to keep pollution emission levels low and to maintain the machin...

Page 45: ...ance on the engine allow the engine and the components to cool FIG 1 Battery disconnect switch IMPORTANT Park the machine on a hard level surface Location of battery disconnect switch 1 FIG 2 Disconne...

Page 46: ...pen FIG 5 Remove right hand guard NOTE Right hand side guard does not need to be removed if replacing just the alternator serpentine belt Remove bolts 1 and remove guard 2 FIG 4 P012306001 1 2 FIG 5 P...

Page 47: ...tension 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...

Page 48: ...e bodily injury Use caution in releasing belt tension 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 Slow...

Page 49: ...oner makes contact with belt When the belt tensioner has tensioned the serpentine belt remove ratchet FIG 10 Air conditioning compressor serpentine belt install m WARNING Equipment or parts under spri...

Page 50: ...uard 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 FIG 11 P012906001 1 1 1 2 2 2 2...

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