Challenger MT500B Service Manual

Challenger

MT525B-535B-545B-555B-

565B-575B Series

Agricultural Tractors

AGCO - SA - Beauvais - France - RC B562 104 539 January 2005

N° 3378697M1

Issue 1

Challenger MT500B EU

English

OPERATOR INSTRUCTION BOOK

CONTENTS

Chapter 1

TRACTOR IDENTIFICATION

Chapter 2

INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

Chapter 3

INSTRUMENTS AND CONTROLS

Chapter 4

OPERATION

1

2

3

4

Chapter 5

MAINTENANCE AND ADJUSTMENTS

Chapter 6

SPECIFICATIONS

Chapter 7

ACCESSORIES AND OPTIONS

Chapter 8

TROUBLESHOOTING

Appendix

CONVERSION TABLES

Index

5

6

7

8

Challenger MT500B EU

Chapter 1

1 . TRACTOR IDENTIFICATION

1

TRACTOR IDENTIFICATION

Challenger MT500B EU

1.1

1 . TRACTOR IDENTIFICATION

CONTENTS

1.1 - SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5

1

Challenger MT500B EU

1.3

1 . TRACTOR IDENTIFICATION

1.4

Challenger MT500B EU

1 . TRACTOR IDENTIFICATION

1.1 - SERIAL NUMBERS

IMPORTANT: WHEN CONTACTING YOUR DEALER OR
AGENT, ALWAYS INDICATE YOUR TRACTOR SERIAL
NUMBER.

Registration plate (according to country)

CE -013- 01-0 5

Fig. 1

Front axle Serial number

1

Z2-095

Fig. 3

"CAT" engine serial number

Name plate with serial number (according to country).

CE-014-01-05

Fig. 2

MT0041103

Cab serial number

Fig. 4

Challenger MT500B EU

CE -012- 01-0 5

Fig. 5

1.5

1 . TRACTOR IDENTIFICATION

MODEL:..............................................................................

............................................................................................

SERIAL NUMBER:..............................................................

............................................................................................

ENGINE SERIAL NUMBER:................................................

............................................................................................

OWNER NAME AND ADDRESS (if applicable):

............................................................................................

............................................................................................

............................................................................................

............................................................................................

DEALER: ............................................................................

............................................................................................

............................................................................................

STREET: .............................................................................

TOWN:................................................................................

STATE:................................................................................

ZIP CODE:...........................................................................

DEALER CODE: .................................................................

............................................................................................

TRACTOR RECEIVED FROM:
(tick one of the following)

................ FACTORY

................ OTHER DEALER (transfer)

1.6

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

Chapter 2

2

INTRODUCTION - SAFETY INSTRUCTIONS AND

WARRANTY

Challenger MT500B EU

2.1

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

CONTENTS

2.1 - NOTE TO THE USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

2.2 - THIS BOOK MUST ALWAYS BE KEPT WITH THE TRACTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

2.3 - WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

2.4 - SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

2.5 - SAFETY - ALERT SYMBOLS AND TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

2.6 - TRACTOR AND IMPLEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

2.7 - MAXIMUM TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

2.8 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

2.9 - NOTE TO THE OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

2.10 - DANGER, WARNING AND CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

2.11 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

2.12 - SAFETY PROCEDURE TO FOLLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.12.1 For proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.12.2 Observe the following instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.13 - PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.13.1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.13.2 Damage to the ROPS cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.14 - PREPARING FOR SAFE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.14.1 Know your equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

2.14.2 Protect yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

2.14.3 Use all available protective and safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

2.14.4 Equipment check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

2.14.5 Clean the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

2.14.6 Protect the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

2.15 - SERVICING THE TRACTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

2

2.16 - STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

2.16.1 Warn personnel before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

2.16.2 Get on and off the tractor safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

2.16.3 Safe start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

2.16.4 Follow recommended start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

2.16.5 Controls test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

2.16.6 Starting fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

2.17 - WORKING SAFELY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

2.17.1 Make the right moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

2.17.2 Safety instructions to be observed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

2.17.3 Safety of bystanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

2.17.4 Risk of overturning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

2.17.5 To avoid side overturns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

2.17.6 To avoid rear overturns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

2.17.7 Other risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

2.17.8 Implements and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

2.17.9 Tractor Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

2.17.10 Road use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

2.17.11 Highway code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

Challenger MT500B EU

2.3

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.18 - SAFETY - AFTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

2.19 - DESCRIPTION OF DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

2.4

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.1 - NOTE TO THE USER

The purpose of the contents of the present Book (text and
illustrations) is to help the user to better master tractor op­eration and maintenance.

Every vehicle part must be maintained to a certain level in
order to remain in perfect operating condition. The utmost
has been done to include all settings and adjustments for
use in all possible operating conditions. However, special
attention is required in certain cases.

Please read this Operator Instruction Book very carefully in
order to familiarise yourself with all the operating settings,
adjustments and procedures before using the tractor. Al­ways remember that this machine has been designed and
tested to work effectively in most operating conditions and
that its operation depends on the maintenance it receives.

Ask the dealer if certain cases require special attention. His
Spare Parts and Service team will be pleased to help and to
answer any questions relating to the operation and mainte­nance of the machine.

2.2 - THIS BOOK MUST ALWAYS BE KEPT

WITH THE TRACTOR

The present book includes all information available about
the product at the time of publication. The manufacturer re­serves the right to modify it at any time.

WARNING: In some illustrations in this Book,
safety guards and protective panels have
been removed for the sake of clarity. Never

use the tractor if these elements are not in
place. If safety guards and protective panels have been
removed for repair purposes, they MUST be refitted
before use.

2

2.3 - WARRANTY

The warranty that applies to this tractor can be found on the
purchase order and warranty conditions card given by the
dealer at the time of purchase.
As set out by the terms and conditions listed on the pur­chase order form signed by the buyer and dealer, the vehi­cle buyer is responsible for all inspections and for
transporting the vehicle to and from the dealer.

2.4 - SAFETY

Driver safety is one of the major concerns taken into ac­count when designing and tuning the new tractor. The de­signers have included as many safety systems as possible.
In spite of these precautions, each year a number of acci­dents happen which could have been avoided by a few sec­onds consideration and greater care when using
agricultural machines and implements.

For this reason you are strongly advised to carefully read
and strictly apply the safety instructions set out in this
Book.

Challenger MT500B EU

2.5

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.5 - SAFETY - ALERT SYMBOLS AND TERMS

This Safety Alert Symbol means CAUTION!
BE ALERT! YOUR SAFETY DEPENDS ON IT!

SAFETY is essential! Why?

• ACCIDENTS DISABLE AND KILL

• ACCIDENTS ARE COSTLY

• ACCIDENTS CAN BE AVOIDED

2.6 - TRACTOR AND IMPLEMENTS

The tractor is a source of power - Mechanical - Hydraulic

• On its own, the tractor is of little practical value. Only

when used in conjunction with an implement or other
attachment does it become a working unit.

• This Operator Instruction Book is compiled to cover the

safe working practices when the tractor runs under nor­mal conditions.

• It does not cover all operation and safety instructions

relevant to all known implements and attachments that
may be fitted at the time of tractor delivery or later.

• It is essential that operators use and understand the rel-

evant instruction books of such implements and attach­ments.

The safety alert symbol identifies important
safety messages on machines, safety signs, in
manuals, or elsewhere. When you see this
symbol, be alert to the risk of personal injury or
death. Follow the instructions in the safety
message.

2.7 - MAXIMUM TRAVEL SPEEDS

DANGER: Road use of agricultural tractors is
subject to speed restrictions depending on
the bulkiness of the equipment and weight of
the transported load. Consult the regulatory

texts in force in the relevant countries.

2.6

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.8 - INTRODUCTION

The present Safety chapter sets out certain typical situa­tions that may be encountered during normal tractor oper­ation and maintenance, and suggests solutions to remedy
them. This chapter DOES NOT replace the other safety in­structions in the other chapters of this book.

Other precautions must be taken depending on the equip­ment used and the working conditions on the site or in the
maintenance area. The manufacturer is unable to directly
control the use, operation, checking, lubrication and main­tenance of the tractor. The DRIVER is therefore responsi­ble for applying the safety measures relevant to all these
operations.

NOTE: This Book is intended for distribution in North
America; it is possible that some default equipment or
attachments mentioned are not available in the country
where the tractor is used. Please consult your dealer for
further information on this subject.

Only use approved attachments and equipment.

2.9 - NOTE TO THE OPERATOR

It is YOUR responsibility to read and understand the Safety
chapter in this book before starting your tractor. You must
follow these safety instructions that take you step by step
through your working day.

In reading this section, you will note that illustrations have
been used to highlight certain situations. Each item illus­trated is numbered and the same number appears in the
text, in parentheses. This number is placed at the end of
the written text that refers to the item illustrated.

Remember that YOU are the key to safety. Good safety
practices not only protect you, but also bystanders. Study
the features in this book with care and make them a work­ing part of your safety program.
Keep in mind that this safety section is written only for this
type of machine. Also study the usual protective measures
taken when working and in particular -

CAUTION: This signal, displayed with the
word CAUTION, indicates a potentially haz­ardous situation that, if not avoided, may
result in MINOR INJURY.

IMPORTANT: Indicates a special instruction or proce­dure that, if not strictly observed may cause damage to,
or destruction of the machine, the process, or the sur­roundings.

NOTE: The word NOTE indicates additional information
about a subject or procedure for more efficient or con­venient operation or repair.

2

2.11 - DECALS

WARNING: DO NOT remove or obscure DAN­GER, WARNING, CAUTION or Instruction
Decals.

Replace any Danger, Warning, Caution or Instruction De­cals that are not readable or are missing. Replacement de­cals are available from your Dealer in the event of loss or
damage. The actual location of these Safety Signs is illus­trated at the end of this chapter.

If a used tractor has been purchased, refer to the illustra­tions at the end of this book to ensure that all the safety
signs are in the correct position and are readable.

REMEMBER THAT SAFETY DEPENDS ON YOU. YOU
CAN PREVENT SERIOUS INJURY OR DEATH.

2.10 - DANGER, WARNING AND CAUTION

Whenever you see the words and symbols shown below,
used in this book and on decals, you MUST apply their in­structions as they relate to personal safety.

DANGER: This signal, displayed with the
word DANGER, indicates an imminently haz­ardous situation that, if not avoided, may
result in DEATH OR VERY SERIOUS INJURY.

WARNING: This signal, displayed with the
word WARNING, indicates a potentially haz­ardous situation that, if not avoided, may
result in DEATH OR SERIOUS INJURY.

Challenger MT500B EU

2.7

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.12 - SAFETY PROCEDURE TO FOLLOW

2.12.1 - For proper operation

For proper operation of an agricultural tractor, you must be
a qualified and approved operator. To be qualified you must
understand the written instructions supplied in this manual,
have training, and know the safety rules and regulations for
the job.
Some regulations specify that no one under the age of 16
years, for example, may operate power machinery. This in­cludes tractors. It is your responsibility to know what these
regulations are, and respect them, in the operating area or
situation.
These will include, but are not limited to, the following in­structions for safe tractor operation.

WARNING: The operator must not drink alco­hol or take any medication that may affect his
concentration or coordination. If taking medi-

cation, whether prescribed or not, the opera­tor must seek medical advice as regards his ability to
safely operate machinery.

2.12.2 - Observe the following instructions

• DO NOT ALLOW children or unqualified persons to

operate your tractor. Keep others away from the work­ing area.

• Always wear your seat belt securely fastened.

• Where possible, avoid operating the tractor near

ditches, embankments and holes. Reduce speed when
turning, crossing slopes, and on rough, slippery, or
muddy surfaces.

• Stay off slopes too steep for safe operation.

• Watch where you are going, especially at row ends, on

roads, and around trees.

• Passenger seat is only intended for short periods of use

• Do not allow children in the passenger seat.

• DO NOT PERMIT others to ride on the tractor or the

implement unless an approved passenger seat is fitted.

• Only hitch attachments and implements to the drawbar

and hitch points recommended, and never above the
centre line of the rear axle.

• Operate the tractor smoothly - no jerky turns, starts or

stops. When the tractor is stopped, apply the parking
brake securely. Lower the implement and remove the
ignition key.

• DO NOT MODIFY OR REMOVE any part of the equip-

ment and DO NOT USE attachments unless they are
properly matched to your tractor.

2.13 - PROTECTION

2.13.1 - Cab

The ROPS (Roll Over Protective Structure) cab has been
designed for this tractor series and meets all the safety and
sound legal requirements.
The ROPS cab conforms to the various international safety
standards. The ROPS cab must NEVER be drilled or modi­fied to install attachments or implements. Welding on cab
components IS NOT PERMITTED. DO NOT attach chains
or ropes to the main frame of the cab for pulling purposes.
If additional controls or displays are to be added to the op­erator’s area contact your dealer for information.
The ROPS cab together with the seat belt is effective in re­ducing injuries during overturn accidents. Wearing the seat
belt is an important part of this protection.

• Always wear your seat belt adjusted snugly.

• Check the seat belt for damage. A damaged seat belt
must be replaced (Fig. 1).

1

MT-0011103

2.13.2 - Damage to the ROPS cab

If the ROPS cab has been damaged as a result of tractor
rollover or incident, it must be replaced, NOT repaired.

DO NOT use the tractor with a damaged ROPS cab.

Fig. 1

2.14 - PREPARING FOR SAFE OPERATION

2.14.1 - Know your equipment

It is important to know the tractor and operation of all its ac­cessories, implements and additional equipment. It is also
important to know how to use all the controls, gauges and
dials, as well as the rated load capacity, speed range, brak­ing and steering characteristics, turning radius, and operat­ing clearances.

Remember that rain, snow, ice, loose gravel, soft ground,
etc. can change the performance of your tractor.

Under poor conditions, slow down and be extra careful,
and engage four-wheel drive if fitted.

2.8

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

Study the DANGER, WARNING and CAUTION safety
symbols on your tractor and the information signs also.

READ THIS OPERATOR INSTRUCTION BOOK CARE­FULLY BEFORE STARTING THE ENGINE.
STUDY IT BEFORE YOU START WORK (Fig. 2).

Z2-530-05-03

Fig. 2

DO NOT wear loose clothing, jewellery or other items and
tie up long hair which could catch on controls or other parts
of the equipment.

Z2-531-05-03

Learn where fire extinguishers and first-aid or emergency
equipment is kept and where to get help in a hurry. Make
sure you know how to use this equipment (Fig. 4).

Fig. 3

2

IF THERE IS SOMETHING IN THE BOOK YOU DON’T UN­DERSTAND, ASK SOMEONE (for example your equipment
dealer) TO EXPLAIN IT TO YOU.
This book covers general safety practice for agricultural
tractors. It must always be kept with the tractor. For extra
copies contact your Dealer.

2.14.2 - Protect yourself

Wear all protective clothing and equipment provided or
which is appropriate for certain working conditions. Do not
take any risks (Fig. 3).

For example, you may need:

• A safety helmet.

• Goggles, or a face shield.

• Hearing protection.

• Respirator or filter mask.

• Inclement weather clothing.

• Reflective clothing.

• Heavy gloves (neoprene for chemicals, leather for rough
work).

• Safety shoes.

Fig. 4

2.14.3 - Use all available protective and safety devices

Ensure that all protective devices, guards and safety sig­nals are fitted as required and are in a good condition.

To help keep you and others around you safe, your tractor
should be equipped with:

• ROPS cab and safety belt

• PTO guard

• Back rear-view mirror

• SMV warning triangle

• Additional lights and decals
Depending on the work to be carried out, the following ac-

cessories may also be required:

Challenger MT500B EU

2.9

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

• Fire extinguisher

• Backup alarm

• Any other suitable protective devices

Make sure all required equipment is in place and in good
working order. DO NOT remove or disconnect any safety
devices.

2.14.4 - Equipment check

Before you begin your working day, take time to check your
tractor and ensure that all systems are in good operating
condition.

• DO NOT SMOKE while refuelling the tractor. Keep any
type of naked flame away (Fig. 5).

• Stop the engine and wait for it to cool before refuelling.

WARNING: Diesel fuel or hydraulic fluid under
pressure can penetrate the skin or eyes and
cause serious personal injury, blindness or
death.

Fluid leaks, under pressure, may not be visible. Use a
piece of cardboard or wood to detect leaks. DO NOT
USE YOUR BARE HANDS. Wear safety goggles for eye
protection. If any fluid is injected into the skin, it MUST
be surgically removed within a few hours by a doctor
familiar with this type of injury (Fig. 6).

Z2-532-05-03

• Check for loose, broken, missing, or damaged parts.
Have everything put into good repair. Make certain all
safety devices are in place.

• Check the seat belt for damage. A damaged seat belt
must be replaced.

• Check that all implements and equipment are correctly
fitted and that the tractor and implement PTO ratios
(rpm) are respected.

• Check the condition and pressure of tyres (absence of
cuts and bulges). Replace worn or damaged tyres.
Check the hand and foot brake operation. Adjust if nec­essary.

• Check the oil level. Add some oil if necessary.

• Perform all servicing procedures outlined in the Mainte­nance and Adjustments chapter in this book.

• Check that the PTO shaft locking devices are latched.

• Check that the tractor PTO shield and shaft guards are in
place and operating properly.

• Check the tractor and implement hydraulic system.
Have any leaks or damaged parts repaired or replaced.

Fig. 5

D-58 42A

Before applying pressure to the fuel or hydraulic system,
be sure all connections are tight and that lines, pipes, and
hoses are not damaged. Before disconnecting fuel or hy­draulic lines, be sure to relieve all pressure.
Make sure that all hydraulic lines are correctly installed and
not crossed.

WARNING: Liquid cooling systems build up
pressure as the engine gets hot. Before
removing the radiator cap, stop the engine
and let the system cool.

• Check the engine cooling system and add coolant as
required.

2.14.5 - Clean the tractor

• Keep work surfaces and engine compartments clean.

• Before cleaning the machine, always lower implements
to the ground, place transmission in neutral, engage the
parking brake, stop the engine and remove the ignition
key.

• Clean footsteps, pedals and floor. Remove grease or oil.
Brush away dust or mud. In winter, scrape away snow
and ice. Remember - slippery surfaces are hazardous.

• Remove or put away implements, buckets, chains and
hooks.

Fig. 6

2.10

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.14.6 - Protect the environment

• It is illegal to pollute drains, water courses or soil. Use
authorized waste disposal facilities, including civic
amenity sites and garages providing facilities for dis­posal of used oil. If in doubt, contact your local authority
for advice.

2.15 - SERVICING THE TRACTOR

• DO NOT SERVICE the tractor while the engine is run­ning or hot, or if the tractor is in motion (Fig. 7).

2.16 - STARTING

2.16.1 - Warn personnel before starting

Before starting, walk completely around the tractor and any
attached equipment. Make sure that no one is under it, on
it, or close to it. Tell other workers or people nearby that the
tractor is about to start. Do not start the tractor while there
are people near the tractor, tools or trailed implements.
Ensure that all bystanders, particularly children, are a suita­ble distance away before starting the engine.

2.16.2 - Get on and off the tractor safely

Always use "three point contact" with the machine, and
face the machine when you get on it. (Three point contact
means both hands and one foot or one hand and both feet
are in contact with the machine at all times when getting
on and off).

Clean your shoes and wipe your hands before getting on.
Use handrails, grab handles, ladders or footsteps (as pro­vided) when getting on and off.

DO NOT use control levers as a hand hold and never step
on pedals when getting on and off.

DO NOT attempt to get on or off a moving tractor. DO NOT
jump off a tractor other than in an emergency.

2

Z2-534-05-03

Fig. 7

• Before making adjustments to or servicing the electrical
system, disconnect the battery cables, negative (-) cable
first.

• To prevent fires or explosions keep open flame away
from the battery or cold weather starting aids. To pre­vent sparks which could cause explosions use jumper
cables according to instructions.

• When making repairs or adjustments it is recommended
that you consult your Dealer, and have the work carried
out by trained personnel.

• The implement and/or tractor must be supported on
suitable blocks or stands, NOT a hydraulic jack.

• Check all nuts and bolts periodically for tightness, espe­cially wheel hub and rim nuts. Tighten to the prescribed
torque values.

2.16.3 - Safe start-up

WARNING: Before starting the engine make
sure there is plenty of ventilation. DO NOT
operate the engine in a closed building. The
exhaust fumes may cause asphyxiation.

Always start the engine from the driver’s seat with all the
transmission levers and the PTO lever in neutral.

Make sure that the tractor dual brake pedals are locked to­gether at all times unless you are making turns in the field
which require independent use of the brakes. Make sure
the brakes are properly adjusted so that both brakes en­gage at the same time.
Adjust the seat, fasten the seat belt (as specified in the
book), apply the handbrake and put all controls in neutral
before starting up.

DANGER: Start the engine, with the ignition
key, from the driver’s seat only. DO NOT
ATTEMPT to start the engine by shorting

across the starter terminals. The machine will
start in gear if the neutral start circuit is bypassed. This
could cause serious injury or death to anyone in the
vicinity of the tractor (Fig. 8).

Challenger MT500B EU

2.11

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

Z2-535-05-03

Fig. 8

2.16.4 - Follow recommended start-up procedures

Follow the start-up procedures recommended in the Oper­ation chapter of this Operator instruction Book. This chap­ter includes normal starting, cold starting, and the use of
starting fluids.

2.16.5 - Controls test

After starting, check all gauges and lights again. Make sure
everything is functioning correctly. If the tractor does not
respond correctly when each control is operated, DO NOT
USE the machine until the fault is remedied.
Ensure that the starter solenoid cover is always in position.

2.16.6 - Starting fluid

WARNING: It is very important that you read
and follow the starter fluid instructions before
using it. DO NOT use aerosol cans of starter

fluid on tractors with the thermostat con­nected to the electrical system. Ether combined with
thermostat can cause an explosion with damage to
engine, personal injury, or both.

Handle starting fluid correctly. Starting fluid must only be
used in conjunction with an ether-start aid fitted as original
equipment by the manufacturer or installed by a Dealer as
an accessory. In cases of tractors being fitted with glow
plugs or a thermostat, these must be removed prior to the
installation of an ether-start aid (Fig. 9).

If aerosol cans of starting fluid are to be used the thermo­stat must be disconnected. Remove the wire from the
thermostat which will be found on the manifold. Tape the
end of the wire to prevent an electrical short circuit.

WC1952

Fig. 9

2.17 - WORKING SAFELY

WARNING: An unbalanced tractor could over­turn and cause injury or death.

Make sure front frame counterweights, wheel

weights and wheel ballast are used as recom­mended by the manufacturer. DO NOT add extra coun­terweights to compensate for an overloaded tractor; it
is recommended to reduce the load. Keep all parts of
your body inside the cab while operating the tractor.

2.17.1 - Make the right moves

Ensure that the tractor is ready for the work to be carried
out. Make sure you know the tractor nominal load capaci­ties and never exceed them. Be certain that any attach­ments or implements you intend to use DO NOT EXCEED
the load rating of your tractor. Be sure the tractor and im­plement PTO speed match.

Keep in mind that tractors normally operate on uneven, un­paved, and often bumpy or sloping surfaces. Operating
conditions can reduce the amount of weight you should
carry or pull.

2.17.2 - Safety instructions to be observed

• Operate the controls smoothly - don’t jerk the steering

wheel or other controls.

• NEVER get on or off a moving tractor. Keep a firm grip

on the steering wheel at all times, with the thumbs clear
of the spokes when driving the tractor.

• Make sure you have adequate clearance in all directions

for the tractor and implement.

• DO NOT play with a tractor or equipment. Use only for

intended purpose.

• DO NOT attempt to work the controls except from the

driver’s seat.

2.12

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

• Before getting off, always disengage the PTO, lower all
attachments and implements to the ground, set the
tractor to neutral, activate the Park Lock, stop the
engine and remove the ignition key.

NOTE: DO NOT TOUCH, lean on, or reach through any
implement mechanism or permit others to do so.

Stay alert! If a part breaks, loosens or does not operate
correctly, stop work, switch off the engine, check the ma­chine and carry out any necessary adjustments or repairs
before resuming work.

2.17.3 - Safety of bystanders

Watch out for others. DO NOT allow inexperienced or un­qualified people to operate the tractor. They may cause in­jury to themselves or to others.

WARNING: A tractor is a personal piece of
machinery. Do not allow others to drive the
tractor or to use the implement (Fig. 10). DO

NOT ALLOW another person to get on the
implements or any other equipment, including trailers,
except in the case of harvesters specially designed for
this purpose (for the harvest itself and not for transport
purposes). Space should be provided on such equip­ment so that this type of transport can be carried out
in complete safety. DO NOT ALLOW children on the
tractor.

• DO NOT LIFT a load over anyone.

• Keep others away from the working area. DO NOT
ALLOW others to stand beside or walk beneath a raised
implement (Fig. 11).

2

S-1125

Fig. 11

• DO NOT lift objects that do not fit safely into the
bucket. Obtain the correct equipment.

• When using a loader, avoid sudden stops, starts, turns,
or change of direction. Keep loads close to the ground
when transporting.

• DO NOT stand (or allow anyone else to stand) in front
of, under, or behind loaded or loading equipment. DO
NOT DRIVE a tractor up to someone standing in front of
a fixed object.

• Keep others away from universal joints, hitches, draw­bars, lift arms, PTO shafts, cylinders, belts, pulleys, and
other moving parts. Keep all shields and guards in place.

WARNING: DO NOT STAND, or allow anyone
else to stand, between the tractor and imple­ment unless the engine is turned off and the

parking brake is engaged, the transmission
control lever is in neutral, and all attachments or imple­ments are lowered to the ground.

Z2-536-05-03

Fig. 10

• Be certain you can control both speed and steering
before moving. Move slowly until you are sure that
everything is operating properly. After starting, recheck
the steering, right and left. Be certain you have full
steering and brake control. If differential is locked, DO
NOT operate at high speed or turn the tractor until the
differential lock is disengaged.

Challenger MT500B EU

2.17.4 - Risk of overturning

In the event of an overturn with a tractor fitted with a cab,
hold the steering wheel firmly and do not attempt to leave
the seat until the tractor has come to a standstill (Fig. 12).
If the doors of the cab are obstructed, leave through the
rear window or roof hatch.

2.13

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

• When driving down a slope, use the gas control to slow
the tractor engine and choose the same gear ratio as
used when climbing a slope. Shift into gear before you
start downhill.

• Engage four-wheel drive (if fitted), this will give four­wheel braking.

WARNING: DO NOT disengage the clutch or
attempt to shift gear after you have started
downhill.

• The tractor is less likely to turn over if you drive up or
down a steep slope rather than driving across it.

• Avoid steep slopes whenever possible. If this is not pos­sible, avoid holes and dips when driving downhill. Avoid
stumps, stones, bumps and raised areas when driving
uphill. Keep the tractor behind the shear line when

Z2-538-05-03

Fig. 12

Fig. 13: Do not operate near the edge of ditches or banks.
The distance from the edge should always be equal to or
greater than the height of the bank, to prevent it from col­lapsing.

working close to ditches or banks. (Fig. 13). Avoid
ditches, banks and riversides which might give way.

• When you must drive on a steep slope, avoid turning at
the top of the slope. Slow down and turn in a wide turn­ing circle. Drive straight on uphill or downhill slopes, and
never drive across them. Keep the heavier end of the
tractor facing towards the top of the slope when driving
up and down it.

• If a tractor fitted with lateral implements is used on a
steep slope, the implement must always face up the
slope. Do not raise implements. Keep them as low to
the ground as possible when crossing a slope.

• When towing a load at transport speed, lock the draw­bar in the centre position and use a safety chain.

• DO NOT use your tractor to round up farm animals.

S-1031

Fig. 13

2.17.5 - To avoid side overturns

• Set the wheel track at the widest setting suitable for the
work being done.

• Lock the brake pedals together before driving at trans­port speeds.

• Reduce speed to match operating conditions. If the trac­tor is equipped with a front-end loader, carry the bucket
and load as low as possible.

• Make wide slow turns at reduced speed. Don’t let your
tractor bounce. You may lose steering control.

• Don’t pull a load too heavy for your tractor. It could run
down the slope or the tractor could jackknife around a
towed load.

• Don’t brake suddenly. Apply brakes smoothly and gradu­ally.

2.17.6 - To avoid rear overturns

WARNING: Hitching to the rear axle, or any
other point above the swinging drawbar, can
cause a rear overturn.

• DO NOT PULL anything using the top link connection,
or from any point on the rear axle or above. Always use
a manufacturer approved drawbar, and only use a draw­bar pin of the correct size and that can be locked in
place.

• High hitching can cause rear overturn, which may cause
serious injury or death. Hitch loads to the drawbar only.

• Only use a three-point linkage drawbar when stays are
fitted to keep it in the down position.

• Use front counterweights to increase tractor stability
when towing a heavy load or to counterbalance a heavy
rear mounted implement.

• Start forward slowly and gradually increase your speed.
DO NOT reverse or release the clutch. If the tractor is
attached to a heavy load or immovable object, improper
clutching may cause rear overturn.

• If the front end of the tractor starts to lift, reduce your
speed and, if necessary, disengage the clutch.

2.14

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

• If your tractor is bogged down in mud or frozen to the
ground, DO NOT attempt to drive forward. The tractor
can rotate around its rear wheels and overturn. Lift any
attached implement and attempt to BACK OUT. If this
is not possible, tow it out with another vehicle.

• If you get stuck in a ditch, BACK OUT, if possible. If you
must go forward, do so slowly and carefully.

• A bare tractor or tractor with rear mounted attachments
should be backed up the slope in reverse and travel for­ward downhill.

• A tractor with a loaded front-end bucket should be
backed down the slope and travel forward uphill. Keep
the loader bucket as low as possible.

• Always keep the tractor in gear when going downhill.
DO NOT PERMIT the tractor to coast with clutch disen­gaged or transmission in neutral.

DANGER

2

Z2-541-05-03

Fig. 15

2.17.7 - Other risks

• Ensure that the PTO shield (1) is in place when the PTO
driveline is not in use (Fig. 14).

1

Z2-540-05-03

• Before attaching, detaching, cleaning or adjusting PTO
driven implements, disengage the PTO, stop the
engine, remove the ignition key, and make sure that the
PTO transmission shaft has stopped.

• Ensure that all the PTO transmission shaft guards and
shields are in place and check the presence of all safety
decals (Fig. 15).

Fig. 14

• Be sure everyone is clear of your machine before engag­ing the PTO. For stationary PTO operation, always place
transmission control lever in neutral, engage parking
brake, and chock both tractor and implement wheels.

• When operating mobile PTO driven equipment, DO
NOT leave the tractor seat until the PTO drive is disen­gaged, the transmission is in neutral, the parking brake
is engaged, the engine shut off and the ignition key
removed.

• DO NOT use PTO adapters, reducers or extensions as
they extend the PTO coupler and universal joint out
beyond the protection offered by the PTO shield.

• The deployment of drawbars and lift rods must not
allow the threads to show.

DANGER: DO NOT attempt to unplug the
hydraulic connections, or adjust an imple­ment with the engine running or the PTO
drive in operation. To do so may result in seri-

ous injury or death.

• When using chemicals, carefully follow the chemical
manufacturer’s instructions for use, storage and dis­posal. Also follow the chemical application equipment
manufacturer’s instructions.

• When operating under poor visibility conditions, or in the
dark, use your tractor work headlights and reduce your
ground speed (DO NOT use your work headlights when
travelling on a roadway because rear pointed white
lights are illegal except when reversing and may con­fuse following drivers).

• Operate your tractor with tyres of suitable width, con­sistent with the particular task you are performing. To
adjust tyre width, see chapter Maintenance and Adjust­ments.

• Reduce your speed when operating over rough or slip­pery ground and when foliage restricts your view of haz­ards.

• DO NOT make sharp turns at high speed.

Challenger MT500B EU

2.15

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.17.8 - Implements and attachments

WARNING: A front-end loader (bucket or
forks) must be equipped with a suitable hold­ing device to prevent the load (bales, fence

posts, rolls of fence, wire etc.) from rolling
down the lift arms into the driver’s compartment and
crushing the driver when the loader is raised. Inade­quately secured objects could also fall and injure
bystanders.

• Three-point hitch and side mounted implements make a

much larger arc when turning than towed equipment-.
Make certain to maintain sufficient clearance for turning.
Use only manufacturer approved equipment.

• When using attachments or implements with the trac-

tor, be sure to read and understand the instructions in
the Operator Instruction Book for that attachment or
implement and follow its safety instructions. Use only
manufacturer approved attachments and implements.

• DO NOT overload a towed attachment or equipment.

Use proper counterweights to maintain tractor stability.
Hitch loads to the drawbar only.

• A transport chain (1) will help control drawn equipment

should it be accidentally separated from the drawbar
while transporting. Using the appropriate adapter parts,
attach the chain to the tractor’s safety chain anchor or
any other specified anchor point. Provide only enough
slack in the chain to permit turning. Contact your dealer
for a chain of equal or greater strength than the weight
of the trailed implement (Fig. 16).

• Ensure that all trailed implements are fitted with a

safety chain linking the tractor to the implement, if
required by law (Fig. 16).

Z2-543-05-03

2.17.8.1 - Safety measures when towing

• For towed equipment WITHOUT brakes, DO NOT tow
equipment:

- at speeds over 32 kph (20 mph), or

- when, fully loaded, its weight exceeds 1t5 (3,300 lb)

and is 1.5 times heavier than the tractor.

• For towed equipment WITH BRAKES, DO NOT tow
equipment:

- at speeds over 40 kph (25 mph), or

- when, fully loaded, its weight exceeds 4.5 times the

weight of the tractor.

NOTE: The tractor requires correct trailer braking sys­tem installed and connected to the equipment.

Fig. 17

1

Z2-542-05-03

Fig. 16

• Pull only from the approved drawbars. Towing or attach­ing to other locations may cause the tractor to overturn
(Fig. 17).

Stopping distance increases with speed and weight of
towed loads, and on hills and slopes. Towed loads with or
without brakes that are too heavy for the tractor or are
towed too fast can cause loss of control. Consider the total
weight of the equipment and its load.

2.17.9 - Tractor Towing

WARNING: Towing: the following instruc­tions must be followed when towing:

If the engine is not running:

• Maximum towing speed: 10 kph.

• Maximum towing distance: 8 km.

If the engine is running:

• Towing speed is identical to that of a trailer without
brakes at the speed authorised by legislation in force in
the country concerned.

2.16

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.17.10 - Road use

Take the following precautions before using the tractor on
a public road.

• Respect national laws and local regulations in force
relating to tractor use.

• Lock the brake pedals together.

• Place all implements in transport position and lock.

• Place all implements into their narrowest transport con­figuration.

• Disengage the PTO and differential lock.

• Make sure any required clearance flags or hazard warn­ing lights are in place and in working order.

• Clean off all reflectors and road lights, front and rear,
and be certain they are in working order.

• Ensure that the tractor and equipment are fitted with
emergency warning triangles and other markings rec­ommended to improve visibility when driving on roads,
unless otherwise indicated (Fig. 18).

• Beware of blind intersections. Slow down until you have
a clear view.

• DO NOT attempt to pass at any intersection.

• Slow down for turns and curves.

• Make wide, gentle turns.

• Signal your intent to slow, stop or turn.

• Shift to a lower gear before going up or down hills.

• Keep tractor in gear. Do not coast with the clutch disen­gaged or transmission in neutral.

• Stay out of the path of oncoming traffic.

• Drive in your correct lane keeping as near to the curb as
possible.

• If traffic builds up behind you, pull off the road and let it
go by.

• Drive carefully. Anticipate what other drivers might do.

• When towing a load, start braking sooner than normal
and slow down gradually.

• Watch out for overhead obstructions.

• Make sure load does not obscure hazard warning or
transport lights.

2.18 - SAFETY - AFTER OPERATION

Whenever stopping, bring the tractor to a complete halt,
apply the parking brake, disengage the PTO, place the
PowerShuttle lever in neutral position, lower the imple­ment to the ground, stop the engine and remove the igni­tion key BEFORE leaving the seat.

2

Z2-544-05-03

Fig. 18

2.17.11 - Highway code

When operating your tractor on a public road the following
precautions must be taken.

WARNING: NEVER allow any persons to ride
on the tractor or on the towed equipment.

• Know the road you are going to travel.

• Turn on flashing warning lights when travelling on roads,
day or night, unless prohibited by law.

• Take care when towing a load at transport speeds,
especially if the towed equipment is NOT fitted with
brakes.

• Observe all local or national regulations regarding the
road speed of your tractor.

• Use extreme caution when transporting on snow-cov­ered or slippery roads.

• Wait for traffic to clear before entering a public road.

DANGER: PowerShuttle control: Before leav­ing the seat it is mandatory to move the Pow­erShuttle control to NEUTRAL position.

Remove ignition key if the tractor is to be left
unattended.

IMPORTANT: Electromechanic ParkLock control: Move
lever to locked position (symbol: closed padlock) to
engage ParkLock before stopping the engine.

Challenger MT500B EU

2.17

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

2.19 - DESCRIPTION OF DECALS

High pressure steam and hot water.
Remove cap carefully.

CAUTION

DO NOT REMOVE OR OBSCURE DECAL

3596029 M1

Located on top of the bonnet (access to

radiator cap)

CAUTION

Disconnect the negative cables from
all batteries before starting work on
the tractor.

CAUTION

Before removing a battery, discon­nect the negative cables before the
positive cables.

DO NOT REMOVE OR OBSCURE DECAL

Located on the battery cover

Keep all shields, covers and guards fastened
in place while engine is running.

WARNING

CAUTION

Beware hot parts.

DO NOT REMOVE OR OBSCURE DECAL

Located on the right- and left-hand sides of the bonnet

CAUTION

Always disengage the PTO and stop the
engine before attaching or detaching a
PTO shaft or before working on an im­plement towed by the PTO. Always fit
the PTO guard when the PTO is not in
use.

Do not stand between tractor and equip­ment when operating controls.
Tow only with MF approved tractor draw­bar or hitch.

WARNING

3596045 M1

3596037 M1

Located at the rear of the tractor

4271915M1

Located to the left

and right of the

radiator

CAUTION

TO AVOID POSSIBLE TRAC­TOR OVERTURN, TOW ONLY
FROM THE DRAWBAR OR
LOWER LINKS OF THREE
POINT HITCH.

539613 M1

Located on the

fenders to the rear of

the cab

DO NOT REMOVE OR OBSCURE DECAL

3581564 M1

3782489 M1

Located on the RH

inner column of the

cab

Located on the RH

inner column of the cab

3777021M2

Located on the accumulator

2.18

Challenger MT500B EU

2 . INTRODUCTION - SAFETY INSTRUCTIONS AND WARRANTY

CAUTION

Before working on the tractor or remov­ing this cover, disconnect negative ca­bles to all batteries.

WARNING

Do not short across starter terminals to
start engine.
Only start the tractor when sat in the
seat.
Start engine only with ignition key, ensur­ing that transmission and PTO are in neu­tral with handbrake applied.

DO NOT REMOVE OR OBSCURE DECAL

3596467 M1

Located on the starter motor

Located on the inner side of the right-

hand door

WARNING

If tractor is overturning, hold onto the steer­ing wheel.
Do not leave seat.

DO NOT REMOVE OR OBSCURE DECAL

3580313 M1

Located at the rear of the passenger seat

Do not stop the
engine while the
tractor is running.

3783395M1

Located on the inner side of the right-

hand door

IT IS IMPERATIVE TO USE
THE TRANSMISSION OIL
RECOMMENDED IN THE OP­ERATOR INSTRUCTION
BOOK.

3713698 M1

Located on the fenders

to the rear of the cab

2

Front linkage decals and front PTO decals

WARNING: Read the Operator Instruction Book
before starting work.

DANGER: Keep a safe distance from the rotating
PTO.

DANGER: Avoid being caught by moving parts

DANGER: Keep a safe distance from moving parts.
DANGER:

Challenger MT500B EU

2.19