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McCormick MC100 Tractor Service Repair Manual

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This is the Highly Detailed factory service repair manual for theMCCORMICK MC100 TRACTOR , this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.MCCORMICK MC100 TRACTOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: General Engine Fuel System Electrical Steering Transmission Brakes Hydraulic Chassis and Mounted Equipment Controller Systems File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveMCCORMICK MC100 TRACTOR Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!

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MC Series Tractors Service Manual SM 8-11102 Section Pub. No. 1 GENERAL Safety Rules, General Information and Torque Specifications ............................1001 SM General Specifications and Torques.....................................................................1002 SM 2 E NGINE Engine Removal ..................................................................................................2001 SM NOTE: For Service and Overhaul procedures refer to your Engine Service 1000 Series Manual SM 8-10041. 1100 Series 4 Cyl 1100 Series 6 Cyl 3 FUEL SYSTEM Fuel Tank Removal and Servicing........................................................................3005 SM NOTE: For Service and Overhaul procedures refer to your Engine Service Manual SM 8-10041. 4 ELECTRICAL Electrical Schematics...........................................................................................4001 SM Instrument Cluster Programming.........................................................................4002 SM Battery Servicing and Testing..............................................................................4004 SM 5 STEERING Steering Column and Steering Hand Pump.........................................................5001 SM Steering Hand Pump ...........................................................................................5002 SM 6 TRANSMISSION HOW IT WORKS………………………………………………………………………………….. Separating the Tractor (Engine and Speed Transmission) and Torque Dampener ................................................................................................6002 SM Separating the Speed and Range Transmission..................................................6003 SM Powershift Transmission Servicing ......................................................................6006 SM Range Transmission Servicing ............................................................................6007 SM Powershift Valve ..................................................................................................6009 SM Shuttle Valve.........................................................................................................6010 SM Synchronizer Creep Transmission........................................................................6011 SM Differential and Differential Lock...........................................................................6012 SM MFD Output Shaft and Bearing ............................................................................6015 SM Rear Axles and Planetaries ..................................................................................6018 SM PTO - Reversible and Shiftable ............................................................................6019 SM 20.14 MFD Front Axle...........................................................................................6021 SM 20.19 and 20. 25 MFD Front Axle ........................................................................6021 SM Independent Front Suspension Axle (20.19 and 20. 25 Axle) ..............................6022 SM PTO Front Drive Shaft and Hydraulic Pump Drive Gear ......................................6023 SM 7 BRAKES Service Brakes.....................................................................................................7002 SM
Hydraulic Trailer Brake Valve ..............................................................................7004 SM 8 HYDRAULICS HOW IT WORKS………………………………………………………………………………… Hydraulic Troubleshooting and Schematic (MC Series Tractors up to P.I.N JJE2020415) ...................................................8001 SM Hydraulic Troubleshooting and Schematic (MC Series Tractors P.I.N JJE2020416 and After)..............................................8001 SM Charge Lubrication Pump....................................................................................8003 SM Hydraulic Valves .................................................................................................8006 SM Remote Valves ....................................................................................................8008 SM 9 CHASSIS AND MOUNTED EQUIPMENT Pedal, Lever Adjustments....................................................................................9001 SM Air Conditioner Troubleshooting (Visual and Operating) ....................................9003 SM Air Conditioner Troubleshooting (Gauges and Testing) .....................................9004 SM Air Conditioner System Components Servicing .............................................. ...9005 SM Cab Removal and Cab Roof Panel Tilting ..........................................................9006 SM 10 CONTROLLER SYSTEMS Hitch/MFD/Differential Lock Controller - Calibration, Error Codes Troubleshooting and Schematics ........................................................................10002 SM Independent Front Suspension Axle Controller Calibration, Error Codes, Troubleshooting and Schematics................................10003 SM Speed Sequencer Controller, F/N/R and powershift - Calibration, Error Codes Troubleshooting and Schematics (For Tractors With Speed Sequencer).................................................................10004 SM PTO Controller (For Tractors With Speed Sequencer), F/N/R Controller and Powershift (For Tractors Without Speed Sequencer) - Configuration, Error Codes, Troubleshooting and Schematics ........................10006 SM Hitch and PTO Controller Programming ............................................................10010 SM There is a large selection of McCormick tractor models available for vastly differing applications. This Service Manual may include some information, illustrations and photographs, which may differ to the standard equipment and accessories on your tractor.
Section 1001 1001 © 2001 McCormick Tractors International Limited. SM 8-10080 March 2001 SAFETY, GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS
SECTION 10012 SM 8-10080 Issued 03-2001 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
SECTION 1001 SM 8-10080 Issued 03-2001 3 SAFETY 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. 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. ! WARNING: Read the operators manual to familiarize yourself with the correct control functions. WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. WARNING: This is one a man machine, no riders allowed. ! DO NOT OPERATE NE PAS UTILISER NICHT BETREIBEN NO UTILIZAR REASON/RAISON VERNUNFT/RAZON 2-1000 ! ! ! 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. 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. WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. 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. WARNING: Use insulated gloves or mittens when working with hot parts. ! ! ! ! ! !
SECTION 10014 SM 8-10080 Issued 03-2001 CAUTION: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. 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. 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. 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). 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. ! ! ! ! ! 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. CAUTION: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual. 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. 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. 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. ! ! ! ! !
SECTION 1001 SM 8-10080 Issued 03-2001 5 GENERAL INFORMATION Cleaning 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. 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. Gears Check all gears for wear and damage. Replace gears that have wear or damage. 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.
SECTION 10016 SM 8-10080 Issued 03-2001 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) Chart 2 (Phosphate Coated Nuts/Bolts) BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 3.0 4.0 3.4 4.5 4.3 5.8 4.8 6.5 M5 4.8 6.5 5.5 7.5 7.0 9.5 7.8 10.5 M6 8.2 11.0 9.2 12.5 11.8 16.0 13.3 18.0 M8 20.0 27.0 22.5 31.0 28.7 39.0 32.3 44.0 M10 40.0 54.0 45.0 61.0 56.0 77.0 64.0 87.0 M12 69.0 94.0 78.0 106.0 100.0 134.0 110.0 151.0 M14 110.0 150.0 125.0 170.0 160.0 215.0 180.0 240.0 M16 175.0 235.0 190.0 260.0 245.0 335.0 275.0 375.0 M20 345.0 470.0 390.0 530.0 480.0 650.0 540.0 730.0 M22 475.0 640.0 530.0 720.0 655.0 890.0 735.0 1000.0 M24 600.0 810.0 675.0 915.0 830.0 1125.0 930.0 1265.0 M30 1190.0 1615.0 1340.0 1815.0 1645.0 2235.0 1855.0 2515.0 M36 2080.0 2825.0 2340.0 3175.0 2875.0 3900.0 3235.0 4390.0 BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 2.3 3.0 2.6 3.4 3.2 4.4 3.6 4.9 M5 3.6 4.9 4.1 5.6 5.2 7.1 5.9 8.0 M6 6.2 8.3 6.9 9.4 8.9 12.0 10.0 13.5 M8 15.0 20.3 16.9 23.3 21.5 29.2 24.2 32.8 M10 30.0 41.0 34.0 46.0 42.0 58.0 48.0 65.0 M12 52.0 71.0 59.0 80.0 75.0 101.0 83.0 113.0 M14 83.0 113.0 94.0 126.0 120.0 161.0 135.0 180.0 M16 131.0 176.0 143.0 195.0 185.0 251.0 205.0 280.0 M20 259.0 353.0 293.0 400.0 360.0 490.0 405.0 550.0 M22 355.0 480.0 400.0 540.0 490.0 665.0 550.0 750.0 M24 450.0 608.0 506.0 686.0 625.0 845.0 700.0 950.0 M30 893.0 1211.0 1005.0 1361.0 1235.0 1675.0 1390.0 1885.0 M36 1560.0 2119.0 1755.0 2381.0 2156.0 2925.0 2425.0 3295.0
SECTION 1001 SM 8-10080 Issued 03-2001 7 Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 2.6 3.5 2.9 3.9 3.7 5.0 4.1 5.6 M5 4.1 5.6 4.6 6.3 5.9 8.0 6.6 9.0 M6 7.0 9.5 7.8 10.6 10.0 13.6 11.3 15.3 M8 17.0 23.1 19.1 25.9 24.4 33.1 27.4 37.2 M10 34.0 46.0 38.3 52.0 48.0 65.0 54.0 74.0 M12 59.0 80.0 66.0 90.0 85.0 114.0 94.0 128.0 M14 94.0 128.0 106.0 145.0 136.0 183.0 153.0 205.0 M16 149.0 200.0 161.0 220.0 208.0 285.0 235.0 320.0 M20 293.0 400.0 330.0 450.0 408.0 555.0 460.0 620.0 M22 400.0 545.0 450.0 615.0 555.0 755.0 625.0 850.0 M24 510.0 690.0 575.0 780.0 705.0 955.0 790.0 1075.0 M30 1010.0 1375.0 1140.0 1545.0 1400.0 1900.0 1580.0 2140.0 M36 1770.0 2400.0 1990.0 2700.0 2445.0 3315.0 2750.0 3730.0
Section 1002 1002 © 2002 McCormick Tractors International Limited. SM 8-10641 March 2001 (Revised June 2002) GENERAL SPECIFICATIONS AND TORQUES MC Series Tractors
SECTION 10022 SM 8-10641 Issued 06-2002 TABLE OF CONTENTS GENERAL SPECIFICATIONS Lubricants and Capacities ....................................................................................................................................3 Engine ..................................................................................................................................................................3 Fuel ......................................................................................................................................................................3 Electrical ...............................................................................................................................................................4 Transmission ........................................................................................................................................................4 Hydraulics .............................................................................................................................................................5 Air Conditioning ....................................................................................................................................................7 Conversion Table .................................................................................................................................................8 SPECIAL TORQUES Engine ..................................................................................................................................................................9 Transmission ........................................................................................................................................................9 Hydraulics ...........................................................................................................................................................10 Cab and Chassis ................................................................................................................................................10
SECTION 1002 SM 8-10641 Issued 06-2002 3 GENERAL SPECIFICATIONS Lubricants and Capacities ENGINE Oil Type ...................................................................................................... McCormick Engine Oil, SAE 15W - 40 Capacity (With Filter Change) .....................................................................................................................7 Litres ENGINE COOLANT Coolant Mix ........................................................................................................ McCormick Universal Anti-freeze Solution of 33% to 50% Ethylene Glycol (depending on market requirements) Capacity ................................................................................................................................................17. 5 Litres AIR CONDITIONER SYSTEM Compressor Oil .................................................................................................................Sanden SP - 20 Pag Oil Capacities.......................................................................................................................................Refer to Page 7 TRANSMISSION Oil Type ........................................................................................................................................ McCormick HTX Factory Fill Capacity..................................................................................................................................75 Litres Refill Capacity (Approximately) ..............................................................................................................66.3 Litres MFD AXLE Oil Type .......................................................................................................... McCormick Multi-Purpose Gear Oil SAE 85W - 140 EP Gear Oil to API GL-5 or MIL-L-2105 Specification MC80 (20.14 Axle) Differential Oil............................................................................................................5.0 Litres MC90, MC100 and MC115 (20.19 Axle) Differential Oil...........................................................................6.0 Litres Axle Planetaries (Each)............................................................................................................................0.6 Litres FUEL TANK Fuel Capacity ..........................................................................................................................................189 Litres FRONT PTO (Kitchin) Oil Type .........................................................................................................................................McCormick HTX Capacity .................................................................................................................................................0.65 Litres FRONT PTO (Hydrac) Oil Type ............................................................................................. McCormick Super Universal, SAE 10W - 30 Capacity .................................................................................................................................................0.75 Litres 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.
SECTION 10024 SM 8-10641 Issued 06-2002 Electrical System Type.................................................................................................................... 12 Volt Negative Ground Batteries .......................................................................... One or Two 12 Volt, Low Maintenance Hybrid Batteries Connected in Parallel, DIN Type 60527, Top Stud Terminals Alternator....................................................................................................................................... 12 Volt, 95 Amp Starter Motor................................................................................................................................... 12 Volt, 3.1 kW Transmission POWERSHIFT TRANSMISSION Friction Plate Thickness ................................................................................................................2.45 to 2.60 mm Separator Plate Thickness ............................................................................................................2.16 to 2.31 mm Backing Plate Thickness ...............................................................................................................5.58 to 5.71 mm Total Thickness ...........................................................................................................................10.8 to 11.05 mm Number of Plates 1st Clutch Pack (Input Shaft) ...........................................................4 Friction 4 Separator 3rd Clutch Pack (Input Shaft) ..........................................................4 Friction 4 Separator 2nd Clutch Pack (Dropshaft)............................................................5 Friction 5 Separator 4th Clutch Pack (Dropshaft).............................................................4 Friction 5 Separator RANGE TRANSMISSION Intermediate Shaft End Play..................................................................................................... 0.025 to 0.102 mm Shuttle Shaft End Play ..............................................................................................................0.025 to 0.102 mm Friction Plate Thickness ................................................................................................................2.45 to 2.60 mm Separator Plate Thickness ............................................................................................................2.16 to 2.31 mm Backing Plate Thickness ...............................................................................................................5.58 to 5.71 mm Total Thickness ......................................................................................................................10.8 to 11.05 mm Pinion Shaft Bearing Preload Rolling Pull .........................................................................................2.0 to 3.2 kg/f MFD CLUTCH Slip Torque MC80 Tractors New Tractor.............................................................................................................................................. 1300 Nm Used Tractors.................................................................................................................................. 790 to 960 Nm Tractor with Worn Plates ................................................................................................................ 620 Nm or less Slip Torque MC90, MC100 and MC115 Tractors New Tractor.......................................................................................................................................... 2100 Nm Used Tractors..........................................................................................................................1260 to 1540 Nm Tractor with Worn Plates.......................................................................................................... 1000 Nm or less Number of Clutch Plates MC80 Tractors Friction Plates ...............................................................................................................................................5 Separator Plates ...........................................................................................................................................5 Number of Clutch Plates MC90, MC100 and MC115 Tractors Friction Plates ...............................................................................................................................................8 Separator Plates ...........................................................................................................................................8 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
SECTION 1002 SM 8-10641 Issued 06-2002 5 MFD Clutch Friction Plate Thickness ............................................................................................2.45 to 2.60 mm MFD Clutch Separator Plate Thickness ........................................................................................2.16 to 2.31 mm Belleville Washer Free Height ......................................................................................................................11 mm MFD Clutch Assembly End Play ..................................................................................................1.00 to 1.25 mm MFD Bearing Housing End Play....................................................................................................0.03 to 0.12 mm MFD Idler Gear End Play ..........................................................................................................0.025 to 0.102 mm MFD OUTPUT SHAFT Output Shaft End Play.....................................................................................................................0.1 to 0.15 mm CREEP TRANSMISSION Creep Layshaft End Play.............................................................................................................0.03 to 0.127 mm Creep Main Shaft End Play...........................................................................................................0.03 to 0.10 mm DIFFERENTIAL AND DIFFERENTIAL LOCK Ring Gear and Pinion Backlash ....................................................................................................0.20 to 0.25 mm Differential Lock Clutch Number of Plates Friction Plate................................................................................................................................................ 9 Separator Plate............................................................................................................................................ 8 Plate Thickness Friction Plate .................................................................................................................................1.98 to 2.13 mm Separator Plate .............................................................................................................................1.05 to 1.18 mm Piston Return Plate .......................................................................................................................4.11 to 4.23 mm REAR AXLES Axle Shaft Bearing (without Seal).......................................................................................................... 3.4 to 5.7 Nm PTO DRIVE SHAFT AND HYDRAULIC PUMP DRIVE GEAR Hydraulic Pump Drive Gear End Play .......................................................................................0.025 to 0.125 mm PTO - REVERSIBLE/SHIFTABLE PTO Input Shaft End Play .............................................................................................................0.03 to 0.13 mm PTO Output Shaft End Play.......................................................................................................0.025 to 0.125 mm PTO Clutch Friction Plate Thickness.............................................................................................2.45 to 2.60 mm PTO Clutch Steel Separator Plate Thickness................................................................................2.16 to 2.31 mm PTO Clutch Backing Plate Thickness............................................................................................5.58 to 5.71 mm PARKING BRAKE Plate Thickness Friction Plate .............................................................................................................................6.25 to 6.40 mm Backing Plate ............................................................................................................................2.16 to 2.31 mm Hydraulics HYDRAULIC PUMP Manufacturer ...............................................................................................................................................Vickers Type...............................................................................................................Pressure, Flow Compensated (PFC) Maximum Pressure at Rated Engine rpm at Pump ..........................................................................198 to 206 bar Maximum Flow at Couplers........................................................................................................................ 95l/min. POWERSHIFT VALVE Control Spool Pilot Spring Free Length.........................................................................................................................................47.91 mm Outside Diameter ....................................................................................................................15.24 to 15.5 mm Test Length .........................................................................................................................................28.50 mm Test Load ................................................................................................................................... 56.04 to 68.6 N
SECTION 10026 SM 8-10641 Issued 06-2002 Inlet Spool Pilot Spring Free Length.........................................................................................................................................47.91 mm Outside Diameter ....................................................................................................................15.24 to 15.5 mm Test Length..........................................................................................................................................28.50 mm Test Load....................................................................................................................................56.04 to 68.6 N Modulation Spring (Inner) Free Length.........................................................................................................................................38.79 mm Outside Diameter .................................................................................................................. 11.05 to 11.31 mm Test Length..........................................................................................................................................33.17 mm Test Load..............................................................................................................................124.09 to 151.69 N Modulation Spring (Outer) Free Length.........................................................................................................................................38.71 mm Outside Diameter ..................................................................................................................18.03 to 18.26 mm Test Length..........................................................................................................................................33.17 mm Test Load..............................................................................................................................256.17 to 313.17 N Reducing Spring Free Length.........................................................................................................................................35.82 mm Outside Diameter ..................................................................................................................10.87 to 11.13 mm Test Length..........................................................................................................................................27.00 mm Test Load.................................................................................................................................. 24.02 to 29.36 N HITCH VALVE Compression Spring Free Length.......................................................................................................................................29.642 mm Outside Diameter ................................................................................................................................14.22 mm SHUTTLE VALVE Modulation Spring Outer Free Length.......................................................................................................................................107.34 mm Outside Diameter .................................................................................................................20.09 to 21. 35 mm Test Length............................................................................................................................................88.6 mm Test Load.................................................................................................................................. 37.23 to 45.51 N Modulation Spring Inner Free Length.........................................................................................................................................78.36 mm Outside Diameter ..................................................................................................................13.05 to 13.31 mm Test Length..........................................................................................................................................39.50 mm Test Load................................................................................................................................ 96.08 to 117.42 N Inching Spool Return Spring (Yellow) Free Length.........................................................................................................................................91.73 mm Outside Diameter ....................................................................................................................20.44 to 20.7 mm Test Length..........................................................................................................................................26.67 mm Test Load.................................................................................................................................. 40.03 to 48.93 N Forward/Reverse Spool Centring Spring Free Length.........................................................................................................................................51.75 mm Outside Diameter ..................................................................................................................17.65 to 17.91 mm Test Length..........................................................................................................................................25.43 mm Test Load.................................................................................................................................. 63.37 to 69.97 N Feathering Spring (Low Pressure) Free Length.........................................................................................................................................25.02 mm Outside Diameter ..................................................................................................................10.84 to 11.10 mm Test Length..........................................................................................................................................14.86 mm Test Load.................................................................................................................................. 22.14 to 27.06 N Feathering Spring (High Pressure) Free Length.........................................................................................................................................23.64 mm Outside Diameter .................................................................................................................. 11.50 to 11.76 mm Test Length..........................................................................................................................................16.25 mm Test Load................................................................................................................................ 96.07 to 117.43 N
SECTION 1002 SM 8-10641 Issued 06-2002 7 PRIORITY REGULATOR VALVE Priority Spring Free Length.........................................................................................................................................58.07 mm Outside Diameter ..................................................................................................................21.97 to 22.23 mm Test Length .........................................................................................................................................41.91 mm Test Load ............................................................................................................................. 240.20 to 293.60 N Regulator Spring Free Length.........................................................................................................................................72.11 mm Outside Diameter ..............................................................................................................22.043 to 22.397 mm Test Length .........................................................................................................................................41.91 mm Test Load ............................................................................................................................. 476.38 to 582.24 N Check Valve Spring Free Length.........................................................................................................................................31.10 mm Outside Diameter ......................................................................................................................5.97 to 6.23 mm Test Length .........................................................................................................................................26.01 mm Test Load ................................................................................................................................... 8.41 to 10.27 N Pilot Relief Valve Spring Free Length.........................................................................................................................................29.56 mm Outside Diameter ..................................................................................................................6.227 to 6.727 mm Test Length .........................................................................................................................................20.98 mm Test Load ............................................................................................................................... 82.08 to 100.28 N Air Conditioning REFRIGERANT Type........................................................................................................................................................HFC-134A 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 ...........................................................................................................................................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 Drive Belt Tension (New).................................................................................................................... 422 to 516 N Drive Belt Tension (Used)................................................................................................................... 400 to 489 N COMPRESSOR AND SYSTEM LUBRICATION (Nominal) Lubrication 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 m Condenser.............................................................................................................................................45 to 50 ml Evaporator.............................................................................................................................................35 to 40 ml Hoses and Tubes (Total) .......................................................................................................................45 to 50 ml HIGH PRESSURE SWITCH Location..............................................................................Discharge Hose from Compressor at Condenser Inlet Operation................................................................................................... Closed by Excessive System Pressure Cut Out Pressure............................................................................................................................26.9 to 28.3 bar
SECTION 10028 SM 8-10641 Issued 06-2002 LOW PRESSURE SWITCH Location............................................................................................................. Evaporator outlet in the Cab Roof Operation.............................................................................................................Closed by Low System 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 Conversion Table Conversion 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
SECTION 1002 SM 8-10641 Issued 06-2002 9 SPECIAL TORQUES Engine Engine to Transmission Retaining Bolts 12 mm Flange Type Bolts ........................................................................................................... 100 to 110 Nm Torque Dampener Retaining Bolts .................................................................................................... 88 to 112 Nm Front Bolster to Engine Retaining Bolts (With Loctite 271) ............................................................. 258 to 284 Nm Engine Lifting Bracket Retaining Bolts ........................................................................................................ 44 Nm Transmission POWERSHIFT TRANSMISSION Transmission Front Cover Retaining Bolts 16 mm Retaining Bolts................................................................................................................ 251 to 280 Nm 12 mm Retaining Bolts................................................................................................................ 101 to 113 Nm Front Bearing Carrier Retaining Bolts ............................................................................................. 101 to 113 Nm Oil Distributor Retaining Bolts ............................................................................................................. 58 to 65 Nm Drive Gear Retaining Bolt (with Loctite 638) .................................................................................. 101 to 113 Nm RANGE TRANSMISSION AND MFD CLUTCH Speed to Range Transmission Retaining Bolts ............................................................................... 251 to 280 Nm Bearing Carrier (Sandwich Plate) Mounting Bolts ........................................................................... 235 to 265 Nm Gear Shifter Lever Clamping Bolt...................................................................................................... 94 to 106 Nm MFD Clutch Mounting Bolts and Nut ............................................................................................... 251 to 280 Nm Parking Brake Mounting Bolts ......................................................................................................... 101 to 113 Nm Pinion Shaft Bolt Plain Bolt Part Number 826-16110.............................................................................................. 335 to 375 Nm Phosphate Coated Bolt Part Number 828-16110........................................................................ 265 to 285 Nm IMPORTANT: When the pinion bolt is removed it must be discarded and replaced with a new bolt. It is important that the correct torque is used for the type of bolt installed. DIFFERENTIAL AND DIFFERENTIAL LOCK Ring Gear Retaining Bolts............................................................................................................... 276 to 308 Nm Differential Lock Clutch Cage Retaining Bolts............................................................................................ 130 Nm Differential Bearing Carrier Retaining Bolts......................................................................................... 58 to 65 Nm REAR AXLES Rear Axle Mounting Bolts................................................................................................................ 251 to 280 Nm MFD DRIVE SHAFT MFD Drive Shaft Mounting Bolts ......................................................................................................... 39 to 44 Nm PTO DRIVE SHAFT GEAR PTO Drive Gear Retaining Bolt ....................................................................................................... 101 to 113 Nm Transmission Cont. PTO - REVERSIBLE/SHIFTABLE PTO Housing Retaining Bolts and Nuts M16 Retaining Bolts.................................................................................................................... 251 to 280 Nm M20 Retaining Bolts and Nuts..................................................................................................... 251 to 280 Nm PTO Selector Lever Retaining Bolt.................................................................................................. 101 to 113 Nm Front Bearing Carrier Retaining Bolts ............................................................................................... 98 to 110 Nm Oil Baffle Plate Retaining Bolts............................................................................................................ 39 to 44 Nm Seal Retainer Retaining Bolts.............................................................................................................. 27 to 31 Nm PTO Clutch Retaining Bolt............................................................................................................... 147 to 166 Nm
SECTION 100210 SM 8-10641 Issued 06-2002 Hydraulics HITCH VALVE Mounting Bolt ...................................................................................................................................... 47 to 54 Nm PRIORITY REGULATOR VALVE Mounting Bolt ...................................................................................................................................... 47 to 54 Nm Regulator Adjusting Plug Nut .............................................................................................................. 36 to 53 Nm Pilot Relief Valve................................................................................................................................75 to 108 Nm Pilot Relief Valve Adjusting Plug Nut................................................................................................... 16 to 19 Nm POWERSHIFT VALVE Retaining Bolts .................................................................................................................................... 48 to 54 Nm Test Port Plugs .................................................................................................................................... 34 to 54 Nm M18 Spool End Plugs ......................................................................................................................... 34 to 54 Nm M27 Spool End Plugs ......................................................................................................................... 34 to 54 Nm Solenoid Valve .................................................................................................................................... 12 to 18 Nm Solenoid Coil Retaining Nut ....................................................................................................................5 to 8 Nm Shuttle Valve Retaining Bolts .............................................................................................................. 48 to 54 Nm Solenoid Valve..................................................................................................................................... 12 to 18 Nm Solenoid Retaining Nut............................................................................................................................5 to 8 Nm Diagnostic Test Fitting ......................................................................................................................... 23 to 34 Nm 1/2 inch Plug........................................................................................................................................ 30 to 45 Nm 5/8 inch Plug........................................................................................................................................ 40 to 59 Nm 3/4 inch Plug........................................................................................................................................ 40 to 59 Nm M14 Plug ............................................................................................................................................. 23 to 34 Nm Shuttle Valve Cover Retaining Screws (Loctite 242 on threads)...........................................................9 to 13 Nm Solenoid Valve Plug (non-MFD) .......................................................................................................... 30 to 45 Nm Cab and Chassis CAB Cab Mounting Bracket to Rear Axle Bolts .......................................................................................244 to 320 Nm Cab Mounting Bolt to Threaded Plate ................................................................................................ 47 to 61 Nm Cab Mounting Nut ...........................................................................................................................190 to 244 Nm CHASSIS Battery Box Retaining Nut and Bolts ...............................................................................................221 to 250 Nm Front Fuel Tank Bracket Retaining Bolts .........................................................................................285 to 320 Nm Front Hitch Side Rail Retaining Bolts ......................................................................................................... 488 Nm WHEELS Front Wheel to MFD Axle Nuts........................................................................................................300 to 350 Nm Rear Wheel Nuts Flange Type Axle............................................................................................................................. 270 to 310 Nm Bar Type Axle Wheel Hub to Tapered Bushing Evenly Tightened in 50 Nm Intervals ...................................................................................... 244 to 298 Nm Wheel to Wheel Hub .......................................................................................................................485 to 550 Nm
Section 2001 2001 © 2002 McCormick Tractors International Limited. SM 8-10661 March 2001 (Revised June 2002) ENGINE REMOVAL MC Series Tractors
SECTION 20012 SM 8-10661 Issued 06-2002 TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................3 SPECIAL TORQUES ................................................................................................................................................3 ENGINE REMOVAL Removal ...............................................................................................................................................................4 Installation ..........................................................................................................................................................12 FILLING THE COOLING SYSTEM (After Engine Installation) ...................................................................................................................................21
SECTION 2001 SM 8-10661 Issued 06-2002 3 SPECIFICATIONS Coolant .......................................................................................... Solution of 55% Water and 45% Ethylene Glycol Coolant Capacity ......................................................................................................................................... 17.5 litres SPECIAL TORQUES Torque Dampener Retaining Bolts......................................................88 to 112 Nm 65 to 82lb ft Engine to Transmission Retaining Bolts 12mm Flange Type Bolts..............................................................100 to 110 Nm 74 to 81 lb ft Front Bolster to Engine Retaining Bolts (With Loctite 271).............. 258 to 284 Nm 191 to 205 lb ft Front Bolster to Engine Retaining Nuts (With Loctite 271) .............. 258 to 284 Nm 191 to 205 lb ft Front PTO Drive Shaft Retaining Bolts ............................................... 58 to 65 Nm 43 to 47 lb ft Engine Lifting Bracket Retaining Bolts.......................................................... 44 Nm 33 lb ft Front Hitch Side Rail Retaining Bolts.......................................................... 488 Nm 360 lb ft MFD Axle Retaining Bolts ............................................................... 295 to 330 Nm 218 to 243 lb ft Front Wheel Retaining Bolts............................................................ 300 to 350 Nm 2212 258 lb ft
SECTION 20014 SM 8-10661 Issued 06-2002 ENGINE REMOVAL Removal Before removing the Engine it is necessary to carry out the following: • Park the tractor on hard level ground and apply the parking brake. • Stop the engine and remove the key. • Put blocks in front of and behind the rear wheels. • Remove the Front Hitch, if equipped. • Remove the front weights and bracket, if equipped. • Remove the Hood. • Remove the MFD Drive Shaft, refer to Section 6014. STEP 1 Remove the battery box cover, disconnect the battery negative (-) terminals first. Disconnect engine harness clean ground wire (1), remove the battery clamp retaining nuts and clamp (2) and remove the batteries. STEP 2 Raise the front of the tractor and remove the front wheels. Support the tractor on a suitable stand under the speed transmission. STEP 3 Disconnect and cap the steering hoses. Remove the retaining bolts and carefully remove the front axle. STEP 4 Loosen clamp bolts (3) and remove exhaust tube (4). DD98E177 12 DP98B156 DP98B480 DP98E158 3 3 4
SECTION 2001 SM 8-10661 Issued 06-2002 5 STEP 5 Use a suitable hose clamp and clamp heater return hose (5). STEP 6 Close heater tap (A), use a suitable hose clamp and clamp heater feed hose (6). Release the hose clip (7) and disconnect the heater hose, plug the hose with a 16 mm diameter plug and secure with the hose clip. Connect a suitable length of hose to the tap (A) place the open end of the hose into a suitable container, open the tap (A) and drain the coolant from the engine. Remove the retaining bolt and remove fuel hose clamp (8). Release the hose clip and disconnect fuel hose (9) from the fuel filter. Cap the hose and fuel filter. STEP 7 Tractors Equipped with Air Conditioner Refer to Section 9005 (Air Conditioner Components “Strip Away”) and remove the air conditioner compressor, receiver drier and condenser. DO NOT disconnect the components. NOTE: Make sure the condenser remains in the upright position after removal. STEP 8 Remove the retaining bolts and remove the foam insulation bracket (10). Remove tie straps securing the upper engine harness to the air intake tube (11). Loosen the clamps and remove the air filter intake tube (11) and outlet tube (12). Disconnect the air filter restriction switch (13) from the harness. Cap the turbocharger inlet and outlet ports. DP98E160 5 DP98E159 A 7 8 9 6 WARNING: Never touch liquid refrigerant, since even a drop on your skin will cause sever and painful frostbite. SM114A WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your eyes could cause blindness. SM105A ! ! DR98E253 11 12 13 10
SECTION 20016 SM 8-10661 Issued 06-2002 STEP 9 Remove the retaining bolts and remove air filter bracket assembly (14). STEP 10 Remove the retaining clip and disconnect hood release rod (15), remove the retaining bolts and carefully remove lower grille (16). Remove the retaining bolts and front cover (17). STEP 11 Put identification marks on and disconnect the steering hoses (18) and (19). Cap the hoses and fittings. STEP 12 Put identification marks on the fuel cooler hoses. Remove the hose clips and disconnect the fuel cooler hoses (20) and (21), cap the hoses and tubes. Put identification marks on and disconnect the oil cooler hoses (22) and (23), remove and discard the o-rings. Cap the hoses and fittings. STEP 13 Remove the retaining bolt and tube clamp (23). Loosen bolt (24) and remove retaining bolt (25) from both sides of the radiator. Remove the oil/fuel cooler assembly (26). DP98B122 14 DP98E166 15 16 17 DP98E182 18 19 DP98E163 20 21 22 23 DP98E164 23 25 26 24
SECTION 2001 SM 8-10661 Issued 06-2002 7 STEP 14 Loosen radiator seal bracket (27) retaining bolts. Remove the retaining bolts and remove the hood latch bracket (28) and top plate (29). STEP 15 For Tractors equipped with Front PTO and Front Hitch, remove the tie strap (30) securing the Front PTO clutch cable and front hitch hose to the RH steering tube. Remove the front hitch hose from the bolster and place onto the battery box. STEP 16 Put a container under the engine oil cooler, loosen the hose clip and disconnect hose (31), drain any remaining coolant from the radiator and engine. Loosen the hose clip and disconnect bottom radiator hose (32). STEP 17 Remove the tie strap securing the harness to the top radiator hose. Disconnect coolant level sender (33) from the harness. Loosen the hose clip and disconnect top radiator hose (34). STEP 18 Remove the four radiator mounting bolts and remove the radiator assembly (35). DP98E165 27 28 29 DP98B136 30 DP98E167 32 31 DP98E170 33 34 DP98E168 35
SECTION 20018 SM 8-10661 Issued 06-2002 STEP 19 Disconnect and remove the steering tubes (36) and (37), cap the tubes and fittings. NOTE: For Tractors not equipped with Front PTO or Front Hitch go to STEP 22. STEP 20 For Tractors Equipped with Front PTO Disconnect front PTO clutch cable at the firewall and remove the tie straps securing the cable to the engine harness. Place front PTO cable (38) onto the front PTO assembly. STEP 21 For Tractors Equipped with Front PTO Remove retaining bolts and disconnect front PTO drive shaft (39) from the engine. STEP 22 Attach suitable lifting equipment to the front bolster. Remove retaining nuts (40), (41), bolts (42) and washers. Remove the shims (if equipped) from between the bolster and engine sump. Carefully remove the front bolster. DP98E173 3637 DP98B118 38 DP98B137 39 DP98B141 40 41 40 41 DP98B138 42 42
SECTION 2001 SM 8-10661 Issued 06-2002 9 STEP 23 Tractors Equipped with Air Conditioner Remove retaining bolts and compressor bracket (43). STEP 24 Tractors Equipped with Air Conditioner Install front engine lifting bracket (44), install and tighten two 10 x 25 mm flange type bolts to a torque of 44 Nm (33 lb ft). STEP 25 Remove spring clip (45), loosen adjuster nuts (46) and remove throttle cable (47) from the bracket. STEP 26 Remove cover (48) and disconnect the cables and wires from starter motor (49). Remove the retaining nuts and remove starter motor (49). Remove the hose clips, disconnect and remove connector (50) from heater return hoses (51) and (52). Plug hose (52) with a suitable 16 mm diameter plug and secure with a hose clip. Remove the hose clamp installed in STEP 5 on page 5. STEP 27 Release the hose clip and disconnect fuel return hose (53), cap the hose and tube. DP98E171 43 DP98E172 44 DP98E162 46 47 45 DP98B146 49 48 51 50 52 DP98E169 53
SECTION 200110 SM 8-10661 Issued 06-2002 STEP 28 Disconnect fuel auto advance temperature switch connector (54) and chassis ground connector (55). Remove the RH lower hood bracket retaining bolt and chassis ground cable (56). Remove the remaining retaining bolts and hood bracket (57). STEP 29 Install rear engine lifting bracket (58), install and tighten two 10 x 25 mm flange type bolts to a torque of 44 Nm (33 lb ft). STEP 30 Disconnect engine harness connector (59) and unswitched power cables (60) from the firewall. STEP 31 Attach suitable lifting equipment to the engine as shown. Operate the lifting equipment until tension is just applied to the lifting equipment. DO NOT lift the tractor on the lifting equipment. STEP 32 Remove top engine to transmission retaining bolts (61) and bottom bolts (62) from both sides. DP98B152 57 54 56 55 DP98B153 58 DP98B154 60 59 DP98B155 DP98B157 61 DP98B159 62
SECTION 2001 SM 8-10661 Issued 06-2002 11 STEP 33 Remove engine to transmission retaining bolts (63) from both sides and install two alignment studs MC1995A. Remove the remaining engine to transmission retaining bolts and carefully remove the engine. Make sure all tubes, hoses, harnesses and cables have been disconnected. NOTE: The engine to transmission retaining bolts are of different lengths. Make a note of the position of the bolts when removing. STEP 34 Remove drive shaft (64). Check the drive shaft oil seal (B) and replace as necessary, refer to Section 6006. STEP 35 Remove the torque dampener retaining bolts and torque dampener (C). Check the torque dampener for wear or damage, replace as necessary. Check the flywheel for wear or damage, refer to your Engine Service Manual. DP98B158 63 DK98A285 64 B DK98B205 C
SECTION 200112 SM 8-10661 Issued 06-2002 Installation STEP 1 Install torque dampener (C), tighten the retaining bolts to a torque of 88 to 112 Nm (65 to 82 lb ft). NOTE: The torque dampener is marked “FLYWHEEL SIDE” this side must be towards the flywheel. If the marking on the torque dampener cannot be found, install the torque dampener with the offset hub towards the transmission. STEP 2 Install two alignment studs (D), MC1995A, into the transmission front cover as shown. STEP 3 Lubricate the internal and external splines of drive shaft (64) with 251 EPM Lithium grease. Fully install the drive shaft onto the transmission input shaft. STEP 4 Using suitable lifting equipment carefully install the engine onto the alignment studs. STEP 5 When the engine and transmission are aligned use a suitable lever through the starter motor mounting hole onto the flywheel ring gear teeth. Slowly turn the flywheel while gently pushing the engine towards the transmission, until the drive shaft locates into the torque dampener. Fully connect the engine and transmission. NOTE: Do not use excessive force to connect the engine to the transmission. DK98B205 C DD97N124 D D DK98E201 64 DP98B161
SECTION 2001 SM 8-10661 Issued 06-2002 13 STEP 6 Remove two alignment studs, MC1995A, Install bolts (63) and (62), (both sides), tighten to a torque of 100 to 110 Nm (74 to 81 lb ft). STEP 7 Install the top engine to transmission retaining bolts (61), both sides. Tighten all bolts to a torque of 100 to 110 Nm (74 to 81 lb ft). STEP 8 Remove the lifting equipment from the engine. STEP 9 Connect unswitched power cables (60) and engine harness connector (59) to the firewall. STEP 10 Remove the rear engine lifting bracket and install hood bracket (57) and chassis ground cable (56), install and tighten the retaining bolts. Connect the chassis ground connector (55) and fuel auto advance temperature switch connector (54). STEP 11 Remove the caps from the hose and tube, connect fuel return hose (53) and install the hose clip. DP98B158 63 DP98B159 62 DP98B157 61 DP98B154 59 60 DP98B152 57 55 56 54 DP98E169 53
SECTION 200114 SM 8-10661 Issued 06-2002 STEP 12 Use a suitable clamp and clamp heater return hose (52). Remove the plug from hose (52) and install into hose (51), secure with a hose clip. Install hose connector (50) and install the hose clip. Install starter motor (49) and install and tighten the retaining nuts, connect the cables and wires. Install the cover (48), install and tighten the retaining nut. NOTE: Hose (51) will be connected after Installation of the engine has been completed and after the air has been removed from the cooling system, refer to Page 21. STEP 13 Install throttle cable (47) into the bracket and install the spring clip pin (45), adjust the cable and tighten the adjuster nuts (46), refer to Section 9001. STEP 14 Tractors Equipped with Air Conditioner Remove the front engine lifting bracket and install compressor bracket (44), install and tighten the retaining bolts. STEP 15 Attach suitable lifting equipment to the front bolster. Make sure the bolster and engine mounting faces are clean and the locating dowels are installed. Install the front bolster onto the engine, tighten the retaining nuts (40) and (41) (with washers) to a torque of 258 to 284 Nm (191 to 209 lb ft). Release the tension on lifting equipment. DP98B310 52 5051 48 49 DP98E162 46 47 45 DP98E171 44 DP98B141 41 40 40 41
SECTION 2001 SM 8-10661 Issued 06-2002 15 STEP 16 To determine the correct number of shims to be installed between the engine sump and front bolster, measure and make a note of the gap between the LH side of the sump and front bolster using feeler gauges. The gap must be measured at two places (above and below the bottom mounting bolt hole). STEP 17 Repeat STEP 16 for the RH side of the engine sump. STEP 18 Using the smaller of the measurements obtained in STEP 16 and STEP 17, refer to the table below to determine the correct number of shims to be installed between the engine sump and front bolster. IMPORTANT: The measured gap must not be more than 1.29 mm (0.0507 inch). If the gap is greater than 1.29 mm (0.0507 inch) use suitable lifting equipment and remove the front bolster. Clean the mounting faces and check for burrs or damage. Repeat STEP 15 to STEP 18. NOTE: The shim pack thicknesses may be different for both sides of the engine sump. DP98B140 Measured Gap Number of Shims 0 to 0.25 mm (0 to 0.0098 inch) 0 0.26 to 0.5 mm (0.010 to 0.0196 inch) 1 0.51 to 0.75 mm (0.020 to 0.0295 inch) 2 0.76 to 1.00 mm (0.0299 to 0.0394 inch) 3 1.01 to 1.25 mm (0.0397 to 0.0492 inch) 4 1.26 to 1.28 mm (0.0496 to 0.050 inch) 5
SECTION 200116 SM 8-10661 Issued 06-2002 STEP 19 Support the weight of the front bolster on the lifting equipment. Loosen retaining nuts (40) and (41). Install shim(s) determined in STEP 16 between the LH side of the sump and front bolster. Install the shim(s) determined in STEP 17 between RH side of the sump and front bolster. Apply Loctite 271 to the threads of retaining bolts (42) and install retaining bolts (42) (with washers). STEP 20 Remove retaining nuts (40) and (41) and apply Loctite 271 to the threads of studs, install retaining nuts (40) and (41). Remove the lifting equipment and tighten retaining nuts (40), (41) and bolts (42) to a torque of 258 to 284 Nm (191 to 209 lb ft). NOTE: The front bolster center mounting studs also have retaining nuts (41) at the engine side of the stud. Loctite 271 must be applied to both threaded ends of the stud. STEP 21 For Tractors Equipped with Front PTO Connect front PTO drive shaft (39) to the engine. Install and tighten the retaining bolts to a torque of 58 to 65 Nm. STEP 22 For Tractors Equipped with Front PTO Route PTO clutch cable (38) along RH side of the engine. Connect front PTO clutch cable (38) at the firewall and secure to the engine harness with tie straps. DP98B141 41 40 40 41 DP98B138 4242 DP98B137 39 DP98B118 38
SECTION 2001 SM 8-10661 Issued 06-2002 17 STEP 23 Remove the caps and fittings. Connect and tighten the steering tubes (37) and (36). STEP 24 Check the radiator mounting bushes for wear or damage, replace as necessary. Install the radiator assembly (35) and tighten the four retaining bolts with washers. STEP 25 For Tractors equipped with Front PTO and Front Hitch route the front hitch hose along the RH side of the engine and front bolster and to the right of the RH steering tube (37). Secure the front hitch hose and front PTO cable to the steering tube (37) with a tie strap (30). Make sure the hose and cable are free of all moving parts. STEP 26 Connect top radiator hose (34) to the engine and tighten the hose clip. Connect the coolant level sender (33) to the harness. Secure the harness to the top radiator hose (34) with a tie strap. DP98E173 3637 DK98E168 35 DP98B136 30 DP98E170 33 34
SECTION 200118 SM 8-10661 Issued 06-2002 STEP 27 Connect bottom radiator hose (32) and cooler hose (31). Tighten the hose clips. STEP 28 Check seal on bracket (27) for wear or damage and replace if necessary. Install top plate (29) and hood latch bracket (28), tighten the retaining bolts. Push radiator seal bracket (27) against the radiator and tighten the retaining bolts. STEP 29 Install oil/fuel cooler assembly (26). Install and tighten retaining bolt (25) and bolt (24) at both sides of the radiator. Install tube clamp (23) and tighten the retaining bolt. STEP 30 Remove the caps. Lubricate and install new o-rings onto the cooler hose fittings. Connect and tighten oil cooler hoses (23) and (22). Remove the caps and connect the fuel cooler hoses (21) and (20), install the hose clips. STEP 31 Remove the caps. Connect and tighten steering hoses (21) and (20). STEP 32 Install front cover (17) and tighten the retaining bolts. Carefully install lower grille (16) and tighten the retaining bolts. Connect hood release rod (15) and install the clip. DP98E167 32 31 DK98E165 28 27 29 DK98E164 26 25 23 24 DP98E163 20 21 22 23 DP98E182 20 21 DP98E166 15 16 17
SECTION 2001 SM 8-10661 Issued 06-2002 19 STEP 33 Install air filter bracket assembly (14) and tighten the retaining bolts. STEP 34 Remove the caps from the turbocharger inlet and outlet ports and install air filter intake tube (11) and outlet tube (12), tighten the clamps. Secure the upper engine harness to air intake tube (11) with tie straps. Install the foam insulation bracket (10), install and tighten the retaining bolts. Connect air filter restriction switch (13) to the harness. STEP 35 Tractors Equipped with Air Conditioner Refer to Section 9005 (Air Conditioner Components “Strip Away”) and install the air conditioner compressor, receiver drier and condenser. STEP 36 Remove the caps from the fuel hose and fuel filter. Connect fuel hose (9) to the fuel filter, install the hose clip and install hose clamp (8), tighten the retaining bolt. Use a suitable hose clamp and clamp heater feed hose (6) and remove the plug. Connect heater feed hose (6) to heater tap (A) and install the hose clip (7). Remove the clamp. DO NOT open the heater tap (A) at this stage. DP98B122 14 DR98E253 1011 12 13 WARNING: Never touch liquid refrigerant, since even a drop on your skin will cause sever and painful frostbite. SM114A WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your eyes could cause blindness. SM105A ! ! DP98E159 A 7 8 9 6
SECTION 200120 SM 8-10661 Issued 06-2002 STEP 37 Install exhaust tube (4) and tighten clamp bolts (3). STEP 38 Install the front axle, make sure the locating dowels are in place, tighten the retaining bolts to a torque of 295 to 330 Nm (218 to 243 lb ft). Connect the steering hoses. STEP 39 For Tractors equipped with Front Hitch. Install the front hitch and side rail assembly. Install and tighten the bolts to a torque of 488 Nm (360 lb ft). STEP 40 Raise the front of the tractor and install the front wheels and wheel nuts. Remove the stand from the speed transmission. Lower the tractor and tighten the front wheel nuts to a torque of 300 to 350 Nm. STEP 41 Install the batteries, install battery clamp (2) tighten the retaining nuts. Connect the batteries, positive (+) terminals first. Connect engine harness clean ground wire (1) to the battery negative terminal, tighten the retaining nut. Install the battery box cover. After installing the Engine it is necessary to carry out the following: • Install the MFD Drive Shaft, refer to Section 6014. • Fill the radiator with coolant. • Remove the air from the fuel system, refer to your Engine Service Manual. IMPORTANT: DO NOT RUN the engine until air has been removed from the cooling system. • Remove the air from the cooling system, refer to “FILLING THE COOLING SYSTEM (After Engine Installation)” on page 21. • Install the Hood. DP98E158 3 3 4 DP98B480 DD98E177 12
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McCormick MC100 Tractor Service Repair Manual

  • 1. MC Series Tractors Service Manual SM 8-11102 Section Pub. No. 1 GENERAL Safety Rules, General Information and Torque Specifications ............................1001 SM General Specifications and Torques.....................................................................1002 SM 2 E NGINE Engine Removal ..................................................................................................2001 SM NOTE: For Service and Overhaul procedures refer to your Engine Service 1000 Series Manual SM 8-10041. 1100 Series 4 Cyl 1100 Series 6 Cyl 3 FUEL SYSTEM Fuel Tank Removal and Servicing........................................................................3005 SM NOTE: For Service and Overhaul procedures refer to your Engine Service Manual SM 8-10041. 4 ELECTRICAL Electrical Schematics...........................................................................................4001 SM Instrument Cluster Programming.........................................................................4002 SM Battery Servicing and Testing..............................................................................4004 SM 5 STEERING Steering Column and Steering Hand Pump.........................................................5001 SM Steering Hand Pump ...........................................................................................5002 SM 6 TRANSMISSION HOW IT WORKS………………………………………………………………………………….. Separating the Tractor (Engine and Speed Transmission) and Torque Dampener ................................................................................................6002 SM Separating the Speed and Range Transmission..................................................6003 SM Powershift Transmission Servicing ......................................................................6006 SM Range Transmission Servicing ............................................................................6007 SM Powershift Valve ..................................................................................................6009 SM Shuttle Valve.........................................................................................................6010 SM Synchronizer Creep Transmission........................................................................6011 SM Differential and Differential Lock...........................................................................6012 SM MFD Output Shaft and Bearing ............................................................................6015 SM Rear Axles and Planetaries ..................................................................................6018 SM PTO - Reversible and Shiftable ............................................................................6019 SM 20.14 MFD Front Axle...........................................................................................6021 SM 20.19 and 20. 25 MFD Front Axle ........................................................................6021 SM Independent Front Suspension Axle (20.19 and 20. 25 Axle) ..............................6022 SM PTO Front Drive Shaft and Hydraulic Pump Drive Gear ......................................6023 SM 7 BRAKES Service Brakes.....................................................................................................7002 SM
  • 2. Hydraulic Trailer Brake Valve ..............................................................................7004 SM 8 HYDRAULICS HOW IT WORKS………………………………………………………………………………… Hydraulic Troubleshooting and Schematic (MC Series Tractors up to P.I.N JJE2020415) ...................................................8001 SM Hydraulic Troubleshooting and Schematic (MC Series Tractors P.I.N JJE2020416 and After)..............................................8001 SM Charge Lubrication Pump....................................................................................8003 SM Hydraulic Valves .................................................................................................8006 SM Remote Valves ....................................................................................................8008 SM 9 CHASSIS AND MOUNTED EQUIPMENT Pedal, Lever Adjustments....................................................................................9001 SM Air Conditioner Troubleshooting (Visual and Operating) ....................................9003 SM Air Conditioner Troubleshooting (Gauges and Testing) .....................................9004 SM Air Conditioner System Components Servicing .............................................. ...9005 SM Cab Removal and Cab Roof Panel Tilting ..........................................................9006 SM 10 CONTROLLER SYSTEMS Hitch/MFD/Differential Lock Controller - Calibration, Error Codes Troubleshooting and Schematics ........................................................................10002 SM Independent Front Suspension Axle Controller Calibration, Error Codes, Troubleshooting and Schematics................................10003 SM Speed Sequencer Controller, F/N/R and powershift - Calibration, Error Codes Troubleshooting and Schematics (For Tractors With Speed Sequencer).................................................................10004 SM PTO Controller (For Tractors With Speed Sequencer), F/N/R Controller and Powershift (For Tractors Without Speed Sequencer) - Configuration, Error Codes, Troubleshooting and Schematics ........................10006 SM Hitch and PTO Controller Programming ............................................................10010 SM There is a large selection of McCormick tractor models available for vastly differing applications. This Service Manual may include some information, illustrations and photographs, which may differ to the standard equipment and accessories on your tractor.
  • 3. Section 1001 1001 © 2001 McCormick Tractors International Limited. SM 8-10080 March 2001 SAFETY, GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS
  • 4. SECTION 10012 SM 8-10080 Issued 03-2001 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
  • 5. SECTION 1001 SM 8-10080 Issued 03-2001 3 SAFETY 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. 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. ! WARNING: Read the operators manual to familiarize yourself with the correct control functions. WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. WARNING: This is one a man machine, no riders allowed. ! DO NOT OPERATE NE PAS UTILISER NICHT BETREIBEN NO UTILIZAR REASON/RAISON VERNUNFT/RAZON 2-1000 ! ! ! 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. 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. WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. 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. WARNING: Use insulated gloves or mittens when working with hot parts. ! ! ! ! ! !
  • 6. SECTION 10014 SM 8-10080 Issued 03-2001 CAUTION: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. 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. 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. 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). 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. ! ! ! ! ! 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. CAUTION: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual. 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. 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. 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. ! ! ! ! !
  • 7. SECTION 1001 SM 8-10080 Issued 03-2001 5 GENERAL INFORMATION Cleaning 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. 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. Gears Check all gears for wear and damage. Replace gears that have wear or damage. 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.
  • 8. SECTION 10016 SM 8-10080 Issued 03-2001 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) Chart 2 (Phosphate Coated Nuts/Bolts) BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 3.0 4.0 3.4 4.5 4.3 5.8 4.8 6.5 M5 4.8 6.5 5.5 7.5 7.0 9.5 7.8 10.5 M6 8.2 11.0 9.2 12.5 11.8 16.0 13.3 18.0 M8 20.0 27.0 22.5 31.0 28.7 39.0 32.3 44.0 M10 40.0 54.0 45.0 61.0 56.0 77.0 64.0 87.0 M12 69.0 94.0 78.0 106.0 100.0 134.0 110.0 151.0 M14 110.0 150.0 125.0 170.0 160.0 215.0 180.0 240.0 M16 175.0 235.0 190.0 260.0 245.0 335.0 275.0 375.0 M20 345.0 470.0 390.0 530.0 480.0 650.0 540.0 730.0 M22 475.0 640.0 530.0 720.0 655.0 890.0 735.0 1000.0 M24 600.0 810.0 675.0 915.0 830.0 1125.0 930.0 1265.0 M30 1190.0 1615.0 1340.0 1815.0 1645.0 2235.0 1855.0 2515.0 M36 2080.0 2825.0 2340.0 3175.0 2875.0 3900.0 3235.0 4390.0 BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 2.3 3.0 2.6 3.4 3.2 4.4 3.6 4.9 M5 3.6 4.9 4.1 5.6 5.2 7.1 5.9 8.0 M6 6.2 8.3 6.9 9.4 8.9 12.0 10.0 13.5 M8 15.0 20.3 16.9 23.3 21.5 29.2 24.2 32.8 M10 30.0 41.0 34.0 46.0 42.0 58.0 48.0 65.0 M12 52.0 71.0 59.0 80.0 75.0 101.0 83.0 113.0 M14 83.0 113.0 94.0 126.0 120.0 161.0 135.0 180.0 M16 131.0 176.0 143.0 195.0 185.0 251.0 205.0 280.0 M20 259.0 353.0 293.0 400.0 360.0 490.0 405.0 550.0 M22 355.0 480.0 400.0 540.0 490.0 665.0 550.0 750.0 M24 450.0 608.0 506.0 686.0 625.0 845.0 700.0 950.0 M30 893.0 1211.0 1005.0 1361.0 1235.0 1675.0 1390.0 1885.0 M36 1560.0 2119.0 1755.0 2381.0 2156.0 2925.0 2425.0 3295.0
  • 9. SECTION 1001 SM 8-10080 Issued 03-2001 7 Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 2.6 3.5 2.9 3.9 3.7 5.0 4.1 5.6 M5 4.1 5.6 4.6 6.3 5.9 8.0 6.6 9.0 M6 7.0 9.5 7.8 10.6 10.0 13.6 11.3 15.3 M8 17.0 23.1 19.1 25.9 24.4 33.1 27.4 37.2 M10 34.0 46.0 38.3 52.0 48.0 65.0 54.0 74.0 M12 59.0 80.0 66.0 90.0 85.0 114.0 94.0 128.0 M14 94.0 128.0 106.0 145.0 136.0 183.0 153.0 205.0 M16 149.0 200.0 161.0 220.0 208.0 285.0 235.0 320.0 M20 293.0 400.0 330.0 450.0 408.0 555.0 460.0 620.0 M22 400.0 545.0 450.0 615.0 555.0 755.0 625.0 850.0 M24 510.0 690.0 575.0 780.0 705.0 955.0 790.0 1075.0 M30 1010.0 1375.0 1140.0 1545.0 1400.0 1900.0 1580.0 2140.0 M36 1770.0 2400.0 1990.0 2700.0 2445.0 3315.0 2750.0 3730.0
  • 10. Section 1002 1002 © 2002 McCormick Tractors International Limited. SM 8-10641 March 2001 (Revised June 2002) GENERAL SPECIFICATIONS AND TORQUES MC Series Tractors
  • 11. SECTION 10022 SM 8-10641 Issued 06-2002 TABLE OF CONTENTS GENERAL SPECIFICATIONS Lubricants and Capacities ....................................................................................................................................3 Engine ..................................................................................................................................................................3 Fuel ......................................................................................................................................................................3 Electrical ...............................................................................................................................................................4 Transmission ........................................................................................................................................................4 Hydraulics .............................................................................................................................................................5 Air Conditioning ....................................................................................................................................................7 Conversion Table .................................................................................................................................................8 SPECIAL TORQUES Engine ..................................................................................................................................................................9 Transmission ........................................................................................................................................................9 Hydraulics ...........................................................................................................................................................10 Cab and Chassis ................................................................................................................................................10
  • 12. SECTION 1002 SM 8-10641 Issued 06-2002 3 GENERAL SPECIFICATIONS Lubricants and Capacities ENGINE Oil Type ...................................................................................................... McCormick Engine Oil, SAE 15W - 40 Capacity (With Filter Change) .....................................................................................................................7 Litres ENGINE COOLANT Coolant Mix ........................................................................................................ McCormick Universal Anti-freeze Solution of 33% to 50% Ethylene Glycol (depending on market requirements) Capacity ................................................................................................................................................17. 5 Litres AIR CONDITIONER SYSTEM Compressor Oil .................................................................................................................Sanden SP - 20 Pag Oil Capacities.......................................................................................................................................Refer to Page 7 TRANSMISSION Oil Type ........................................................................................................................................ McCormick HTX Factory Fill Capacity..................................................................................................................................75 Litres Refill Capacity (Approximately) ..............................................................................................................66.3 Litres MFD AXLE Oil Type .......................................................................................................... McCormick Multi-Purpose Gear Oil SAE 85W - 140 EP Gear Oil to API GL-5 or MIL-L-2105 Specification MC80 (20.14 Axle) Differential Oil............................................................................................................5.0 Litres MC90, MC100 and MC115 (20.19 Axle) Differential Oil...........................................................................6.0 Litres Axle Planetaries (Each)............................................................................................................................0.6 Litres FUEL TANK Fuel Capacity ..........................................................................................................................................189 Litres FRONT PTO (Kitchin) Oil Type .........................................................................................................................................McCormick HTX Capacity .................................................................................................................................................0.65 Litres FRONT PTO (Hydrac) Oil Type ............................................................................................. McCormick Super Universal, SAE 10W - 30 Capacity .................................................................................................................................................0.75 Litres 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.
  • 13. SECTION 10024 SM 8-10641 Issued 06-2002 Electrical System Type.................................................................................................................... 12 Volt Negative Ground Batteries .......................................................................... One or Two 12 Volt, Low Maintenance Hybrid Batteries Connected in Parallel, DIN Type 60527, Top Stud Terminals Alternator....................................................................................................................................... 12 Volt, 95 Amp Starter Motor................................................................................................................................... 12 Volt, 3.1 kW Transmission POWERSHIFT TRANSMISSION Friction Plate Thickness ................................................................................................................2.45 to 2.60 mm Separator Plate Thickness ............................................................................................................2.16 to 2.31 mm Backing Plate Thickness ...............................................................................................................5.58 to 5.71 mm Total Thickness ...........................................................................................................................10.8 to 11.05 mm Number of Plates 1st Clutch Pack (Input Shaft) ...........................................................4 Friction 4 Separator 3rd Clutch Pack (Input Shaft) ..........................................................4 Friction 4 Separator 2nd Clutch Pack (Dropshaft)............................................................5 Friction 5 Separator 4th Clutch Pack (Dropshaft).............................................................4 Friction 5 Separator RANGE TRANSMISSION Intermediate Shaft End Play..................................................................................................... 0.025 to 0.102 mm Shuttle Shaft End Play ..............................................................................................................0.025 to 0.102 mm Friction Plate Thickness ................................................................................................................2.45 to 2.60 mm Separator Plate Thickness ............................................................................................................2.16 to 2.31 mm Backing Plate Thickness ...............................................................................................................5.58 to 5.71 mm Total Thickness ......................................................................................................................10.8 to 11.05 mm Pinion Shaft Bearing Preload Rolling Pull .........................................................................................2.0 to 3.2 kg/f MFD CLUTCH Slip Torque MC80 Tractors New Tractor.............................................................................................................................................. 1300 Nm Used Tractors.................................................................................................................................. 790 to 960 Nm Tractor with Worn Plates ................................................................................................................ 620 Nm or less Slip Torque MC90, MC100 and MC115 Tractors New Tractor.......................................................................................................................................... 2100 Nm Used Tractors..........................................................................................................................1260 to 1540 Nm Tractor with Worn Plates.......................................................................................................... 1000 Nm or less Number of Clutch Plates MC80 Tractors Friction Plates ...............................................................................................................................................5 Separator Plates ...........................................................................................................................................5 Number of Clutch Plates MC90, MC100 and MC115 Tractors Friction Plates ...............................................................................................................................................8 Separator Plates ...........................................................................................................................................8 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
  • 14. SECTION 1002 SM 8-10641 Issued 06-2002 5 MFD Clutch Friction Plate Thickness ............................................................................................2.45 to 2.60 mm MFD Clutch Separator Plate Thickness ........................................................................................2.16 to 2.31 mm Belleville Washer Free Height ......................................................................................................................11 mm MFD Clutch Assembly End Play ..................................................................................................1.00 to 1.25 mm MFD Bearing Housing End Play....................................................................................................0.03 to 0.12 mm MFD Idler Gear End Play ..........................................................................................................0.025 to 0.102 mm MFD OUTPUT SHAFT Output Shaft End Play.....................................................................................................................0.1 to 0.15 mm CREEP TRANSMISSION Creep Layshaft End Play.............................................................................................................0.03 to 0.127 mm Creep Main Shaft End Play...........................................................................................................0.03 to 0.10 mm DIFFERENTIAL AND DIFFERENTIAL LOCK Ring Gear and Pinion Backlash ....................................................................................................0.20 to 0.25 mm Differential Lock Clutch Number of Plates Friction Plate................................................................................................................................................ 9 Separator Plate............................................................................................................................................ 8 Plate Thickness Friction Plate .................................................................................................................................1.98 to 2.13 mm Separator Plate .............................................................................................................................1.05 to 1.18 mm Piston Return Plate .......................................................................................................................4.11 to 4.23 mm REAR AXLES Axle Shaft Bearing (without Seal).......................................................................................................... 3.4 to 5.7 Nm PTO DRIVE SHAFT AND HYDRAULIC PUMP DRIVE GEAR Hydraulic Pump Drive Gear End Play .......................................................................................0.025 to 0.125 mm PTO - REVERSIBLE/SHIFTABLE PTO Input Shaft End Play .............................................................................................................0.03 to 0.13 mm PTO Output Shaft End Play.......................................................................................................0.025 to 0.125 mm PTO Clutch Friction Plate Thickness.............................................................................................2.45 to 2.60 mm PTO Clutch Steel Separator Plate Thickness................................................................................2.16 to 2.31 mm PTO Clutch Backing Plate Thickness............................................................................................5.58 to 5.71 mm PARKING BRAKE Plate Thickness Friction Plate .............................................................................................................................6.25 to 6.40 mm Backing Plate ............................................................................................................................2.16 to 2.31 mm Hydraulics HYDRAULIC PUMP Manufacturer ...............................................................................................................................................Vickers Type...............................................................................................................Pressure, Flow Compensated (PFC) Maximum Pressure at Rated Engine rpm at Pump ..........................................................................198 to 206 bar Maximum Flow at Couplers........................................................................................................................ 95l/min. POWERSHIFT VALVE Control Spool Pilot Spring Free Length.........................................................................................................................................47.91 mm Outside Diameter ....................................................................................................................15.24 to 15.5 mm Test Length .........................................................................................................................................28.50 mm Test Load ................................................................................................................................... 56.04 to 68.6 N
  • 15. SECTION 10026 SM 8-10641 Issued 06-2002 Inlet Spool Pilot Spring Free Length.........................................................................................................................................47.91 mm Outside Diameter ....................................................................................................................15.24 to 15.5 mm Test Length..........................................................................................................................................28.50 mm Test Load....................................................................................................................................56.04 to 68.6 N Modulation Spring (Inner) Free Length.........................................................................................................................................38.79 mm Outside Diameter .................................................................................................................. 11.05 to 11.31 mm Test Length..........................................................................................................................................33.17 mm Test Load..............................................................................................................................124.09 to 151.69 N Modulation Spring (Outer) Free Length.........................................................................................................................................38.71 mm Outside Diameter ..................................................................................................................18.03 to 18.26 mm Test Length..........................................................................................................................................33.17 mm Test Load..............................................................................................................................256.17 to 313.17 N Reducing Spring Free Length.........................................................................................................................................35.82 mm Outside Diameter ..................................................................................................................10.87 to 11.13 mm Test Length..........................................................................................................................................27.00 mm Test Load.................................................................................................................................. 24.02 to 29.36 N HITCH VALVE Compression Spring Free Length.......................................................................................................................................29.642 mm Outside Diameter ................................................................................................................................14.22 mm SHUTTLE VALVE Modulation Spring Outer Free Length.......................................................................................................................................107.34 mm Outside Diameter .................................................................................................................20.09 to 21. 35 mm Test Length............................................................................................................................................88.6 mm Test Load.................................................................................................................................. 37.23 to 45.51 N Modulation Spring Inner Free Length.........................................................................................................................................78.36 mm Outside Diameter ..................................................................................................................13.05 to 13.31 mm Test Length..........................................................................................................................................39.50 mm Test Load................................................................................................................................ 96.08 to 117.42 N Inching Spool Return Spring (Yellow) Free Length.........................................................................................................................................91.73 mm Outside Diameter ....................................................................................................................20.44 to 20.7 mm Test Length..........................................................................................................................................26.67 mm Test Load.................................................................................................................................. 40.03 to 48.93 N Forward/Reverse Spool Centring Spring Free Length.........................................................................................................................................51.75 mm Outside Diameter ..................................................................................................................17.65 to 17.91 mm Test Length..........................................................................................................................................25.43 mm Test Load.................................................................................................................................. 63.37 to 69.97 N Feathering Spring (Low Pressure) Free Length.........................................................................................................................................25.02 mm Outside Diameter ..................................................................................................................10.84 to 11.10 mm Test Length..........................................................................................................................................14.86 mm Test Load.................................................................................................................................. 22.14 to 27.06 N Feathering Spring (High Pressure) Free Length.........................................................................................................................................23.64 mm Outside Diameter .................................................................................................................. 11.50 to 11.76 mm Test Length..........................................................................................................................................16.25 mm Test Load................................................................................................................................ 96.07 to 117.43 N
  • 16. SECTION 1002 SM 8-10641 Issued 06-2002 7 PRIORITY REGULATOR VALVE Priority Spring Free Length.........................................................................................................................................58.07 mm Outside Diameter ..................................................................................................................21.97 to 22.23 mm Test Length .........................................................................................................................................41.91 mm Test Load ............................................................................................................................. 240.20 to 293.60 N Regulator Spring Free Length.........................................................................................................................................72.11 mm Outside Diameter ..............................................................................................................22.043 to 22.397 mm Test Length .........................................................................................................................................41.91 mm Test Load ............................................................................................................................. 476.38 to 582.24 N Check Valve Spring Free Length.........................................................................................................................................31.10 mm Outside Diameter ......................................................................................................................5.97 to 6.23 mm Test Length .........................................................................................................................................26.01 mm Test Load ................................................................................................................................... 8.41 to 10.27 N Pilot Relief Valve Spring Free Length.........................................................................................................................................29.56 mm Outside Diameter ..................................................................................................................6.227 to 6.727 mm Test Length .........................................................................................................................................20.98 mm Test Load ............................................................................................................................... 82.08 to 100.28 N Air Conditioning REFRIGERANT Type........................................................................................................................................................HFC-134A 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 ...........................................................................................................................................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 Drive Belt Tension (New).................................................................................................................... 422 to 516 N Drive Belt Tension (Used)................................................................................................................... 400 to 489 N COMPRESSOR AND SYSTEM LUBRICATION (Nominal) Lubrication 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 m Condenser.............................................................................................................................................45 to 50 ml Evaporator.............................................................................................................................................35 to 40 ml Hoses and Tubes (Total) .......................................................................................................................45 to 50 ml HIGH PRESSURE SWITCH Location..............................................................................Discharge Hose from Compressor at Condenser Inlet Operation................................................................................................... Closed by Excessive System Pressure Cut Out Pressure............................................................................................................................26.9 to 28.3 bar
  • 17. SECTION 10028 SM 8-10641 Issued 06-2002 LOW PRESSURE SWITCH Location............................................................................................................. Evaporator outlet in the Cab Roof Operation.............................................................................................................Closed by Low System 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 Conversion Table Conversion 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
  • 18. SECTION 1002 SM 8-10641 Issued 06-2002 9 SPECIAL TORQUES Engine Engine to Transmission Retaining Bolts 12 mm Flange Type Bolts ........................................................................................................... 100 to 110 Nm Torque Dampener Retaining Bolts .................................................................................................... 88 to 112 Nm Front Bolster to Engine Retaining Bolts (With Loctite 271) ............................................................. 258 to 284 Nm Engine Lifting Bracket Retaining Bolts ........................................................................................................ 44 Nm Transmission POWERSHIFT TRANSMISSION Transmission Front Cover Retaining Bolts 16 mm Retaining Bolts................................................................................................................ 251 to 280 Nm 12 mm Retaining Bolts................................................................................................................ 101 to 113 Nm Front Bearing Carrier Retaining Bolts ............................................................................................. 101 to 113 Nm Oil Distributor Retaining Bolts ............................................................................................................. 58 to 65 Nm Drive Gear Retaining Bolt (with Loctite 638) .................................................................................. 101 to 113 Nm RANGE TRANSMISSION AND MFD CLUTCH Speed to Range Transmission Retaining Bolts ............................................................................... 251 to 280 Nm Bearing Carrier (Sandwich Plate) Mounting Bolts ........................................................................... 235 to 265 Nm Gear Shifter Lever Clamping Bolt...................................................................................................... 94 to 106 Nm MFD Clutch Mounting Bolts and Nut ............................................................................................... 251 to 280 Nm Parking Brake Mounting Bolts ......................................................................................................... 101 to 113 Nm Pinion Shaft Bolt Plain Bolt Part Number 826-16110.............................................................................................. 335 to 375 Nm Phosphate Coated Bolt Part Number 828-16110........................................................................ 265 to 285 Nm IMPORTANT: When the pinion bolt is removed it must be discarded and replaced with a new bolt. It is important that the correct torque is used for the type of bolt installed. DIFFERENTIAL AND DIFFERENTIAL LOCK Ring Gear Retaining Bolts............................................................................................................... 276 to 308 Nm Differential Lock Clutch Cage Retaining Bolts............................................................................................ 130 Nm Differential Bearing Carrier Retaining Bolts......................................................................................... 58 to 65 Nm REAR AXLES Rear Axle Mounting Bolts................................................................................................................ 251 to 280 Nm MFD DRIVE SHAFT MFD Drive Shaft Mounting Bolts ......................................................................................................... 39 to 44 Nm PTO DRIVE SHAFT GEAR PTO Drive Gear Retaining Bolt ....................................................................................................... 101 to 113 Nm Transmission Cont. PTO - REVERSIBLE/SHIFTABLE PTO Housing Retaining Bolts and Nuts M16 Retaining Bolts.................................................................................................................... 251 to 280 Nm M20 Retaining Bolts and Nuts..................................................................................................... 251 to 280 Nm PTO Selector Lever Retaining Bolt.................................................................................................. 101 to 113 Nm Front Bearing Carrier Retaining Bolts ............................................................................................... 98 to 110 Nm Oil Baffle Plate Retaining Bolts............................................................................................................ 39 to 44 Nm Seal Retainer Retaining Bolts.............................................................................................................. 27 to 31 Nm PTO Clutch Retaining Bolt............................................................................................................... 147 to 166 Nm
  • 19. SECTION 100210 SM 8-10641 Issued 06-2002 Hydraulics HITCH VALVE Mounting Bolt ...................................................................................................................................... 47 to 54 Nm PRIORITY REGULATOR VALVE Mounting Bolt ...................................................................................................................................... 47 to 54 Nm Regulator Adjusting Plug Nut .............................................................................................................. 36 to 53 Nm Pilot Relief Valve................................................................................................................................75 to 108 Nm Pilot Relief Valve Adjusting Plug Nut................................................................................................... 16 to 19 Nm POWERSHIFT VALVE Retaining Bolts .................................................................................................................................... 48 to 54 Nm Test Port Plugs .................................................................................................................................... 34 to 54 Nm M18 Spool End Plugs ......................................................................................................................... 34 to 54 Nm M27 Spool End Plugs ......................................................................................................................... 34 to 54 Nm Solenoid Valve .................................................................................................................................... 12 to 18 Nm Solenoid Coil Retaining Nut ....................................................................................................................5 to 8 Nm Shuttle Valve Retaining Bolts .............................................................................................................. 48 to 54 Nm Solenoid Valve..................................................................................................................................... 12 to 18 Nm Solenoid Retaining Nut............................................................................................................................5 to 8 Nm Diagnostic Test Fitting ......................................................................................................................... 23 to 34 Nm 1/2 inch Plug........................................................................................................................................ 30 to 45 Nm 5/8 inch Plug........................................................................................................................................ 40 to 59 Nm 3/4 inch Plug........................................................................................................................................ 40 to 59 Nm M14 Plug ............................................................................................................................................. 23 to 34 Nm Shuttle Valve Cover Retaining Screws (Loctite 242 on threads)...........................................................9 to 13 Nm Solenoid Valve Plug (non-MFD) .......................................................................................................... 30 to 45 Nm Cab and Chassis CAB Cab Mounting Bracket to Rear Axle Bolts .......................................................................................244 to 320 Nm Cab Mounting Bolt to Threaded Plate ................................................................................................ 47 to 61 Nm Cab Mounting Nut ...........................................................................................................................190 to 244 Nm CHASSIS Battery Box Retaining Nut and Bolts ...............................................................................................221 to 250 Nm Front Fuel Tank Bracket Retaining Bolts .........................................................................................285 to 320 Nm Front Hitch Side Rail Retaining Bolts ......................................................................................................... 488 Nm WHEELS Front Wheel to MFD Axle Nuts........................................................................................................300 to 350 Nm Rear Wheel Nuts Flange Type Axle............................................................................................................................. 270 to 310 Nm Bar Type Axle Wheel Hub to Tapered Bushing Evenly Tightened in 50 Nm Intervals ...................................................................................... 244 to 298 Nm Wheel to Wheel Hub .......................................................................................................................485 to 550 Nm
  • 20. Section 2001 2001 © 2002 McCormick Tractors International Limited. SM 8-10661 March 2001 (Revised June 2002) ENGINE REMOVAL MC Series Tractors
  • 21. SECTION 20012 SM 8-10661 Issued 06-2002 TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................3 SPECIAL TORQUES ................................................................................................................................................3 ENGINE REMOVAL Removal ...............................................................................................................................................................4 Installation ..........................................................................................................................................................12 FILLING THE COOLING SYSTEM (After Engine Installation) ...................................................................................................................................21
  • 22. SECTION 2001 SM 8-10661 Issued 06-2002 3 SPECIFICATIONS Coolant .......................................................................................... Solution of 55% Water and 45% Ethylene Glycol Coolant Capacity ......................................................................................................................................... 17.5 litres SPECIAL TORQUES Torque Dampener Retaining Bolts......................................................88 to 112 Nm 65 to 82lb ft Engine to Transmission Retaining Bolts 12mm Flange Type Bolts..............................................................100 to 110 Nm 74 to 81 lb ft Front Bolster to Engine Retaining Bolts (With Loctite 271).............. 258 to 284 Nm 191 to 205 lb ft Front Bolster to Engine Retaining Nuts (With Loctite 271) .............. 258 to 284 Nm 191 to 205 lb ft Front PTO Drive Shaft Retaining Bolts ............................................... 58 to 65 Nm 43 to 47 lb ft Engine Lifting Bracket Retaining Bolts.......................................................... 44 Nm 33 lb ft Front Hitch Side Rail Retaining Bolts.......................................................... 488 Nm 360 lb ft MFD Axle Retaining Bolts ............................................................... 295 to 330 Nm 218 to 243 lb ft Front Wheel Retaining Bolts............................................................ 300 to 350 Nm 2212 258 lb ft
  • 23. SECTION 20014 SM 8-10661 Issued 06-2002 ENGINE REMOVAL Removal Before removing the Engine it is necessary to carry out the following: • Park the tractor on hard level ground and apply the parking brake. • Stop the engine and remove the key. • Put blocks in front of and behind the rear wheels. • Remove the Front Hitch, if equipped. • Remove the front weights and bracket, if equipped. • Remove the Hood. • Remove the MFD Drive Shaft, refer to Section 6014. STEP 1 Remove the battery box cover, disconnect the battery negative (-) terminals first. Disconnect engine harness clean ground wire (1), remove the battery clamp retaining nuts and clamp (2) and remove the batteries. STEP 2 Raise the front of the tractor and remove the front wheels. Support the tractor on a suitable stand under the speed transmission. STEP 3 Disconnect and cap the steering hoses. Remove the retaining bolts and carefully remove the front axle. STEP 4 Loosen clamp bolts (3) and remove exhaust tube (4). DD98E177 12 DP98B156 DP98B480 DP98E158 3 3 4
  • 24. SECTION 2001 SM 8-10661 Issued 06-2002 5 STEP 5 Use a suitable hose clamp and clamp heater return hose (5). STEP 6 Close heater tap (A), use a suitable hose clamp and clamp heater feed hose (6). Release the hose clip (7) and disconnect the heater hose, plug the hose with a 16 mm diameter plug and secure with the hose clip. Connect a suitable length of hose to the tap (A) place the open end of the hose into a suitable container, open the tap (A) and drain the coolant from the engine. Remove the retaining bolt and remove fuel hose clamp (8). Release the hose clip and disconnect fuel hose (9) from the fuel filter. Cap the hose and fuel filter. STEP 7 Tractors Equipped with Air Conditioner Refer to Section 9005 (Air Conditioner Components “Strip Away”) and remove the air conditioner compressor, receiver drier and condenser. DO NOT disconnect the components. NOTE: Make sure the condenser remains in the upright position after removal. STEP 8 Remove the retaining bolts and remove the foam insulation bracket (10). Remove tie straps securing the upper engine harness to the air intake tube (11). Loosen the clamps and remove the air filter intake tube (11) and outlet tube (12). Disconnect the air filter restriction switch (13) from the harness. Cap the turbocharger inlet and outlet ports. DP98E160 5 DP98E159 A 7 8 9 6 WARNING: Never touch liquid refrigerant, since even a drop on your skin will cause sever and painful frostbite. SM114A WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your eyes could cause blindness. SM105A ! ! DR98E253 11 12 13 10
  • 25. SECTION 20016 SM 8-10661 Issued 06-2002 STEP 9 Remove the retaining bolts and remove air filter bracket assembly (14). STEP 10 Remove the retaining clip and disconnect hood release rod (15), remove the retaining bolts and carefully remove lower grille (16). Remove the retaining bolts and front cover (17). STEP 11 Put identification marks on and disconnect the steering hoses (18) and (19). Cap the hoses and fittings. STEP 12 Put identification marks on the fuel cooler hoses. Remove the hose clips and disconnect the fuel cooler hoses (20) and (21), cap the hoses and tubes. Put identification marks on and disconnect the oil cooler hoses (22) and (23), remove and discard the o-rings. Cap the hoses and fittings. STEP 13 Remove the retaining bolt and tube clamp (23). Loosen bolt (24) and remove retaining bolt (25) from both sides of the radiator. Remove the oil/fuel cooler assembly (26). DP98B122 14 DP98E166 15 16 17 DP98E182 18 19 DP98E163 20 21 22 23 DP98E164 23 25 26 24
  • 26. SECTION 2001 SM 8-10661 Issued 06-2002 7 STEP 14 Loosen radiator seal bracket (27) retaining bolts. Remove the retaining bolts and remove the hood latch bracket (28) and top plate (29). STEP 15 For Tractors equipped with Front PTO and Front Hitch, remove the tie strap (30) securing the Front PTO clutch cable and front hitch hose to the RH steering tube. Remove the front hitch hose from the bolster and place onto the battery box. STEP 16 Put a container under the engine oil cooler, loosen the hose clip and disconnect hose (31), drain any remaining coolant from the radiator and engine. Loosen the hose clip and disconnect bottom radiator hose (32). STEP 17 Remove the tie strap securing the harness to the top radiator hose. Disconnect coolant level sender (33) from the harness. Loosen the hose clip and disconnect top radiator hose (34). STEP 18 Remove the four radiator mounting bolts and remove the radiator assembly (35). DP98E165 27 28 29 DP98B136 30 DP98E167 32 31 DP98E170 33 34 DP98E168 35
  • 27. SECTION 20018 SM 8-10661 Issued 06-2002 STEP 19 Disconnect and remove the steering tubes (36) and (37), cap the tubes and fittings. NOTE: For Tractors not equipped with Front PTO or Front Hitch go to STEP 22. STEP 20 For Tractors Equipped with Front PTO Disconnect front PTO clutch cable at the firewall and remove the tie straps securing the cable to the engine harness. Place front PTO cable (38) onto the front PTO assembly. STEP 21 For Tractors Equipped with Front PTO Remove retaining bolts and disconnect front PTO drive shaft (39) from the engine. STEP 22 Attach suitable lifting equipment to the front bolster. Remove retaining nuts (40), (41), bolts (42) and washers. Remove the shims (if equipped) from between the bolster and engine sump. Carefully remove the front bolster. DP98E173 3637 DP98B118 38 DP98B137 39 DP98B141 40 41 40 41 DP98B138 42 42
  • 28. SECTION 2001 SM 8-10661 Issued 06-2002 9 STEP 23 Tractors Equipped with Air Conditioner Remove retaining bolts and compressor bracket (43). STEP 24 Tractors Equipped with Air Conditioner Install front engine lifting bracket (44), install and tighten two 10 x 25 mm flange type bolts to a torque of 44 Nm (33 lb ft). STEP 25 Remove spring clip (45), loosen adjuster nuts (46) and remove throttle cable (47) from the bracket. STEP 26 Remove cover (48) and disconnect the cables and wires from starter motor (49). Remove the retaining nuts and remove starter motor (49). Remove the hose clips, disconnect and remove connector (50) from heater return hoses (51) and (52). Plug hose (52) with a suitable 16 mm diameter plug and secure with a hose clip. Remove the hose clamp installed in STEP 5 on page 5. STEP 27 Release the hose clip and disconnect fuel return hose (53), cap the hose and tube. DP98E171 43 DP98E172 44 DP98E162 46 47 45 DP98B146 49 48 51 50 52 DP98E169 53
  • 29. SECTION 200110 SM 8-10661 Issued 06-2002 STEP 28 Disconnect fuel auto advance temperature switch connector (54) and chassis ground connector (55). Remove the RH lower hood bracket retaining bolt and chassis ground cable (56). Remove the remaining retaining bolts and hood bracket (57). STEP 29 Install rear engine lifting bracket (58), install and tighten two 10 x 25 mm flange type bolts to a torque of 44 Nm (33 lb ft). STEP 30 Disconnect engine harness connector (59) and unswitched power cables (60) from the firewall. STEP 31 Attach suitable lifting equipment to the engine as shown. Operate the lifting equipment until tension is just applied to the lifting equipment. DO NOT lift the tractor on the lifting equipment. STEP 32 Remove top engine to transmission retaining bolts (61) and bottom bolts (62) from both sides. DP98B152 57 54 56 55 DP98B153 58 DP98B154 60 59 DP98B155 DP98B157 61 DP98B159 62
  • 30. SECTION 2001 SM 8-10661 Issued 06-2002 11 STEP 33 Remove engine to transmission retaining bolts (63) from both sides and install two alignment studs MC1995A. Remove the remaining engine to transmission retaining bolts and carefully remove the engine. Make sure all tubes, hoses, harnesses and cables have been disconnected. NOTE: The engine to transmission retaining bolts are of different lengths. Make a note of the position of the bolts when removing. STEP 34 Remove drive shaft (64). Check the drive shaft oil seal (B) and replace as necessary, refer to Section 6006. STEP 35 Remove the torque dampener retaining bolts and torque dampener (C). Check the torque dampener for wear or damage, replace as necessary. Check the flywheel for wear or damage, refer to your Engine Service Manual. DP98B158 63 DK98A285 64 B DK98B205 C
  • 31. SECTION 200112 SM 8-10661 Issued 06-2002 Installation STEP 1 Install torque dampener (C), tighten the retaining bolts to a torque of 88 to 112 Nm (65 to 82 lb ft). NOTE: The torque dampener is marked “FLYWHEEL SIDE” this side must be towards the flywheel. If the marking on the torque dampener cannot be found, install the torque dampener with the offset hub towards the transmission. STEP 2 Install two alignment studs (D), MC1995A, into the transmission front cover as shown. STEP 3 Lubricate the internal and external splines of drive shaft (64) with 251 EPM Lithium grease. Fully install the drive shaft onto the transmission input shaft. STEP 4 Using suitable lifting equipment carefully install the engine onto the alignment studs. STEP 5 When the engine and transmission are aligned use a suitable lever through the starter motor mounting hole onto the flywheel ring gear teeth. Slowly turn the flywheel while gently pushing the engine towards the transmission, until the drive shaft locates into the torque dampener. Fully connect the engine and transmission. NOTE: Do not use excessive force to connect the engine to the transmission. DK98B205 C DD97N124 D D DK98E201 64 DP98B161
  • 32. SECTION 2001 SM 8-10661 Issued 06-2002 13 STEP 6 Remove two alignment studs, MC1995A, Install bolts (63) and (62), (both sides), tighten to a torque of 100 to 110 Nm (74 to 81 lb ft). STEP 7 Install the top engine to transmission retaining bolts (61), both sides. Tighten all bolts to a torque of 100 to 110 Nm (74 to 81 lb ft). STEP 8 Remove the lifting equipment from the engine. STEP 9 Connect unswitched power cables (60) and engine harness connector (59) to the firewall. STEP 10 Remove the rear engine lifting bracket and install hood bracket (57) and chassis ground cable (56), install and tighten the retaining bolts. Connect the chassis ground connector (55) and fuel auto advance temperature switch connector (54). STEP 11 Remove the caps from the hose and tube, connect fuel return hose (53) and install the hose clip. DP98B158 63 DP98B159 62 DP98B157 61 DP98B154 59 60 DP98B152 57 55 56 54 DP98E169 53
  • 33. SECTION 200114 SM 8-10661 Issued 06-2002 STEP 12 Use a suitable clamp and clamp heater return hose (52). Remove the plug from hose (52) and install into hose (51), secure with a hose clip. Install hose connector (50) and install the hose clip. Install starter motor (49) and install and tighten the retaining nuts, connect the cables and wires. Install the cover (48), install and tighten the retaining nut. NOTE: Hose (51) will be connected after Installation of the engine has been completed and after the air has been removed from the cooling system, refer to Page 21. STEP 13 Install throttle cable (47) into the bracket and install the spring clip pin (45), adjust the cable and tighten the adjuster nuts (46), refer to Section 9001. STEP 14 Tractors Equipped with Air Conditioner Remove the front engine lifting bracket and install compressor bracket (44), install and tighten the retaining bolts. STEP 15 Attach suitable lifting equipment to the front bolster. Make sure the bolster and engine mounting faces are clean and the locating dowels are installed. Install the front bolster onto the engine, tighten the retaining nuts (40) and (41) (with washers) to a torque of 258 to 284 Nm (191 to 209 lb ft). Release the tension on lifting equipment. DP98B310 52 5051 48 49 DP98E162 46 47 45 DP98E171 44 DP98B141 41 40 40 41
  • 34. SECTION 2001 SM 8-10661 Issued 06-2002 15 STEP 16 To determine the correct number of shims to be installed between the engine sump and front bolster, measure and make a note of the gap between the LH side of the sump and front bolster using feeler gauges. The gap must be measured at two places (above and below the bottom mounting bolt hole). STEP 17 Repeat STEP 16 for the RH side of the engine sump. STEP 18 Using the smaller of the measurements obtained in STEP 16 and STEP 17, refer to the table below to determine the correct number of shims to be installed between the engine sump and front bolster. IMPORTANT: The measured gap must not be more than 1.29 mm (0.0507 inch). If the gap is greater than 1.29 mm (0.0507 inch) use suitable lifting equipment and remove the front bolster. Clean the mounting faces and check for burrs or damage. Repeat STEP 15 to STEP 18. NOTE: The shim pack thicknesses may be different for both sides of the engine sump. DP98B140 Measured Gap Number of Shims 0 to 0.25 mm (0 to 0.0098 inch) 0 0.26 to 0.5 mm (0.010 to 0.0196 inch) 1 0.51 to 0.75 mm (0.020 to 0.0295 inch) 2 0.76 to 1.00 mm (0.0299 to 0.0394 inch) 3 1.01 to 1.25 mm (0.0397 to 0.0492 inch) 4 1.26 to 1.28 mm (0.0496 to 0.050 inch) 5
  • 35. SECTION 200116 SM 8-10661 Issued 06-2002 STEP 19 Support the weight of the front bolster on the lifting equipment. Loosen retaining nuts (40) and (41). Install shim(s) determined in STEP 16 between the LH side of the sump and front bolster. Install the shim(s) determined in STEP 17 between RH side of the sump and front bolster. Apply Loctite 271 to the threads of retaining bolts (42) and install retaining bolts (42) (with washers). STEP 20 Remove retaining nuts (40) and (41) and apply Loctite 271 to the threads of studs, install retaining nuts (40) and (41). Remove the lifting equipment and tighten retaining nuts (40), (41) and bolts (42) to a torque of 258 to 284 Nm (191 to 209 lb ft). NOTE: The front bolster center mounting studs also have retaining nuts (41) at the engine side of the stud. Loctite 271 must be applied to both threaded ends of the stud. STEP 21 For Tractors Equipped with Front PTO Connect front PTO drive shaft (39) to the engine. Install and tighten the retaining bolts to a torque of 58 to 65 Nm. STEP 22 For Tractors Equipped with Front PTO Route PTO clutch cable (38) along RH side of the engine. Connect front PTO clutch cable (38) at the firewall and secure to the engine harness with tie straps. DP98B141 41 40 40 41 DP98B138 4242 DP98B137 39 DP98B118 38
  • 36. SECTION 2001 SM 8-10661 Issued 06-2002 17 STEP 23 Remove the caps and fittings. Connect and tighten the steering tubes (37) and (36). STEP 24 Check the radiator mounting bushes for wear or damage, replace as necessary. Install the radiator assembly (35) and tighten the four retaining bolts with washers. STEP 25 For Tractors equipped with Front PTO and Front Hitch route the front hitch hose along the RH side of the engine and front bolster and to the right of the RH steering tube (37). Secure the front hitch hose and front PTO cable to the steering tube (37) with a tie strap (30). Make sure the hose and cable are free of all moving parts. STEP 26 Connect top radiator hose (34) to the engine and tighten the hose clip. Connect the coolant level sender (33) to the harness. Secure the harness to the top radiator hose (34) with a tie strap. DP98E173 3637 DK98E168 35 DP98B136 30 DP98E170 33 34
  • 37. SECTION 200118 SM 8-10661 Issued 06-2002 STEP 27 Connect bottom radiator hose (32) and cooler hose (31). Tighten the hose clips. STEP 28 Check seal on bracket (27) for wear or damage and replace if necessary. Install top plate (29) and hood latch bracket (28), tighten the retaining bolts. Push radiator seal bracket (27) against the radiator and tighten the retaining bolts. STEP 29 Install oil/fuel cooler assembly (26). Install and tighten retaining bolt (25) and bolt (24) at both sides of the radiator. Install tube clamp (23) and tighten the retaining bolt. STEP 30 Remove the caps. Lubricate and install new o-rings onto the cooler hose fittings. Connect and tighten oil cooler hoses (23) and (22). Remove the caps and connect the fuel cooler hoses (21) and (20), install the hose clips. STEP 31 Remove the caps. Connect and tighten steering hoses (21) and (20). STEP 32 Install front cover (17) and tighten the retaining bolts. Carefully install lower grille (16) and tighten the retaining bolts. Connect hood release rod (15) and install the clip. DP98E167 32 31 DK98E165 28 27 29 DK98E164 26 25 23 24 DP98E163 20 21 22 23 DP98E182 20 21 DP98E166 15 16 17
  • 38. SECTION 2001 SM 8-10661 Issued 06-2002 19 STEP 33 Install air filter bracket assembly (14) and tighten the retaining bolts. STEP 34 Remove the caps from the turbocharger inlet and outlet ports and install air filter intake tube (11) and outlet tube (12), tighten the clamps. Secure the upper engine harness to air intake tube (11) with tie straps. Install the foam insulation bracket (10), install and tighten the retaining bolts. Connect air filter restriction switch (13) to the harness. STEP 35 Tractors Equipped with Air Conditioner Refer to Section 9005 (Air Conditioner Components “Strip Away”) and install the air conditioner compressor, receiver drier and condenser. STEP 36 Remove the caps from the fuel hose and fuel filter. Connect fuel hose (9) to the fuel filter, install the hose clip and install hose clamp (8), tighten the retaining bolt. Use a suitable hose clamp and clamp heater feed hose (6) and remove the plug. Connect heater feed hose (6) to heater tap (A) and install the hose clip (7). Remove the clamp. DO NOT open the heater tap (A) at this stage. DP98B122 14 DR98E253 1011 12 13 WARNING: Never touch liquid refrigerant, since even a drop on your skin will cause sever and painful frostbite. SM114A WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your eyes could cause blindness. SM105A ! ! DP98E159 A 7 8 9 6
  • 39. SECTION 200120 SM 8-10661 Issued 06-2002 STEP 37 Install exhaust tube (4) and tighten clamp bolts (3). STEP 38 Install the front axle, make sure the locating dowels are in place, tighten the retaining bolts to a torque of 295 to 330 Nm (218 to 243 lb ft). Connect the steering hoses. STEP 39 For Tractors equipped with Front Hitch. Install the front hitch and side rail assembly. Install and tighten the bolts to a torque of 488 Nm (360 lb ft). STEP 40 Raise the front of the tractor and install the front wheels and wheel nuts. Remove the stand from the speed transmission. Lower the tractor and tighten the front wheel nuts to a torque of 300 to 350 Nm. STEP 41 Install the batteries, install battery clamp (2) tighten the retaining nuts. Connect the batteries, positive (+) terminals first. Connect engine harness clean ground wire (1) to the battery negative terminal, tighten the retaining nut. Install the battery box cover. After installing the Engine it is necessary to carry out the following: • Install the MFD Drive Shaft, refer to Section 6014. • Fill the radiator with coolant. • Remove the air from the fuel system, refer to your Engine Service Manual. IMPORTANT: DO NOT RUN the engine until air has been removed from the cooling system. • Remove the air from the cooling system, refer to “FILLING THE COOLING SYSTEM (After Engine Installation)” on page 21. • Install the Hood. DP98E158 3 3 4 DP98B480 DD98E177 12
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