McCormick CX105 Tractor Service Repair Manual PDF

CX Series Tractors
Service Manual SM 8-10602
Section Pub. No.
1 GENERAL
Safety, General Information and Standard Torque Specifications...............1001
General Specifications and Torques ...........................................................1002
2 ENGINE
NOTE: For the Engine Service and Overhaul procedures refer to your Engine
Service Manual SM 8-10010 (3 Cylinder Engines) or SM 8-10040 (for 4 Cylinder
Engines).
3 FUEL SYSTEM
Fuel Tank Removal and Servicing...............................................................3005
NOTE: For the Fuel System Service and Overhaul procedures refer to your Engine
Service Manual SM 8-10010 (3 Cylinder Engines) or SM 8-10040 (for 4 Cylinder
Engines).
4 ELECTRICAL
Electrical Schematics ..................................................................................4001
Instrument Cluster Programming.................................................................4002
Battery Servicing and Testing......................................................................4004
5 STEERING
Steering Column and Steering Hand Pump ................................................5001
2 Wheel Drive Steering Cylinder..................................................................5003
2 Wheel Drive Front Axle.............................................................................5004
6 TRANSMISSION
HOW IT WORKS………………………………………………………………………..
Engine Clutch, Master Cylinder and Slave Cylinder ....................................6002
Powershift and Forward/Reverse Transmission Servicing ..........................6003
Creep Transmission Servicing......................................................................6004
8 Speed Transmission Servicing .................................................................6005
Synchronizer Speed Transmission Servicing ..............................................6006
Range Transmission Servicing (2 Wheel Drive Tractors).............................6007
Range Transmission Servicing (MFD Tractors)............................................6008
3 Speed Powershift Transmission Servicing (XtraShift) ..............................6009
Differential and Differential Lock...................................................................6012
MFD Clutch, Transfer Gearbox, Drive Shaft and Parking Brake .................6017
Rear Axles and Planetaries .........................................................................6018
Non Shiftable PTO
(XtraShift Prior to Pin JJE0200493)
(Synchronizer Prior to Pin JJE0902626) ......................................................6019
Non Shiftable PTO
(XtraShift Pin JJE0200494 and After)
(Synchronizer Pin JJE0902627 and After) ..................................................6019
Shiftable PTO..
(XtraShift Prior to Pin JJE0200493)
(Synchronizer Prior to Pin JJE0902626) .....................................................6020
Shiftable PTO
(XtraShift Pin JJE0200494 and After)
(Synchronizer Pin JJE0902627 and After) ..................................................6020
MFD Axle .....................................................................................................6021
Front PTO ....................................................................................................6025
7 BRAKES
HOW IT WORKS……………………………………………………………………….
Service Brakes ........................................................................................... 7001
Parking Brake (2 Wheel Drive Tractors) ..................................................... 7002
Hydraulic Trailer Brake ............................................................................... 7004
8 HYDRAULICS
HOW IT WORKS……………………………………………………………………….
Hydraulic Troubleshooting and Schematic ................................................. 8001
Filter Manifold and Main Hydraulic Pump ................................................... 8002
Steering Hydraulic Pump (Engine Driven) .................................................. 8003
Regulator Valve .......................................................................................... 8004
Unloading Valve.......................................................................................... 8006
Remote Valves ........................................................................................... 8007
Hitch Valve and EDC Manifold.................................................................... 8009
Hydraulic Lift Housing Servicing ................................................................. 8010
Front Hitch .................................................................................................. 8011
9 CHASSIS AND MOUNTED EQUIPMENT

Pedal, Lever and Switch Adjustments ......................................................... 9001
Cab Mountings ............................................................................................ 9008
10CONTROLLER SYSTEMS
Hitch Controller Calibration, Error Codes,
Troubleshooting and Schematics
(Tractors Not Equipped with Ride Control)................................................. 10002
Hitch/MFD/Differential Lock Controller Calibration, Error Codes,
Troubleshooting and Schematics
(Tractors Equipped with Ride Control) ....................................................... 10002
Calibration, Error Codes Troubleshooting and Schematics ....................... 10006
Programming the PTO/FNR Controller
and Hitch/MFD/Differential Lock Controller ................................................ 10010
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND STANDARD TORQUE SPECIFICATIONS
© 2001 McCormick Tractors International Limited.

SM 8-10080 March 2001
2 SECTION 1001
TABLE OF CONTENTS
SAFETY ................................................................................................................................................................... 3
GENERAL INFORMATION
Cleaning ............................................................................................................................................................... 5
Inspection ............................................................................................................................................................. 5
Bearings ............................................................................................................................................................... 5
Needle Bearings .................................................................................................................................................. 5
Gears ................................................................................................................................................................... 5
Oil Seals, O-Rings And Gaskets .......................................................................................................................... 5
Shafts ................................................................................................................................................................... 5
Service Parts ........................................................................................................................................................ 5
Lubrication ........................................................................................................................................................... 5
STANDARD TORQUE DATA FOR NUTS AND BOLTS

Chart 1 (Plain Nuts/Bolts) .................................................................................................................................... 6
Chart 2 (Phosphate Coated Nuts/Bolts) ............................................................................................................... 6
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ...................................................................................................... 7
SM 8-10080 Issued 03-2001

SECTION 1001 3
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED. The message that follows the symbol contains
! important information about safety. Carefully read the message.
Make sure you fully understand the causes of possible injury or
death.
To prevent injury always follow the Warning,

Caution and Danger notes in this section and WARNING: Before starting engine, study
throughout the manual. Operator’s Manual safety messages.
Read all safety signs on machine. Clear
Put a warning tag as shown below on the key for the the area of other persons. Learn and
key switch when carrying out servicing or repairs to practice safe use of controls before
the tractor. Warning tags (publication number 2-1000) operating.
are available from your McCormick dealer. ! It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service, and to
REASON/RAISON
observe pertinent laws and regulations.
!
VERNUNFT/RAZON
Operator’s and Service Manuals may be

obtained from you McCormick dealer.
DO NOT OPERATE WARNING: If you wear clothing that is too

NE PAS UTILISER loose or do not use the correct safety
NICHT BETREIBEN equipment for your job, you can be
NO UTILIZAR
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.
2-1000
WARNING: When working in the area of

WARNING: Read the operators manual to the fan belt with the engine running, avoid
! familiarize yourself with the correct ! loose clothing if possible, and use
control functions. extreme caution.
WARNING: Operate the machine and WARNING: When doing checks and tests
equipment controls from the seat on the equipment hydraulics, follow the
! position only. Any other method could ! procedures as they are written. DO NOT
result in serious injury. change the procedure.
WARNING: This is one a man machine, no WARNING: When putting the hydraulic
! riders allowed . 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.
SM 8-10080 Issued 03-2001

4 SECTION 1001
CAUTION: Lower all attachments to the CAUTION: When servicing or repairing

ground or use stands to safely support the machine. Keep the shop floor and
! the attachments before you do any operator’s compartment and steps free of
maintenance or service. ! oil, water, grease, tools, etc. Use oil
absorbing material and or shop cloths as
required. Use safe practices at all times.
CAUTION: Pin sized and smaller streams
of hydraulic oil under pressure can
penetrate the skin and result in serious CAUTION: Some components of this
infection. If hydraulic oil under pressure machine are very heavy. Use suitable
does penetrate the skin, seek medical ! lifting equipment or additional help as
treatment immediately. Maintain all hoses instructed in this Service Manual.
! and tubes in good condition. Make sure
all connections are tight. Make a
replacement of any tube or hose that is DANGER: Engine exhaust fumes can
damaged or thought to be damaged. DO cause death. If it is necessary to start the
NOT use your hand to check for leaks, engine in a closed place, remove the
use a piece of cardboard or wood.
! exhaust fumes from the area with an
exhaust pipe extension. Open the doors
and get outside air into the area.
CAUTION: When removing hardened pins
such as a pivot pin, or a hardened shaft,
use a soft head (brass or bronze) hammer DANGER: When the battery electrolyte is
! or use a driver made from brass or bronze frozen, the battery can explode if (1), you
and a steel head hammer. try to charge the battery, or (2), you try to
jump start and run the engine. To prevent
! that battery electrolyte from freezing, try
CAUTION: When using a hammer to to keep the battery at full charge. If you do
remove and install pivot pins or separate not follow these instructions, you or
parts using compressed air or using a others in the area can be injured.
! grinder, wear eye protection that
completely encloses the eyes (approved
goggles or other approved eye DANGER: Batteries contain acid and
protectors). explosive gas. Explosions can result from
sparks, flames or wrong cable
connections. To connect the jumper
CAUTION: Use suitable floor (service) ! cables correctly to the battery of this
jacks or chain hoist to raise wheels or machine see the Operator’s Manual.
! tracks off the floor. Always block machine Failure to follow these instructions can
in place with suitable safety stands. cause serious injury or death.
SM 8-10080 Issued 03-2001

SECTION 1001 5
GENERAL INFORMATION
Cleaning Gears
Clean all metal parts except bearings, in mineral Check all gears for wear and damage. Replace
spirits or by steam cleaning. Do not use caustic gears that have wear or damage.
soda for steam cleaning. After cleaning dry and put
oil on all parts. Clean oil passages with compressed Oil Seals, O-Rings And Gaskets
air. Clean bearings in kerosene, dry the bearings
completely and put oil on the bearings. Always install new oil seals, o-rings and gaskets.
Put petroleum jelly on seals and o-rings.
Inspection
Shafts
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small Check all shafts that have wear or damage. Check
scoring or grooves can be removed with a hone or the bearing and oil seal surfaces of the shafts for
crocus cloth. Complete visual inspection for damage.
indications of wear, pitting and the replacement of
parts necessary will prevent early failures. Service Parts
Always install genuine McCormick service parts,
Bearings when ordering refer to the Parts Catalog for the
Check bearings for easy action. If bearings have a correct part number of the genuine McCormick
loose fit or rough action replace the bearing. Wash replacement items. Failures due to the use of other
bearings with a good solvent or kerosene and than genuine McCormick replacement parts are not
permit to air dry. DO NOT DRY BEARINGS WITH covered by warranty.
COMPRESSED AIR.
Lubrication
Needle Bearings Only use the oils and lubricants specified in the
Before you press needle bearings in a bore always Operators or Service Manual. Failures due to the
remove any metal protrusions in the bore or edge of use of non specified oils and lubricants are not
the bore. Before you press bearings into position covered by warranty.
put petroleum jelly on the inside and outside
diameter of the bearings.
SM 8-10080 Issued 03-2001

6 SECTION 1001
STANDARD TORQUE DATA FOR NUTS AND BOLTS

NOTE: A “click type” torque wrench is recommended for the bolt torques listed below.
Chart 1 (Plain Nuts/Bolts)
BOLT TYPE 8.8 TYPE 10.9

SIZE MIN MAX MIN MAX
(mm) 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
Chart 2 (Phosphate Coated Nuts/Bolts)

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
SM 8-10080 Issued 03-2001

SECTION 1001 7
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)

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
SM 8-10080 Issued 03-2001

1002
Section
1002
GENERAL SPECIFICATIONS
AND TORQUES

SM 8-10090 March 2001
2 SECTION 1002
TABLE OF CONTENTS
Capacities ............................................................................................................................................................. 3
Electrical Specifications ........................................................................................................................................ 3
Steering Specifications.......................................................................................................................................... 3
Transmission Specifications.................................................................................................................................. 3
Brake Specifications.............................................................................................................................................. 5
Hydraulic Specifications ........................................................................................................................................ 5
Air Conditioning System Specifications................................................................................................................. 6
Conversion Table .................................................................................................................................................. 6
SPECIAL TORQUES
Steering.................................................................................................................................................................7
Transmission......................................................................................................................................................... 7
Brakes ................................................................................................................................................................... 8
Hydraulics ............................................................................................................................................................. 9
Chassis and Mounted Equipment ......................................................................................................................... 9
SM 8-10090 Issued 0-3-2001

SECTION 1002 3
Capacities
TRANSMISSION/HYDRAULIC (HY-TRAN ® ULTA) OIL CAPACITY
2WD Tractors ......................................................................................................................................... 34.5 Litres
MFD Tractors ............................................................................................................................................ 37 Litres
Fuel Tank................................................................................................................................................. 155 Litres
Electrical Specifications
Type of System....................................................................................................................12 Volt, Negative Ground
Batteries .............................................................................. One or Two 12 Volt, Low Maintenance Hybrid Batteries
Connected in Parallel
DIN Type 60527, Top Stud Terminals
BATTERY SAE (COLD CRANKING AMPERE RESERVE

IEC DIN
TYPE CAPACITY) HOURS CAPACITY
644 660 Amps 440 Amps 400 Amps 95 180 mins
Fuel Level Sender Resistance

Empty .............................................................................................................................................. 28 to 34 Ohms
Full .............................................................................................................................................. 240 to 250 Ohms
Steering Specifications
TRACK ADJUSTMENT
2WD Toe-in ......................................................................................... 0 to 5 mm
MFD Toe-in.......................................................................................... 0 to 2 mm
STEERING PUMP (ENGINE DRIVEN)
CX50 and CX60
Direction of Rotation ...........................................................................................................................Clockwise
Flow at 2250 engine rpm .................................................................................................................. 27.7 L/min.
Rated Working Pressure.........................................................................................................................160 bar
CX70, CX80, CX90 and CX100
Direction of Rotation ...............................................................................................................Counterclockwise
Flow at 2200 engine rpm .................................................................................................................. 30.3 L/min.
Rated Working Pressure.........................................................................................................................160 bar
Transmission Specifications
CLUTCH
CX50/60/70 Tractors
Maximum Clutch Plate Thickness.........................................................................................................10.4 mm
Clutch Plate Diameter ............................................................................................................................305 mm
Number of Friction Plate Pads ......................................................................................................... 5 each side
CX80/90/100 Tractors
Maximum Clutch Plate Thickness.........................................................................................................10.4 mm
Clutch Plate Diameter ............................................................................................................................310 mm
Number of Friction Plate Pads ......................................................................................................... 7 each side
SM 8-10090 Issued 03-2001

4 SECTION 1002
SPEED TRANSMISSION
Speed Transmission Synchronizer End Play ............................ 0.05 to 0.30 mm
RANGE TRANSMISSION
Pinion Bearing End Play (Maximum) ...................................................................................................... 0.076 mm
Synchronizer Running Clearance ................................................................................................. 0.05 to 0.30 mm
Selector Fork Running Clearance ............................................................................................................. 0.05 mm
REAR AXLE
Planetary Gear/Planetary Gear Carrier Shimming ................................................................ refer to Section 6018
DIFFERENTIAL
Differential Lock Selector Ring Clearance (Engaged Position) ................................................... 0.025 to 0.90 mm
Ring Gear to Pinion Backlash ................................................................................................... 0.152 to 0.304 mm
Ring Gear to Differential Housing Run-out....................................................................................... 0 to 0.102 mm
Differential Bearing Rolling Pull .......................................................................................................... 2.0 to 6.5 kg
PTO CLUTCH
Standard Clutch
Number of Friction Plates ................................................................................................................................. 5
Number of Steel Separator Plates (2 between each Friction Plate) .................................................................8
Heavy Duty Clutch
Number of Friction Plates ................................................................................................................................. 6
Number of Steel Separator Plates .................................................................................................................... 5
MFD CLUTCH
Friction Plate Thickness (New) .....................................................................................................2.25 to 2.35 mm
Friction Plate Thickness (Minimum) .......................................................................................................... 2.00 mm
MFD Clutch Torque ......................................................................................................................... 638 to 792 Nm
Output Shaft Bearing Preload (without oil seals) ................................................................................... 20 to 40 N
MFD Drive Shaft Deflection (below the centre line of the shaft)
(measured at Centre Support Bearing).....................................................................................0.50 to 0.55 mm
MFD PARKING BRAKE
Front and Rear Brake Pads (New) ............................................................................................ 10.70 to 10.90 mm
Front and Rear Brake Pads (Minimum) .................................................................................................. 10.50 mm
Central Brake Pads (New) ............................................................................................................4.00 to 4.10 mm
Central Brake Pads (Minimum) ................................................................................................................. 3.50 mm
MFD AXLE
Differential
Separator Plate Thickness......................................................................................................................1.5 mm
Friction Disc Thickness ............................................................................................................... 1.45 to 1.6 mm
Thrust Plate Thickness ................................................................................................................. 2.7 to 2.8 mm
Pinion Shaft Bearing Preload......................................................................................................... 105 to 157 N
Pinion Shaft/Differential Bearing
Total Preload .........................................................................................................105 to 157 (+ 29.5 to 44.1) N
Bevel Gear to Pinion Backlash......................................................................................................0.16 to 0.22 mm
Lubricants
Planetary and Wheel Hub
Type.................................................................................................................................... SAE 85W-140EP
Capacity, per Hub ............................................................................................................................ 0.6 Litres
Differential/Axle Housing
Type.................................................................................................................................... SAE 85W-140EP
Capacity.............................................................................................................................................. 6 Litres
Grease .................................................................................................................... Multi-Purpose Lithium Grease
SM 8-10090 Issued 03-2001

SECTION 1002 5
Brake Specifications
2WD PARKING BRAKE
Number of Friction Discs .......................................................................................................................................3
Number of Stationary Discs ..................................................................................................................................3
Friction Disc (New) ....................................................................................................................................2.90 mm
Stationary Disc Thickness (New) ..............................................................................................................1.80 mm
Type ..........................................................................................................Hydraulically Operated Oil Cooled Disc
Inner Brake Ring Backlash........................................................................................................0.127 to 0.635 mm
Brake Piston Test Pressure
Low Pressure Test .......................................................................................... 4 Steps of 3.4 bar up to 13.8 bar
High Pressure Test.................................................................................................................................27.6 bar
Hydraulic Specifications
CX50/60 CX70/80/90/100
Hydraulic System Type Open

Steering Hydraulic Pump 27.7 L/min. 30.3 L/min.
at 2250 engine rpm at 2200 engine rpm
Transfer Pump 36 L/min.
Flow to 540/750 PTO 50.2 L/min.
Remotes 59.4 L/min.
540/1000 PTO 51.7 L/min.
Main Hydraulic 540/750 PTO 50.2 L/min.
Pump 59.4 L/min.
540/1000 PTO 51.7 L/min.
Pump gear 540/750 PTO 23 19
(No. of teeth)
540/1000 PTO 27 23
Pump mounting N/A 5.31 to 5.43 mm
plate thickness
Main Relief Valve Pressure ......................................................................................................................172.5 bar

Remote Detent Kick-out Pressure..............................................................................................144.7 to 172.3 bar
Steering Relief Valve Pressure.........................................................................................................141 to 148 bar
Regulated Pressure ......................................................................................................................................20 bar
Oil Cooler By-pass Pressure ......................................................................................................................10.4 bar
Steering Return Flow
CX50/60 at 2250 engine rpm ............................................................................................................ 27.7 L/min.
CX70/80/90/100 at 2200 engine rpm ................................................................................................ 30.3 L/min.
Oil Cooler Flow
CX50/60 at 2250 engine rpm ............................................................................................................ 23.7 L/min.
CX70/80/90/100 at 2200 engine rpm ................................................................................................ 26.3 L/min.
PTO Control Spool Assembly
Return Spring - Free Length ...............................................................................................................79.63 mm
High Pressure Spring - Free Length .................................................................................................. 29.65 mm
Low Pressure Spring - Free Length ................................................................................................... 24.42 mm
Hitch Valve
Load Check Spring - Free Length........................................................................................................ 29.7 Mm
Secondary Raise Spring - Free Length................................................................................................ 40.4 mm
Hydraulic Oil Test Temperature ......................................................................................................................49° C
SM 8-10090 Issued 03-2001

6 SECTION 1002
Air Conditioning System Specifications

Refrigerant Type............................................................................................... HFC - 134a Per ARI Standard 700
System Capacity ..................................................................................................................................... 1.93 kg
Boiling Point at Atmospheric Pressure.....................................................................................................- 26° C
Compressor
Manufacturer........................................................................................................................................ SANDEN
Model ......................................................................................................................................SD 7H15MD4609
Number of Cylinders ......................................................................................................................................... 7
Displacement Per Revolution................................................................................................................... 155 cc
Clutch Voltage.............................................................................................................................................. 12V
Clutch Coil Amperage Draw at 12 Volts............................................................................... 3.6 to 4.2 Amperes
Front Clutch Plate Air Gap ............................................................................................................ 0.4 to 0.8 mm
Drive Belt Tension (New) ............................................................................................................... 422 to 516 N
Drive Belt Tension (Used) .............................................................................................................. 400 to 489 N
Compressor and System Lubrication (Nominal)
Lubricant Type .............................................................................................................Sanden SP - 20 PAG Oil
Compressor Capacity (New)......................................................................................................... 270 to 300 ml
Compressor Capacity (Previously Run).......................................................................................... 50 to 100 ml
Component Capacity (add to compressor when component has been replaced)
Receiver Dryer.............................................................................................................................. 25 to 30 ml
Condenser ................................................................................................................................... 45 to 50 ml
Evaporator .................................................................................................................................... 35 to 40 ml
Hose and Tubes (Total) ................................................................................................................ 45 to 50 ml
High Pressure Switch
Location ................................................................................. Discharge Hose from Compressor to Condenser
Operation ........................................................................................................... Closed by Excessive Pressure
Cut Out Pressure .......................................................................................................................26.9 to 28.3 bar
Low Pressure Switch
Location ........................................................................................................Evaporator Outlet in the Cab Roof
Operation .....................................................................................................................Closed by Low Pressure
Cut Out Pressure .......................................................................................................................0.14 to 0.41 bar
Temperature Control Switch
Location ......................................................................................................... Evaporator Core in the Cab Roof
Cut Out Temperature (Maximum Cold Setting)............................................................................ 0.8° to 2.5° C
Cut In Temperature (Maximum Cold Setting)............................................................................... 5.8° to 7.5° C
Coolant
Fluid Type .............................................................................................. 50 percent Ethylene Glycol and Water
CX50 and CX60 Tractors
Capacity.......................................................................................................................................... 13.4 litres
CX70, Cx80, CX90 and CX100 Tractors
Capacity ......................................................................................................................................... 17.5 litres
Conversion Table
Conversion 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
SM 8-10090 Issued 03-2001

SECTION 1002 7
SPECIAL TORQUES
NOTE: To convert NM to lb. ft. see Conversion Table on Page 6.
Steering
Steering Wheel Retaining Nut ................................................................................................................. 45 to 51 Nm
Steering Hand Pump Retaining Bolts ...................................................................................................... 45 to 51 Nm
Steering Hand Pump End Cover Retaining Bolts .................................................................................... 25 to 35 Nm
Steering Relief Valve Plug ....................................................................................................................... 40 to 60 Nm
Front Weight Bracket Retaining Bolts.................................................................................................. 481 to 542 Nm
Front Wheel Nuts.......................................................................refer to Operators Manual for correct wheel rim size
Wheel Bearing Nut ............................................................................. refer to Section 5003 for tightening procedure
2WD Front Axle
Tie Rod Lock Nut................................................................................................................................. 34 to 40 Nm
Tie Rod Lock Bolt ................................................................................................................................ 81 to 88 Nm
Tie Rod Tube Lock Nut.................................................................................................................... 235 to 250 Nm
Steering Arm Clamp Bolt................................................................................................................. 108 to 122 Nm
Wheel Bearing Nut ................................................................................................................ refer to Section 5003
2WD Steering Cylinder
Cylinder Clevis (with Loctite 270) .................................................................................................... 110 to 135 Nm
Cylinder Clevis Pin Retaining Bolt....................................................................................................... 27 to 31 Nm
Lower Bearing Carrier Retaining Bolts ............................................................................................ 110 to 122 Nm
Steering Pump (Engine Driven)
Retaining Bolts .................................................................................................................................... 41 to 48 Nm
Inlet Tube Retaining Screws ............................................................................................................... 23 to 31 Nm
Front Bolster to Engine Retaining Bolts (with Loctite 271) .................................................................. 258 to 284 Nm
Front Bolster to Engine Retaining Nuts (with Loctite 271)................................................................... 258 to 284 Nm
Transmission
Flywheel Retaining Bolts ..................................................................................................................... 116 to 130 Nm
Clutch Retaining Bolts ............................................................................................................................. 20 to 23 Nm
Engine to Speed Transmission Mounting Bolts ................................................................................... 122 to 129 Nm
Speed to Range Transmission Retaining Bolts
1/2 inch Bolts (With Loctite 271) ..................................................................................................... 101 to 104 Nm
5/8 inch Bolts (With Loctite 271).......................................................................................................... 205 to 230 Nm
Main Shaft Retaining Bolts ...................................................................................................................... 42 to 47 Nm
Selector Fork to Selector Rail Lock Bolt ................................................................................................ 89 to 100 Nm
Selector Fork to Selector Rail Lock Nut................................................................................................... 53 to 59 Nm
PTO Bearing Retainer Bolts (with Loctite 271) ........................................................................................ 42 to 47 Nm
Clutch Release Bearing Carrier Retaining Bolts (with Loctite 271) ......................................................... 42 to 47 Nm
Pinion Shaft Retaining Bolts .................................................................................................................... 42 to 47 Nm
Planet Carrier Retaining Bolt ............................................................................................................... 290 to 330 Nm
Rear Axle Mounting Bolt...................................................................................................................... 270 to 305 Nm
Flange Axle - Wheel Nuts.................................................................................................................... 278 to 298 Nm
Bar Axle - Wheel to Hub Bolts ............................................................................................................. 183 to 207 Nm
Differential
Ring Gear Dowel Bolts .................................................................................................................... 156 to 170 Nm
Ring Gear Retaining Bolts............................................................................................................... 156 to 170 Nm
Bearing Carrier Retaining Bolts....................................................................................................... 156 to 170 Nm
PTO Clutch Access Cover ................................................................................................................... 117 to 133 Nm
PTO Shaft Cover Retaining Bolts ............................................................................................................ 45 to 50 Nm
PTO Clutch Access Cover Retaining Bolts.......................................................................................... 117 to 133 Nm
PTO Housing
3/8 inch Retaining Bolts ...................................................................................................................... 45 to 50 Nm
1/2 inch Retaining Bolts .................................................................................................................. 136 to 152 Nm
SM 8-10090 Issued 03-2001

8 SECTION 1002
MFD Transfer Gearbox

Mounting Bolts .................................................................................................................................117 to 133 Nm
Drain Plug .................................................................................................................................................... 80 Nm
Front Cover Retaining Bolts ......................................................................................................................... 23 Nm
Rear Cover Retaining Bolts.......................................................................................................................... 23 Nm
Brake Pad Guide Pin Plug ......................................................................................................................... 150 Nm
Solenoid Cover Retaining Bolts ................................................................................................................... 12 Nm
Solenoid Valve ............................................................................................................................................. 27 Nm
Drive Shaft Coupling Locknut .................................................................................................................. 54 to 61 Nm
MFD Axle
Axle Support Housing Retaining Bolts ....................................................................................................... 200 Nm
Wheel Hub Drain/Filler Plug......................................................................................................................... 80 Nm
Axle/Differential Housing Drain Plug ............................................................................................................ 70 Nm
Axle Dipstick................................................................................................................................................. 10 Nm
Wheel Hub to Planetary Gear Carrier Countersunk Screws ........................................................................ 25 Nm
Planetary Gear Carrier to Swivel Housing Retaining Bolts .......................................................................... 78 Nm
Upper and Lower King Pin Retaining Bolts ................................................................................................ 120 Nm
Differential Housing to Axle Retaining Bolts............................................................................................... 169 Nm
Bevel Gear Retaining Bolts (with Loctite 270).............................................................................................. 78 Nm
Differential Bearing Cap Retaining Bolts .................................................................................................... 266 Nm
Locking Plate Retaining Bolts ...................................................................................................................... 12 Nm
Ball Joint Assembly to Steering Cylinder Piston Rod................................................................................. 300 Nm
Ball Joint Locknut ....................................................................................................................................... 165 Nm
Steering Cylinder Retaining Bolts .............................................................................................................. 120 Nm
Front Wheel Nuts ............................................................................................................................ 300 to 350 Nm
Front Weight Bracket....................................................................................................................... 481 to 542 Nm
Wheel Stud................................................................................................................................................... 70 Nm
Brakes
Parking Brake Cable Bracket Bolts ......................................................................................................... 45 to 50 Nm
Parking Brake Support Bolts ................................................................................................................... 45 to 50 Nm
Parking Brake Assembly Support Nuts ............................................................................................... 156 to 176 Nm
Hydraulic Trailer Brake Valve
End Cap Socket Head Screws ..................................................................................................................... 10 Nm
Bleed Valve ................................................................................................................................................. 2.5 Nm
SM 8-10090 Issued 03-2001

SECTION 1002 9
Hydraulics
Filter Manifold Retaining Bolts ............................................................................................................... 45 to 50 Nm
Hydraulic Filter Retaining Bolt ............................................................................................................... 16 to 21 Nm
Main Hydraulic Pump Retaining Bolts ................................................................................................... 24 to 28 Nm
Main Hydraulic Pump Drive Gear Locknut ............................................................................................ 61 to 68 Nm
Main Hydraulic Pump End Plate
Retaining Bolt ..................................................................................................................................... 27 to 31 Nm
Cap Screw.......................................................................................................................................... 24 to 27 Nm
Main Relief Valve ................................................................................................................................... 34 to 54 Nm
Fitting, PTO Spool Supply ..................................................................................................................... 34 to 54 Nm
Elbow, Filter Manifold Inlet ..................................................................................................................... 34 to 54 Nm
Plug, PTO Spool .................................................................................................................................... 34 to 54 Nm
Hitch Valve Plugs and Cap Screws ........................................................................................... refer to Section 8009
Regulator Valve
Solenoid Valve to Regulator Valve ...................................................................................................... 10 to 15 Nm
Coil to Solenoid Retaining Nut ................................................................................................................ 5 to 8 Nm
Regulator Pressure Valve Locknut ...................................................................................................... 34 to 54 Nm
Oil Cooler By-Pass Valve Plug ............................................................................................................ 34 to 54 Nm
Solenoid Valve Plug (8 Speed Transmission) ..................................................................................... 34 to 54 Nm
Differential Lock Solenoid
Coil to Solenoid Retaining Nut ................................................................................................................ 5 to 8 Nm
Unloader Valve
Regulator Valve Plug........................................................................................................................... 34 to 54 Nm
Remote Valve
Hydraulic Housing
3/8 inch Retaining Bolts ...................................................................................................................... 45 to 50 Nm
1/2 inch Retaining Bolts .................................................................................................................. 108 to 122 Nm
Front Hitch
Mounting Bolts ................................................................................................................................ 406 to 490 Nm
Front Cover Bolts ....................................................................................................................................... 257 Nm
Piston Retaining Nut .................................................................................................................................. 776 Nm
Chassis and Mounted Equipment

Cab Mounting Nuts......................................................................... 190 to 244 Nm 140 to 180 lb ft
Cab Mounting Bolt to Threaded Plate ................................................ 47 to 61 Nm 35 to 45 lb ft
Air Conditioning System

Fittings With O-Rings THREAD
FITTING TORQUE M10-1.25 5/8-18 3/4-16/18 7/8-14/18 1-14
Steel to Steel Nm - 31 to 36 40 to 46 45 to 52 -
Brass, Copper or
Aluminium to Nm 10 to 14 18 to 23 24 to 30 30 to 37 45 to52
Steel
IMPORTANT: Lubricate all threads and o-rings with mineral oil.
IMPORTANT: When tightening the air conditioner tubes and hoses, always use a second wrench for
support.
SM 8-10090 Issued 03-2001

1000 Series Engine
Service Manual
Naturally Aspirated 4 Cylinder Engines

Turbocharger 4 Cylinder Engines
Turbocharger 6 Cylinder Engines
This Service Manual Replaces SM 8-10040,

Containing SM 8-10050 (Table of Contents) and SM 8-10060

SM 8-10041 March 2001 (Revised May 2002)
2 1000 Series Engine - Table of Contents
Table of Contents
1 General information
Introduction ..............................................................................................................................................11
Engine views ........................................................................................................................................... 12
Engine identification ............................................................................................................................13
Safety precautions ................................................................................................................................15
Viton seals ................................................................................................................................................16
Engine lift equipment ...........................................................................................................................17
2 Specifications
Basic engine data ..................................................................................................................................19
Data and dimensions ...........................................................................................................................20
Thread sealant ........................................................................................................................................42
Standard torque tensions .................................................................................................................. 43
Specific torque tensions .....................................................................................................................44
Compression test data ........................................................................................................................ 46
SM 8-10041 Issued 05-2002

1000 Series Engine - Table of Contents 3
3 Cylinder Head Assembly

General description .............................................................................................................................. 47
Rocker cover
To remove ................................................................................................................................................ 48
To Install................................................................................................................................................... 49
Rocker assembly
To remove and to install........................................................................................................................... 50
To dismantle and to assemble ................................................................................................................. 51
To inspect and to correct.......................................................................................................................... 51
Valve tip clearances

To check and to adjust (four cylinder engines) ........................................................................................ 52
To check and to adjust (six cylinder engines) .......................................................................................... 53
Valve springs
To change the valve springs (with cylinder head installed)...................................................................... 54
Manifolds .................................................................................................................................................. 56
To remove and to install an intake manifold............................................................................................. 56
To remove and to install an exhaust manifold (one-piece) ...................................................................... 58
Cylinder head assembly

To remove ................................................................................................................................................ 60
To install (engine types AQ, AT, YH, YJ and YK) .................................................................................... 62
To install (engine type AS) ....................................................................................................................... 65
Valves and valve springs

To remove ................................................................................................................................................ 68
To install................................................................................................................................................... 69
Valve guides ............................................................................................................................................ 71

To inspect................................................................................................................................................. 71
To remove ................................................................................................................................................ 72
To install................................................................................................................................................... 73
Cylinder head
To correct a valve seat with a valve seat cutter ....................................................................................... 75
To install valve seat inserts ...................................................................................................................... 77
SM 8-10041 Issued 05-2002

4 Piston and connecting rod assemblies

General description ..............................................................................................................................79
Big end bearing

To remove ................................................................................................................................................ 81
To install ................................................................................................................................................... 82
To inspect ................................................................................................................................................. 82
Piston and connecting rod

To remove ................................................................................................................................................ 83
To install ................................................................................................................................................... 84
To check the piston height above the cylinder block ................................................................................ 86
Piston rings
To remove ................................................................................................................................................ 87
To install ................................................................................................................................................... 88
Piston and connecting rod assembly

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

To inspect ................................................................................................................................................. 92
Connecting rod
To inspect ................................................................................................................................................. 93
Partially finished small end bush

To remove and to install ........................................................................................................................... 94
Piston cooling jets

To remove and to install ........................................................................................................................... 95
To check the jet alignment........................................................................................................................ 96
5 Crankshaft assembly
General description ..............................................................................................................................97
Crankshaft pulley
To remove and to install (four cylinder engines)....................................................................................... 99
Crankshaft pulley and damper

To remove (six cylinder engines)............................................................................................................ 100
To install (six cylinder engines) .............................................................................................................. 101
To inspect ............................................................................................................................................... 102
SM 8-10041 Issued 05-2002

Rear oil seal assembly ...................................................................................................................... 103

To remove and to install (one-piece assembly) ..................................................................................... 103
To remove and to install (two-piece assembly)...................................................................................... 105
To renew the rear end oil seal (two-piece assembly)............................................................................. 106
To remove and to install a wear sleeve.................................................................................................. 107
Thrust washers
To check crankshaft end-float ................................................................................................................ 108
To remove .............................................................................................................................................. 109
To install................................................................................................................................................. 110
Main bearings
To remove (with the crankshaft in position) ........................................................................................... 111
To install................................................................................................................................................. 112
To inspect............................................................................................................................................... 112
Crankshaft
To remove .............................................................................................................................................. 113
To install................................................................................................................................................. 114
To inspect............................................................................................................................................... 116
Balancer unit
To remove and to install......................................................................................................................... 117
To dismantle........................................................................................................................................... 118
To assemble........................................................................................................................................... 120
To inspect............................................................................................................................................... 123
To remove and to install the needle roller bearings for the drive shaft .................................................. 124
To remove and to install the bushes for the balance weights ................................................................ 125
6 Timing case and drive assembly

General description ............................................................................................................................ 127
Timing case cover

To remove .............................................................................................................................................. 128
To install................................................................................................................................................. 129
Front oil seal

To remove .............................................................................................................................................. 131
To install................................................................................................................................................. 132
To remove and to install a wear sleeve.................................................................................................. 134
Idler gear and hub

To remove .............................................................................................................................................. 135
To install................................................................................................................................................. 137
Fuel pump gear .................................................................................................................................... 139

To remove .............................................................................................................................................. 139
To install................................................................................................................................................. 141
SM 8-10041 Issued 05-2002

Camshaft gear
To remove and to install ......................................................................................................................... 143
Crankshaft gear
Timing case
To remove .............................................................................................................................................. 145
To install ................................................................................................................................................. 146
Camshaft and tappets

To remove .............................................................................................................................................. 148
To install ................................................................................................................................................. 149
7 Cylinder block assembly

General description ............................................................................................................................151
Cylinder block
To dismantle ........................................................................................................................................... 152
To assemble ........................................................................................................................................... 153
To inspect ............................................................................................................................................... 154
To remove and to install a new type ‘D’ plug to the tappet chamber...................................................... 155
Cylinder liner
To inspect ............................................................................................................................................... 157
To remove .............................................................................................................................................. 158
To install a service liner .......................................................................................................................... 160
To install a partially finished liner............................................................................................................ 163
Cylinder bore, engine type AS

To inspect ............................................................................................................................................... 166
8 Engine timing
Engine timing
To set number 1 piston to TDC on the compression stroke ................................................................... 169
Another method to set number 1 piston to TDC on the compression stroke.......................................... 170
To check the valve timing ....................................................................................................................... 171
To check the timing of the fuel injection pump ....................................................................................... 172
SM 8-10041 Issued 05-2002

9 Aspiration system
Turbocharger
To remove .............................................................................................................................................. 175
To install................................................................................................................................................. 176
To clean the impeller and the compressor casing.................................................................................. 178
To remove and to install the actuator assembly of the waste-gate unit ................................................. 179
To check and adjust the operation of the waste-gate ............................................................................ 180
Turbocharger faults ............................................................................................................................ 181
List of possible causes ..................................................................................................................... 182
Open engine breather ........................................................................................................................ 183

To clean and to renew............................................................................................................................ 183
To Inspect .............................................................................................................................................. 185
10 Lubrication system
General description - four cylinder engine lubrication system ....................................... 187
General description - Six cylinder engine lubrication system ......................................... 188
Filter canister
To renew ................................................................................................................................................ 191
Filter head
Sump
Oil strainer and suction pipe

To inspect and to correct........................................................................................................................ 195
Lubricating oil pump .......................................................................................................................... 196

To remove .............................................................................................................................................. 196
To install................................................................................................................................................. 197
To inspect............................................................................................................................................... 198
Lubricating oil pump idler gear shaft .......................................................................................... 199

To remove (six cylinder engines) ........................................................................................................... 199
To install (six cylinder engines) .............................................................................................................. 201
To remove and to install (four cylinder engines) .................................................................................... 202
SM 8-10041 Issued 05-2002

Relief valve
To dismantle and to assemble................................................................................................................ 204
To inspect ............................................................................................................................................... 204
Flexible oil pipes ..................................................................................................................................205

To remove .............................................................................................................................................. 205
To install ................................................................................................................................................. 206
To Inspect............................................................................................................................................... 206
11 Fuel system
Cold start advance unit .....................................................................................................................210
Typical fuel system .............................................................................................................................212
Fuel filters ...............................................................................................................................................213
Fuel filter element

To renew - separate element type.......................................................................................................... 214
To renew - canister type ......................................................................................................................... 215
To renew - quick release canister type................................................................................................... 216
Atomisers ................................................................................................................................................217
To remove .............................................................................................................................................. 218
To install ................................................................................................................................................. 219
Fuel lift pump

To dismantle ........................................................................................................................................... 222
To assemble ........................................................................................................................................... 223
To test..................................................................................................................................................... 224
Lucas/Delphi DP 200 Series fuel injection pump ...................................................................225

To remove .............................................................................................................................................. 227
To install ................................................................................................................................................. 229
To adjust................................................................................................................................................. 232
Electrical shut off solenoid (ESOS) ........................................................................................................ 233
Air in the fuel system .........................................................................................................................235

To eliminate air from the fuel system...................................................................................................... 235
SM 8-10041 Issued 05-2002

12 Cooling system
Thermostats
To remove .............................................................................................................................................. 240
To install................................................................................................................................................. 241
To test .................................................................................................................................................... 242
Coolant pump - gear driven pumps ............................................................................................. 243

To remove .............................................................................................................................................. 243
To install................................................................................................................................................. 244
To dismantle........................................................................................................................................... 245
To assemble........................................................................................................................................... 248
Coolant pump - belt driven .............................................................................................................. 252

To remove high position pump............................................................................................................... 252
To install high position pump.................................................................................................................. 254
To dismantle........................................................................................................................................... 256
To assemble........................................................................................................................................... 257
Fan
Fan drive (engines with gear driven coolant pumps)

Lubricating oil cooler

To remove (six cylinder turbocharged engines) ..................................................................................... 262
To install (six cylinder turbocharged engines)........................................................................................ 263
To dismantle and to assemble (six cylinder engines) ............................................................................ 264
To remove and to install (canister type) ................................................................................................. 265
To remove and to install cooler bypass valve ........................................................................................ 265
Intercoolers ............................................................................................................................................ 266

To remove .............................................................................................................................................. 267
To install................................................................................................................................................. 268
To clean and to inspect .......................................................................................................................... 270
13 Flywheel and housing

Flywheel
Ring gear
Flywheel housing
SM 8-10041 Issued 05-2002

14 Electrical equipment
To check the drive belts.......................................................................................................................... 275
To adjust drive belt tension..................................................................................................................... 276
To remove and to install the drive belts.................................................................................................. 277
To remove and to install the alternator ................................................................................................... 278
To maintain............................................................................................................................................. 278
Starting aids ...........................................................................................................................................279

To remove and to install a fuelled starting aid ........................................................................................ 279
To remove and to install a twin-fuelled starting aid ................................................................................ 280
To check the fuelled starting aid............................................................................................................. 281
To remove and to install a port heater.................................................................................................... 281
15 Special tools
List of special tools ............................................................................................................................284
SM 8-10041 Issued 05-2002

Section 1 - General Information 11
General information 1
Introduction
This Workshop Manual has been written to provide assistance in the service and overhaul of 1000 Series
engines. For overhaul procedures the assumption is made that the engine is removed from the application.
The engine conforms with USA (EPA/CARB) stage 1 and EEC stage 1 emissions legislation for agricultural
and industrial applications.
Most of the general information which is included in the relevant User's Handbook has not been repeated in
this workshop manual and the two publications should be used together.
Where the information applies only to certain engine types, this is indicated in the text.
When reference is made to the “left” or “right” side of the engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available, for a list of these, see Chapter 15, Special tools . Reference to the
relevant special tools is also made at the beginning of each operation, where relevant.
Data and dimensions are included in Chapter 2, Specifications .
Read and remember the "Safety precautions" on page 15. They are given for your protection and must be used
at all times.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
SM 8-10041 Issued 05-2002

12 Section 1 - General Information
Engine views
A0378N
A0379
SM 8-10041 Issued 05-2002

Engine identification
The New 1000 Series engines have been designed for industrial and agricultural applications. There are both
four and six cylinder engines, each of which will have three basic engine types, naturally aspirated,
turbocharged and turbocharged with an intercooler.
In this workshop manual, the different engine types are indicated by their code letters. These are the first two
letters of the engine number as indicated below:
AQ Four cylinder, turbocharged, belt driven coolant pump
AS Four cylinder, naturally aspirated, belt driven coolant pump, 103 mm cylinder bore
AT Four cylinder, turbocharged, belt driven coolant pump, air to air
YG Six cylinder, naturally aspirated
YH Six cylinder, turbocharged
YJ Six cylinder, charge cooled, air to air
YK Six cylinder, turbocharged and intercooled
The correct identification of the engine is by the full engine number.

The engine number is stamped on a label which is fastened to the left side (A2) of the cylinder block. An
example of an engine number is:
AS50665*U510256B*
The components of the engine number are as follows:
AS50665*U510256B*
AS Model code number
50665 Build list number
U Built in the UK
510256 Engine serial number
B Year of manufacture
Continued
1 2
A A0043
SM 8-10041 Issued 05-2002

Date letters for engines start from the 1st of January each year. To comply with the new emissions legislation
that engines built before 1st April 1999 can be clearly identified from those built after this date, a new letter has
been used from the 1st of April 1999. The date letters used are as follows:
From the 1st of January 1999 to the 31st of March 1999 the date letter is E.
From the 1st of April 1999 to the 31st of January 1999 the date letter is F.
If you need parts, service or information for your engine, you must give the complete engine number to your
McCormick dealer. If there is a number in the area of the label marked TPL No, then this number must also be
given to your McCormick dealer.
Other identification labels fitted to the engine include:
An emissions legislation label (A3) fitted to the side of the cylinder block.
A label (A1) with the fuel injection pump part numbers.
If a short engine has been fitted in service two engine serial numbers and a TPL number are stamped on the
engine serial number pad (B3).
Examples of the serial numbers are shown in (B).
If parts for the short engine are needed in service, use the serial number (B4). If parts which were moved from
the original engine to the short engine are needed, use the serial number (B1) and the TPL number (B2).
AK80920*U510256B* 1
1 2 AJ39770 TPL N o 212 2

3
3 4
A A0043 B A0045
SM 8-10041 Issued 05-2002

Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only refer to specific applications.
* Only use these engines in the type of application for which they have been designed.
* Do not change the specification of the engine.
* Do not smoke when you put fuel in the tank.
* Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
* Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
* Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme care must be used to prevent injury).
* Do not make adjustments that you do not understand.
* Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
* Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
* Do not permit loose clothing or long hair near moving parts.
* Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
* Do not operate the engine if a safety guard has been removed.
* Do not remove the filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
* Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
* Disconnect the battery terminals before a repair is made to the electrical system.
* Only one person must control the engine.
* Ensure that the engine is operated only from the control panel or from the operators position.
* If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
* Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
* Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
* Discard used lubricating oil in a safe place to prevent contamination.
* Ensure that the control lever of the transmission drive is in the “out-of-drive” position before the engine is
started.
* Use extreme care if emergency repairs must be made in adverse conditions.
* The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes, see "Viton seals" on page 16 for safety precautions.
* Read and use the instructions relevant to lift equipment, see "Engine lift equipment" on page 17.
Continued
SM 8-10041 Issued 05-2002

* Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
* Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
* Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
* Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components
on the engine may be damaged.
* Fit only genuine McCormick parts.
Viton seals
Some seals used in engines and in components fitted to engines are made of Viton.
Viton is used by many manufacturers and is a safe material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components which have been burnt, ensure that the precautions
which follow are used:
* Ensure that the components have cooled
* Use neoprene gloves and discard the gloves safely after use
* Wash the area with calcium hydroxide solution and then with clean water
* Disposal of components and gloves which are contaminated must be in accordance with local regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or
with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.
SM 8-10041 Issued 05-2002

Engine lift equipment
The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different
applications. It is recommended that lift equipment of the minimum capacity listed below is used:
Four cylinder engines 500 kg (1100 lbs)
Six cylinder engines 600 kg (1320 lbs)
Before the engine is lifted:

* Always use lift equipment of the approved type and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above
the engine lift brackets (A1). Never use a single lift bracket to raise an engine
* Check the engine lift brackets for damage and that they are secure before the engine is lifted. The torque
for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m
* To prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker
cover
* Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder
head, balancer unit, flywheel housing, crankshaft and flywheel.
A A0044
SM 8-10041 Issued 05-2002

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CX Series Tractors

Service Manual SM 8-10602

Section Pub. No.

9 CHASSIS AND MOUNTED EQUIPMENT

SAFETY, GENERAL INFORMATION

© 2001 McCormick Tractors International Limited.

STANDARD TORQUE DATA FOR NUTS AND BOLTS

SM 8-10080 Issued 03-2001

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

To prevent injury always follow the Warning,

observe pertinent laws and regulations.

Operator’s and Service Manuals may be

DO NOT OPERATE WARNING: If you wear clothing that is too

WARNING: When working in the area of

WARNING: Use insulated gloves or

SM 8-10080 Issued 03-2001

CAUTION: Lower all attachments to the CAUTION: When servicing or repairing

SM 8-10080 Issued 03-2001

SM 8-10080 Issued 03-2001

STANDARD TORQUE DATA FOR NUTS AND BOLTS

Chart 1 (Plain Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

Chart 2 (Phosphate Coated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SM 8-10080 Issued 03-2001

Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SM 8-10080 Issued 03-2001

© 2001 McCormick Tractors International Limited.

SM 8-10090 Issued 0-3-2001

Fuel Tank................................................................................................................................................. 155 Litres

BATTERY SAE (COLD CRANKING AMPERE RESERVE

644 660 Amps 440 Amps 400 Amps 95 180 mins

Fuel Level Sender Resistance

SM 8-10090 Issued 03-2001

SM 8-10090 Issued 03-2001

Hydraulic System Type Open

Main Relief Valve Pressure ......................................................................................................................172.5 bar

SM 8-10090 Issued 03-2001

Air Conditioning System Specifications

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

SM 8-10090 Issued 03-2001

SM 8-10090 Issued 03-2001

MFD Transfer Gearbox

SM 8-10090 Issued 03-2001

Chassis and Mounted Equipment

Air Conditioning System

IMPORTANT: Lubricate all threads and o-rings with mineral oil.

SM 8-10090 Issued 03-2001

Naturally Aspirated 4 Cylinder Engines

This Service Manual Replaces SM 8-10040,

© 2002 McCormick Tractors International Limited.

Engine views ........................................................................................................................................... 12

Engine identification ............................................................................................................................13

Safety precautions ................................................................................................................................15

Viton seals ................................................................................................................................................16

Engine lift equipment ...........................................................................................................................17

Data and dimensions ...........................................................................................................................20

Thread sealant ........................................................................................................................................42

Standard torque tensions .................................................................................................................. 43

Specific torque tensions .....................................................................................................................44