Arriving in Antarctica brand new in February 2010, the French Polar Institute’s (IPEV) Challenger No. 11 has logged 8,720 hours on the ice. It is currently in our workshops (Allonnes, France) for a mid-life overhaul. Disassembly is nearly complete. Next steps include a full mechanical overhaul and a series of modifications requested by the teams that operate the machine in the field.
A machine already adapted for the cold
Challenger No. 11 is a tracked MT865C “Traverse Special” model, powered by an 18-liter Caterpillar C18 engine. It was modified specifically for Antarctica from the outset, featuring specialized seals and fluids. A key requirement in the project specifications is that all cold-weather adaptations must be retained; installing standard, off-the-shelf parts would compromise these capabilities.
Overhaul program
Engine:
Removal, cylinder head disassembly, replacement of the turbocharger and water pump, and reconditioning of the injectors. Cylinder liners, pistons, the crankshaft, and the camshaft will be inspected, with a formal report to follow.
Transmission:
Removal, opening of the unit, replacement of seals and wear components, and bench testing. While it was operational, it had not undergone calibration for two or three seasons.
Undercarriage:
Wheels, bogies, bearings, seals, and tracks—utilizing rubber wheels exclusively.
40 kW Generator:
Bearings, wiring, drive pulleys, and tensioning system.
Issues identified in the field:
Steering sensor errors, unintended disengagement of the automatic engine speed (RPM) mode, load-sensing valve issues within the hydraulic control valve, and gear-shifter locking. Planned Modifications
Autonomy and Safety
Oil sump capacity increased to a total of 60 liters; an additional fuel tank (approx. 100 liters) integrated into the chassis; a dual 24V backup starter system; and an ECM-controlled, variable-speed Horton fan.
Maintenance Access
Additional side access doors on the engine hood; a top-access door with a magnetic latch and quick-release handle; circuit breakers relocated near a side access door; and a hinged, handled cover for the main power switch.
Cab
An alternator voltage indicator for diagnostics; a rear-facing camera positioned over the tow hitch; a heated rear window for defrosting; UV-protective window film; a storage net; and protective trim for the door seals.
Structure
The roof-mounted light frame weighs approximately 200 kg but is currently secured by only 4 bolts; 4 additional bolts, complete with spacers, will be installed.
Preparing for Future Repairs
Several requests stem from a common reality: out in the field, repairs must be performed on-site. It must be possible to re-bond the double-glazed windshield without tilting the cab; therefore, a removable support bracket will be added to bear the full weight of the glass while the adhesive cures. The sliding door windows will be moved to the inner track—as ice buildup on the exterior currently obstructs their movement—and will feature a three-position locking mechanism.
Next Steps
Disassembly is nearly complete. Up next: a comprehensive inspection!