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CX Series Tractors Service Manual SM 8-10602 Section Pub. No. 1 GENERAL Safety, General Information and Standard Torque Specifications...............1001 General Specifications and Torques ...........................................................1002 2 ENGINE NOTE: For the Engine Service and Overhaul procedures refer to your Engine Service Manual SM 8-10010 (3 Cylinder Engines) or SM 8-10040 (for 4 Cylinder Engines).

3 FUEL SYSTEM Fuel Tank Removal and Servicing...............................................................3005 NOTE: For the Fuel System Service and Overhaul procedures refer to your Engine Service Manual SM 8-10010 (3 Cylinder Engines) or SM 8-10040 (for 4 Cylinder Engines). 4 ELECTRICAL Electrical Schematics ..................................................................................4001 Instrument Cluster Programming.................................................................4002 Battery Servicing and Testing......................................................................4004 5 STEERING Steering Column and Steering Hand Pump ................................................5001 2 Wheel Drive Steering Cylinder..................................................................5003 2 Wheel Drive Front Axle.............................................................................5004 6 TRANSMISSION HOW IT WORKS……………………………………………………………………….. Engine Clutch, Master Cylinder and Slave Cylinder ....................................6002 Powershift and Forward/Reverse Transmission Servicing ..........................6003 Creep Transmission Servicing......................................................................6004 8 Speed Transmission Servicing .................................................................6005 Synchronizer Speed Transmission Servicing ..............................................6006 Range Transmission Servicing (2 Wheel Drive Tractors).............................6007 Range Transmission Servicing (MFD Tractors)............................................6008 3 Speed Powershift Transmission Servicing (XtraShift) ..............................6009 Differential and Differential Lock...................................................................6012 MFD Clutch, Transfer Gearbox, Drive Shaft and Parking Brake .................6017 Rear Axles and Planetaries .........................................................................6018 Non Shiftable PTO (XtraShift Prior to Pin JJE0200493) (Synchronizer Prior to Pin JJE0902626) ......................................................6019 Non Shiftable PTO (XtraShift Pin JJE0200494 and After) (Synchronizer Pin JJE0902627 and After) ..................................................6019 Shiftable PTO..


(XtraShift Prior to Pin JJE0200493) (Synchronizer Prior to Pin JJE0902626) .....................................................6020 Shiftable PTO (XtraShift Pin JJE0200494 and After) (Synchronizer Pin JJE0902627 and After) ..................................................6020 MFD Axle .....................................................................................................6021 Front PTO ....................................................................................................6025 7 BRAKES HOW IT WORKS………………………………………………………………………. Service Brakes ........................................................................................... 7001 Parking Brake (2 Wheel Drive Tractors) ..................................................... 7002 Hydraulic Trailer Brake ............................................................................... 7004 8 HYDRAULICS HOW IT WORKS………………………………………………………………………. Hydraulic Troubleshooting and Schematic ................................................. 8001 Filter Manifold and Main Hydraulic Pump ................................................... 8002 Steering Hydraulic Pump (Engine Driven) .................................................. 8003 Regulator Valve .......................................................................................... 8004 Unloading Valve.......................................................................................... 8006 Remote Valves ........................................................................................... 8007 Hitch Valve and EDC Manifold.................................................................... 8009 Hydraulic Lift Housing Servicing ................................................................. 8010 Front Hitch .................................................................................................. 8011 9 CHASSIS AND MOUNTED EQUIPMENT Pedal, Lever and Switch Adjustments ......................................................... 9001 Cab Mountings ............................................................................................ 9008 10CONTROLLER SYSTEMS Hitch Controller Calibration, Error Codes, Troubleshooting and Schematics (Tractors Not Equipped with Ride Control)................................................. 10002 Hitch/MFD/Differential Lock Controller Calibration, Error Codes, Troubleshooting and Schematics (Tractors Equipped with Ride Control) ....................................................... 10002 Calibration, Error Codes Troubleshooting and Schematics ....................... 10006 Programming the PTO/FNR Controller and Hitch/MFD/Differential Lock Controller ................................................ 10010


1001

Section 1001 SAFETY, GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS

SM 8-10080

© 2001 McCormick Tractors International Limited. March 2001


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SECTION 1001

TABLE OF CONTENTS SAFETY ................................................................................................................................................................... 3 GENERAL INFORMATION Cleaning ............................................................................................................................................................... 5 Inspection ............................................................................................................................................................. 5 Bearings ............................................................................................................................................................... 5 Needle Bearings .................................................................................................................................................. 5 Gears ................................................................................................................................................................... 5 Oil Seals, O-Rings And Gaskets .......................................................................................................................... 5 Shafts ................................................................................................................................................................... 5 Service Parts ........................................................................................................................................................ 5 Lubrication ........................................................................................................................................................... 5 STANDARD TORQUE DATA FOR NUTS AND BOLTS Chart 1 (Plain Nuts/Bolts) .................................................................................................................................... 6 Chart 2 (Phosphate Coated Nuts/Bolts) ............................................................................................................... 6 Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ...................................................................................................... 7

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SAFETY This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.

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To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put a warning tag as shown below on the key for the key switch when carrying out servicing or repairs to the tractor. Warning tags (publication number 2-1000) are available from your McCormick dealer.

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WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from you McCormick dealer.

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WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing.

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WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution.

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WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure.

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WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way.

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WARNING: Use insulated gloves mittens when working with hot parts.

REASON/RAISON

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VERNUNFT/RAZON

DO NOT OPERATE NE PAS UTILISER NICHT BETREIBEN NO UTILIZAR

2-1000

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WARNING: Read the operators manual to familiarize yourself with the correct control functions.

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WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.

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WARNING: This is one a man machine, no riders allowed

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SECTION 1001

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CAUTION: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service.

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CAUTION: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood.

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CAUTION: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer.

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CAUTION: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors).

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CAUTION: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands.

SM 8-10080

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CAUTION: When servicing or repairing the machine. Keep the shop floor and operator’s compartment and steps free of oil, water, grease, tools, etc. Use oil absorbing material and or shop cloths as required. Use safe practices at all times.

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CAUTION: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual.

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DANGER: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area.

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DANGER: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent that battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

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DANGER: Batteries contain acid and explosive gas. Explosions can result from sparks, flames or wrong cable connections. To connect the jumper cables correctly to the battery of this machine see the Operator’s Manual. Failure to follow these instructions can cause serious injury or death.

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5

GENERAL INFORMATION Cleaning

Gears

Clean all metal parts except bearings, in mineral spirits or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in kerosene, dry the bearings completely and put oil on the bearings.

Check all gears for wear and damage. Replace gears that have wear or damage.

Inspection Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete visual inspection for indications of wear, pitting and the replacement of parts necessary will prevent early failures.

Bearings Check bearings for easy action. If bearings have a loose fit or rough action replace the bearing. Wash bearings with a good solvent or kerosene and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR.

Needle Bearings Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.

SM 8-10080

Oil Seals, O-Rings And Gaskets Always install new oil seals, o-rings and gaskets. Put petroleum jelly on seals and o-rings.

Shafts Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage.

Service Parts Always install genuine McCormick service parts, when ordering refer to the Parts Catalog for the correct part number of the genuine McCormick replacement items. Failures due to the use of other than genuine McCormick replacement parts are not covered by warranty.

Lubrication Only use the oils and lubricants specified in the Operators or Service Manual. Failures due to the use of non specified oils and lubricants are not covered by warranty.

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SECTION 1001

STANDARD TORQUE DATA FOR NUTS AND BOLTS NOTE: A “click type” torque wrench is recommended for the bolt torques listed below.

Chart 1 (Plain Nuts/Bolts) BOLT SIZE (mm) M4 M5 M6 M8 M10 M12 M14 M16 M20 M22 M24 M30 M36

TYPE 8.8 MIN lb ft 3.0 4.8 8.2 20.0 40.0 69.0 110.0 175.0 345.0 475.0 600.0 1190.0 2080.0

TYPE 10.9 MAX

Nm 4.0 6.5 11.0 27.0 54.0 94.0 150.0 235.0 470.0 640.0 810.0 1615.0 2825.0

lb ft 3.4 5.5 9.2 22.5 45.0 78.0 125.0 190.0 390.0 530.0 675.0 1340.0 2340.0

Nm 4.5 7.5 12.5 31.0 61.0 106.0 170.0 260.0 530.0 720.0 915.0 1815.0 3175.0

MIN lb ft 4.3 7.0 11.8 28.7 56.0 100.0 160.0 245.0 480.0 655.0 830.0 1645.0 2875.0

MAX Nm 5.8 9.5 16.0 39.0 77.0 134.0 215.0 335.0 650.0 890.0 1125.0 2235.0 3900.0

lb ft 4.8 7.8 13.3 32.3 64.0 110.0 180.0 275.0 540.0 735.0 930.0 1855.0 3235.0

Nm 6.5 10.5 18.0 44.0 87.0 151.0 240.0 375.0 730.0 1000.0 1265.0 2515.0 4390.0

Chart 2 (Phosphate Coated Nuts/Bolts) BOLT SIZE (mm) M4 M5 M6 M8 M10 M12 M14 M16 M20 M22 M24 M30 M36

SM 8-10080

TYPE 8.8 MIN lb ft 2.3 3.6 6.2 15.0 30.0 52.0 83.0 131.0 259.0 355.0 450.0 893.0 1560.0

TYPE 10.9 MAX

Nm 3.0 4.9 8.3 20.3 41.0 71.0 113.0 176.0 353.0 480.0 608.0 1211.0 2119.0

lb ft 2.6 4.1 6.9 16.9 34.0 59.0 94.0 143.0 293.0 400.0 506.0 1005.0 1755.0

Nm 3.4 5.6 9.4 23.3 46.0 80.0 126.0 195.0 400.0 540.0 686.0 1361.0 2381.0

MIN lb ft 3.2 5.2 8.9 21.5 42.0 75.0 120.0 185.0 360.0 490.0 625.0 1235.0 2156.0

MAX Nm 4.4 7.1 12.0 29.2 58.0 101.0 161.0 251.0 490.0 665.0 845.0 1675.0 2925.0

lb ft 3.6 5.9 10.0 24.2 48.0 83.0 135.0 205.0 405.0 550.0 700.0 1390.0 2425.0

Nm 4.9 8.0 13.5 32.8 65.0 113.0 180.0 280.0 550.0 750.0 950.0 1885.0 3295.0

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Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) BOLT SIZE (mm) M4 M5 M6 M8 M10 M12 M14 M16 M20 M22 M24 M30 M36

SM 8-10080

TYPE 8.8 MIN lb ft 2.6 4.1 7.0 17.0 34.0 59.0 94.0 149.0 293.0 400.0 510.0 1010.0 1770.0

TYPE 10.9 MAX

Nm 3.5 5.6 9.5 23.1 46.0 80.0 128.0 200.0 400.0 545.0 690.0 1375.0 2400.0

lb ft 2.9 4.6 7.8 19.1 38.3 66.0 106.0 161.0 330.0 450.0 575.0 1140.0 1990.0

Nm 3.9 6.3 10.6 25.9 52.0 90.0 145.0 220.0 450.0 615.0 780.0 1545.0 2700.0

MIN lb ft 3.7 5.9 10.0 24.4 48.0 85.0 136.0 208.0 408.0 555.0 705.0 1400.0 2445.0

MAX Nm 5.0 8.0 13.6 33.1 65.0 114.0 183.0 285.0 555.0 755.0 955.0 1900.0 3315.0

lb ft 4.1 6.6 11.3 27.4 54.0 94.0 153.0 235.0 460.0 625.0 790.0 1580.0 2750.0

Nm 5.6 9.0 15.3 37.2 74.0 128.0 205.0 320.0 620.0 850.0 1075.0 2140.0 3730.0

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1002

Section 1002 GENERAL SPECIFICATIONS AND TORQUES

SM 8-10090

© 2001 McCormick Tractors International Limited. March 2001


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SECTION 1002

TABLE OF CONTENTS GENERAL SPECIFICATIONS Capacities ............................................................................................................................................................. 3 Electrical Specifications ........................................................................................................................................ 3 Steering Specifications.......................................................................................................................................... 3 Transmission Specifications.................................................................................................................................. 3 Brake Specifications.............................................................................................................................................. 5 Hydraulic Specifications ........................................................................................................................................ 5 Air Conditioning System Specifications................................................................................................................. 6 Conversion Table .................................................................................................................................................. 6 SPECIAL TORQUES Steering.................................................................................................................................................................7 Transmission......................................................................................................................................................... 7 Brakes ................................................................................................................................................................... 8 Hydraulics ............................................................................................................................................................. 9 Chassis and Mounted Equipment ......................................................................................................................... 9

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GENERAL SPECIFICATIONS Capacities TRANSMISSION/HYDRAULIC (HY-TRAN ® ULTA) OIL CAPACITY 2WD Tractors ......................................................................................................................................... 34.5 Litres MFD Tractors ............................................................................................................................................ 37 Litres Fuel Tank................................................................................................................................................. 155 Litres

Electrical Specifications Type of System....................................................................................................................12 Volt, Negative Ground Batteries .............................................................................. One or Two 12 Volt, Low Maintenance Hybrid Batteries Connected in Parallel DIN Type 60527, Top Stud Terminals BATTERY TYPE

SAE (COLD CRANKING CAPACITY)

IEC

DIN

AMPERE HOURS

RESERVE CAPACITY

644

660 Amps

440 Amps

400 Amps

95

180 mins

664

770 Amps

515 Amps

465 Amps

105

210 mins

648

810 Amps

545 Amps

490 Amps

120

220 mins

Fuel Level Sender Resistance Empty .............................................................................................................................................. 28 to 34 Ohms Full .............................................................................................................................................. 240 to 250 Ohms

Steering Specifications TRACK ADJUSTMENT 2WD Toe-in ......................................................................................... 0 to 5 mm MFD Toe-in.......................................................................................... 0 to 2 mm STEERING PUMP (ENGINE DRIVEN) CX50 and CX60 Direction of Rotation ...........................................................................................................................Clockwise Flow at 2250 engine rpm .................................................................................................................. 27.7 L/min. Rated Working Pressure.........................................................................................................................160 bar CX70, CX80, CX90 and CX100 Direction of Rotation ...............................................................................................................Counterclockwise Flow at 2200 engine rpm .................................................................................................................. 30.3 L/min. Rated Working Pressure.........................................................................................................................160 bar

Transmission Specifications CLUTCH CX50/60/70 Tractors Maximum Clutch Plate Thickness.........................................................................................................10.4 mm Clutch Plate Diameter ............................................................................................................................305 mm Number of Friction Plate Pads ......................................................................................................... 5 each side CX80/90/100 Tractors Maximum Clutch Plate Thickness.........................................................................................................10.4 mm Clutch Plate Diameter ............................................................................................................................310 mm Number of Friction Plate Pads ......................................................................................................... 7 each side

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SECTION 1002

SPEED TRANSMISSION Speed Transmission Synchronizer End Play ............................ 0.05 to 0.30 mm RANGE TRANSMISSION Pinion Bearing End Play (Maximum) ...................................................................................................... 0.076 mm Synchronizer Running Clearance ................................................................................................. 0.05 to 0.30 mm Selector Fork Running Clearance ............................................................................................................. 0.05 mm REAR AXLE Planetary Gear/Planetary Gear Carrier Shimming ................................................................ refer to Section 6018 DIFFERENTIAL Differential Lock Selector Ring Clearance (Engaged Position) ................................................... 0.025 to 0.90 mm Ring Gear to Pinion Backlash ................................................................................................... 0.152 to 0.304 mm Ring Gear to Differential Housing Run-out....................................................................................... 0 to 0.102 mm Differential Bearing Rolling Pull .......................................................................................................... 2.0 to 6.5 kg PTO CLUTCH Standard Clutch Number of Friction Plates ................................................................................................................................. 5 Number of Steel Separator Plates (2 between each Friction Plate) .................................................................8 Heavy Duty Clutch Number of Friction Plates ................................................................................................................................. 6 Number of Steel Separator Plates .................................................................................................................... 5 MFD CLUTCH Friction Plate Thickness (New) .....................................................................................................2.25 to 2.35 mm Friction Plate Thickness (Minimum) .......................................................................................................... 2.00 mm MFD Clutch Torque ......................................................................................................................... 638 to 792 Nm Output Shaft Bearing Preload (without oil seals) ................................................................................... 20 to 40 N MFD Drive Shaft Deflection (below the centre line of the shaft) (measured at Centre Support Bearing).....................................................................................0.50 to 0.55 mm MFD PARKING BRAKE Front and Rear Brake Pads (New) ............................................................................................ 10.70 to 10.90 mm Front and Rear Brake Pads (Minimum) .................................................................................................. 10.50 mm Central Brake Pads (New) ............................................................................................................4.00 to 4.10 mm Central Brake Pads (Minimum) ................................................................................................................. 3.50 mm MFD AXLE Differential Separator Plate Thickness......................................................................................................................1.5 mm Friction Disc Thickness ............................................................................................................... 1.45 to 1.6 mm Thrust Plate Thickness ................................................................................................................. 2.7 to 2.8 mm Pinion Shaft Bearing Preload......................................................................................................... 105 to 157 N Pinion Shaft/Differential Bearing Total Preload .........................................................................................................105 to 157 (+ 29.5 to 44.1) N Bevel Gear to Pinion Backlash......................................................................................................0.16 to 0.22 mm Lubricants Planetary and Wheel Hub Type.................................................................................................................................... SAE 85W-140EP Capacity, per Hub ............................................................................................................................ 0.6 Litres Differential/Axle Housing Type.................................................................................................................................... SAE 85W-140EP Capacity.............................................................................................................................................. 6 Litres Grease .................................................................................................................... Multi-Purpose Lithium Grease

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Brake Specifications 2WD PARKING BRAKE Number of Friction Discs .......................................................................................................................................3 Number of Stationary Discs ..................................................................................................................................3 Friction Disc (New) ....................................................................................................................................2.90 mm Stationary Disc Thickness (New) ..............................................................................................................1.80 mm Type ..........................................................................................................Hydraulically Operated Oil Cooled Disc Inner Brake Ring Backlash........................................................................................................0.127 to 0.635 mm Brake Piston Test Pressure Low Pressure Test .......................................................................................... 4 Steps of 3.4 bar up to 13.8 bar High Pressure Test.................................................................................................................................27.6 bar

Hydraulic Specifications CX50/60 Hydraulic System Type Steering Hydraulic Pump

CX70/80/90/100 Open

27.7 L/min. at 2250 engine rpm

Transfer Pump

30.3 L/min. at 2200 engine rpm 36 L/min.

Flow to Remotes

540/750 PTO

50.2 L/min.

540/1000 PTO

51.7 L/min.

Main Hydraulic Pump

540/750 PTO

50.2 L/min.

540/1000 PTO

51.7 L/min.

Pump gear (No. of teeth)

540/750 PTO

23

19

540/1000 PTO

27

23

N/A

5.31 to 5.43 mm

Pump mounting plate thickness

59.4 L/min.

59.4 L/min.

Main Relief Valve Pressure ......................................................................................................................172.5 bar Remote Detent Kick-out Pressure..............................................................................................144.7 to 172.3 bar Steering Relief Valve Pressure.........................................................................................................141 to 148 bar Regulated Pressure ......................................................................................................................................20 bar Oil Cooler By-pass Pressure ......................................................................................................................10.4 bar Steering Return Flow CX50/60 at 2250 engine rpm ............................................................................................................ 27.7 L/min. CX70/80/90/100 at 2200 engine rpm ................................................................................................ 30.3 L/min. Oil Cooler Flow CX50/60 at 2250 engine rpm ............................................................................................................ 23.7 L/min. CX70/80/90/100 at 2200 engine rpm ................................................................................................ 26.3 L/min. PTO Control Spool Assembly Return Spring - Free Length ...............................................................................................................79.63 mm High Pressure Spring - Free Length .................................................................................................. 29.65 mm Low Pressure Spring - Free Length ................................................................................................... 24.42 mm Hitch Valve Load Check Spring - Free Length........................................................................................................ 29.7 Mm Secondary Raise Spring - Free Length................................................................................................ 40.4 mm Hydraulic Oil Test Temperature ......................................................................................................................49° C

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SECTION 1002

Air Conditioning System Specifications Refrigerant Type............................................................................................... HFC - 134a Per ARI Standard 700 System Capacity ..................................................................................................................................... 1.93 kg Boiling Point at Atmospheric Pressure.....................................................................................................- 26° C Compressor Manufacturer........................................................................................................................................ SANDEN Model ......................................................................................................................................SD 7H15MD4609 Number of Cylinders ......................................................................................................................................... 7 Displacement Per Revolution................................................................................................................... 155 cc Clutch Voltage.............................................................................................................................................. 12V Clutch Coil Amperage Draw at 12 Volts............................................................................... 3.6 to 4.2 Amperes Front Clutch Plate Air Gap ............................................................................................................ 0.4 to 0.8 mm Drive Belt Tension (New) ............................................................................................................... 422 to 516 N Drive Belt Tension (Used) .............................................................................................................. 400 to 489 N Compressor and System Lubrication (Nominal) Lubricant Type .............................................................................................................Sanden SP - 20 PAG Oil Compressor Capacity (New)......................................................................................................... 270 to 300 ml Compressor Capacity (Previously Run).......................................................................................... 50 to 100 ml Component Capacity (add to compressor when component has been replaced) Receiver Dryer.............................................................................................................................. 25 to 30 ml Condenser ................................................................................................................................... 45 to 50 ml Evaporator .................................................................................................................................... 35 to 40 ml Hose and Tubes (Total) ................................................................................................................ 45 to 50 ml High Pressure Switch Location ................................................................................. Discharge Hose from Compressor to Condenser Operation ........................................................................................................... Closed by Excessive Pressure Cut Out Pressure .......................................................................................................................26.9 to 28.3 bar Low Pressure Switch Location ........................................................................................................Evaporator Outlet in the Cab Roof Operation .....................................................................................................................Closed by Low Pressure Cut Out Pressure .......................................................................................................................0.14 to 0.41 bar Temperature Control Switch Location ......................................................................................................... Evaporator Core in the Cab Roof Cut Out Temperature (Maximum Cold Setting)............................................................................ 0.8° to 2.5° C Cut In Temperature (Maximum Cold Setting)............................................................................... 5.8° to 7.5° C Coolant Fluid Type .............................................................................................. 50 percent Ethylene Glycol and Water CX50 and CX60 Tractors Capacity.......................................................................................................................................... 13.4 litres CX70, Cx80, CX90 and CX100 Tractors Capacity ......................................................................................................................................... 17.5 litres

Conversion Table Conversion

SM 8-10090

Conversion

mm X 0.03937 = inches

N (Newtons) X 0.225 = lbf

Bar X 14.5038 = PSI

NM X 0.738 = lb. ft

Litres X 0.22 = Imperial Gallons

NM X 8.85 = lb. in

Litres X 0.264 = U.S Gallons

° C X 1.8 (=32) = ° F

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7

SPECIAL TORQUES NOTE: To convert NM to lb. ft. see Conversion Table on Page 6.

Steering Steering Wheel Retaining Nut ................................................................................................................. 45 to 51 Nm Steering Hand Pump Retaining Bolts ...................................................................................................... 45 to 51 Nm Steering Hand Pump End Cover Retaining Bolts .................................................................................... 25 to 35 Nm Steering Relief Valve Plug ....................................................................................................................... 40 to 60 Nm Front Weight Bracket Retaining Bolts.................................................................................................. 481 to 542 Nm Front Wheel Nuts.......................................................................refer to Operators Manual for correct wheel rim size Wheel Bearing Nut ............................................................................. refer to Section 5003 for tightening procedure 2WD Front Axle Tie Rod Lock Nut................................................................................................................................. 34 to 40 Nm Tie Rod Lock Bolt ................................................................................................................................ 81 to 88 Nm Tie Rod Tube Lock Nut.................................................................................................................... 235 to 250 Nm Steering Arm Clamp Bolt................................................................................................................. 108 to 122 Nm Wheel Bearing Nut ................................................................................................................ refer to Section 5003 2WD Steering Cylinder Cylinder Clevis (with Loctite 270) .................................................................................................... 110 to 135 Nm Cylinder Clevis Pin Retaining Bolt....................................................................................................... 27 to 31 Nm Lower Bearing Carrier Retaining Bolts ............................................................................................ 110 to 122 Nm Steering Pump (Engine Driven) Retaining Bolts .................................................................................................................................... 41 to 48 Nm Inlet Tube Retaining Screws ............................................................................................................... 23 to 31 Nm Front Bolster to Engine Retaining Bolts (with Loctite 271) .................................................................. 258 to 284 Nm Front Bolster to Engine Retaining Nuts (with Loctite 271)................................................................... 258 to 284 Nm

Transmission Flywheel Retaining Bolts ..................................................................................................................... 116 to 130 Nm Clutch Retaining Bolts ............................................................................................................................. 20 to 23 Nm Engine to Speed Transmission Mounting Bolts ................................................................................... 122 to 129 Nm Speed to Range Transmission Retaining Bolts 1/2 inch Bolts (With Loctite 271) ..................................................................................................... 101 to 104 Nm 5/8 inch Bolts (With Loctite 271).......................................................................................................... 205 to 230 Nm Main Shaft Retaining Bolts ...................................................................................................................... 42 to 47 Nm Selector Fork to Selector Rail Lock Bolt ................................................................................................ 89 to 100 Nm Selector Fork to Selector Rail Lock Nut................................................................................................... 53 to 59 Nm PTO Bearing Retainer Bolts (with Loctite 271) ........................................................................................ 42 to 47 Nm Clutch Release Bearing Carrier Retaining Bolts (with Loctite 271) ......................................................... 42 to 47 Nm Pinion Shaft Retaining Bolts .................................................................................................................... 42 to 47 Nm Planet Carrier Retaining Bolt ............................................................................................................... 290 to 330 Nm Rear Axle Mounting Bolt...................................................................................................................... 270 to 305 Nm Flange Axle - Wheel Nuts.................................................................................................................... 278 to 298 Nm Bar Axle - Wheel to Hub Bolts ............................................................................................................. 183 to 207 Nm Differential Ring Gear Dowel Bolts .................................................................................................................... 156 to 170 Nm Ring Gear Retaining Bolts............................................................................................................... 156 to 170 Nm Bearing Carrier Retaining Bolts....................................................................................................... 156 to 170 Nm PTO Clutch Access Cover ................................................................................................................... 117 to 133 Nm PTO Shaft Cover Retaining Bolts ............................................................................................................ 45 to 50 Nm PTO Clutch Access Cover Retaining Bolts.......................................................................................... 117 to 133 Nm PTO Housing 3/8 inch Retaining Bolts ...................................................................................................................... 45 to 50 Nm 1/2 inch Retaining Bolts .................................................................................................................. 136 to 152 Nm

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8

SECTION 1002

MFD Transfer Gearbox Mounting Bolts .................................................................................................................................117 to 133 Nm Drain Plug .................................................................................................................................................... 80 Nm Front Cover Retaining Bolts ......................................................................................................................... 23 Nm Rear Cover Retaining Bolts.......................................................................................................................... 23 Nm Brake Pad Guide Pin Plug ......................................................................................................................... 150 Nm Solenoid Cover Retaining Bolts ................................................................................................................... 12 Nm Solenoid Valve ............................................................................................................................................. 27 Nm Drive Shaft Coupling Locknut .................................................................................................................. 54 to 61 Nm MFD Axle Axle Support Housing Retaining Bolts ....................................................................................................... 200 Nm Wheel Hub Drain/Filler Plug......................................................................................................................... 80 Nm Axle/Differential Housing Drain Plug ............................................................................................................ 70 Nm Axle Dipstick................................................................................................................................................. 10 Nm Wheel Hub to Planetary Gear Carrier Countersunk Screws ........................................................................ 25 Nm Planetary Gear Carrier to Swivel Housing Retaining Bolts .......................................................................... 78 Nm Upper and Lower King Pin Retaining Bolts ................................................................................................ 120 Nm Differential Housing to Axle Retaining Bolts............................................................................................... 169 Nm Bevel Gear Retaining Bolts (with Loctite 270).............................................................................................. 78 Nm Differential Bearing Cap Retaining Bolts .................................................................................................... 266 Nm Locking Plate Retaining Bolts ...................................................................................................................... 12 Nm Ball Joint Assembly to Steering Cylinder Piston Rod................................................................................. 300 Nm Ball Joint Locknut ....................................................................................................................................... 165 Nm Steering Cylinder Retaining Bolts .............................................................................................................. 120 Nm Front Wheel Nuts ............................................................................................................................ 300 to 350 Nm Front Weight Bracket....................................................................................................................... 481 to 542 Nm Wheel Stud................................................................................................................................................... 70 Nm

Brakes Parking Brake Cable Bracket Bolts ......................................................................................................... 45 to 50 Nm Parking Brake Support Bolts ................................................................................................................... 45 to 50 Nm Parking Brake Assembly Support Nuts ............................................................................................... 156 to 176 Nm Hydraulic Trailer Brake Valve End Cap Socket Head Screws ..................................................................................................................... 10 Nm Bleed Valve ................................................................................................................................................. 2.5 Nm

SM 8-10090

Issued 03-2001


9

SECTION 1002

Hydraulics Filter Manifold Retaining Bolts ............................................................................................................... 45 to 50 Nm Hydraulic Filter Retaining Bolt ............................................................................................................... 16 to 21 Nm Main Hydraulic Pump Retaining Bolts ................................................................................................... 24 to 28 Nm Main Hydraulic Pump Drive Gear Locknut ............................................................................................ 61 to 68 Nm Main Hydraulic Pump End Plate Retaining Bolt ..................................................................................................................................... 27 to 31 Nm Cap Screw.......................................................................................................................................... 24 to 27 Nm Main Relief Valve ................................................................................................................................... 34 to 54 Nm Fitting, PTO Spool Supply ..................................................................................................................... 34 to 54 Nm Elbow, Filter Manifold Inlet ..................................................................................................................... 34 to 54 Nm Plug, PTO Spool .................................................................................................................................... 34 to 54 Nm Hitch Valve Plugs and Cap Screws ........................................................................................... refer to Section 8009 Regulator Valve Retaining Bolts .................................................................................................................................... 42 to 47 Nm Solenoid Valve to Regulator Valve ...................................................................................................... 10 to 15 Nm Coil to Solenoid Retaining Nut ................................................................................................................ 5 to 8 Nm Regulator Pressure Valve Locknut ...................................................................................................... 34 to 54 Nm Oil Cooler By-Pass Valve Plug ............................................................................................................ 34 to 54 Nm Solenoid Valve Plug (8 Speed Transmission) ..................................................................................... 34 to 54 Nm Differential Lock Solenoid Coil to Solenoid Retaining Nut ................................................................................................................ 5 to 8 Nm Unloader Valve Retaining Bolts .................................................................................................................................... 42 to 47 Nm Regulator Valve Plug........................................................................................................................... 34 to 54 Nm Remote Valve Retaining Bolts .................................................................................................................................... 16 to 20 Nm Hydraulic Housing 3/8 inch Retaining Bolts ...................................................................................................................... 45 to 50 Nm 1/2 inch Retaining Bolts .................................................................................................................. 108 to 122 Nm Front Hitch Mounting Bolts ................................................................................................................................ 406 to 490 Nm Front Cover Bolts ....................................................................................................................................... 257 Nm Piston Retaining Nut .................................................................................................................................. 776 Nm

Chassis and Mounted Equipment Cab Mounting Nuts......................................................................... 190 to 244 Nm Cab Mounting Bolt to Threaded Plate ................................................ 47 to 61 Nm

140 to 180 lb ft 35 to 45 lb ft

Air Conditioning System

THREAD

Fittings With O-Rings FITTING

TORQUE

M10-1.25

5/8-18

3/4-16/18

7/8-14/18

1-14

Steel to Steel

Nm

-

31 to 36

40 to 46

45 to 52

-

Brass, Copper or Aluminium to Steel

Nm

10 to 14

18 to 23

24 to 30

30 to 37

45 to52

IMPORTANT: Lubricate all threads and o-rings with mineral oil. IMPORTANT: When tightening the air conditioner tubes and hoses, always use a second wrench for support.

SM 8-10090

Issued 03-2001


1000 Series Engine Service Manual Naturally Aspirated 4 Cylinder Engines Turbocharger 4 Cylinder Engines Turbocharger 6 Cylinder Engines

This Service Manual Replaces SM 8-10040, Containing SM 8-10050 (Table of Contents) and SM 8-10060

SM 8-10041

Š 2002 McCormick Tractors International Limited. March 2001 (Revised May 2002)


2

1000 Series Engine - Table of Contents

Table of Contents 1 General information Introduction ..............................................................................................................................................11 Engine views ........................................................................................................................................... 12 Engine identification ............................................................................................................................13 Safety precautions ................................................................................................................................15 Viton seals ................................................................................................................................................16 Engine lift equipment ...........................................................................................................................17

2 Specifications Basic engine data ..................................................................................................................................19 Data and dimensions ...........................................................................................................................20 Thread sealant ........................................................................................................................................42 Standard torque tensions .................................................................................................................. 43 Specific torque tensions .....................................................................................................................44 Compression test data ........................................................................................................................ 46

SM 8-10041

Issued 05-2002


1000 Series Engine - Table of Contents

3

3 Cylinder Head Assembly General description .............................................................................................................................. 47 Rocker cover To remove ................................................................................................................................................ 48 To Install................................................................................................................................................... 49

Rocker assembly To remove and to install........................................................................................................................... 50 To dismantle and to assemble ................................................................................................................. 51 To inspect and to correct.......................................................................................................................... 51

Valve tip clearances To check and to adjust (four cylinder engines) ........................................................................................ 52 To check and to adjust (six cylinder engines) .......................................................................................... 53

Valve springs To change the valve springs (with cylinder head installed)...................................................................... 54

Manifolds .................................................................................................................................................. 56 To remove and to install an intake manifold............................................................................................. 56 To remove and to install an exhaust manifold (one-piece) ...................................................................... 58

Cylinder head assembly To remove ................................................................................................................................................ 60 To install (engine types AQ, AT, YH, YJ and YK) .................................................................................... 62 To install (engine type AS) ....................................................................................................................... 65

Valves and valve springs To remove ................................................................................................................................................ 68 To install................................................................................................................................................... 69 To inspect and to correct.......................................................................................................................... 70

Valve guides ............................................................................................................................................ 71 To inspect................................................................................................................................................. 71 To remove ................................................................................................................................................ 72 To install................................................................................................................................................... 73

Cylinder head To inspect and to correct.......................................................................................................................... 74 To correct a valve seat with a valve seat cutter ....................................................................................... 75 To install valve seat inserts ...................................................................................................................... 77

SM 8-10041

Issued 05-2002


1000 Series Engine - Table of Contents

4

4 Piston and connecting rod assemblies General description ..............................................................................................................................79 Big end bearing To remove ................................................................................................................................................ 81 To install ................................................................................................................................................... 82 To inspect ................................................................................................................................................. 82

Piston and connecting rod To remove ................................................................................................................................................ 83 To install ................................................................................................................................................... 84 To check the piston height above the cylinder block ................................................................................ 86

Piston rings To remove ................................................................................................................................................ 87 To install ................................................................................................................................................... 88

Piston and connecting rod assembly To dismantle ............................................................................................................................................. 89 To assemble ............................................................................................................................................. 90 To check the length of a connecting rod................................................................................................... 91

Piston and piston rings To inspect ................................................................................................................................................. 92

Connecting rod To inspect ................................................................................................................................................. 93

Partially finished small end bush To remove and to install ........................................................................................................................... 94

Piston cooling jets To remove and to install ........................................................................................................................... 95 To check the jet alignment........................................................................................................................ 96

5 Crankshaft assembly General description ..............................................................................................................................97 Crankshaft pulley To remove and to install (four cylinder engines)....................................................................................... 99

Crankshaft pulley and damper To remove (six cylinder engines)............................................................................................................ 100 To install (six cylinder engines) .............................................................................................................. 101 To inspect ............................................................................................................................................... 102

SM 8-10041

Issued 05-2002


1000 Series Engine - Table of Contents

5

Rear oil seal assembly ...................................................................................................................... 103 To remove and to install (one-piece assembly) ..................................................................................... To remove and to install (two-piece assembly)...................................................................................... To renew the rear end oil seal (two-piece assembly)............................................................................. To remove and to install a wear sleeve..................................................................................................

103 105 106 107

Thrust washers To check crankshaft end-float ................................................................................................................ 108 To remove .............................................................................................................................................. 109 To install................................................................................................................................................. 110

Main bearings To remove (with the crankshaft in position) ........................................................................................... 111 To install................................................................................................................................................. 112 To inspect............................................................................................................................................... 112

Crankshaft To remove .............................................................................................................................................. 113 To install................................................................................................................................................. 114 To inspect............................................................................................................................................... 116

Balancer unit To remove and to install......................................................................................................................... To dismantle........................................................................................................................................... To assemble........................................................................................................................................... To inspect............................................................................................................................................... To remove and to install the needle roller bearings for the drive shaft .................................................. To remove and to install the bushes for the balance weights ................................................................

117 118 120 123 124 125

6 Timing case and drive assembly General description ............................................................................................................................ 127 Timing case cover To remove .............................................................................................................................................. 128 To install................................................................................................................................................. 129

Front oil seal To remove .............................................................................................................................................. 131 To install................................................................................................................................................. 132 To remove and to install a wear sleeve.................................................................................................. 134

Idler gear and hub To remove .............................................................................................................................................. 135 To install................................................................................................................................................. 137

Fuel pump gear .................................................................................................................................... 139 To remove .............................................................................................................................................. 139 To install................................................................................................................................................. 141

SM 8-10041

Issued 05-2002


1000 Series Engine - Table of Contents

6 Camshaft gear

To remove and to install ......................................................................................................................... 143

Crankshaft gear To remove and to install ......................................................................................................................... 144

Timing case To remove .............................................................................................................................................. 145 To install ................................................................................................................................................. 146

Camshaft and tappets To remove .............................................................................................................................................. 148 To install ................................................................................................................................................. 149

7 Cylinder block assembly General description ............................................................................................................................151 Cylinder block To dismantle ........................................................................................................................................... To assemble ........................................................................................................................................... To inspect ............................................................................................................................................... To remove and to install a new type ‘D’ plug to the tappet chamber......................................................

152 153 154 155

Cylinder liner To inspect ............................................................................................................................................... To remove .............................................................................................................................................. To install a service liner .......................................................................................................................... To install a partially finished liner............................................................................................................

157 158 160 163

Cylinder bore, engine type AS To inspect ............................................................................................................................................... 166

8 Engine timing General description ............................................................................................................................167 Engine timing To set number 1 piston to TDC on the compression stroke ................................................................... Another method to set number 1 piston to TDC on the compression stroke.......................................... To check the valve timing ....................................................................................................................... To check the timing of the fuel injection pump .......................................................................................

SM 8-10041

169 170 171 172

Issued 05-2002


1000 Series Engine - Table of Contents

7

9 Aspiration system General description ............................................................................................................................ 173 Turbocharger To remove .............................................................................................................................................. To install................................................................................................................................................. To clean the impeller and the compressor casing.................................................................................. To remove and to install the actuator assembly of the waste-gate unit ................................................. To check and adjust the operation of the waste-gate ............................................................................

175 176 178 179 180

Turbocharger faults ............................................................................................................................ 181 List of possible causes ..................................................................................................................... 182 Open engine breather ........................................................................................................................ 183 To clean and to renew............................................................................................................................ 183 To Inspect .............................................................................................................................................. 185

10 Lubrication system General description - four cylinder engine lubrication system ....................................... 187 General description - Six cylinder engine lubrication system ......................................... 188 Filter canister To renew ................................................................................................................................................ 191

Filter head To remove and to install......................................................................................................................... 192

Sump To remove and to install......................................................................................................................... 193

Oil strainer and suction pipe To remove and to install......................................................................................................................... 194 To inspect and to correct........................................................................................................................ 195

Lubricating oil pump .......................................................................................................................... 196 To remove .............................................................................................................................................. 196 To install................................................................................................................................................. 197 To inspect............................................................................................................................................... 198

Lubricating oil pump idler gear shaft .......................................................................................... 199 To remove (six cylinder engines) ........................................................................................................... 199 To install (six cylinder engines) .............................................................................................................. 201 To remove and to install (four cylinder engines) .................................................................................... 202

SM 8-10041

Issued 05-2002


1000 Series Engine - Table of Contents

8 Relief valve

To remove and to install ......................................................................................................................... 203 To dismantle and to assemble................................................................................................................ 204 To inspect ............................................................................................................................................... 204

Flexible oil pipes ..................................................................................................................................205 To remove .............................................................................................................................................. 205 To install ................................................................................................................................................. 206 To Inspect............................................................................................................................................... 206

11 Fuel system General description ............................................................................................................................207 Cold start advance unit .....................................................................................................................210 Typical fuel system .............................................................................................................................212 Fuel filters ...............................................................................................................................................213 Fuel filter element To renew - separate element type.......................................................................................................... 214 To renew - canister type ......................................................................................................................... 215 To renew - quick release canister type................................................................................................... 216

Atomisers ................................................................................................................................................217 To remove .............................................................................................................................................. 218 To install ................................................................................................................................................. 219

Fuel lift pump To remove and to install ......................................................................................................................... To dismantle ........................................................................................................................................... To assemble ........................................................................................................................................... To test.....................................................................................................................................................

221 222 223 224

Lucas/Delphi DP 200 Series fuel injection pump ...................................................................225 To remove .............................................................................................................................................. To install ................................................................................................................................................. To adjust................................................................................................................................................. Electrical shut off solenoid (ESOS) ........................................................................................................

227 229 232 233

Air in the fuel system .........................................................................................................................235 To eliminate air from the fuel system...................................................................................................... 235

SM 8-10041

Issued 05-2002


1000 Series Engine - Table of Contents

9

12 Cooling system General description ............................................................................................................................ 239 Thermostats To remove .............................................................................................................................................. 240 To install................................................................................................................................................. 241 To test .................................................................................................................................................... 242

Coolant pump - gear driven pumps ............................................................................................. 243 To remove .............................................................................................................................................. To install................................................................................................................................................. To dismantle........................................................................................................................................... To assemble...........................................................................................................................................

243 244 245 248

Coolant pump - belt driven .............................................................................................................. 252 To remove high position pump............................................................................................................... To install high position pump.................................................................................................................. To dismantle........................................................................................................................................... To assemble...........................................................................................................................................

252 254 256 257

Fan To remove and to install......................................................................................................................... 260

Fan drive (engines with gear driven coolant pumps) To remove and to install......................................................................................................................... 261

Lubricating oil cooler To remove (six cylinder turbocharged engines) ..................................................................................... To install (six cylinder turbocharged engines)........................................................................................ To dismantle and to assemble (six cylinder engines) ............................................................................ To remove and to install (canister type) ................................................................................................. To remove and to install cooler bypass valve ........................................................................................

262 263 264 265 265

Intercoolers ............................................................................................................................................ 266 To remove .............................................................................................................................................. 267 To install................................................................................................................................................. 268 To clean and to inspect .......................................................................................................................... 270

13 Flywheel and housing General description ............................................................................................................................ 271 Flywheel To remove and to install......................................................................................................................... 271

Ring gear To remove and to install......................................................................................................................... 272

Flywheel housing To remove and to install......................................................................................................................... 273

SM 8-10041

Issued 05-2002


1000 Series Engine - Table of Contents

10

14 Electrical equipment To check the drive belts.......................................................................................................................... To adjust drive belt tension..................................................................................................................... To remove and to install the drive belts.................................................................................................. To remove and to install the alternator ................................................................................................... To maintain.............................................................................................................................................

275 276 277 278 278

Starting aids ...........................................................................................................................................279 To remove and to install a fuelled starting aid ........................................................................................ To remove and to install a twin-fuelled starting aid ................................................................................ To check the fuelled starting aid............................................................................................................. To remove and to install a port heater....................................................................................................

279 280 281 281

15 Special tools List of special tools ............................................................................................................................284

SM 8-10041

Issued 05-2002


Section 1 - General Information

11

1

General information Introduction This Workshop Manual has been written to provide assistance in the service and overhaul of 1000 Series engines. For overhaul procedures the assumption is made that the engine is removed from the application. The engine conforms with USA (EPA/CARB) stage 1 and EEC stage 1 emissions legislation for agricultural and industrial applications.

Most of the general information which is included in the relevant User's Handbook has not been repeated in this workshop manual and the two publications should be used together. Where the information applies only to certain engine types, this is indicated in the text. When reference is made to the “left” or “right” side of the engine, this is as seen from the flywheel end of the engine. Special tools have been made available, for a list of these, see Chapter 15, Special tools . Reference to the relevant special tools is also made at the beginning of each operation, where relevant. Data and dimensions are included in Chapter 2, Specifications . Read and remember the "Safety precautions" on page 15. They are given for your protection and must be used at all times. Danger is indicated in the text by two methods: Warning! This indicates that there is a possible danger to the person. Caution: This indicates that there is a possible danger to the engine. Note: Is used where the information is important, but there is not a danger.

SM 8-10041

Issued 05-2002


12

Section 1 - General Information

Engine views

A0378N

A0379

SM 8-10041

Issued 05-2002


Section 1 - General Information

13

Engine identification The New 1000 Series engines have been designed for industrial and agricultural applications. There are both four and six cylinder engines, each of which will have three basic engine types, naturally aspirated, turbocharged and turbocharged with an intercooler. In this workshop manual, the different engine types are indicated by their code letters. These are the first two letters of the engine number as indicated below: AQ

Four cylinder, turbocharged, belt driven coolant pump

AS

Four cylinder, naturally aspirated, belt driven coolant pump, 103 mm cylinder bore

AT

Four cylinder, turbocharged, belt driven coolant pump, air to air

YG

Six cylinder, naturally aspirated

YH

Six cylinder, turbocharged

YJ

Six cylinder, charge cooled, air to air

YK

Six cylinder, turbocharged and intercooled

The correct identification of the engine is by the full engine number. The engine number is stamped on a label which is fastened to the left side (A2) of the cylinder block. An example of an engine number is: AS50665*U510256B* The components of the engine number are as follows: AS50665*U510256B* AS

Model code number 50665

Build list number U

Built in the UK 510256

Engine serial number B

Year of manufacture Continued

1

2

3

A SM 8-10041

A0043

Issued 05-2002


Section 1 - General Information

14

Date letters for engines start from the 1st of January each year. To comply with the new emissions legislation that engines built before 1st April 1999 can be clearly identified from those built after this date, a new letter has been used from the 1st of April 1999. The date letters used are as follows: From the 1st of January 1999 to the 31st of March 1999 the date letter is E. From the 1st of April 1999 to the 31st of January 1999 the date letter is F. If you need parts, service or information for your engine, you must give the complete engine number to your McCormick dealer. If there is a number in the area of the label marked TPL No, then this number must also be given to your McCormick dealer. Other identification labels fitted to the engine include: An emissions legislation label (A3) fitted to the side of the cylinder block. A label (A1) with the fuel injection pump part numbers. If a short engine has been fitted in service two engine serial numbers and a TPL number are stamped on the engine serial number pad (B3). Examples of the serial numbers are shown in (B). If parts for the short engine are needed in service, use the serial number (B4). If parts which were moved from the original engine to the short engine are needed, use the serial number (B1) and the TPL number (B2).

1

2

AK80920*U510256B*

1

AJ39770 TPL N o 212

2 3

4

3

A SM 8-10041

A0043

B

A0045

Issued 05-2002


Section 1 - General Information

15

Safety precautions These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only refer to specific applications. * Only use these engines in the type of application for which they have been designed. * Do not change the specification of the engine. * Do not smoke when you put fuel in the tank. * Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place. * Do not put fuel in the tank while the engine runs (unless it is absolutely necessary). * Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training; even then extreme care must be used to prevent injury). * Do not make adjustments that you do not understand. * Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions. * Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation. * Do not permit loose clothing or long hair near moving parts. * Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly while the engine runs. * Do not operate the engine if a safety guard has been removed. * Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged. * Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes. * Disconnect the battery terminals before a repair is made to the electrical system. * Only one person must control the engine. * Ensure that the engine is operated only from the control panel or from the operators position. * If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately. * Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin. * Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets of clothing. * Discard used lubricating oil in a safe place to prevent contamination. * Ensure that the control lever of the transmission drive is in the “out-of-drive� position before the engine is started. * Use extreme care if emergency repairs must be made in adverse conditions. * The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes, see "Viton seals" on page 16 for safety precautions. * Read and use the instructions relevant to lift equipment, see "Engine lift equipment" on page 17. Continued

SM 8-10041

Issued 05-2002


16

Section 1 - General Information

* Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested. * Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately. * Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces. * Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components on the engine may be damaged. * Fit only genuine McCormick parts.

Viton seals Some seals used in engines and in components fitted to engines are made of Viton. Viton is used by many manufacturers and is a safe material under normal conditions of operation. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes. If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used: * Ensure that the components have cooled * Use neoprene gloves and discard the gloves safely after use * Wash the area with calcium hydroxide solution and then with clean water * Disposal of components and gloves which are contaminated must be in accordance with local regulations. If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

SM 8-10041

Issued 05-2002


Section 1 - General Information

17

Engine lift equipment The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different applications. It is recommended that lift equipment of the minimum capacity listed below is used: Four cylinder engines

500 kg (1100 lbs)

Six cylinder engines

600 kg (1320 lbs)

Before the engine is lifted: * Always use lift equipment of the approved type and of the correct capacity to lift the engine. It is recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above the engine lift brackets (A1). Never use a single lift bracket to raise an engine * Check the engine lift brackets for damage and that they are secure before the engine is lifted. The torque for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m * To prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker cover * Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder head, balancer unit, flywheel housing, crankshaft and flywheel.

1

A SM 8-10041

A0044

Issued 05-2002


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