McCormick ZTX 230, 260, 280 Tractor Full Service & Repair Manual

Table of Contents ZTX Series Tractors Service Manual SM 8-12602 Section Pub. No. 1 GENERAL Safety Rules, General Information and Torque Specifications ............................1001 General Specifications and Torques ...................................................................1002 2 ENGINE Engine How it Works .................................................................................................2 Fault Codes 3 FUEL 4 ELECTRICAL Electrical How it Works ......................................................................................... ..4 Electrical Schematics.........................................................................................4001 Instrument Cluster Programming.......................................................................4002 Battery Servicing and Testing............................................................................4004 5 STEERING Steering How it Works ...............................................................................................5 Steering Column and Steering Hand Pump Removal ........................................5001 Rexroth Steering Hand Pump.............................................................................5002 6 TRANSMISSION Transmission How it Works ......................................................................................6 Splitting the Tractor .............................................................................................6003 Full Powershift Transmission ..............................................................................6006 MFD Clutch..........................................................................................................6017 Rear Axle.............................................................................................................6018 Power Take Off ...................................................................................................6019 MFD Front Axle - 20.49 Axle ...............................................................................6021 Front Suspended Axle - 20.49 Axle.....................................................................6022 7 BRAKES Brakes How it Works .................................................................................................7 Parking Brake ......................................................................................................7001 8 HYDRAULICS Hydraulics How it Works............................................................................................8 Hydraulic Troubleshooting and Schematic ..........................................................8001 Left Hand and Right Hand Hydraulic Covers........................................................8005 Hydraulic Priority Valve Blocks ............................................................................8006 Auxiliary/Remote Spool Valves............................................................................8008 9 CHASSIS AND MOUNTED EQUIPMENT Climate Control How it Works.....................................................................................9 Pedal, Lever And Switch Adjustments .................................................................9001

10 CONTROLLER SYSTEMS Electrical Controllers How it Works..........................................................................10 Auxiliary/Remote Valve Controller - Error Codes, Troubleshooting and Schematics ..................................................................10001 Hitch Controller - Error Codes, Troubleshooting and Schematics ..................................................................10002 Front Suspended Axle Controller Calibration, Error Codes, Troubleshooting and Schematics..........................10003 Transmission and Cab (MCC) Controller - Calibration, Error Codes, Troubleshooting and Schematics ..................................................................10006 Instrument Cluster Controller - Error Codes, Troubleshooting and Schematics ..................................................................10009 Controller Programming ................................................................................10010 Automatic Temperature Control.....................................................................10012

SECTION 1001 2 SM 8-10080 Issued 03-2001 TABLE OF CONTENTS SAFETY ................................................................................................................................................................... 3 GENERAL INFORMATION Cleaning ............................................................................................................................................................... 5 Inspection ............................................................................................................................................................. 5 Bearings ............................................................................................................................................................... 5 Needle Bearings .................................................................................................................................................. 5 Gears ................................................................................................................................................................... 5 Oil Seals, O-Rings And Gaskets .......................................................................................................................... 5 Shafts ................................................................................................................................................................... 5 Service Parts ........................................................................................................................................................ 5 Lubrication ........................................................................................................................................................... 5 STANDARD TORQUE DATA FOR NUTS AND BOLTS Chart 1 (Plain Nuts/Bolts) .................................................................................................................................... 6 Chart 2 (Phosphate Coated Nuts/Bolts) ............................................................................................................... 6 Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ...................................................................................................... 7

SECTION 1001 SM 8-10080 Issued 03-2001 3 SAFETY To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put a warning tag as shown below on the key for the key switch when carrying out servicing or repairs to the tractor. Warning tags (publication number 2-1000) are available from your McCormick dealer. This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death. ! WARNING: Read the operators manual to familiarize yourself with the correct control functions. WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. WARNING: This is one a man machine, no riders allowed ! DO NOT OPERATE NE PAS UTILISER NICHT BETREIBEN NO UTILIZAR REASON/RAISON VERNUNFT/RAZON 2-1000 ! ! ! WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from you McCormick dealer. WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing. WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way. WARNING: Use insulated gloves or mittens when working with hot parts. ! ! ! ! ! !

SECTION 1001 4 SM 8-10080 Issued 03-2001 CAUTION: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. CAUTION: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood. CAUTION: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. CAUTION: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors). CAUTION: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands. ! ! ! ! ! CAUTION: When servicing or repairing the machine. Keep the shop floor and operator’s compartment and steps free of oil, water, grease, tools, etc. Use oil absorbing material and or shop cloths as required. Use safe practices at all times. CAUTION: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual. DANGER: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area. DANGER: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent that battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. DANGER: Batteries contain acid and explosive gas. Explosions can result from sparks, flames or wrong cable connections. To connect the jumper cables correctly to the battery of this machine see the Operator’s Manual. Failure to follow these instructions can cause serious injury or death. ! ! ! ! !

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

SECTION 1001 6 SM 8-10080 Issued 03-2001 STANDARD TORQUE DATA FOR NUTS AND BOLTS NOTE: A “click type” torque wrench is recommended for the bolt torques listed below. Chart 1 (Plain Nuts/Bolts) Chart 2 (Phosphate Coated Nuts/Bolts) BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 3.0 4.0 3.4 4.5 4.3 5.8 4.8 6.5 M5 4.8 6.5 5.5 7.5 7.0 9.5 7.8 10.5 M6 8.2 11.0 9.2 12.5 11.8 16.0 13.3 18.0 M8 20.0 27.0 22.5 31.0 28.7 39.0 32.3 44.0 M10 40.0 54.0 45.0 61.0 56.0 77.0 64.0 87.0 M12 69.0 94.0 78.0 106.0 100.0 134.0 110.0 151.0 M14 110.0 150.0 125.0 170.0 160.0 215.0 180.0 240.0 M16 175.0 235.0 190.0 260.0 245.0 335.0 275.0 375.0 M20 345.0 470.0 390.0 530.0 480.0 650.0 540.0 730.0 M22 475.0 640.0 530.0 720.0 655.0 890.0 735.0 1000.0 M24 600.0 810.0 675.0 915.0 830.0 1125.0 930.0 1265.0 M30 1190.0 1615.0 1340.0 1815.0 1645.0 2235.0 1855.0 2515.0 M36 2080.0 2825.0 2340.0 3175.0 2875.0 3900.0 3235.0 4390.0 BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 2.3 3.0 2.6 3.4 3.2 4.4 3.6 4.9 M5 3.6 4.9 4.1 5.6 5.2 7.1 5.9 8.0 M6 6.2 8.3 6.9 9.4 8.9 12.0 10.0 13.5 M8 15.0 20.3 16.9 23.3 21.5 29.2 24.2 32.8 M10 30.0 41.0 34.0 46.0 42.0 58.0 48.0 65.0 M12 52.0 71.0 59.0 80.0 75.0 101.0 83.0 113.0 M14 83.0 113.0 94.0 126.0 120.0 161.0 135.0 180.0 M16 131.0 176.0 143.0 195.0 185.0 251.0 205.0 280.0 M20 259.0 353.0 293.0 400.0 360.0 490.0 405.0 550.0 M22 355.0 480.0 400.0 540.0 490.0 665.0 550.0 750.0 M24 450.0 608.0 506.0 686.0 625.0 845.0 700.0 950.0 M30 893.0 1211.0 1005.0 1361.0 1235.0 1675.0 1390.0 1885.0 M36 1560.0 2119.0 1755.0 2381.0 2156.0 2925.0 2425.0 3295.0

SECTION 1001 SM 8-10080 Issued 03-2001 7 Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) BOLT SIZE (mm) TYPE 8.8 TYPE 10.9 MIN MAX MIN MAX lb ft Nm lb ft Nm lb ft Nm lb ft Nm M4 2.6 3.5 2.9 3.9 3.7 5.0 4.1 5.6 M5 4.1 5.6 4.6 6.3 5.9 8.0 6.6 9.0 M6 7.0 9.5 7.8 10.6 10.0 13.6 11.3 15.3 M8 17.0 23.1 19.1 25.9 24.4 33.1 27.4 37.2 M10 34.0 46.0 38.3 52.0 48.0 65.0 54.0 74.0 M12 59.0 80.0 66.0 90.0 85.0 114.0 94.0 128.0 M14 94.0 128.0 106.0 145.0 136.0 183.0 153.0 205.0 M16 149.0 200.0 161.0 220.0 208.0 285.0 235.0 320.0 M20 293.0 400.0 330.0 450.0 408.0 555.0 460.0 620.0 M22 400.0 545.0 450.0 615.0 555.0 755.0 625.0 850.0 M24 510.0 690.0 575.0 780.0 705.0 955.0 790.0 1075.0 M30 1010.0 1375.0 1140.0 1545.0 1400.0 1900.0 1580.0 2140.0 M36 1770.0 2400.0 1990.0 2700.0 2445.0 3315.0 2750.0 3730.0

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McCormick ZTX 230, 260, 280 Tractor Full Service & Repair Manual

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