Challenger MT945E Workshop Service Manual
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Challenger MT945E Workshop Service Manual

Articulated tractor
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Workshop Service Manual
Articulated Tractor
MT945E
MT955E
MT965E
MT975E
North America
March 2017
4205 River Green Parkway, Duluth GA 30096 USA
79036231D
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
NA
© AGCO 2017
English

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Summary of Contents for Challenger MT945E

  • Page 1 Workshop Service Manual Articulated Tractor MT945E MT955E MT965E MT975E North America March 2017 4205 River Green Parkway, Duluth GA 30096 USA 79036231D Challenger is a registered trademark of Caterpillar Inc. and is used under license by AGCO. © AGCO 2017 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 Axles Frame and suspension Steering system Drive train system Brake system Compressed air system Hydraulic system Electrical system Air conditioning and heating system Chassis Wheels 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 information 1.1.1 A word to the technician .
  • Page 5 Table of contents Articulated Tractor 79036231D Find manuals at https://best-manuals.com...

  • Page 6: Safety Information

    1. General 1.1 Safety information 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 [V4] 1.1.6 Safety signs WARNING: Do not remove the safety signs. Replace safety signs that can not be read, are damaged, or are missing. Clean the machine surface with a weak soap and water solution before replacing the safety signs.

  • 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 Starting The Engine

    1. General GUID-344A454E-7D26-49D5-9AB4-3FEEFA88AFD5 [V2] 1.1.13 Before starting 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: Parking

    1. General Only operate the machine while in the operator's seat. Securely fasten the seat belt while operating the machine. Only operate the controls while the engine is operating. 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.

  • Page 13: Cut And Crushing 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 [V3] 1.1.19 Cut and crushing 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: Serial Number Definition

    1. General GUID-AD7B2D47-0705-443F-A0EE-32DA7EDAF677 [V6] 1.2 Serial number definition GUID-6A49518D-AF69-449D-9237-C047CCBF1E02-high.jpg [High] Fig. 18 Definition of the serial number. Beginning Symbol Option Code World Manufacturer Code Option Code Brand Code Machine Sequence Number - sequence Model Identifier (Model Number) number will start over at the beginning of Check Letter each model year.
  • Page 20 1. General Code Definition Ag-Chem Challenger Willmar Massey Ferguson Brand code definitions Code Definition No code 0738 0740 0743 Position 8 option code definition Code Definition No code EAME ag (MT700) EAME scraper (MT700) ROW ag (MT700) ROW ag wide (MT700)

  • Page 21: Proper Disposal Of Waste

    1. General GUID-D27C9EFF-D3E3-4F5E-93ED-A6E5560C23DF [V3] 1.3 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 22: Lubricant Viscosities And Refill Capacities

    1. General 1.4 Lubricant viscosities and refill capacities GUID-E8D816FA-6438-4587-B33A-299C7258D0EB [V1] 1.4.1 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 23: Service Intervals

    1. General GUID-1F5EE02F-A8A6-44BB-B444-52254EC6FDDF [V2] 1.5 Service intervals IMPORTANT: Always stop the engine and take the key with you 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 24: Maintenance Schedule

    1. General GUID-DB9F97E3-2BE1-4B29-BF5E-7C33227F8B78 [V6] 1.5.2 Maintenance schedule Initial checks: Make sure that all hose clamps on the engine are tight at 10 hours and again at 50 hours. If it is necessary, tighten and torque the hose clamps . Do the checks again when a hose is replaced. Every 10 Every Every...
  • Page 25 1. General Every 10 Every Every Every 50 Every 400 hours or 1000 Other Service Item hours hours daily hours hours Examine the ROPS Examine the seat belt .1200 hours or annually, that which occurs first. Replace the DEF / AdBlue pump - main filter 1200 hours or annually, that which occurs first.

  • Page 26: Engine Specifications - Mt900E

    111 mm x 145 mm (4.37 in x 5.71 displacement 1025 cu in (16.8 L) 1025 cu in (16.8 L) 1025 cu in (16.8 L) MT945E MT955E MT965E MT975E AP168, wastegate turbo, air to air intercooled, 12 cylinders, twin series turbo chargers...
  • Page 27 1. General MT945E MT955E MT965E MT975E 2200 rpm in gears 1-15 2200 rpm in gears 1-15 2200 rpm in gears 1-15 2200 rpm in gears 1-15 forward, neutral, reverse, forward, neutral, reverse, forward, neutral, reverse, forward, neutral, reverse, park; 2300 rpm in 16th park;...

  • Page 28: Torque Specifications

    1. General GUID-0BAF2E7B-A615-4A36-871A-E23E5E1880B6 [V1] 1.7 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 29 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 30 1. General GUID-03108AC9-D116-472B-8878-816A93A7CD2D-high.jpg [High] Fig. 21 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 31: 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...
  • Page 32 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. 22 Articulated Tractor 1-29 79036231D...

  • Page 33: Machine Specifications

    1. General 1.8 Machine specifications GUID-26C8EFB1-D9FA-4D1B-B865-5ED51498CE21 [V4] 1.8.1 Machine specifications MT900E Machine specifications MT900E Transmission is a direct drive full power shift. Transmission Transmission has the following standard features: • 16 forward gears • Four reverse gears • Seven rotating countershaft clutches, two stationary planetary clutches •...
  • Page 34 1. General Machine specifications MT900E Hydraulic System Implement hydraulic system has the following characteristics: • Closed center • Load sensing • Pressure and flow compensating pump Hydraulic pump for implement hydraulic system • Type - variable displacement axial piston pump •...

  • Page 35: Shipping Weights Mt900E

    1. General Machine specifications MT900E Rear axle: 9C, permanently lubricated U-joint, and greasable support bearing Articulation: 9C, permanently lubricated U-joint, and greasable slip joint Engine block heater Warms engine coolant to make cold weather starts easier, 120 volt or 240 volt Drawbar capacity The vertical weight capacity of the drawbar is dependent on the category.
  • Page 36 1. General Weight chart With front counter 20 400 44 890 weight GP 32 weights With full front and 21 300 46 890 four factory installed weights on rear axle Standard with four 19 300 42 530 factory installed rear weights Shipping weight includes at least 300 L (79.2 gal) fuel - No hubs for duals.
  • Page 37 1. General 1-34 Articulated Tractor 79036231D...
  • Page 38 Table of contents 2. Engine, fuel, and exhaust system 2.1 Engine maintenance ........... . 2-5 2.1.1 Replacing the engine air filter .
  • Page 39 Table of contents 2.5.6 Installing the secondary fuel filter ........2-177 2.5.7 Removing the fuel / water separator .
  • Page 40 Table of contents 2.11.13.1 SCR system components and their functions ..... . . 2-235 2.11.14 Engine control system ..........2-236 2.11.14.1 Engine wiring .
  • Page 41 Table of contents 2.22.6 Fitting the low pressure turbochargers with the mounting bracket ....2-268 2.22.7 Removing the turbocharger ......... . . 2-269 2.22.8 Checking the turbocharger .

  • Page 42: Engine, Fuel, And Exhaust System

    2. Engine, fuel, and exhaust system 2.1 Engine maintenance GUID-7795FF0C-9FCB-4870-A683-9CED2BF62BCB [V3] 2.1.1 Replacing the engine air filter WARNING: Chemical remains can be present in dirt on the filter elements. Do not breathe the dust. Wear the gloves and the respiratory protection while servicing the filter elements. IMPORTANT: The filter no longer has a warranty, once the filter is cleaned.
  • Page 43 2. Engine, fuel, and exhaust system IMPORTANT: Care must be taken to be sure that the fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluid. Dispose all fluids in accordance with local regulations and mandates.

  • Page 44: Engine System Components

    2. Engine, fuel, and exhaust system 2.2 Engine system components GUID-B3744325-7883-4A60-8D72-77A3140245CE [V1] 2.2.1 Removing the main serpentine belt Procedure WARNING: Hot components can burn. Severe personal injury can result. Let the engine and the components cool before doing maintenance. Park the machine on a solid level surface. Stop the engine, apply the park brake, and take the key with you.

  • Page 45: Installing The Main Serpentine Belt

    2. Engine, fuel, and exhaust system WARNING: Equipment or parts under spring tension can cause bodily injury. Use caution in releasing belt tension. Install a 3/4 inch drive breaker bar into the square drive (1) of the main serpentine belt tensioner (2).

  • Page 46: Removing The Accessories Belt

    2. Engine, fuel, and exhaust system Fasten the right-hand side engine screen to the machine with hardware (1). TREJA0110126101 GUID-7B7D1E65-5A69-4C84-B22B-035A5C9DCAFF-high.eps [High] Fig. 11 Close the engine cover. Fasten the latch (1) to the keeper on both sides of the frame. IMPORTANT: Make sure to fasten the latches on both sides of the engine cover.
  • Page 47 2. Engine, fuel, and exhaust system Turn the battery disconnect switch key (1) counterclockwise to disconnect the battery power. NOTE: The battery disconnect switch is shown in the off position. GUID-57C975DA-BFD1-4013-AE90-52262183416A-high.jpg [High] Fig. 14 Remove the battery disconnect switch key (1).

  • Page 48: Installing The Accessories Belt

    2. Engine, fuel, and exhaust system Remove the hardware (1) and the left-hand fan guard (2). GUID-3978DDBE-5060-43F8-861E-BFF8A5CE3C04-high.jpg [High] Fig. 17 WARNING: Equipment or parts under spring tension can cause bodily injury. Use caution in releasing belt tension. NOTE: The fan drive belt must first be removed to replace the accessories belt.
  • Page 49 2. Engine, fuel, and exhaust system Install the left-hand fan guard (2) with the hardware (1). GUID-3978DDBE-5060-43F8-861E-BFF8A5CE3C04-high.jpg [High] Fig. 20 Close the engine cover (2) all the way and connect both side latches (1). GUID-47B58FBC-4263-4ED9-9E37-CCA29DE10FF0-high.jpg [High] Fig. 21 Install the battery disconnect switch key (1). GUID-413DAA31-908C-454D-B08A-596FDBD23FC4-high.jpg [High] Fig.

  • Page 50: Removing The Alternators

    2. Engine, fuel, and exhaust system GUID-245DEBF2-E7D2-4505-A45B-6158943E14B5 [V1] 2.2.5 Removing the alternators WARNING: Hot components can burn. Severe personal injury can result. Let the engine and components cool before doing maintenance. Procedure Park the machine on a solid level surface. Stop the engine, apply the parking brake, and take the key with you.
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