McCormick GX40 GX45 GX50 Repair Manual

Factory Service Repair Manual For McCormick GX40 GX45 GX50 Tractors.

Detailed Step by Step Instructions, diagrams, illustrations, specifications for repair, overhaul, disassembly and assembly, testing, adjustment, replacement, change, and much more for service and repair McCormick Tractor.

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MODELS Covered

McCormick GX40

McCormick GX45

McCormick GX50

SECTIONS covered

* General Information
* Engine
* Clutch
* Gearbox
* Transmission
* Power Take Off
* Hydraulic System
* Steering System
* Brakes
* Electrical System
* Maintenance
* Technical Information
* Technical Specifications

General Information
SAFETY NOTES
Personal risk
Avoid accidents
General rules
Starting
Engine
Electrical systems
Hydraulic circuits
Wheels and tyres
Splitting and remounting parts
GENERAL INSTRUCTIONS
Battery
Adjuster shims
Spinning shaft seals
“O-ring” seals
Bearings
Spring pins
Notes about spare parts
Specific equipment
SYMBOLS
Meaning and use
DANGER SIGNS
Positions of the danger decals – WEO markets
Positions of the danger decals – NAO markets
SEALING AND FIXING SEALANTS
LUBRICANTS AND FUELS
CONVENTIONAL UNITS OF MEASUREMENT
Units of measurement (international system)
Conversion values for Imperial measurement system
STANDARD DRIVING TORQUE VALUES
Screws with metric threads
Nuts with metric threads
Engine
GENERAL FEATURES
MAIN SPECIFICATIONS
DRIVING TORQUES
SPECIFIC EQUIPMENT
SECTIONS
LUBRICATION, COOLING AND FUELLING CIRCUIT DIAGRAMS
ENGINE TROUBLESHOOTING
ENGINE SPLITTING AND REMOUNTING
Splitting
Remounting
COMPRESSION TEST
Compression degree
Measuring procedure
ENGINE – OVERHAUL
Demounting
Assembly of tappets and drive shaft with main bearing caps, bearings and bearing rings
Assembly of pistons complete with piston rings, pins, connecting rods, caps and bearings
Assembly of timing, lubrication, starting, recharging, cooling and fuelling components
Valve play adjustment
How to check the belt tension
INJECTOR NOZZLE AND INJECTION PRESSURE MEASURING AND MONITORING
Injection pressure measurement
Jet inspection
Atomizer valve sliding test
Identification number of the atomizer casing
INJECTION TIMING ADJUSTMENT AND MONITORING
IDLING RATE ADJUSTMENT (MINIMUM AND MAXIMUM)
HOW TO CHECK THE COOLING SYSTEM AND RADIATOR TO FIND LEAKS
SENSOR INSPECTION
Thermostat
Thermal switch
Hydraulic switch
CYLINDER HEAD INSPECTIONS, MEASUREMENTS AND REPAIRS
Warping and inspection of the combustion surfaces
Valve impression
Valve housing width and angle
Valve housing intervention procedure
Grinding and milling tool use procedure
Valve housing removal
Valve housing insertion
Valve stem wear and warping
Valve stem and valve guide
Valve head thickness
Valve guide replacement
Valve stem seal
Valve spring inspection
Spring cap and cotter inspection
CRANKCASE AND CYLINDER LINER INSPECTIONS, MEASUREMENTS AND REPAIRS
Crankcase inspection
Measurement of cylinder liner bore and warping
Lapping
ROCKER ARM INSPECTIONS, MEASUREMENTS AND REPAIRS !
Measurement of the outer diameter of the rocker arm pin and inner diameter of the rocker arrr
Tappet rod curve inspection, measurement of the outer diameter of the tappets and inspection of the contacting surfaces ;
Other inspections ;
PISTON AND PISTON RING INSPECTIONS, MEASUREMENTS AND REPAIRSI
Piston inspection;
Measurement of the outer piston diameter ;
Shape of the piston rings;
Measurement of the groove width of the piston ring, the piston ring and the distance
between ends
Piston ring assembly
Measurement of the outer diameter of the pin and relative hole
CONNECTION ROD INSPECTIONS, MEASUREMENTS AND REPAIRS
Visual inspection
Twist and parallelism measurement
Measurement of the bush and connecting rod pin play
Measure the play between the pin bush and the pin itself
Checking the connecting rod pin bearing contact
Mounting the piston and connecting rod
Connecting rod side play
CAMSHAFT INSPECTIONS, MEASUREMENTS AND REPAIRS
Camshaft float
Visual inspection of the camshaft
Camshaft incurvation measurement
Intake/exhaust cam height measurement
Measurement of the play between the camshaft pins
and their relative bushes:
DRIVE SHAFT INSPECTIONS, MEASUREMENTS AND REPAIRS
Drive shaft float
Checking the colour of the drive shaft
Bearing inspection
Drive shaft incurvation
Measurement of the connecting rod pin and main bearing
Precautions for bearing assembly
GEAR INSPECTIONS, MEASUREMENTS AND REPAIRS
Checking and measuring the intermediate gear shaft and the gear itself
Gear train
OIL PUMP INSPECTIONS, MEASUREMENTS AND REPAIRS
Play between the external rotor and pump casing
Play between inner and outer rotor
Float between the pump casing and the inner and outer rotor
Play between the rotor shaft and housing hole
Miscellaneous
YANMAR INJECTION PUMP
How to bleed air from the fuel circuit
INJECTION PUMP – OVERHAUL
Demounting
Assembly
Plunger inspection
Delivery valve inspection
Plunger guide, plunger cylinder inspection
Camshaft and bearing inspection
Fuel regulating pinion and rack inspection
REGULATOR UNIT – OVERHAUL
Demounting
Assembly
Checking the centrifugal weights of the regulator
Regulator sleeve inspection
Regulator lever shaft assembly inspection
Spring inspection
Checking the torque adjuster spring assembly
Checking the torsion spring assembly
Clutch
GENERAL SPECIFICATIONS OF THE LX 9″/9″ CLUTCH
DRIVING TORQUE VALUES
SPECIFIC EQUIPMENT
SECTIONS
TROUBLESHOOTING FOR THE CLUTCH ASSEMBLY
WHERE THE SEALANT IS APPLIED FOR THE CLUTCH HOUSING ON THE TRANSMISSION HOUSING
CLUTCH SPLITTING-REMOUNTING
Splitting
Remounting
CONTROL ADJUSTMENT
GEARSHIFT CLUTCH
CONTROL ADJUSTMENT
POWER TAKE-OFF CLUTCH
Gearbox
MAIN SPECIFICATIONS OF THE GEARBOX AND FINAL DRIVE
MAIN SPECIFICATIONS OF REVERSE SHUTTLE
MAIN SPECIFICATIONS OF THE SUPPLEMENTARY FINAL DRIVE (16+16 VERSION)____
DRIVING TORQUE VALUES
SECTIONS
DESCRIPTION AND OPERATION
Gearbox and reverse shuttle
Supplementary final drive (16 + 16 version)
TROUBLESHOOTING FOR THE GEARBOX, FINAL DRIVE AND REVERSE SHUTTLE
TROUBLESHOOTING FOR THE SUPPLEMENTARY FINAL DRIVE (16-16 VERSION)
WHERE THE SEALANT IS APPLIED FOR THE GEARBOX-REAR TRANSMISSION HOUSING
GEARBOX TRANSMISSION HOUSING SPLITTING-REMOUNTING
Splitting
Remounting
GEARBOX TRANSMISSION HOUSING – OVERHAUL
Demounting
Assembly
Main shaft float adjustment
Reverse shuttle gear float adjustment
CLUTCH HOUSING – OVERHAUL
Demounting
Assembly
Rear Differential Axle
MAIN SPECIFICATIONS OF THE BEVEL GEAR PAIR AND DIFFERENTIAL
DRIVING TORQUE VALUES
SECTIONS
DESCRIPTION AND OPERATION
TROUBLESHOOTING FOR THE BEVEL GEAR PAIR AND DIFFERENTIAL
TROUBLESHOOTING FOR THE SIDE FINAL DRIVES
WHERE THE SEALANT IS APPLIED FOR THE GEARBOX-REAR TRANSMISSION HOUSING
REAR TRANSMISSION HOUSING – OVERHAUL
Demounting
Assembly
RIGHT OR LEFT SIDE FINAL DRIVE HOUSING-ASSEMBLY SPLITTING REMOUNTING
Splitting
Remounting
DRIVING WHEEL SHAFT – OVERHAUL
Demounting
Assembly
BEVEL GEAR PAIR ADJUSTMENT
Front Axle
MAIN SPECIFICATIONS
DRIVING TORQUE VALUES
SPECIFIC EQUIPMENT
SECTIONS
DESCRIPTION AND OPERATION
Axle assembly
Differential lock
TROUBLESHOOTING FOR THE FRONT AXLE DIFF LOCK DEVICE
FRONT AXLE
Splitting
Remounting
FRONT AXLE DIFFERENTIAL AND BEVEL GEAR PAIR SUPPORT
Splitting
Remounting
FRONT BEVEL GEAR PAIR – OVERHAUL
Demounting
Bevel pinion bearing preload
Adjustment of the axial position of the bevel pinion
Pinion – ring gear play adjustment
Ring gear bearing float adjustment
FRONT DIFF LOCK – OVERHAUL
Demounting
Assembly
WHEEL HUB – OVERHAUL
Demounting
Assembly
FRONT FINAL DRIVE – SPLITTING REMOUNTING
Splitting
Remounting
FRONT FINAL DRIVE – OVERHAUL
Demounting
Assembly
AXLE STEERING CYLINDER – SPLITTING REMOUNTING
Splitting
Remounting
Power Take Off
MAIN SPECIFICATIONS
DRIVING TORQUE VALUES
SECTIONS
DESCRIPTION AND OPERATION
Power take-off controlled directly by the main clutch
Power take-off synchronized with the gearbox
TROUBLESHOOTING FOR THE MECHANICALLY ENGAGED POWER TAKE-OFF
WHERE THE SEALANT IS APPLIED ON THE POWER TAKE-OFF COVER
MECHANICALLY ENGAGED POWER TAKE-OFF OVERHAUL
Demounting
Assembly
Hydraulic Circuits – Rear Power Lift
MAIN SPECIFICATIONS – REAR HYDRAULIC POWER LIFT
SPECIFIC EQUIPMENT
SECTIONS AND PERSPECTIVE VIEWS
DESCRIPTION OF THE OPERATING MODE OF THE HYDRAULIC POWER LIFT
Position control
Draft control
Mixed position and draft control
Floating position
DESCRIPTION OF THE OPERATING MODE OF THE HYDRAULIC POWER LIFT’S VALVE SYSTEM
Neutral phase
Lifting phase
Discharge phase
POWER LIFT’S VALVE SYSTEM – OVERHAUL
Demounting
Assembly
VALVE SYSTEM OF THE HYDRAULIC POWER LIFT – HYDRAULIC TESTS
Check for leaks from the discharge valve
Checking and adjusting the cylinder safety valve
Non-return valve test
Over-pressure valve setting test
POWER LIFT – ADJUSTMENTS
Sensitivity adjustment
Draft control adjustment
Position control adjustment
HYDRAULIC POWER LIFT – OPERATING PRESSURE TEST
Checking the valve pressure setting for the auxiliary control valves
Hydraulic Circuits – Auxiliary Control Valves
MAIN SPECIFICATIONS – REAR HYDRAULIC POWER LIFT
SPECIFIC EQUIPMENT
SECTIONS AND PERSPECTIVE VIEWS
DESCRIPTION OF THE OPERATING MODE OF THE HYDRAULIC POWER LIFT
Position control
Draft control
Mixed position and draft control
Floating position
DESCRIPTION OF THE OPERATING MODE OF THE HYDRAULIC POWER LIFT’S VALVE SYSTEM
Neutral phase
Lifting phase
Discharge phase
POWER LIFT’S VALVE SYSTEM – OVERHAUL
Demounting
Assembly
VALVE SYSTEM OF THE HYDRAULIC POWER LIFT – HYDRAULIC TESTS
Check for leaks from the discharge valve
Checking and adjusting the cylinder safety valve
Non-return valve test
Over-pressure valve setting test
POWER LIFT – ADJUSTMENTS
Sensitivity adjustment
Draft control adjustment
Position control adjustment
HYDRAULIC POWER LIFT – OPERATING PRESSURE TEST
Checking the valve pressure setting for the auxiliary control valves
Steering System
MAIN SPECIFICATIONS
SECTIONS AND EXPLODED VIEWS
DESCRIPTION AND OPERATION
Power steering circuit oil supply
Differential locking and unlocking
Reverse shuttle and gearbox lubrication
OPERATING PRESSURE TESTS
Steering circuit pressure test
Checking the pressure setting of the utility pressure governor valve (18 bar)
Brakes
MAIN SPECIFICATIONS
DRIVING TORQUE VALUES
SECTIONS
DESCRIPTION AND OPERATION
Main brakes
Parking brake
BRAKE SYSTEM TROUBLESHOOTING
WHERE THE SEALANT IS APPLIED ON THE BRAKE ASSEMBLY AND SIDE FINAL DRIVES ON THE
TRANSMISSION HOUSING
RIGHT OR LEFT BRAKE SPLITTING-REMOUNTING
Splitting
Remounting
ADJUSTMENTS
Adjustment of the right and left brakes
Parking brake hand lever travel adjustment
Electrical System – Instruments
INSTRUMENTS
Warning light identification
Instrument panel
Wiring diagram of indicator light panel interior
Indicator lights
RPM meter and hour counter
Fuel level gauge
Engine coolant temperature indicator
TRANSMITTERS, SENSORS AND SWITCHES
MAINTENANCE
Warning light replacement
Electrical System – Components
CONTROL PANEL WITH ANALOGUE INSTRUMENT
LIGHT SWITCH
Turn indicators
Driving beam blinking function
Side lights
Driving/dipped beams
Horn
HAZARD LIGHT SWITCH
ROTATING BEAM SWITCH
IGNITION SWITCH
CONTROLS ON THE RIGHT-HAND SIDE
DIFF LOCK CONTROL BUTTON
CONTROLS ON THE LEFT-HAND SIDE
MAINTENANCE
Headlight bulbs Replacement
Bulbs in front side lights and turn indicators Replacement
Rear field light bulb Replacement
Bulbs in rear side lights, brake lights and turn indicators Replacement
License plate light bulb Replacement
Electrical System – Ignition System
TECHNICAL SPECIFICATIONS
DESCRIPTION AND OPERATION
TROUBLESHOOTING
TESTS
Ignition system test on the tractor
Power draw in the starter motor circuit
Resistance in the ignition system circuit (voltage drop)
Positive battery cable
Ground connection of the starter motor
Battery ground cable
STARTER MOTOR SPLITTING-REMOUNTING
Electrical System – Recharging System
TECHNICAL SPECIFICATIONS
DESCRIPTION AND OPERATION
Description of the alternator
Alternator operation
TESTS AND TROUBLESHOOTING
Precautions to take during the operation
Preliminary inspections
Initial tests
Alternator connection test
Charge current and regulated voltage tests
Alternator component tests
ALTERNATOR SPLITTING-REMOUNTING
Electrical System – Battery
TECHNICAL SPECIFICATIONS
DESCRIPTION AND OPERATION
Description of the alternator
Alternator operation
TESTS AND TROUBLESHOOTING
Precautions to take during the operation
Preliminary inspections
Initial tests
Alternator connection test
Charge current and regulated voltage tests
Alternator component tests
ALTERNATOR SPLITTING-REMOUNTING