Challenger MT900 Series Service Manual Download

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Workshop Service Manual

MT900 Series Articulated Tractor

North America
4205 River Green Parkway, Duluth GA 30096 USA
Challenger is a registered trademark of Caterpillar
Inc. and is used under license by AGCO.
© AGCO 2015

February 2015

79036231B

551006D1

English

Summary of Contents for MT900 Series

Page 1: ...Series Articulated Tractor North America 4205 River Green Parkway Duluth GA 30096 USA Challenger is a registered trademark of Caterpillar Inc and is used under license by AGCO AGCO 2015 February 2015...

Page 2: ...o 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 canc...

Page 3: ...train system 6 Brake system 7 Compressed air system 8 Hydraulic system 9 Electrical system 10 Cab 11 Air conditioning and heating system 12 Chassis 13 Wheels 14 Implement drive system 15 Implement lif...

Page 4: ...1 11 1 1 24 High pressure lines 1 11 1 1 25 Fluid penetration 1 12 1 1 26 Batteries 1 12 1 1 27 Exhaust fumes 1 13 1 1 28 Noise prevention 1 14 1 1 29 Fire and explosion prevention 1 14 1 1 30 Fire e...

Page 5: ...Table of contents 1 2 MT900 Series Articulated Tractor 79036231B Find manuals at http best manuals com search s CHAL 79036231...

Page 6: ...n also suggests possible ways to deal with these situations The safety section does not replace safety practices in other parts of this service manual Practice good safety to help prevent injury or de...

Page 7: ...he safety alert symbol means Attention Become Alert Your Safety Is Involved Look for the safety alert symbol both in this manual and on safety signs on this machine The safety alert symbol will direct...

Page 8: ...t limited to physical dimensions type strength and material Failure to heed this warning can get untimely failures product damage personal injury or death Failure to obey basic safety rules and precau...

Page 9: ...part of the machine Know the appropriate work location hand signals and the personnel that are authorized to give the hand signals Get hand signals from one person only Never put maintenance fluids i...

Page 10: ...ng an electrical storm stay in the operator s station If you are on the ground during an electrical storm stay away from the machine 1 1 12 Mounting and dismounting the machine Mount the machine and d...

Page 11: ...nsmission control lever is in neutral and the engine is idling WARNING Do not use ether at any time Use will cause engine damage and or personal injury Do not start the engine until the area is free o...

Page 12: ...tch of trailing equipment to align equipment with drawbar Know the maximum dimensions of the machine When operating on icy or muddy roads reduce the travel speed to prevent losing control of machine A...

Page 13: ...Wear gloves when touching wire cable When hitting a retainer pin the retainer pin can fly out causing personal injury Make sure that there are no people in the area when hitting a retainer pin To pre...

Page 14: ...ove the filler cap slowly to relieve the pressure The cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact skin eyes or mouth Fig 9 1 1 23 Oils Pr...

Page 15: ...kink Outer coverings have embedded armoring The end fittings are displaced IMPORTANT Take care to contain fluids during the performance of the inspection the maintenance the testing the adjusting and...

Page 16: ...n flames or sparks away from the top of the battery Do not smoke in the battery charging areas Incorrect jumper cable connections can cause an explosion causing an injury To prevent an explosion never...

Page 17: ...materials to accumulate on machine Store fuels and lubricants in correctly identified containers away from not approved persons Store rags with oil and any flammable materials in protective containers...

Page 18: ...ed correctly to prevent vibration rubbing and excessive heat during the machine operation Fig 17 1 1 31 Public road transportation Always walk around and visually inspect the machine before moving on...

Page 19: ...10 Machine Sequence Number sequence number will start over at the beginning of each model year The first machine of each model year will start with sequence 1001 11 Ending Symbol NOTE For serial numbe...

Page 20: ...erage container s may mislead someone into drinking from them Do not pour or spill waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping into the air can d...

Page 21: ...ble oil film thickness Consult a dealer if additional information is needed 1 4 2 Lubricant viscosities Compartme nt or system Oil type and classification Oil viscosities Celsius Fahrenheit Engine cra...

Page 22: ...tor drain Window washer reservoir fill Window wipers inspect replace Windows clean Water temperature regulator 1 5 1 Maintenance schedule Initial checks Check all hose clamps on engine at 10 hours and...

Page 23: ...ystem notified by specific service code x Batteries inspect x Air conditioner belt inspect replace x Fan belt inspect replace x Power train system oil sample obtain x Hydraulic implement system oil sa...

Page 24: ...DEF pump main filter Every 1500 hours Clean power train oil suction screen Every 2000 hours Air dryer cartridge replace Change every two years or at 3000 hours Cooling system coolant Replace every tw...

Page 25: ...d at rated power 2100 rpm 2100 rpm 2100 rpm low idle 1000 rpm 1000 rpm 1000 rpm electrical system 12 V 12 V 12 V maximum altitude at full power 2000 m 6560 ft 2000 m 6560 ft 2000 m 6560 ft bore and st...

Page 26: ...full power 2000 m 6560 ft bore and stroke 111 mm x 145 mm 4 37 in x 5 71 in displacement 1025 cu in 16 8 L 1 General MT900 Series Articulated Tractor 1 23 79036231B Find manuals at http best manuals...

Page 27: ...orrectly under the following conditions Screw tip 1 extends 6 35 mm 25 in A beyond housing Belleville springs are collapsed nearly flat after screw 2 is tightened to a torque of 11 Nm 8 1 lbf ft Fig 1...

Page 28: ...s Nm 1 4 6 8 5 16 13 17 3 8 26 35 7 16 33 45 1 2 48 65 5 8 80 110 3 4 125 170 7 8 190 260 1 300 400 1 1 8 390 525 1 1 4 550 750 1 3 8 700 950 1 1 2 880 1200 Four bolt split flange Make sure the sealin...

Page 29: ...rk Tighten both the tube and the hose connections finger tight and wrench 1 4 turn O ring fittings must be tightened as for initial assembly JIC SWIVEL NUTS 37 SEAT The maximum recommended torque valu...

Page 30: ...values for metric fasteners Standard High Low Thread Size Pound Feet lbf ft Newton Meters Nm Pound Feet lbf ft Newton Meters Nm Pound Feet lbf ft Newton Meters Nm M6 x 1 8 to 10 9 to 15 9 to 11 10 to...

Page 31: ...n Meters Nm M6 6 8 M8 13 17 M10 26 35 M12 48 65 M16 80 110 M20 125 170 M24 300 400 M30 550 750 M36 880 1200 Metric bolt and cap screws Fig 22 1 General 1 28 MT900 Series Articulated Tractor 79036231B...

Page 32: ...has hazard lamps and turn signals Three exterior courtesy lamps are mounted in the over hang of cab roof Deluxe lighting package consists of standard lighting package in addition to the following lam...

Page 33: ...egory IVN and category IV implements Lift Capacity for non steerable 3 point linkage All models Category III and IVN 8845 kg 19 500 lb Category IV 8845 kg 19 500 lb Power Take Off Machine is equipped...

Page 34: ...0 lb Category V 500 mm 19 7 in 5670 kg 12 500 lb NOTE Drawbar can be permitted to swing or can be in a fixed position Tire size Rolling circumference mm in 480 80 R46 5832 mm 230 in 520 85 R42 710 70...

Page 35: ...ndard with four factory installed rear weights 19 300 42 530 58 42 Shipping weight includes at least 300 L 79 2 gal fuel No hubs for duals No spacer or dual triple Weight is based on 710 70 R42 tires...

Page 36: ...2 35 2 2 10 Installing the radiator core 2 47 2 2 11 Removing the implement oil cooler 2 56 2 2 12 Installing the implement oil cooler 2 67 2 2 13 Removing the transmission cooler 2 77 2 2 14 Install...

Page 37: ...Table of contents 2 2 MT900 Series Articulated Tractor 79036231B Find manuals at http best manuals com search s CHAL 79036231...

Page 38: ...t if the gaskets are damaged or missing 6 Replace the air filter element with a new element every year IMPORTANT Remove the air filter element only if being replaced Replace the air filter when dirty...

Page 39: ...4 Disconnect prefilter water detector connector 1 5 Turn filter element 2 counterclockwise and remove element from mounting bracket Collect fuel into a applicable container 6 Remove the water detector...

Page 40: ...ct switch key 1 in the off position to close off the battery power Remove the battery disconnect switch key Fig 5 3 CAUTION Safely prop open the engine cover Closing the engine cover creates a pinch p...

Page 41: ...in serpentine belt on all the pulleys except the alternator pulley 4 Correctly seat the belt in the pulley grooves 3 WARNING Equipment or parts under spring tension can cause bodily injury Use caution...

Page 42: ...key 1 Fig 13 7 Turn the battery disconnect switch key 1 clockwise to connect the power 2 2 3 Removing the accessories belt WARNING Hot components can burn Severe personal injury can result Let the eng...

Page 43: ...attery disconnect switch key 1 Fig 15 4 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 t...

Page 44: ...sories belt tensioner to the neutral position Remove the breaker bar Fig 18 2 2 4 Installing the accessories belt Procedure 1 WARNING Equipment or parts under spring tension can cause bodily injury Us...

Page 45: ...se the engine cover 2 all the way and connect both side latches 1 Fig 21 4 Install the battery disconnect switch key 1 Fig 22 2 Engine fuel and exhaust system 2 10 MT900 Series Articulated Tractor 790...

Page 46: ...ing maintenance Procedure 1 Park the machine on a solid level surface Stop the engine apply the parking brake and take the key with you 2 Turn the battery disconnect switch key 1 counterclockwise to d...

Page 47: ...njury Use caution in releasing belt tension NOTE The fan drive belt must first be removed to replace the accessories belt Install the correct breaker bar into the square drive 1 of the accessories bel...

Page 48: ...rdware 1 and the alternators 2 Fig 30 2 2 6 Installing the alternators Procedure 1 Install the alternators 2 with the hardware 1 Fig 31 2 Engine fuel and exhaust system MT900 Series Articulated Tracto...

Page 49: ...rpentine belt tensioner 2 Push the breaker bar counterclockwise and install the accessories serpentine belt 3 to the pulleys Slowly release the accessories serpentine belt tensioner to the neutral pos...

Page 50: ...injury can result Let the engine and components cool before doing maintenance WARNING Contact with refrigerant is a hazard Refrigerant can cause frostbite and other serious injury Serious personal in...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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