SERVICE MANUAL
SERVICE MANUAL
MC22 / MC28 / MC35 Commercial Mower MC22 MC28 MC35 Commercial Mower
Print No. 604.55.081.00
Print No. 604.55.081.00
CONTENTS
SECTION 00 - GENERAL INFORMATION SECTION 10 - ENGINE AND FUEL SYSTEMS SECTION 25 - FOUR WHEEL DRIVE REAR AXLE SECTION 27 - DIFFERENTIAL, AXLES SECTION 31- PTO SECTION 33 – BRAKES SECTION 35 - HYDRAULIC SYSTEM SECTION 41 – STEERING SECTION 44 - TWO-WHEEL DRIVE REAR AXLE SECTION 55 – ELECTRICAL SECTION 90 - PLATFORM
SECTION 00 - GENERAL INFORMATION Chapter 1 - General Information CONTENTS Section
Description
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 Instruction Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 International Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-17 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-18 Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-25 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-27 Torque Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-28 00 400
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-29 Touch-Up Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-30
00 100
Pre-Season and Predelivery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-31
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SECTION 00 - GENERAL INFORMATION
INTRODUCTION This repair manual provides the technical information needed to properly service the New Holland MC22, MC28, and MC35 tractors. Use this manual in conjunction with the operator’s manual for complete operation, adjustment, and maintenance information.
On New Holland equipment, left and right are determined by standing behind the unit, looking in the direction of travel.
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SECTION 00 - GENERAL INFORMATION
PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”, “WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them.
DANGER This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.
WARNING This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.
CAUTION This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also used to alert against unsafe practices. The color associated with Caution is YELLOW.
FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH.
MACHINE SAFETY The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for machine safety. IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.
INFORMATION NOTE: Instructions used to identify and present supplementary information.
00-3
SECTION 00 - GENERAL INFORMATION
TECHNICAL INFORMATION HARDWARE GENERAL
Approximately 90% of the torque applied during assembly goes to overcoming friction between the parts. The other 10% is used to tension (stretch) the bolt. After assembly, the frictional forces disappear, which is the basis for the saying “If it does not fail during assembly, it will not fail in service.� The bolt may later fail due to other factors, but not from being overtightened.
The MC22, MC28, and MC35 tractors have been built using metric hardware. NOTE: Be sure to use the hardware specified when using tapped holes, as trying to install a metric bolt in an inch thread, or an inch bolt in a metric thread, will damage the thread. Certain hardware must be tightened to specific torque specifications. If specific torque specifications are not noted, tighten the hardware to the standard torque chart specification listed in this manual.
LOCKNUTS Most locknuts are coated with a special lubricant that is dry to the touch. Any time a locknut is used, a lower than normal torque is required. Refer to the torque charts in this manual for specific values.
PLATING Hardware used on New Holland balers is plated with zinc chromate (gold color). Gold colored hardware has different torquing requirements from unplated or zinc plated (silver color) hardware because of the difference in the coefficient of friction of the plating material. The torque charts in this manual list the correct specifications for gold, silver, and unplated bolts.
JAM NUTS When using a jam nut to lock a regular nut, the jam nut should be installed first and tightened to one half the recommended torque, then held in place while installing a regular nut to the recommended torque.
THREAD LUBRICATION The addition of antiseize compound, Molykote, oil, graphite, or any other lubricant to a bolt decreases the friction between it and a nut. This makes it necessary to reduce the recommended torque to prevent overtensioning of the bolt. When using the torque charts in this manual, decrease the value by 20% whenever a lubricant is used.
NUT TIGHTENING Whenever possible, the nut should be tightened, not the head of the bolt. When tightening using the bolt head, the clamp load can be lost because some of the torque applied twists the bolt instead of tensioning (stretching) it. The tension on the bolt is what holds the joint together.
00-4
SECTION 00 - GENERAL INFORMATION
SAFETY PRECAUTIONS The following precautions are suggested to help prevent accidents. SEE SPECIFIC INSTRUCTIONS IN TEXT FOR DETAIL. A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. Read and take the following precautions, before operating the commercial mower, to prevent accidents. Equipment should be operated only by those who are responsible and instructed to do so.
Servicing the Commercial Mower
This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death.
2. Do not smoke while refueling the unit. Keep any type of open flame away. Wait for the engine to cool before refueling.
COMMERCIAL MOWER 1. All persons who will operate the unit should read the Operators Manual carefully before using the equipment. Lack of operating knowledge can lead to accidents. 2. Permit only properly trained and qualified persons to operate the unit. 3. Use the step plates when getting on and off the unit to prevent falls. Keep steps and platform cleared of mud and debris. 4. Use an approved Rollover Protective Structure (ROPS) and seat belt for safe operation. Overturning a unit without a ROPS and seat belt can result in death or injury. If the standard ROPS or seat belt has been removed, see your New Holland Dealer for a replacement. 5. Always use the seat belt with ROPS. If the ROPS has been removed, do not use the seat belt. 6. Do not permit anyone but the operator to ride on the unit. There is no safe place for extra riders. 7. Replace missing, illegible, or damaged safety decals. 8. Keep safety decals clean of dirt and grime.
00-5
1. The cooling system operates under pressure which is controlled by the radiator cap. It is dangerous to remove the cap while the system is hot. Always turn the cap slowly to the first stop and allow the pressure to escape before removing the cap entirely.
3. Keep the Commercial Mower in good operating condition for your safety. An improperly maintained unit can be hazardous. 4. Keep open flame away from battery or cold weather starting aids to prevent fires or explosions. Use jumper cables, according to instructions, to prevent sparks which could cause explosion. 5. Before servicing, park the unit on a firm, level surface and apply the parking brake. Remove the key to prevent accidental start-up. 6. Escaping hydraulic/diesel fluid under pressure can penetrate the skin, causing serious injury. Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. • Stop the engine and relieve pressure before connecting or disconnecting lines. • Tighten all connections before starting the engine or pressurizing lines. • If fluid is injected into skin, obtain medical attention immediately or gangrene may result. 7. Do not modify, alter, or permit anyone else to modify or alter this unit or any of its components, or any unit function without first consulting your New Holland Dealer. •
SECTION 00 - GENERAL INFORMATION
SAFETY PRECAUTIONS DRIVING THE COMMERCIAL MOWER
8. The fuel oil in the injection system is under high pressure and can penetrate the skin. Unqualified persons should not remove or attempt to adjust a pump, injector nozzle, or any other part of the fuel injection system. Failure to follow these instructions can result in serious injury.
1. Watch where you are going, especially at row ends, on roads, around trees and low hanging obstacles. 2. To avoid upsets, drive the Commercial mower with care and at speeds compatible with safety, especially when operating over rough ground, when crossing ditches or slopes, and when turning corners.
9. Some components on your Commercial Mower, such as gaskets, may contain asbestos. Breathing asbestos dust is dangerous to your health. You are therefore advised to have any maintenance or repair operations on such components carried out by an authorized New Holland Dealer. If, however, service operations are to be undertaken on parts that contain asbestos, the essential precautions listed below must be observed:
3. Keep the unit in the same gear when going downhill as used when going uphill. Do not coast or free wheel down hills. 4. When the unit is stuck or tires are frozen to the ground, go up forward to prevent upset.
Work out of doors or in a well ventilated area. Dust found on the unit or produced during work on the unit should be removed by extraction, not by blowing. • Dust waste should be dampened, placed in a sealed container and marked to ensure safe disposal. • If any cutting, drilling, etc., is attempted on materials containing asbestos, the item should be dampened and only hand tools or low speed power tools used. 10. Continuous long term contact with used engine oil has caused skin cancer in animal tests. Avoid prolonged skin contact with used engine oil. Wash skin promptly with soap and water. • •
5. Always check overhead clearance, especially when transporting the Commercial Mower. 6. Avoid quick stops, especially when an attachment is raised or not installed. Quick stops can cause upsets. 7. Do not attach chains or ropes to the ROPS for pulling purposes.
OPERATING THE POWER TAKE OFF (PTO) Before installing or using PTO-driven equipment, read the manufacturer’s manual and review the safety labels attached to the equipment. 1. When operating PTO-driven equipment, shut off the engine and wait until the PTO stops before getting off the unit and disconnecting the equipment.
11. Do not work under a raised attachment unless it is securely supported by a suitable hoist or floor jack and multiple jack stands.
2. Do not wear loose clothing when operating the power take-off or when near rotating equipment.
12. The ROPS and seat belt must be properly maintained and must not be modified, drilled, or altered in any way. If the ROPS is damaged, if must be replaced and should not be straightened or welded.
3. When operating stationary PTO-driven equipment, always place the gear shift lever in neutral, apply the parking brake and block in front wheels front and back. 4. To avoid injury, do not clear, adjust, unclog or service PTO-driven equipment when the tractor engine is running.
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SECTION 00 - GENERAL INFORMATION
SAFETY PRECAUTIONS OPERATING THE MOWER DECK 1. Release the Commercial Mower HST foot pedal, apply the parking brake, place PTO lever in the “OFF� position, the lift control lever in neutral position and the transmission in neutral before starting the engine. 2. Do not start the engine or operate controls while standing beside the unit. Always sit in the seat when starting the engine or operating controls. 3. Do not bypass the neutral safety start switch. Consult your New Holland Dealer if your neutral safety start controls malfunction. 4. Use jumper cables only in the recommended manner. Improper use can result in the unit running away. 5. Avoid accidental contact with the gear shift lever while the engine is running. 6. Do not get off the Commercial Mower while it is in motion. 7. Disengage the PTO, shut off the engine and apply the parking brake before getting off the unit.
17. Do not drive the machine on streets or highways. Watch for traffic when you cross roads or operate near roads. 18. Look to the rear before and when backing. You must disengage blades before shifting into reverse. Make sure that the area immediately behind you is clear of obstructions or holes and small children. Use extra caution when the machine is equipped with a grass catcher. 19. Do not cross gravel roads with the PTO engaged. 20. Do not operate the mower deck without locking the hood and seat. 21. Disengage power to the mower deck when transporting or when not in use. 22. Disengage power to the mower deck before backing up. Do not mow in reverse unless absolutely necessary and then only after careful observation of the entire area behind the mower deck. 23. When mowing proceed as follows: a.
8. Do not park the Commercial Mower on a steep incline.
Mow only in daylight or in good artificial light.
b.
9. Do not operate the engine in an enclosed building without adequate ventilation. Exhaust fumes can cause death.
Never make a cutting height adjustment while the engine is running if the operator must dismount to do so.
c.
10. If the engine operates erratically, stop the engine immediately.
Check the blade mounting bolts for proper tightness at frequent intervals.
d.
Shut off the engine when removing the grass catcher or clearing the chute.
11. Do not leave equipment in the raised position. 12. Do not operate the Commercial Mower or any attachments while under the influence of alcohol, medication, controlled substances or when tired. 13. Do not operate near ditches, holes, embankments or any other terrain which may collapse under machine weight. The risk of machine tipover increases when the ground is loose or wet. 14. When working in cooperation with other operators, always let others know what you are doing ahead of time. 15. Never try to mount or dismount from a moving unit. 16. Do not operate the Commercial Mower with bare feet. Keep hands, feet and clothing away from power-driven parts.
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24. Watch for holes in the terrain and other hidden hazards. 25. Do not stop or start suddenly when going uphill or downhill. Mow up and down the face of steep slopes, never cross the face. 26. Disengage power to attachment(s) and stop the engine before leaving the operators position. 27. Never leave equipment in the raised position. 28. Always keep the discharge side of the cutter directed away from people and objects which could be struck by debris thrown from the cutter. 29. Install Commercial Mower weights to increase stability when operating on slopes.
SECTION 00 - GENERAL INFORMATION
SAFETY PRECAUTIONS 30. Avoid quick stops especially when the mower deck is raised. Quick stops will cause upset.
4. Maintain control of the fuel filler pipe nozzle when filling the tank.
31. Keep all shields in place.
5. Do not fill the fuel tank to capacity. Allow room for expansion.
32. Replace safety and warning decals when they become illegible.
6. Wipe up spilled fuel immediately. 7. Always tighten the fuel tank cap securely.
33. The vehicle and attachments should be stopped and inspected for damage after striking a foreign object and the damage should be repaired before restarting and operating equipment.
8. If the original fuel tank cap is lost, replace it with an approved cap. A non-approved, proprietary cap may not be safe.
34. Do not lubricate or make mechanical adjustments while the unit is in motion or when the engine is running. However, if minor engine adjustments must be made, apply the parking brake securely, block the wheels and use extreme caution.
9. Keep equipment clean and properly maintained. 10. Do not drive equipment near open fires. 11. Never use fuel for cleaning purposes. 12. Arrange fuel purchases so that winter grade fuels are not held over and used in the Spring.
35. Periodically maintain the mower deck. Tighten nuts, bolts and fittings periodically for safe operation. Check the blade for tightness.
AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search for leaks.
DIESEL FUEL 1. Under no circumstances should gasoline, alcohol or blended fuels be added to diesel fuel. These combinations can create an increased fire or explosive hazard. Such blends are more explosive than pure gasoline in a closed container such as a fuel tank. Do not use these blends.
If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.
2. Never remove the fuel cap or refuel with the engine running or hot. 3. Do not smoke while refuelling or when standing near fuel.
Whenever you see this symbol it means: WARNING! BECOME ALERT! YOUR SAFETY IS INVOLVED!
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SECTION 10 - ENGINE AND FUEL SYSTEMS Chapter 1 - Engine and Fuel Systems CONTENTS Section
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 Engine Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 10 012
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
10 106
Engine Gears and Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
10 102
Oil Pan and Pick-up Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
10 102
Connecting Rods, Bearings, and Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 Disassembly, Inspection, and Assembly of Engine Components . . . . . . . . . . . . . . . . . . 10-41
10 101
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
10 001
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
10 105
Pistons, Piston Rings, and Connecting Rods - Disassembly and Inspection . . . . . . . . . 10-49 Pistons, Rings, and Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
10 103
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
10 304
Oil Pump Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64 Camshaft and Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
10 103
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68 Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
10 102
Oil Pick-up and Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
10 102
Oil Pump, Idler Gear, and Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
10 101
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77 Lubrication System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
10 304
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
10 206
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
10-1
SECTION 10 - ENGINE AND FUEL SYSTEMS
CONTENTS (continued) Engine Oil Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89 Engine Oil Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91 10 400
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
10 402
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 Cooling System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
10 406
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
10 402
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
10 402
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
10 242
Injection Pump (MC22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
10 242
Injection Pump (MC28 and MC35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119 Pumping Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124 Delivery Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
10 230
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
10 218
Description of Operatio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132 Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
10 230
Governor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
10 218
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
10-2
SECTION 10 - ENGINE AND FUEL SYSTEMS
SPECIFICATIONS GENERAL ENGINE SPECIFICATIONS Tractor Model
MC 22
MC 28
MC 35
Engine Model
S773
J843
N843L
3
3
3
Bore X Stroke
77 x 72 mm (3.03 x 2.83 in.)
84 x 80 mm (3.31 x 3.15 in.)
84 x 100 mm 3.3x 3.94 in.
Displacement
1005 cc (61.3 cu in.)
1330 cc (81.2 cu. in.)
1662 cc (101.4 cu in.)
23:1
22.5:1
22.5:1
Rated Engine Speed
2700 rpm
2700 rpm
2700 rpm
Low Idle Speed
1000 rpm
1000 rpm
1000 rpm
Maximum Idle SpeedNo Load
2940 rpm
2940 rpm
2940 rpm
1-2-3
1-2-3
1-2-3
Inline Vertical
Inline Vertical
Inline Vertical
Overhead
Overhead
Overhead
29.4 ± 3.5 bar (427±50 psi)
29.4 ± 3.5 bar (427±50 psi)
29.4 ± 3.5 bar (427±50 psi)
Number Of Cylinders
Compression Ratio
Firing Order Cylinder Arrangement Valve Arrangement Compression Pressure @ 200 rpm (cylinder speed)
CYLINDER BLOCK SPECIFICATIONS Tractor Model
MC 22
MC 28
MC 35
Engine Model
S773
J843
N843L
77.0 mm (3.0315 - 3.0322 in.) 77.52 mm (3.0520 in.)
84.0 mm (3.3071 - 3.3078 in.) 85.2 mm (3.3543 in.)
84.0 mm (3.3071 - 3.3078 in.) 85.2 mm (3.3543 in.)
1.0 mm (.040 in.) oversize
72 mm (3.0510 - 3.0520 in.) N/A
84.2 mm (3.3268 - 3.3275 in.) 84.7 mm (3.3465 - 3.3472 in.)
84.2 mm (3.3268 - 3.3275 in.) 84.7 mm (3.3465 - 3.3472 in.)
Head Surface Warp Standard Maximum
0.05 mm (0.002 in.) 0.12 mm (0.005 in.)
0.05 mm (0.002 in.) 0.12 mm (0.005 in.)
0.05 mm (0.002 in.) 0.12 mm (0.005 in.)
Bore Standard Maximum Re-Bore Size! .5 mm (0.020 in.) oversize
1
If MC 22 bore exceeds 77.7 mm (3.059 in.), replace the cylinder block. If MC 28 or MC 35 bore exceeds 85.2 mm (3.3543 in.), replace the cylinder block.
10-3
SECTION 10 - ENGINE AND FUEL SYSTEMS
ENGINE DESCRIPTION OF OPERATION General MC model tractors are equipped with three-cylinder inline diesel engines. These engines are all four cycle, overhead valve, liquid cooled engines. These engines are mechanically fuel injected by an injection pump and fuel injectors. Each cylinder has an injector, for a total of three. Due to the placement of the fuel tank, a small, inline electric fuel pump assists fuel delivery to the fuel injection pump. The cooling system utilizes and engine mounted water pump that circulates coolant through the engine and radiator. A thermostat is used to direct coolant flow. The engines in the MC model tractors are similar and therefore utilize similar repair procedures. Each model’s engine is identified by a code, 1, which is cast into the lower right side of the cylinder block. NOTE: The numeric value, 2, listed under the engine code indicates the displacement of the engine, in liters.
1 2
3 Engine Identification
Tractor Model
Engine Horsepower
S773
MC 22
21.5
J843
MC 28
28
N843L
MC 35
35
10-16
SECTION 10 - ENGINE AND FUEL SYSTEMS
20005204
Model S773 4
20005205
Model S773 5
10-17
SECTION 10 - ENGINE AND FUEL SYSTEMS
MODEL J843
MODEL N843 6
MODEL J843
MODEL N843 7
10-18
SECTION 10 - ENGINE AND FUEL SYSTEMS Cylinder Block The cylinder block assembly houses the pistons, connecting rods, crankshaft, timing gears, camshaft, and the engine oil pump. The crankshaft is supported by four main bearings. The first bearing is positioned in a bore in the front of the block. The second, third and fourth bearings are split and are held in place by holders bolted to the engine block. The connecting rods are bolted to the crankshaft and spin on split bearings between the crankshaft and connecting rods. The connecting rods are attached to the pistons, which move up and down inside the block. The camshaft utilizes two ball bearings, one on each end of the camshaft, which ride on the inside of the block.
Cylinder head and Valve Train Components The cylinder head contains the valve assemblies, the rocker arms and rocker arm shaft, push rods and lifters. The fuel injectors and glow plugs are also housed in the cylinder head. A swirl chamber located between the injector assemblies and the main combustion chambers of the cylinders provides improved starting and better fuel efficiency. Initial fuel combustion begins in the pre-combustion chamber, which in turn creates a strong swirl pattern into the main combustion chamber. This aids in complete combustion of the air-fuel mixture. The MC 22 valve cover also serves as a pre-combustion chamber/air intake manifold, whereas the valve cover on the MC 28 and 35 is separate from the pre-combustion chamber/air intake manifold. The exhaust manifold is bolted to the left side of the cylinder head. The cylinder head also uses integral valve guides and standard size valves only for ease of replacement.
10-19
SECTION 10 - ENGINE AND FUEL SYSTEMS
COMPRESSION TEST 8. Disconnect the wiring harness lead, 1, from the fuel shutoff solenoid, 2.
1
2 8
NOTE: Be sure all glow plugs are removed from the engine before proceeding with the compression test.
2
NOTE: The MC 28 and MC 35 model shown; the MC 22 model is similar. 9. Remove the glow plug bus bar, 1, from the glow plugs, 2. Remove the glow plugs from the each cylinder.
1 10000896
9 NOTE: It may be necessary to remove some injector fuel lines to be able to install the adapter. 10. Install the adapter, 1, of special tool FNH00120 into the first cylinder and attach the gauge and hose to the adapter.
1
10
10-24
SECTION 10 - ENGINE AND FUEL SYSTEMS 11. Crank the tractor engine and observe the pressure gauge. Crank the engine until pressure stabilizes. The gauge should indicate 29.4 Âą 3.5 bar (427Âą50 psi). 12. Perform steps 3 and 4 for each cylinder. The compression should not differ more than 3.5 bar (50 psi) between each cylinder. If results of the test indicate a difference grater than 3.5 bar (50 psi), the head gasket may be blown or there may be internal engine damage. 13. After completing the test, install the glow plugs and bus bar back into the tractor engine. 11
10-25
SECTION 10 - ENGINE AND FUEL SYSTEMS
ENGINE OVERHAUL Op. 10 012
ENGINE REMOVAL IMPORTANT: It is advisable to label parts, hoses, electrical connections, etc., when removing the engine from the tractor. This will ensure that the installation of the engine goes smoothly. 1. Disconnect the negative battery cable from the battery. 2. Lift the engine cover and remove the two (2) bolts, 1, which secure the cover, 2, to the tractor.
2
3. Drain the engine oil from the engine.
1 30005617
12 4. Place a suitable pan under the radiator petcock, 1, and open the petcock to drain the engine coolant from the radiator and engine.
1
10005091
13
10-26
SECTION 10 - ENGINE AND FUEL SYSTEMS 5. Remove the bolts, 1, that secure the muffler, 2, to the tractor engine. Remove the muffler from the engine.
1
1
20002270
2
MC22
1
1
30002310
2
MC28 and 35
14 6. Remove the air intake hose, 1, and air filter canister, 2, from the tractor engine.
1 2
50005206
15
10-27
SECTION 10 - ENGINE AND FUEL SYSTEMS NOTE: When removing the radiator hoses from the engine, residual engine coolant may leak from the tractor engine.
1
7. Remove the upper radiator hose, 1, and lower radiator hose, 2, from the tractor engine.
2 40006095
16 8. Disconnect the throttle cable, 1, from the throttle linkage, 2.
2
50005207
1 17
10-28
SECTION 10 - ENGINE AND FUEL SYSTEMS NOTE: Disconnecting the hydraulic lines to the hydraulic pump may facilitate removal of the pump, but is not necessary. 9. Remove the four retaining bolts, 1, that secure the hydraulic pump, 2, to the engine. Disconnect the coolant petcock hose, 3, from the radiator side of the petcock.
1
10005088
2
3
18 10. Disconnect the fuel supply line, 1, and the fuel return line, 2, from the engine. 11. Label and disconnect all engine electrical connections. If necessary, see “Section 55, Electrical Systems� for removal of engine electrical components such as the alternator, switches, and sending units.
1 2
10000896
19 12. Remove the three bolts, 1, that secure the HST driveshaft/vibration damper, 2, to the engine.
1
2 50005208
20
10-29
SECTION 10 - ENGINE AND FUEL SYSTEMS 13. Remove the two (2) bolts, 1, from each side of the engine mounting plate, 2.
2
1
50005209
21 14. Using a suitable lifting device secured to the engine lift points, lift the engine from the tractor frame.
50005210
22 15. Remove the two (2) bolts, 1, that secure the flywheel guard, 2, to the rear of the engine.
1
16. Remove the six (6) bolts, 3, which secure the flywheel, 4, to the rear of the engine. Remove the flywheel from the engine.
2 3
17. Remove the cooling fan from the engine.
4
50005211
23
10-30
SECTION 10 - ENGINE AND FUEL SYSTEMS
ENGINE DISASSEMBLY NOTE: It advisable that the engine be installed onto an engine stand to make overhaul procedures easier. Fuel Injector and Glow Plug Removal 1. Clean all dirt and oil from the injectors and surrounding areas.
5
4
2. Disconnect the fuel lines, 1, from the injectors and cap all openings. 3. Remove the fuel injector leak-off line, 3. NOTE: The fuel injectors are very susceptible to damage and debris. Store the injectors in an area where they will be free from damage and contamination.
3
2 1
4. Remove the injector assemblies, 2.
24
5. Remove the glow plug bus connector, 5, and the glow plus, 4, from the tractor engine. Valve Cover/Air Intake Removal - MC 22 1. Remove the three (3) cap nuts, 1, from the top of the valve cover, 2.
1
2
2. Carefully pry the valve cover off of the cylinder head.
20006080
25 Air Intake Manifold Removal - MC 28 and MC 35 1. Remove the six (6) retaining bolts, 1, securing the air intake manifold, 2, to the cylinder head.
1
2
2. Lift the air intake manifold off of the cylinder head.
26
10-31
SECTION 10 - ENGINE AND FUEL SYSTEMS Valve Cover Removal - MC 28 and MC 35 1. Remove the three (3) cap nuts, 1, which secure the valve cover, 2, to the cylinder head.
2
1
2. Remove the valve cover from the cylinder head.
27 Oil Transfer Tube Removal 1. Remove the banjo bolt, 1, which secures the external oil transfer tube, 2, to the cylinder head.
1
2. Remove the banjo bolt from the opposite end of the external oil transfer tube and remove the tube from the engine.
2 20006081
28 Water Pump Removal Refer to the “Water Pump Removal�, in the cooling system portion of this manual.
10-32
SECTION 10 - ENGINE AND FUEL SYSTEMS Rocker Arm and Pushrod Removal - MC 22 IMPORTANT: If valve train components will be reused, label each component for location in the cylinder head/engine block. This is so the components can be returned to their removal location upon assembly of the engine. 1. Remove the three (3) nuts retaining the rocker arm assembly, 1, to the cylinder head, 2. The rocker arms and rocker arm shaft can then be removed as an assembly. 2. Remove the pushrods, 3, from the cylinder head.
3 1 2
29 Rocker Arm, Support Bracket, and Pushrod Removal - MC 28 and MC 35 IMPORTANT: When removing the rocker arm assembly and support bracket, loosen each bolt onehalf turn in a crossing pattern until all of the head bolts can be finger-turned or the bolts no longer secure the assembly to the cylinder head.
1
IMPORTANT: If valve train components will be reused, label each component for location in the cylinder head/engine block. This is so the components can be returned to their removal location upon assembly of the engine. 1. Remove the bolts which retain the rocker arm shaft and support bracket to the cylinder head and remove from the cylinder head as an assembly, 1.
10-33
30
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SECTION 10 - ENGINE AND FUEL SYSTEMS 2. Remove the pushrods, 1, from the cylinder head.
1
31 Exhaust Manifold Removal 1. Remove the six (6) nuts, 1, holding the exhaust manifold, 2, to the cylinder head. Tap the exhaust manifold from the cylinder head.
1
2 20006082
32 Op. 10 101 Engine Cylinder Head Removal IMPORTANT: Be sure to remove the cylinder head bolts incrementally to avoid head warp. Loosen each bolt one-half turn in a crossing pattern until all of the head bolts can be finger-turned or the bolts no longer secure the cylinder head to the engine block. 1. Remove the cylinder head bolts, 1, from the cylinder head. 2. Pry the cylinder head from the engine block.
1 33
10-34
SECTION 10 - ENGINE AND FUEL SYSTEMS Lifter (Valve Tappet) Removal NOTE: When removing the lifters from the bores in the engine block, note what bore each lifter came from so that the lifter can be returned to the corresponding bore upon assembly of the engine. 1. Remove the lifters, 1, from the bores in the engine block.
1
34 Engine Timing Cover NOTE: Remove the fuel shutoff solenoid, 1, if the solenoid was not previously removed.
1
35
10-35
SECTION 10 - ENGINE AND FUEL SYSTEMS 1. Remove the four (4) nuts/bolts, 1, securing the fuel injection pump, 2, to the pump body.
2
1 20006083
36 NOTE: When removing the injection pump, retain the shim(s) that are between the engine block and injection pump. These shims are for injection pump timing.
3 1
2. Lift the injection pump, 3, from the mounting bolts, 2, and remove the cotter pin, 1, that retains the governor link to the pump.
2
2
3. Remove the injection pump from the pump body.
37 NOTE: It may be necessary to use a puller to remove the crankshaft pulley.
2
4. Remove the retaining nut and washer, 1, that secures the crankshaft pulley, 2, to the crankshaft, 3. Remove crankshaft key, 4, from groove in crankshaft.
3
1 4
38
10-36
SECTION 10 - ENGINE AND FUEL SYSTEMS 5. Remove the bolts, 1, which secure the timing cover, 2, to the engine block. Lift the cover from the locating dowels.
1 2
39
Op. 10 106 Timing Gears and Camshaft Removal 1. Remove the retaining ring, 1, the oil pump assembly, 2, and the idler gear, 3, from the engine block.
1
2 3 40
10-37