McCormick ZTX260 Tractor Service Repair Manual

Table of Contents ZTX Series Tractors Service Manual SM 8-12602 Section Pub. No. 1 GENERAL Safety Rules, General Information and Torque Specifications ............................1001 General Specifications and Torques ...................................................................1002 2 ENGINE Engine How it Works .................................................................................................2 Fault Codes 3 FUEL 4 ELECTRICAL Electrical How it Works ......................................................................................... ..4 Electrical Schematics.........................................................................................4001 Instrument Cluster Programming.......................................................................4002 Battery Servicing and Testing............................................................................4004 5 STEERING Steering How it Works ...............................................................................................5 Steering Column and Steering Hand Pump Removal ........................................5001 Rexroth Steering Hand Pump.............................................................................5002 6 TRANSMISSION Transmission How it Works ......................................................................................6 Splitting the Tractor .............................................................................................6003 Full Powershift Transmission ..............................................................................6006 MFD Clutch..........................................................................................................6017 Rear Axle.............................................................................................................6018 Power Take Off ...................................................................................................6019 MFD Front Axle - 20.49 Axle ...............................................................................6021 Front Suspended Axle - 20.49 Axle.....................................................................6022 7 BRAKES Brakes How it Works .................................................................................................7 Parking Brake ......................................................................................................7001 8 HYDRAULICS Hydraulics How it Works............................................................................................8 Hydraulic Troubleshooting and Schematic ..........................................................8001 Left Hand and Right Hand Hydraulic Covers........................................................8005 Hydraulic Priority Valve Blocks ............................................................................8006 Auxiliary/Remote Spool Valves............................................................................8008 9 CHASSIS AND MOUNTED EQUIPMENT Climate Control How it Works.....................................................................................9 Pedal, Lever And Switch Adjustments .................................................................9001

10 CONTROLLER SYSTEMS Electrical Controllers How it Works..........................................................................10 Auxiliary/Remote Valve Controller - Error Codes, Troubleshooting and Schematics ..................................................................10001 Hitch Controller - Error Codes, Troubleshooting and Schematics ..................................................................10002 Front Suspended Axle Controller Calibration, Error Codes, Troubleshooting and Schematics..........................10003 Transmission and Cab (MCC) Controller - Calibration, Error Codes, Troubleshooting and Schematics ..................................................................10006 Instrument Cluster Controller - Error Codes, Troubleshooting and Schematics ..................................................................10009 Controller Programming ................................................................................10010 Automatic Temperature Control.....................................................................10012

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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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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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 ZTX Series Tractors

SM 8-12501

© 2004 McCormick Tractors International Limited.

March 2004 (Revised June 2004)

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SECTION 1002

TABLE OF CONTENTS GENERAL SPECIFICATIONS Lubricants and Capacities ....................................................................................................................................3 Engine ..................................................................................................................................................................3 Fuel ......................................................................................................................................................................3 Electrical ...............................................................................................................................................................3 Transmission ........................................................................................................................................................4 Hydraulics .............................................................................................................................................................4 Air Conditioning ....................................................................................................................................................5 SPECIAL TORQUES Engine ..................................................................................................................................................................6 Transmission ........................................................................................................................................................6 Cab and Chassis ..................................................................................................................................................6

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GENERAL SPECIFICATIONS Lubricants and Capacities ENGINE Oil Type....................................................................................................... McCormick Engine Oil, SAE 15W - 40 Capacity (With Filter Change).........................................................................................20 Litres (5.3 US gallons) ENGINE COOLANT Coolant Mix......................................................................................................... McCormick Universal Anti-freeze Solution of 33% to 50% Ethylene Glycol (depending on market requirements) Capacity........................................................................................................................40 Litres (10.6 US gallons) AIR CONDITIONER SYSTEM Compressor Oil................................................................................................................. Sanden SP - 20 Pag Oil Capacities ...................................................................................................................................... Refer to Page 5 TRANSMISSION Oil Type...................................................................................................................................... McCormick UTTO Capacity......................................................................................................................158 Litres (41.7 US gallons) MFD AXLE Oil Type........................................................................................................... McCormick Multi-Purpose Gear Oil SAE 85W - 140 EP Gear Oil to API GL-5 or MIL-L-2105 Specification Differential Oil .................................................................................................................10 Litres (2.6 US gallons) Axle Planetaries (Each) .................................................................................................1.9 Litres (0.5 US gallons) FUEL TANK Fuel Capacity...............................................................................................................570 Litres (150 US gallons)

Engine NOTE: For the Engine Specifications, refer to the your Engine Service Manual.

Fuel NOTE: For the Fuel Specifications, refer to the your Engine Service Manual.

Electrical System Type .................................................................................................................... 12 Volt Negative Ground Batteries....................................................................................... 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

Alternator ..................................................................................................................................... 12 Volt, 150 Amp Starter Motor................................................................................................................................... 12 Volt, 4.2 kW

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Transmission Pinion Shaft Bearing Preload ........................................................................................................0.05 to 0.15 mm MFD Output Shaft End Play .................................................................................................................0 to 0.1 mm MFD CLUTCH Number of Clutch Plates Friction Plates ...............................................................................................................................................8 Separator Plates ...........................................................................................................................................7 DIFFERENTIAL AND DIFFERENTIAL LOCK Ring Gear and Pinion Backlash.....................................................................................................0.15 to 0.45 mm Differential Lock Clutch Number of Plates Friction Plate ................................................................................................................................................ 8 Separator Plate............................................................................................................................................ 7

Hydraulics HYDRAULIC PUMPS Charge Pump 110 l/min ........................................................................................................................... 60 cm3 per revolution 150 l/min ........................................................................................................................... 80 cm3 per revolution Variable Displacement Pump 110 l/min .................................................................................................................... 0 to 45 cm3 per revolution 150 l/min .................................................................................................................... 0 to 60 cm3 per revolution

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Air Conditioning REFRIGERANT Type ....................................................................................................................................................... HFC-134A System Capacity............................................................................................................................................1.9 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 ............................................................................................................................................12 Volts Clutch Ampage Draw at 12 Volts .............................................................................................. 3.6 to 4.2 Amperes Front Clutch Plate Air Gap ................................................................................................................ 0.4 to 0.8 mm COMPRESSOR AND SYSTEM LUBRICATION Lubrication Type............................................................................................................... Sanden SP - 20 PAG Oil HIGH PRESSURE SWITCH Operation ................................................................................................... Closed by Excessive System Pressure LOW PRESSURE SWITCH Operation ............................................................................................................ Closed by Low System Pressure

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SPECIAL TORQUES Engine Engine to Transmission Retaining Bolts Adapter Plate to Engine...........................................................114 to 128 Nm Adapter Plate to Transmission .................................................555 to 620 Nm Torque Dampener Retaining Bolts...............................................74 to 84 Nm Front Bolster to Transmission Retaining Bolts .........................555 to 620 Nm Flywheel ..................................................................................108 to 132 Nm

(84 to 94 lb ft) (409 to 457 lb ft) (54 to 62 lb ft) (409 to 457 lb ft) (80 to 97 lb ft)

Transmission DIFFERENTIAL AND DIFFERENTIAL LOCK Ring Gear Retaining Bolts .......................................................240 to 340 Nm Differential Lock Clutch Cage Retaining Bolts .........................110 to 130 Nm Differential Bearing Carrier Retaining Bolts .............................100 to 130 Nm

(177 to 251 lb ft) (81 to 96 lb ft) (74 to 96 lb ft)

REAR AXLES Rear Axle Mounting Nuts.........................................................247 to 253 Nm

(182 to 187 lb ft)

MFD DRIVE SHAFT MFD Drive Shaft Centre Mounting Bolts.............................................570 Nm

(420 lb ft)

PTO PTO Housing Retaining Bolts ......................................................480 to 640 Nm PTO Clutch Pack Retaining Bolt ..................................................25 to 34 Nm PTO Clutch Assembly Retaining Bolt ..........................................50 to 70 Nm Bearing Carrier Retaining Bolt.....................................................72 to 96 Nm

(354 to 472 lb ft) (18 to 25 lb ft) (37 to 52 lb ft) (53 to 71 lb ft)

Cab and Chassis CAB Cab Mounting Bracket to Rear Axle Bolts ...............................190 to 244 Nm Cab Mounting Bracket to Transmission Bolts Bolts .................205 to 260 Nm Cab Mounting Bolt to Threaded Plate ........................................47 to 61 Nm Cab Mounting Nut....................................................................190 to 244 Nm

(140 to 180 lb ft) (151 to 192 lb ft) (33 to 45 lb ft) (140 to 180 lb ft)

WHEELS Front Wheel to MFD Axle Nuts ................................................530 to 570 Nm Wheel Hub to Tapered Bushing ...............................................500 to 600 Nm Wheel to Wheel Hub................................................................640 to 680 Nm

(391 to 420 lb ft) (369 to 443 lb ft) (472 to 502 lb ft)

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Section 2 ENGINE How it Works ZTX Series Tractors

DT50-50260

© 2004 McCormick Tractors International Limited.

March 2004

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McCormick!Service!Training

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Contents!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

!Page

Engine!Description! ................................................................................................4 Engine!electronic!Control!System! .........................................................................5 Engine!Control!Circuit! ...........................................................................................8 Fuel!Pump!Schematic! ...........................................................................................10 Fuel!Pump!Operation! ............................................................................................11 Caps!Fuel!System! .................................................................................................13 Troubleshooting! ....................................................................................................18 Distributor!Valve!Check!.........................................................................................19 Bleeding!the!Fuel!System! .....................................................................................20

!McCormick!Service!Training!

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Engine!Description The!ZTX,!models!ZTX230,!ZTX!260!and!ZTX!280,!are!fitted!with!the!Cummins!QSC 24!valve!8.3!Litre!Engine.!These!engines!have!full!authority!electronic!control.!A!vast number! of! changes! have! been! implemented! when! compared! to! the! previous! C series!8.3-liter!Cummins!engines.

These! engines! have! 24! valves,! 4! valves! per! cylinder,! to! ensure! optimum! airflow, improved!fuel!economy!and!fully!emissions!compliant.!The!fuel!injector!is!located!in the! center! of! the! cylinder! to! provide! a! more! centralized! injection! and! improved!fuel burn!over!conventional!layouts.

The!fuel!system!itself!is!totally!electronically!controlled!and!uses!an!engine!mounted ECM! (Engine! Control! Module)! to! process! all! relevant! information,! and! make necessary!adjustments.

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Engine!Electronic!Control!System

Fuel!Pump

Engine!Control!Module

(View!left-hand!side!of!engine)

!McCormick!Service!Training!

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Engine!Electronic!Control!System!(Cont'd) The! electronic! control! system! for! the! QSC! Engine! uses! input! information! from! a number!of!sensors!installed!on!the!engine!and!related!equipment.!This!information is!used!to!monitor!the!current!engine!operating!conditions,!and! therefore! allow! the ECM!to!determine!the!quantity!and!timing!of!the!fuel!delivery!to!the!engine.

The! engine! control! module! (ECM)! is! mounted! on! the! left-hand! side! of! the! engine, just!to!the!rear!of!the!fuel!pump.!All!the!information!received,!and!all!corresponding outputs!will!enter!and!exit!the!ECM!via!two!50-pin!connectors!located!on!the!body!of the! controller.! All! inputs! and! outputs! use! the! rearmost! 50-pin! connector,! the! foot throttle!is!the!only!circuit!that!makes!a!connection!through!the!front!50-pin!connector.

Should! there! be! a! requirement! to! download! software! into! the! ECM,! or! to! monitor data! for! the! aid! of! diagnostics,! this! can! be! achieved! using! the! Cummins! EST (Electronic!Service!Tool)!by!an!authorized!Cummins!agent.!Although!a!connection!is provided!for!at!the!controller,!it!is!not!used!by!McCormick!Tractors!as!all!fault!code retrieval;! data! monitoring! functions! can! be! carried! out! through! the! diagnostics connector!found!in!the!operators!cab.

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McCormick!Service!Training

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Engine!Control!Circuits Accumulator Temperature!Sensor Oil!Pressure!Sensor Accumulator!Pressure Sensor Engine!Position Sensor Coolant!Temperature Sensor Engine!Speed Sensor Intake!Manifold Temperature!Sensor Intake!Manifold Pressure!Sensor

Engine!Control!Module

Foot!Throttle

Lift!Pump

Injection Control!Valve

Data!Bus Connection

Rear!Pumping Control!Valve

Power!Supply

Front!Pumping Control!Valve

!McCormick!Service!Training!

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Engine!Control!Circuits The!components!that!send!information!to!the!ECM!are:!•! The! accumulator! fuel! pressure! and! temperature! sensors! are! located! at! the! top rear!of!the!injection!pump!and!indicate!the!pressure!available!to!inject!fuel!to!the engine! and! the! temperature! of! the! fuel! to! be! injected! respectively.! The accumulator! pressure! sensor! has! a! working! range! between! 0! bar! (0! psi)! and 1655!bar!(24000!psi).

•! The!engine!speed!sensor!is!located!at!the!left!rear!of!the!timing!gear!housing!and indicates!the!speed!of!the!engine.!There!is!a!71-position!signal!indicator!ring!on the!rear!of!the!cam!gear,!which!triggers!this!sensor.!At!top!dead!center,!the!signal indent!is!removed!leaving!a!wide!blank.

•! The!engine!position!sensor!is!located!at!the!left!rear!of!the!timing!gear!housing, next! to! the! engine! speed! sensor,! and! indicates! the! position! of! the! crankshaft camshaft!to!allow!for!precise!timing!of!fuel!injection.!There!is!a!71-position!signal indicator!ring!on!the!rear!of!the!cam!gear!that!triggers!this!sensor.

•! The! intake! manifold! air! temperature! sensor! is! located! on! the! left! side! of! the cylinder!head!and!indicates!the!temperature!of!the!intake!air.

•! The! intake! manifold! pressure! sensor! is! located! on! the! left! side! of! the! cylinder head!and!indicates!the!manifold!boost!pressure.

•! The! coolant! temperature! sensor! is! located! on! the! right! side! of! the! engine,! just behind!the!alternator,!and!indicates!the!operating!temperature!of!the!engine.

•! The! engine! oil! pressure! sensor! is! located! on! the! left! side! of! the! engine! block behind! the! fuel! filter.! This! sensor! indicates! the! actual! engine! oil! pressure! and, This!information!is!transmitted!to!the!to!the!instrument!cluster!via!the!data!bus.

•! The!foot!throttle!(accelerator!pedal)!is!located!in!the!cab!and!is!connected!to!the engine!control!module!via!dedicated!wiring!through!the!front!50-pin!connector!on the!ECM.

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Engine!Control!Circuits!(Cont'd) The!outputs!from!the!ECM!that!are!used!to!control!the!operating!state!of!the!engine are:!•! The!electrically!operated!lift!pump!is!located!at!the!left!rear!of!the!engine!and!is controlled!by!the!engine!control!module.!The!lift!pump!only!runs!for!the!first!30!ñ 60! seconds! after! the! key! switch! is! turned! on.! It! draws! fuel! from! the! tank! and supplies!pressurized!fuel!to!prime!the!filter!and!gear!pump.!If!additional!priming!is required,!the!key!switch!can!be!cycled!to!the!off!position!and!then!returned!to!the on! position.! The! gear! pump! provides! the! continuous! fuel! pressure! required! for the!injection!pump.

•! The!Cummins!CAPS!fuel!system!has!two!high-pressure!pumps!to!pressurize!fuel to!the!very!high!pressure!required!for!injection.!An!electrically!actuated!pumping control! valve! individually! controls! each! pumping! element.! The! engine! control module!controls!when!the!pumping!control!valve!closes!during!the!rotation!of!the injection!pump!crankshaft.!At!light!load!and!idle,!the!pumping!control!valve!closes later! during! the! pumping! cycle! so! that! less! fuel! is! delivered! to! the! accumulator.

When! the! engine! is! operating! under! heavy! load! and! additional! fuel! is! required, the! pumping! control! valve! closes! earlier! to! deliver! more! pressurized! fuel! to! the accumulator.

•! The! injection! control! valve! is! an! electrically! operated! valve! controlled! by! the engine! control! module,! which! controls! the! delivery! of! fuel! to! each! cylinder.! The opening!of!the!injection!control!valve!controls!the!timing!of!injection.!The!length!of time! that! the! valve! as! well! as! the! fuel! pressure! stored! within! the! accumulator controls!the!total!amount!of!fuel!delivered!which!in!turn!controls!the!power!output.

The! single! injection! control! valve! ports! fuel! to! each! injector! through! a! rotary distributor!valve.! As! the! injection! pump! rotates,! the! rotary! distributor! valve! ports fuel!to!the!correct!injector!based!on!crankshaft!rotation.

!McCormick!Service!Training!

DT50-50260

Page!9

SECTION!2

Fuel!Pump!Schematic

Page!10

!!!DT50-50260

McCormick!Service!Training

SECTION!2

Fuel!Pump!Operation When!the!key!switch!is!initially!actuated,!the!lift!pump!runs!for!30!-!60!seconds!and draws!fuel!from!the!tank!to!prime!the!system.!The!lift!pump!pressurizes!the!system to!approximately!6.5!bar!(95!psi).!The!lift!pump!also!incorporates!a!check!valve!to allow!fuel!flow!when!it!is!not!running.!The!fuel!filter!is!located!between!the!lift!pump and!gear!pump!on!the!left!side!of!the!engine.

The! gear! pump! is! part! of! the! injection! pump! assembly! and! is! driven! by! the! input shaft.!Its!purpose!is!to!provide!fuel!flow!to!the!system!during!engine!operation.!This fuel!flow!is!delivered!to!both!the!front!and!rear!pumping!control!valves!(PCV),!which are!mounted!on!the!top!of!the!accumulator!housing.!A!pressure!regulator!valve!that is! integral! to! the! gear! pump! housing! controls! the! output! pressure! from! the! gear pump.! This! regulator! valve! is! set! to! a! pressure! of! 11.5! bar! (165! psi)! and! is considered!non!adjustable.

The! two! pumping! control! valves! are! normally! open! solenoid! valves! and! will! close when!commanded!to!do!so!by!the!ECM.!Closing!these!solenoid!valves!will!result!in the!high!pressure!pumping!units!to!increasing!the!fuel!pressure!from!approximately 11.5! bar! (165! psi)! to! between! 345! 1035! bar! (5000! to! 15000! psi)! required! for injection.! The! output! pressure! from! these! pumping! elements! is! determined! by! the fuel!requirement!of!the!engine.

The!input!shaft!in!the!injection!pump!body!has!two!tri-lobe!cams!on!the!shaft,!which actuate!the!high!pressure!pumping!units.!Each!high!pressure-pumping!unit!actuates three!times!each!revolution!of!the!injection!pump!shaft.!The!duration!of!the!revolution that! the! pumping! control! valve! is! closed! controls! the! quantity! of! high-pressure! fuel that!is!delivered.!During!the!time!that!the!pumping!control!valve!is!open,!the!output!of the! high! pressure-pumping! unit! returns! to! the! fuel! tank! via! the! pressure! regulator valve.! When! the! pumping! control! valves! are! closed! the! high! pressure! pumping elements! will! deliver! the! fuel! flow,! through! one! way! check! valves,! into! the accumulator!housing.

!McCormick!Service!Training!

DT50-50260

Page!11

SECTION!2

Fuel!Pump!Operation!!(Cont'd) The!point!at!which!the!pumping!control!valves!are!commanded!on!can!be!monitored using! the! Cummins! Electronic! Service! Tool! (EST).! The! parameter! that! should! be viewed! is! the! Valve! Crank! Angle! (VCA)! and! relates! to! the! angle,! in! degrees! of rotation,!before!top!dead!center!when!the!control!valves!are!energized.

The!accumulator!stores!pressurized!fuel,!typically!at!pressures!between!345!to!1035 bar!(5000!to!15000!psi),!ready!for!injection!event.!The!accumulator!is!also!connected to!the,!normally!closed,!injection!control!valve!(ICV)!via!the!ĂŹRate!Shape!TubeĂŽ.!The injection! control! valve! opens! at! the! required! time! to! control! the! injection! timing! to each!cylinder.!The!length!of!time!that!the!injection!control!valve!is!open!controls!the amount!of!fuel!delivery,!which!in!turn!controls!the!power!output.

The!output!of!the!injection!control!valve!is!connected!to!the!rotary!distributor!valve!at the! lower! rear! of! the! injection! pump.! This! rotary! distributor! valve! is! driven! by! the pump!drive!shaft!and!is!used!to!direct!the!fuel!to!the!required!injector.

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!!!DT50-50260

McCormick!Service!Training

SECTION!2

CAPS!Fuel!System The!Cummins!Accumulator!Pump!System!(CAPS)!consists!of!six!basic!components, components!are!separate!assemblies!and!will!be!discussed!individually.

The!fuel!pump!body!is!directly!connected!to!the!engine!timing!cover!and!includes!the input!shaft!and!camshaft!lobes!that!actuate!the!high!pressure!pumping!units.

The! gear! pump! is! mounted! to! the! rear! of! the! fuel! pump! body! and! is! driven! by! the input!shaft;!a!small!internal!coupling!connects!the!two!components.!The!gear!pump will!take!fuel!from!the!fuel!tank!and!pass!it!through!the!fuel!filter.!It!will!then!make!it available!to!the!inlet!of!the!high!pressure!pumping!units.!The!outlet!pressure!of!this pump!is!regulated!to!approximately!11.5!bar!(165!psi).

The! accumulator! assembly! mounts! directly! to! the! top! of! the! fuel! pump! body! and consists!of!the!following!components:!•! The! camshaft! in! the! fuel! pump! body! actuates! the! high-pressure! pumping! units.

These! units! take! fuel! delivered! by! the! gear! pump! and! increase! the! pressure! to that! required! for! injection! into! the! combustion! chamber.! The! outlet! pressure! of these! units! is! typically! regulated! between! 345! to! 1035! bar! (5000! to! 15000! psi).

Individual!pump!control!valves!control!the!outlet!flow!of!these!pumping!units. •! Electrically! operated! pump! control! valves! are! located! on! the! top! of! the accumulator! assembly.! The! timing! of! the! actuation! of! these! valves! controls! the quantity! of! fuel! delivered! by! the! high! pressure! pumping! units! and! therefore! the injection!pressure.!The!engine!control!module!controls!these!valves.!These!pump control! valves! are! installed! and! calibrated! on! initial! assembly! and! cannot! be adjusted.! Replacement! of! a! faulty! pumping! control! valve! would! require! a! new accumulator!assembly •! The! accumulator! portion! of! the! accumulator! assembly! consists! of! drilled passages!within!the!accumulator!body.!The!accumulator!function!is!based!on!the fact! that! diesel! fuel! is! approximately! 8%! compressible! at! 1035! bar! (15000! psi).

These! drilled! passages! are! sealed! with! plugs! that! have! seal! discs! under! them.

These!seal!discs!are!currently!not!available!as!separate!service!parts.

!McCormick!Service!Training!

DT50-50260

Page!13

SECTION!2

CAPS!Fuel!System!(cont'd) •! The! accumulator!fuel!pressure!and! temperature! sensor! is! located! at! the! rear! of the!accumulator!assembly.!This!sensor!monitors!the!pressure!and!temperature!of the!high-pressure!fuel!stored!in!the!accumulator.!This!sensor!sends!information!to the!engine!control!module. •! The!rate!shape!tube!is!located!at!the!top!rear!of!the!injection!pump!assembly!and ports! the! high-pressure! fuel! from! the! accumulator! to! the! injection! control! valve.

The!length!of!this!tube!controls!the!shape!of!the!injection!line!pressure!rise!curve.

The! length! of! this! tube! affects! NOX! emissions.! Do! not! bend! this! tube! during! or after!installation.

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!!!DT50-50260

McCormick!Service!Training

SECTION!2

CAPS!Fuel!Pump!Components

Rate!Shape!Tube

Accumulator

Distributor!Housing

Gear!Pump Assembly Fuel!Pump Body

!McCormick!Service!Training!

DT50-50260

Page!15

SECTION!2

CAPS!Fuel!Pump Pumping!Control Valves Accumulator Housing

Injection Control!Valve Rate Shape

High!Pressure Pumping Elements

Fuel!Pump Body

Distributor Valve

Tri-lobe Cams

Page!16

Gear Pump

Drive Coupling

Drive Coupling

!!!DT50-50260

McCormick!Service!Training

SECTION!2

CAPS!Fuel!System!(cont'd) The! injection! control! valve! (ICV)! is! located! at! the! rear! of! the! injection! pump.! This control! valve! is! an! electrically! operated! valve! commanded! by! the! engine! control module! (ECM),! which! controls!the! delivery! of!fuel! to! each! cylinder.! The! opening! of the!injection!control!valve!controls!the!timing!of!injection.!The!length!of!time!that!the valve!is!open,!as!well!as!the!fuel!pressure!stored!within!the!accumulator!controls!the total! amount! of! fuel! delivered,! which! in! turn! controls! the! power! output.! The! single injection! control! valve! ports! fuel! to! individual! injectors! through! a! rotary! distributor valve.

The!rotary!distributor!control!valve!is!located!at!the!lower!rear!of!the!injection!pump and! is!driven! from!the! gear! pump! shaft;!a! small! internal! coupling! connects! the! two components.!As!the!injection!pump!rotates,!the!distributor!will!control!which!injector is!supplied!with!fuel,!based!on!the!rotation!of!the!crankshaft.

The! injectors! are! located! at! the! top!of! the! cylinder! head! centered! over! the! pistons.

The! injectors! inject! atomized! fuel! into! the! combustion! chamber! during! the! power stroke!of!the!combustion!cycle.

!McCormick!Service!Training!

DT50-50260

Page!17

SECTION!2

Engine!Troubleshooting Retrieval! of! fault! code! information! from! the! Engine! Control! Module! can! be! done through!the!instrument!cluster,!or!with!the!Cummins!Electronic!Service!Tool!and!the McCormick!Diagnostic!Tool Engine! troubleshooting! information! is! available! in!the! QSC! Engine! Troubleshooting Manual!(available!from!Cummins).

If!QSC!engine!running!problems!are!encountered:!•! Inspect!the!fuel!level!in!the!tanks; •! Check!for!air!leaks!and!restrictions!in!the!fuel!inlet!system; •! Inspect!for!air!intake!problems; •! Inspect!for!mechanical!problems; •! Inspect!for!rotary!distributor!valve!problems; •! Inspect!for!injector!problems; •! Check!for!fault!codes!using!the!tractor!instrumentation!or!the!electronic service!tool.

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!!!DT50-50260

McCormick!Service!Training

SECTION!2

Fuel!Pump!Distributor!Valve!Inspection Remove!the!key!from!the!ignition!switch to! prevent! any! attempt! at! starting! the engine. !Thoroughly! clean! the! area! around! the fuel! pump.! Pay! particular! attention! to the!rear!connections!area.

After! removing! the! front! access! cap, rotate!the!engine!using!the!turn!over!tool until! the! Timing! mark! on! the! pump! drive gear! aligns! with! the! TDC! mark! on! the timing!cover.

Remove!the!distributor!plug!(1).

Do! not! attempt! to! start! the! engine! with the! distributor! plug! removed.! To! do! so could! result! in! the! rotor! being! ejected from! the! distributor,! causing! damage! to the!rotor.

Check! the! position! of! the! notch! on! the rotor.! It! should! line-up! with! the! alignment mark!(A)!on!the!outside!of!the!distributor.!If the! alignment! is! correct! the! rotor! is properly!timed!to!the!engine.

If! the! alignment! is! incorrect! inspect! the internal!drive!couplings.

Replace! distributor! necessary.

!McCormick!Service!Training!

DT50-50260

plug!

oĂ­ring!

as

Page!19

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