Case IH MXU Series Tractors (100/110/115/125/135) OEM Service & Repair Manual

6 - 66172 -01 -2004 i RepairManual -- MXU Series Tractors 6--66172--01--2004 (Includes 6--66170 & 6--66171) CONTENTS -- VOLUME1 GENERAL SECTION 00 General Information Chapter 1 Section Description Page 00 000 General Instructions 2 ........................................................... Health and Safety 5 ............................................................. Ecology and the Environment 13 .................................................. Product Identification 14 ......................................................... International Symbols 17 ......................................................... General Dimensions 18 .......................................................... Vehicle Weights 22 .............................................................. Capacities 24 .................................................................. General Hardware Tightening Torques 25 .......................................... SEPARATING THE TRACTOR SECTION 01 Separating front axle and front support Chapter 1 from the engine Section Description Page Torque Values 2 ................................................................ Special Tools 2 ................................................................. 10 001 Separating Front Axle and Front Support from the Engine 3 .......................... 10 001 Installing Front Axle and Front Support to the Engine 9 .............................. Front Axle to Front Support Shim Calculation 14 .................................... Separating Engine and Front Support from the Transmission Chapter 2 Section Description Page Torque Values 2 ................................................................ Special Tools 2 ................................................................. Separating Engine and Front Support from the Transmission 4 ........................ Installing Engine and Front Support to the Transmission 11 ............................

Contents Continued: 6 - 66172 -01 -2004 ii Separating Transmission, Engine and Front Support Chapter 3 from the Rear Axle Section Description Page Torque Values 2 ................................................................ Special Tools 2 ................................................................. Separating Transmission, Engine and Front Support from the Rear Axle 3 .............. Installing Transmission, Engine and Front Support to the Rear Axle 8 .................. Engine Removal Chapter 4 Section Description Page Torque Values 2 ................................................................ Special Tools 2 ................................................................. Engine Removal 3 .............................................................. Engine Installation 12 ............................................................ Transmission Removal Chapter 5 Section Description Page Torque Values 2 ................................................................ Special Tools 2 ................................................................. Transmission Removal 4 ......................................................... Transmission Installation 7 ....................................................... Cab Removal Chapter 6 Section Description Page Torque Values (Tractors with Cab Suspension) 2 .................................... Torque Values (Tractors with Standard Cab) 3 ...................................... Special Tools 3 ................................................................. 90 150 Cab Removal 4 ................................................................. 90 150 Cab Installation 13 .............................................................. ENGINE SECTION 10 Engine -- 4 Cylinder Electronic Chapter 1 Section Description Page 10 000 General specifications 2 ......................................................... Assembly Clearances -- Data 4 ................................................... Torque wrench settings 7 ........................................................ Tools 12 ....................................................................... Cooling system 14 .............................................................. Lubrication system 15 ........................................................... Lubrication system components 16 ................................................ Engine overhaul 17 .............................................................

Contents Continued: 6 - 66172 -01 -2004 iii Bushings 29 .................................................................... Assembly on the workbench 30 ................................................... Fitting engine components 35 .................................................... Checks, dimensions and repairs (cylinder liner block) 51 ............................. Checks, dimensions and repairs -- crankshaft, bearings 53 ........................... Timing system 57 ............................................................... Bushings 58 .................................................................... Checks, dimensions and repairs -- pistons 59 ....................................... Connecting rod -- piston assembly 68 .............................................. Valves 69 ...................................................................... Valve guides 70 ................................................................. Valve seats 71 .................................................................. Valve springs 72 ................................................................ Fitting the cylinder head 73 ....................................................... Fuel supply gear pump 75 ........................................................ CP3 high--pressure pump 76 ..................................................... Rail (pressure accumulator) 81 ................................................... Pressure relief valve 82 .......................................................... Flow limiters 83 ................................................................. Electro--injector 84 .............................................................. Pressure limiter for fuel return 85 ................................................. Engine -- 6 Cylinder Electronic Chapter 2 Section Description Page 10 000 General specifications 2 ......................................................... Assembly Clearances -- Data 4 ................................................... Torque wrench settings 7 ........................................................ Tools 12 ....................................................................... Cooling system 14 .............................................................. Lubrication system 15 ........................................................... Camshaft timing operations 16 .................................................... Fitting the cylinder head 17 ....................................................... Cylinder block repairs 18 ......................................................... Crankshaft 20 .................................................................. Timing system 23 ............................................................... Bushings 24 .................................................................... Checks, dimensions -- connecting rod--piston assembly 25 ........................... Valves 27 ...................................................................... Valve guides 27 ................................................................. Valve seats 27 .................................................................. Spindle -- Rocker arms 29 ........................................................

Contents Continued: 6 - 66172 -01 -2004 iv Rail (pressure accumulator) 30 ................................................... Engine -- 4 Cylinder Mechanical Chapter 3 Section Description Page General specifications 2 ......................................................... Torque wrench settings 7 ........................................................ Tools 10 ....................................................................... Cooling system 12 .............................................................. Lubrication system 13 ........................................................... Lubrication system components 14 ................................................ Engine overhaul with rotary mechanical pump 15 .................................... Disassembly at the bench 16 ..................................................... Assembly at the bench 29 ........................................................ Checks and measurements 50 .................................................... Crankshaft 52 .................................................................. Timing system 57 ............................................................... Bushings 58 .................................................................... Checks, dimensions and repairs -- connecting rod/piston assembly 59 ................. Cylinder head 68 ................................................................ Valves 70 ...................................................................... Valve guides 71 ................................................................. Valve seats 71 .................................................................. Valve springs 73 ................................................................ Fitting the cylinder head 73 ....................................................... Spindle -- Rocker arms 74 ........................................................ Engine -- 6 Cylinder Mechanical Chapter 4 Section Description Page General specifications 2 ......................................................... Assembly Clearances -- Data 4 ................................................... Torque wrench settings 7 ........................................................ Tools 10 ....................................................................... Cooling system 12 .............................................................. Lubrication system 13 ........................................................... Camshaft timing operations 14 .................................................... Fitting the cylinder head 15 ....................................................... Cylinder block repairs 16 ......................................................... Crankshaft 18 .................................................................. Timing system 21 ............................................................... Bushings 21 .................................................................... Checks, dimensions -- connecting rod--piston assembly 22 ...........................

Contents Continued: 6 - 66172 -01 -2004 v Valves 25 ...................................................................... Valve guides 25 ................................................................. Valve seats 25 .................................................................. Spindle -- Rocker arms 26 ........................................................ Rotary fuel pump disassembly, assembly and timing procedure 28 ..................... Cooling Chapter 5 Section Description Page Specifications 2 ................................................................ Torque Values 2 ................................................................ Description and Operation 3 ...................................................... Troubleshooting 7 ............................................................... Cooling System Drain 8 .......................................................... Cooling System Refill 9 .......................................................... 10 406 Radiator Removal 9 ............................................................. 10 406 Radiator Installation 12 .......................................................... Radiator Inspection and Repair 14 ................................................ . 10 402 Thermostat Removal -- Engines with Common Rail Fuel Injection 14 ................... 10 402 Thermostat Installation -- Engines with Common Rail Fuel Injection 15 ................. 10 402 Thermostat Removal -- Engines with Mechanical Fuel Injection 16 ..................... 10 402 Thermostat Installation -- Engines with Mechanical Fuel Injection 17 ................... Thermostat Inspection 18 ........................................................ Coolant Temperature Sensor Removal -- Engines with Common Rail Fuel Injection 19 .... Coolant Temperature Sensor Installation -- Engines with Common Rail Fuel Injection 19 .. Coolant Temperature Sender Removal -- Engines with Mechanical Fuel Injection 19 ..... Coolant Temperature Sender Installation -- Engines with Mechanical Fuel Injection 19 .... 10 414 Viscous Fan Assembly Removal 20 ............................................... 10 414 Viscous Fan Assembly Installation 21 .............................................. Fan Blade Removal 22 .......................................................... Fan Blade Installation 22 ......................................................... Fan Belt Removal 22 ............................................................ Fan Belt Installation 22 .......................................................... 10 414 Spring--loaded Automatic Fan Belt Tensioner Removal 22 ............................ 10 414 Spring--loaded Automatic Fan Belt Tensioner Installation 23 .......................... Fan Belt Tensioner Inspection and Repair 23 ....................................... 10 402 Coolant Pump Removal 23 ....................................................... 10 402 Coolant Pump Installation 23 .....................................................

Contents Continued: 6 - 66172 -01 -2004 vi Fuel Tank Removal Chapter 6 Section Description Page 10 216 Fuel Tank Removal 2 ............................................................ 10 216 Fuel Tank Installation 3 .......................................................... CLUTCHES SECTION 18 Clutches Chapter 1 Section Description Page 18 000 Specifications, Tightening Torques and Special Tools 1 .............................. Fault Finding 2 ................................................................. Description and Operation 4 ...................................................... 18 110 Clutch Overhaul -- Removal 5 .................................................... Clutch Inspection and Repair 5 ................................................... Hydraulic Release Bearing / Slave Cylinder Assembly Overhaul. 6 .................... TRANSMISSION SYSTEM SECTION 21 16 x 16 Transmission Chapter 1 Section Description Page Specifications 2 ................................................................ Torque Values 3 ................................................................ Special Tools 7 ................................................................. Description And Operation 9 ..................................................... Fault Finding Diagrams 41 ....................................................... Transmission Disassembly/Assembly Information 50 ................................ Transmission Disassembly 52 .................................................... Front Section Removal 53 ....................................................... Middle Section Removal 57 ...................................................... Rear Section Removal 59 ........................................................ Front Section Disassembly/Assembly 62 ........................................... Middle Section Disassembly/Assembly 77 .......................................... Rear Section Disassembly/Assembly 85 ........................................... Transmission Top Cover Overhaul 105 ............................................. Transmission Control Valve Overhaul 107 .......................................... Synchroniser Inspection 111 ....................................................... Transmission Housing Transfer Tubes Removal/Installation 112 ....................... Transmission Assembly 113 ...................................................... Forward/Reverse Synchroniser End--Float Adjustment 117 ........................... Adjustment of Forward/Reverse and Main (1--4/5--8) Synchronisers 122 ................ High/Low Range Cable adjustment 123 ............................................

Contents Continued: 6 - 66172 -01 -2004 vii Adjustment of the High/Low Synchroniser 124 ...................................... 24 x 24 Transmission Chapter 2 Section Description Page 21 000 Specifications 2 ................................................................ Torque Values 4 ................................................................ Special Tools 6 ................................................................. Description And Operation 8 ..................................................... Fault Finding 33 ................................................................ C1/C2 Clutch Housing Removal 36 ................................................ C1/C2 Clutch Housing Disassembly 38 ............................................ C1/C2 Clutch Components Inspection 46 .......................................... C1/C2 Clutch Housing Assembly 46 ............................................... C1/C2 Clutch Plate Set Adjustment 54 ......................................... C1 Clutch Cluster Gear Shaft End Float Adjustment 55 ........................... C1/C2 Clutch Housing Installation 57 .............................................. Lubrication Oil Control Valve Disassembly/assembly 60 .............................. Transmission Disassembly 61 .................................................... Front Section Removal 63 .................................................... Rear Section Removal 64 .................................................... Middle Section Removal 66 ................................................... Transmission Component Disassembly/Assembly 68 ................................ Front Section 72 ............................................................ Rear Section 73 ............................................................. Middle Section 76 ........................................................... Transmission Assembly 81 ....................................................... Middle Section Installation 81 ................................................. Rear Section Installation 83 ................................................... Front Section Installation 85 .................................................. Output Shaft End Float Adjustments 89 ............................................ Gearshift Cable Adjustments 91 ..................................................

Contents Continued: 6 - 66172 -01 -2004 viii 12 x 12 Transmission Chapter 3 Section Description Page 21 100 Specifications 2 ................................................................ Torque Values 3 ................................................................ Special Tools 5 ................................................................. Description And Operation 7 ..................................................... Fault Finding 19 ................................................................ Transmission Disassembly 21 .................................................... Front Section Removal 24 .................................................... Rear Section Removal 25 ..................................................... Middle Section Removal 27 ................................................... Transmission Component Disassembly/Assembly 29 ................................ Front Section 32 ............................................................ Rear Section 34 ............................................................. Middle Section 37 ........................................................... Transmission Assembly 42 ....................................................... Middle Section Instillation 42 .................................................. Rear Section Instillation 44 ................................................... Front Section Instillation 46 ................................................... Output Shaft End Float Adjustment 51 ............................................. Gearshift Cable Adjustments 53 .................................................. Reduction Units Chapter 4 Section Description Page 21 000 Specifications 2 ................................................................ Sectional Views 2 ............................................................... Description and Operation 4 ...................................................... Fault Finding 7 ................................................................. Refer to the rear axle section for the removal of creeper components .............. DRIVE LINES SECTION 23 Drive Lines Chapter 1 Section Description Page 23 000 Specifications 2 ................................................................ Torque Values 3 ................................................................ Special Tools 4 ................................................................. Description and Operation 5 ...................................................... Fault Finding 12 ................................................................ 23 101 Standard Front Axle Four Wheel Driveshaft Removal 13 ............................. 23 101 Standard Front Axle Four Wheel Driveshaft Installation 15 ............................

Contents Continued: 6 - 66172 -01 -2004 ix 23 202 Four Wheel Drive Clutch Removal 17 .............................................. 23 202 Four Wheel Drive Multi--Wet Plate Clutch Disassembly 20 ............................ 23 202 Four Wheel Drive Multi--Wet Plate Clutch Assembly/Adjustments 23 ................... 23 202 Four Wheel Drive Dog Clutch Disassembly 28 ...................................... 23 202 Four Wheel Drive Dog Clutch Assembly 30 ......................................... 23 202 Four Wheel Drive Clutch Installation 31 ............................................ Four Wheel Driveshaft Oil Supply Manifold Removal 34 .............................. Four Wheel Driveshaft Oil Supply Manifold Installation 35 ............................ MECHANICAL FRONT AXLE SECTION 25 Mechanical Front Axle Chapter 1 Section Description Page 25 000 Specifications 2 ................................................................ Torque Values 4 ................................................................ Special Tools 6 ................................................................. Sectional Views 9 ............................................................... Description and Operation 10 ..................................................... Troubleshooting 12 .............................................................. 25 100 Standard Axle Removal 13 ....................................................... 25 100 Standard Axle Installation 16 ..................................................... Hub Cassette Seal Removal / Installation 19 ........................................ Front Axle Overhaul -- All Options 23 .............................................. Multi--Wet Plate Clutch Differential Lock -- Disassembly 29 ........................... Multi--Wet Plate Clutch Differential Lock -- Assembly 33 .............................. Crown Wheel / Differential -- Disassembly -- Multi--Wet Plate Clutch Differential Lock 35 ......................................... Crown Wheel / Differential -- Assembly / Adjustments Multi--Wet Plate Clutch Differential Lock 38 ......................................... Dog Clutch Differential Lock -- Disassembly / Assembly 43 ........................... Crown Wheel / Differential -- Disassembly / Assembly -- Dog Clutch Differential Lock 45 ................................................... Pinion Shaft Removal -- Standard Front Axle 47 ..................................... Pinion Shaft Installation / Adjustments -- Standard Front Axle 49 ...................... Pinion Shaft Removal -- Suspended Front Axle 56 ................................... Pinion Shaft Installation / Adjustments -- Suspended Front Axle 58 .................... Crown Wheel Adjustments -- Multi--Wet Plate Clutch Differential Lock 64 ............... Differential Bearing Preload -- Multi--Wet Plate Clutch Differential Lock 65 .............. Crown Wheel Adjustments -- Dog Clutch Differential Lock 67 ......................... Differential Bearing Preload -- Dog Clutch Differential Lock 69 ........................ Axle Assembly -- All Options 70 ................................................... Swivel Pin & Potentiometer -- Removal / Installation 71 .............................. Stub Axle Adjustments 72 ........................................................

Contents Continued: 6 - 66172 -01 -2004 x Checking the Alignment of Steering & Drive Wheels 74 .............................. Refer to Brake Section Of Repair Manual For Overhaul Of Front Axle Brakes Where Fitted Front Axle Suspension Chapter 2 Section Description Page 25 000 Specifications 2 ................................................................ Tightening Torques 2 ............................................................ Description and Operation 3 ...................................................... System Schematics 8 ........................................................... Suspended Front Axle Calibration Procedure 17 .................................... Fault Code Listing 20 ............................................................ Suspension Control Valve Assembly--Removal 22 ................................... Suspension Control Valve Assembly--Overhaul 22 ................................... MECHANICAL REAR WHEEL DRIVE (Rear Axle) SECTION 27 Mechanical Rear Wheel Drive Chapter 1 Section Description Page 27 000 Specifications 1 ................................................................ Torque Values 3 ................................................................ Special Tools 6 ................................................................. Sectional Views 9 ............................................................... Description and Operation 12 ..................................................... Troubleshooting 15 .............................................................. Rear Axle Disassembly 18 ....................................................... Rear Axle Assembly / Adjustments 29 ............................................. Rear Pinion and Crown Wheel Adjustments 32 ..... ............................... Hydraulic Pump Idler Gear Bearing Adjustment 44 ..... ............................ Hydraulic Differential Lock Control Unit (Multi--Wet plate clutch) Inspection 50 ........... Hydraulic Differential Lock Control Unit (Multi--Wet plate clutch) Disassembly 50 ......... Hydraulic Differential Lock Control Unit (Multi--Wet plate clutch) Assembly/Adjustments 54 Final Drive Case (Left or Right Hand) Removal 60 ................................... Final Drive Case (Left or Right Hand) Installation 63 ................................. Drive Wheel Shaft Removal/Installation 66 ......................................... Planetary Gear Set Removal/Installation 69 ........................................ 50 Km/h Drive (17th Gear) Chapter 2 Section Description Page 27 000 Specifications 2 ................................................................ Torque Values 3 ................................................................ Special Tools 4 .................................................................

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Case IH MXU Series Tractors (100/110/115/125/135) OEM Service & Repair Manual

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