AGCO Challenger MT845E Workshop Service Manual
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AGCO Challenger MT845E Workshop Service Manual

AGCO Challenger MT845E Workshop Service Manual

Rubber track tractor
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Workshop Service Manual
Rubber Track Tractor
MT845E
MT855E
MT865E
MT875E
North America
June 2019
4205 River Green Parkway, Duluth GA 30096 USA
79036240F
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
NA
© AGCO 2019
English

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  • Page 1 Workshop Service Manual Rubber Track Tractor MT845E MT855E MT865E MT875E North America June 2019 4205 River Green Parkway, Duluth GA 30096 USA 79036240F Challenger is a registered trademark of Caterpillar Inc. and is used under license by AGCO. © AGCO 2019 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 Steering system Drivetrain 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 Index Find manuals at https://best-manuals.com...

  • Page 4: Table Of Contents

    Table of contents 1 General ........... . . 1-3 Safety information 1.1.1 A word to the technician .
  • Page 5 Table of contents 1.9.1 Constant torque hose clamps ......... 1-30 1.9.2 Inch fasteners .

  • 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

    Keep the safety signs clean. If necessary, use a weak soap and water solution. GUID-F9D59F68-8014-4549-B346-3FE8D9739D94 [V2] 1.1.7 Important safety information IMPORTANT: Any Modifications to the machine or systems not authorized by AGCO will void the AGCO Warranty. This includes, but is not limited to hitches. WARNING:...

  • 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

    The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). GUID-DABC7CAA-9A08-4236-A20C-E92972E9FAB3 [V1] 1.1.10 Asbestos information AGCO equipment and replacement parts are asbestos free. AGCO recommends the use of only correct AGCO replacement parts. GUID-8A44CF3B-7FC0-4A49-8BDF-71575A27E588 [V1] 1.1.11 Electrical storm injury prevention When lightning is striking in the vicinity of the machine, the operator should not attempt to dismount or mount the machine.

  • 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 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: Operator Station

    Do not change structure by welding, cutting, adding weight, or drilling holes into structure. Any change not specifically authorized by AGCO invalidates AGCO certification for ROPS. The protection offered by ROPS will be impaired if ROPS has structural damage or alteration. Damage to structure can be caused by a turn over or by falling objects.

  • 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: 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-F11D3757-D4E3-4261-8A68-F7D2AB99D696 [V3] 1.2 Machine identification information For reference, record identification numbers in spaces provided in the table below. TREJA0110030501 GUID-44314E1D-D19D-4AD1-89C6-9179CE11A950-high.eps [High] Fig. 17 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...

  • Page 20: Serial Number Definition

    NOTE: For serial number breaks in this manual, only the information from the model year code and following will be given. World Manufacturers Code definitions Code Definition AGCO Corporation AGCO Int'l GmbH Brand Code definitions Code Definition Challenger Model Rubber Track Tractor...
  • Page 21 1. General Model numbers 0846 0845 0851 0945 0738 0855 0861 0955 0740 0865 0856 0965 0743 0875 0866 0975 Model Year Code definition Code Definition Code Definition 2018 2025 2019 2026 2020 2027 2021 2028 2022 2029 2023 2030 2024 2031 Location Built Code definitions...

  • Page 22: 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 23: Lubricant Viscosities And Refill Capacities

    GUID-5A14E848-9A6C-4329-A89F-47C84D125846 [V4] 1.5.3 Refill capacities AGCO Genuine lubricants are the recommended products for this machine. The use of other lubricants may not provide the same level of necessary performance. IMPORTANT: Capacities listed are approximate. Check the fluid levels after filling.
  • Page 24 Common sump / AGCO® Permatran® 821XL Implement Hydraulic differential and Final drive transmission Front idler hub AGCO® Synthetic Final Drive and 0.49 liter (0.13 gal) Axle Oil SAE 50 Midwheel hub AGCO® Synthetic Final Drive and 0.25 liter (0.07gal) Axle Oil SAE 50 Drive wheel hub AGCO®...

  • Page 25: 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 26 1. General Every 10 Every 50 Every 250 Every 400 Every Other Service Item hour or hour hour hour 1000 hour daily Every Replace the hydraulic / power 1500 train oil and filters hours Get a sample of the engine oil for analysis Clean or replace the hydraulic system breather...

  • Page 27: Maintenance Chart

    1. General GUID-9B6C2C63-CEC5-4BA8-A507-2F53810BB387 [V8] 1.6.2 Maintenance chart Maintenance work Service interval / running hours 4500 Check the engine oil level Check the coolant level Check for oil, fuel or coolant leakages Clean the cooling system (from outside) Check the condition of the belt Change the engine oil and the oil filter Change the fuel filters Do a check for a possible engine software update...

  • Page 28: Maintenance Access

    1. General 1.7 Maintenance access GUID-463B5CEE-5B5C-4A35-8578-7BA87EB850A6 [V5] 1.7.1 Remove the guards IMPORTANT: To remove the side and bottom guards, move the machine to a smooth horizontal location. Lower all implements to the ground and lower the 3-point linkage to the ground. Make sure that the transmission control lever is in the park position.

  • Page 29: Install The Guards

    1. General GUID-B797DEF7-2CB0-4E59-B6B1-3346DE3B7321 [V1] 1.7.2 Install the guards IMPORTANT: To install the side and bottom guards, move the machine to a smooth horizontal location. Lower all implements to the ground and lower the 3-point linkage to the ground. Make sure that the transmission control lever is in the park position.

  • Page 30: Install The Engine Fan Guards

    1. General To remove the bolts attaching the left-hand side engine screen, (1) turn the bolts counterclockwise. GUID-8F21148C-222C-4176-9FEA-FCD1E3B738E8-high.jpg [High] Fig. 25 To remove the bolts attaching the right-hand side engine screen, (1) turn the bolts counterclockwise. TREJA0110033701 GUID-04BA3FC5-AE22-48C7-8063-8A7E16C3D4FD-high.eps [High] Fig. 26 GUID-DDBC6767-F32B-4E92-9BD7-7A81EFEC1DFB [V1] 1.7.4 Install the engine fan guards NOTE: When the words right and left are used, it is to refer to the direction the operator points.
  • Page 31 1. General To install the bolts to attach the right side engine screen, (1) turn the bolts clockwise. TREJA0110033701 GUID-04BA3FC5-AE22-48C7-8063-8A7E16C3D4FD-high.eps [High] Fig. 28 1-28 Rubber Track Tractor 79036240F...

  • Page 32: Engine Specifications

    1. General GUID-A4078C5E-9CE3-45E2-855F-F04B048159A1 [V2] 1.8 Engine specifications MT845E MT855E MT865E MT875E AP168-4, aftertreatment system, wastegate turbo, air to air intercooled, 12 cylinders, twin series turbo chargers 336 kW (450 hp) 365 kW (490 hp) 403 kW (540 hp) 440 kW (590 hp) standard maximum power 362kW (486 hp) 394 kW (529hp)

  • Page 33: Torque Specifications

    1. General GUID-0BAF2E7B-A615-4A36-871A-E23E5E1880B6 [V1] 1.9 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 34 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 35 1. General GUID-03108AC9-D116-472B-8878-816A93A7CD2D-high.jpg [High] Fig. 31 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 36: 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 37 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. 32 1-34 Rubber Track Tractor 79036240F...

  • Page 38: Dimensions

    1. General GUID-83A07056-4665-4CD7-B4E6-E049061B23CE [V1] 1.10 Dimensions GUID-A0D93FE4-AFD0-4647-B7D5-FCE075458E12-high.jpg [High] Fig. 33 General dimensions for a standard gauge machine with 63.5 cm (25 in) belts and 1930 gauge spacing 460 mm (18.11 in) 500.0 mm (19.68 in) 535.0 mm (21 in) 68.5 mm (2.70 in) 583.0 mm (23 in) 1253.0 mm (49 in) 1290.0 mm (51 in)
  • Page 39 1. General GUID-9432B7A8-1C64-44D7-8BEF-9CA6C2371F98 [V2] 1.10.1 Dimensions GUID-B37B7716-B8D9-43C6-AD5F-2A88A7CD0787-high.jpg [High] Fig. 34 Rear view dimensions 3325.0 mm (130.9 in) 2985.0 mm (118 in) 2210.0 mm (87 in) 3579.0 mm (141 in) 1376.0 mm (54 in) 1-36 Rubber Track Tractor 79036240F...

  • Page 40: Shipping Weights

    1. General GUID-1AEF2D58-E2BD-4FFD-B3E3-6B6557F151F0 [V2] 1.11 Shipping weights Standard gauge weight Shipping Operating Standard 19 321 kg (42 596 lb) 19 673 kg (43 371 lb) With front counter weight bracket 19 826 kg (43 708 lb) 20 177 kg (44 483 lb) With (20) front counterweights 20 746 kg (45 738 lb) 21 097 kg (46 512 lb)

  • Page 41: Machine Specifications

    1. General GUID-4CE3F144-7BA0-4418-ABD3-B3D73A001857 [V5] 1.12 Machine specifications 16 forward gears, four reverse gears, Transmission Three methods of shifting Electronically controlled direct drive power shift transmission Four batteries - 12 volt maintenance free - Electrical system 1000 cold starting amperes each Type - 12 volt Alternator - 150 Amps each (quantity two) Standard lighting package: Four headlamps...
  • Page 42 1. General Two mounting locations let the chemical tanks be mounted to the outside of the undercarriage. See your dealer for more information about mounting the chemical tanks. Closed center Hydraulic System Load sensing Pressure and flow compensating pump Two pump options: 219.6 l/min (58 gal/min Variable displacement axial piston pumps for the (US)) and 321.8 l/min (85 gal/min (US)) implement hydraulic system...

  • Page 43: Debris Deflectors

    1. General Drawbar can be permitted to swing or drawbar can be secured. An optional controlled drawbar can be used on a wide swinging drawbar. Drawbar is controlled by two hydraulic cylinders, located under the differential case. Machines not equipped with a 3-point linkage can be equipped with a wide swinging drawbar. GUID-D62705AD-7FFB-42D9-9119-7DBFBB6DE917 [V1] 1.12.1 Debris deflectors NOTE:...
  • Page 44 1. General • Wide setting (3) • 2590.8 mm (102 in) and greater gauge setting. • Compatible with all midwheels at the wide setting as long as the part, plate-wear, plastic is shifted down. • Suggested use: All track widths with wide midwheels and within gauge requirements.
  • Page 45 1. General 1-42 Rubber Track Tractor 79036240F...
  • Page 46 Table of contents 2 Engine, fuel, and exhaust system Engine maintenance ........... . 2-7 2.1.1 Replace the engine air filter .
  • Page 47 Table of contents 2.5.6 Install the secondary fuel filter ........2-187 2.5.7 Remove the fuel filter water separator on machines not equipped with DEF .
  • Page 48 Table of contents 2.11.11.2 Interstage charge air cooling ....... . 2-285 2.11.11.3 Throttle valve .
  • Page 49 Table of contents 2.17 .3 Do a check for the cylinder block ........2-344 2.17 .4 Replace the camshaft bushing .
  • Page 50 Table of contents 2.26.1 Do a check for the oil pressure regulating valve ......2-388 2.26.2 Removing the oil pump .
  • Page 51 Table of contents 2.29.9.4 Fitting the pressure control valve ......2-427 2.29.9.5 Removing the pressure sensor .

  • Page 52: Engine, Fuel, And Exhaust System

    2. Engine, fuel, and exhaust system 2.1 Engine maintenance GUID-7795FF0C-9FCB-4870-A683-9CED2BF62BCB [V5] 2.1.1 Replace 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 53 Dispose all fluids in accordance with local regulations and mandates. NOTE: Replace the fuel filter elements at 800 hour intervals or if shown by fault code. IMPORTANT: The engine warranty is applicable only when original AGCO Power Diesel fuel filter elements are used. Procedure Clean the fuel filters and adjacent area.

  • Page 54: Engine System Components

    2. Engine, fuel, and exhaust system 2.2 Engine system components GUID-2A5AAF14-45E8-48D9-977A-C88E11A30615 [V3] 2.2.1 Remove the fan drive belt 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 park brake, and take the key with you.

  • Page 55: Install The Fan Drive Belt

    2. Engine, fuel, and exhaust system Remove the hardware (1, 3) and the right- hand fan guard (2). GUID-7C8D3652-2BB3-4785-9094-AD87E56C7300-high.jpg [High] Fig. 8 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 56 2. Engine, fuel, and exhaust system WARNING: Equipment or parts under spring tension can cause bodily injury. Use caution in releasing belt tension. Put the fan drive belt into position. Install the correct breaker bar into the square drive (1) of the fan drive belt tensioner (2). Push clockwise and install the fan drive belt (3) to the pulleys.

  • Page 57: Remove The Accessories Belt

    2. Engine, fuel, and exhaust system Install the battery disconnect switch key (1). GUID-413DAA31-908C-454D-B08A-596FDBD23FC4-high.jpg [High] Fig. 14 Turn the battery disconnect switch key (1) clockwise to connect the battery power. NOTE: The battery disconnect switch is shown in the on position. GUID-2392B41A-0E5B-4F1E-AAED-7F378E68F1CF-high.jpg [High] Fig.
  • Page 58 2. Engine, fuel, and exhaust system Remove the battery disconnect switch key (1). GUID-413DAA31-908C-454D-B08A-596FDBD23FC4-high.jpg [High] Fig. 17 CAUTION: Safely prop open the engine cover. Closing engine cover creates a pinch point that can cause serious bodily injury. Release both side latches (1) and open the engine cover (2) all the way.

  • Page 59: Installing The Accessories Belt

    2. Engine, fuel, and exhaust system release the accessories belt tensioner to the neutral position. Remove the breaker bar. GUID-620FBB66-AF7F-4312-B894-2C74231E3673 [V2] 2.2.4 Installing the accessories belt Procedure WARNING: Equipment or parts under spring tension can cause bodily injury. Use caution in releasing belt tension.

  • Page 60: Remove The Alternators

    2. Engine, fuel, and exhaust system Install the battery disconnect switch key (1). GUID-413DAA31-908C-454D-B08A-596FDBD23FC4-high.jpg [High] Fig. 24 Turn the battery disconnect switch key (1) clockwise to connect the battery power. NOTE: The battery disconnect switch is shown in the on position. GUID-2392B41A-0E5B-4F1E-AAED-7F378E68F1CF-high.jpg [High] Fig.
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