MF30 Industrial Gas & Diesel Volume 1 of 2

Transcription

1 Massey Harris Massey Ferguson Service Manual MF30 Industrial Gas & Diesel Volume 1 of 2 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF MASSEY HARRIS MASSEY FERGUSON OR IT S SUCCESSORS. MASSEY HARRIS MASSEY FERGUSON AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. MH-S-MF30 IND

2 MF 30 AND MF 30 TURF TRACTORS 1 - ENGINE - AD ENGINE - AG CLUTCH 4 - TRANSMISSION 5 - DRIVE AXLE AND BRAKES 6 - POWER TAKE-OFF 7 - INTERNAL HYDRAULICS 8 - FRONT AXLE AND STEERING 9 - ELECTRICAL 10 - BACKHOE AND LOADER

3 PART 1 - ENGINE - DIESEL - AD4.203 Index INTRODUCTION... 2 Crankshaft Removal General Information... 2 Regrinding Crankshaft Engine Serial Number Location Crankshaft Installation Rear Crankshaft Oil Seal SPECIFICATIONS. " Flywheel General... 3 Removing Flywheel Torque Tension... 3 Replacing Ring Gear Engine Overhaul... 3 Installing Flywheel Lubrication System... 5 Fuel System... 6 LUBRICATION SYSTEM Cooling System... 6 Oil Pump Removal ENGINE REMOVAL AND INSTALLATION... 7 Disassembly and Inspection Removal... 7 Reassembly Installation... 9 Installation..., Oil Filter ENGINE OVERHAUL PROCEDURES Cylinder Head FUEL AND AIR SYSTEM Cylinder Head Removal Fuel Lift Pump Cylinder Head Disassembly/Inspection Disassembly Valves and Valve Seats Assembly Valve Guides Replacing Fuel Filter Elements Exhaust Valve Seat Inserts..., 12 Fuel Injection Pump Valve Springs Removing Fuel Injection Pump Rocker Arm Shaft Assembly Installing Fuel Injection Pump Cylinder Head Reassembly Adjusting Fuel Shut-Off Control Cylinder Head Installation Adjusting Engine Speed Valve Tappet Adjustment Adjusting Throttle Linkage Cylinder Block and Liners Adjusting Fuel Injection Pump Timing Cylinder Block Fuel Injectors Cylinder Liners Removing Injectors Piston and Connecting Rods Installing Injectors Removal of Piston/Rod Assembly Air-Bleeding Fuel System Pistons Air Cleaner Rings Servicing Outer Element Piston Pins Servicing Inner Element Connecting Rods Installation of Piston/Rod Assembly COOLING SYSTEM Timing Gears and Case Water Pump Timing Gear Cover and Front Disassembly Crankshaft Oil Seal Replacement Reassembly Timing Gears Thermostat Camshaft Fan Belt Crankshaft and Main Bearings Crankshaft End-Play TROUBLE-SHOOTING CHART MF 30 - AD4.203 ENGINE

4 Fig Installing Front Seal and Retainer 6. Remove front bearing snap ring. 7. Press two bearings and bearing spacer out front end of water pump body, Fig. 10B. B. Remove front seal and retainer from pump body, Fig. 10B. REASSEMBLY Clean and inspect all parts. Replace as necessary. A water pump repair kit is available to rebuild water pump. 1. Install front seal and retainer, Fig Install bearings and spacer, Fig Pack bearings and 1/2 to 2/3 of space between bearings with Shell Alvania 2 Grease or equivalent. 3. Insert snap ring. 4. Press shaft into body, Fig Support rear of drive shaft, then press pulley fully onto shaft until it bottoms against inner race on front bearing, Fig Secure with washer and nut. Rotate shaft by hand to assure that it turns freely. 6. Apply sealing compound around retainer (outside brass portion) of rear seal, then press it into rear of pump body. Install remainder of seal assembly, Fig Install ceramic counterface (if used), Fig B. Press impeller onto rear of shaft until clearance between front of impeller blades and pump body is Fig Pressing Shaft into Pump Body Fig Installing Bearings and Spacer Fig Pressing Pulley Onto Shaft -40-

5 DIESEL ENGINE TROUBLE-SHOOTING CHART PROBLEM SEE POSSIBLE CAUSE Engine will not turn over... '" ,2,3,4, 5, 6 Engine turns over, but will not start... 1, 2, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 Engine starts, runs for a few moments, then stops... 9,10,11,17,18 Engine misfiring or running erratically... 9, 13, 14, 15, 16, 19, 20, 21, 22, 23 Engine lacks power... 11,13,14,15,16,17,21,24 Excessive exhaust smoke (white)... 13,14,15,16,17,20 Excessive exhaust smoke (black or grey)... 14, 15, 16, 17,22,23,24 Engine noise - combustion knocks , 15, 16, 24, 25 Engine noise - mechanical knocks ,26,27,28,29,30,31,32,33 Engine overheating... 16, 17, 24, 34, 35, 36, 37, 38, 39, 40 Excessive fuel consumption... 14, 15, 16, 17, 20, 21, 22, 23, 24, 41 Excessive oil consumption... 42,43,44,45,47,48,49 Low oil pressure... 26,44,46,50,51,52,53 High oil pressure... 44,46, 54 Low compression pressure... 16, 21, 48, 55, 56, 57, 58 Possible Causes of Diesel Engine Malfunctions 1. Dead or weak battery. Recharge or replace battery. 2. Poor battery cable or ground connections. Inspect, clean and tighten cables and connections. 3. Loose or faulty wiring connections. Clean and tighten connections. 4. Faulty starting switch. Check and replace. 5. Starter motor malfunctioning. Repair or replace. 6. Internal engine seizure. Check for foreign object in gears or cylinders and for piston seizure. 7. Fuel tank empty. Fill tank and bleed fuel system. 8. Fuel shut-off control in "Off' position and/or fuel tank shut-off valve closed. Open control and/or valve. 9. Air in fuel system. Bleed fuel system. 10. Fuel lift pump inoperative. Repair or replace pump. 11. Fuel filter, strainer or fuel lines clogged or damaged. Clean or replace. 12. Engine oil too heavy. Drain and refill with recommended grade and weight. 13. Low compression pressure. Pressures should not exceed 10% variation between cylinders. If compression is uniformly low, a complete engine overhaul is usually required to restore engine. 14. Water in fuel or improper type fuel. Drain and refill with recommended type fuel. 15. Dirty or faulty fuel injectors. Clean or replace. 16. Fuel injection pump or valves incorrectly timed. Reset timing. 17. Restriction in intake or exhaust system. Check and service. 18. Fuel tank cap vent hole blocked. Replace or clean. 19. Insufficient fuel or restricted fuel flow. Check for plugged fuel filter, strainer, loose connections, bent or cracked fuel lines or a defective fuel lift pump. 20. Low operating temperature. Check thermostat. Replace if defective. 21. Incorrect valve clearance. Adjust. 22. Mismatching of fuel injection equipment. Recheck fuel system components for proper parts. 23. Faulty fuel injection pump. Have serviced by authorized CAV Service Station. 24. Engine overloaded. Reduce load or shift to lower gear. 25. Low engine rpm and/or improper operating temperature. Adjust engine rpm to recommended speed. Check that thermostat is installed and operating properly. 26. Excessively low oil level. Repair all oil leaks and refill to "FULL" mark on dipstick. -42-

6 MASSEY-FERGUSON MF 30, 30T CLUTCHES DUAL CLUTCH (11" Primary/g" Secondary) Removal... 1 Installation... 2 Adjustments... 3 Clutch Release Levers... 3 Secondary Pr~ssure Plat~, Clutch Pedal Free-Play Clutch Pedal Linkage This text contains instructions for removal, installation and adjustments of the clutches used in the MF 30 and 30T. To obtain procedures for disassembly, inspection, reassembly and trouble-shooting of the clutch, refer to the D&A section of this Manual. Instructions for removal, installation, etc., of the torque converter may be obtained in the "Transmission" text. Prior to removing the clutch from the engine flywheel, the unit must be "split" between the engine and the transmission case. (Refer to "MF 30 and 30T Transmissions" within this section for procedures.) DUAL CLUTCH (11" Primary/9" Secondary) The dual clutch used consists of two dry-type clutch discs. One 11" primary disc engages the engine flywheel and drives the unit power train. One 9" secondary disc drives the PTO shaft and the hydraulic pump. The primary pressure plate is spring-loaded by twelve coil springs located between the clutch cover and the primary pressure plate. The secondary pressure plate is spring-loaded by a Belleville-type spring located between the clutch cover and the secondary pressure plate. Depressing the clutch pedal through the first stage releases the primary clutch plate. Depressing the clutch pedal through both first and second stages releases both, the primary and secondary, clutch plates. REMOVAL See Fig With tractor "split" between engine and transmission case, install special "T" bolts with nuts and washers through the holes in the clutch cover. The "T" bolts are to hold the clutch assembly together while it is being removed from the flywheel. (These "T" bolts can be made from a 6" length of 1/4" "ready-bolt" with a 3" length of 1/4" rod welded to the end.) 2. Insert clutch pilot tool MFN 753 through the disc hubs and into the pilot bearing in the flywheel. (Tool will allow easier handling of the clutch assembly and flywheel disc.) To maintain original balance between flywheel and clutch, place aligning marks on flywheel and clutch cover. 3. Tighten the "T" bolt nuts evenly until the release levers are completely depressed. 4. Alternately remove the bolts (with lockwashers) securing the clutch to the flywheel. Carefully remove the clutch assembly and the primary (II") clutch disc from the engine flywheel. NOTE: Use care not to damage the air ring between the flywheel and the clutch assembly and do not drop the clutch. Printed in U.S.A. R&I MF 30, 30T 3-1

7 PART 4 - TRANSMISSIONS Contents REMOVING TRANSMISSION... 1 Service Information Separating Between Transmission and Engine Separating Between Transmission and Center Housing... 3 INSTALLING TRANSMISSION... 5 REMOVING/INSTALLING TORQUE CONVERTER... 6 TESTING AND ADJUSTING HYDRAULIC SHUTILE TRANSMISSION (INSTANT REVERSE)... :... 8 TROUBLE-SHOOTING HYDRAULIC SHUTILE TRANSMISSION (INSTANT REVERSE)... 9 SERVICING HYDRAULIC SHUTILE TRANSMISSION (INSTANT REVERSE) SERVICING 8-SPEED TRANSMISSION SERVICING MANUAL SHUTILE TRANSMISSION SERVICING MANUAL SHUTILE TRANSMISSION SHIFT COVER SPEED TRANSMISSION... CS-17 MANUAL SHUTILE WITH PTO... CS-22 INSTANT REVERSE AND TORQUE CONVERTOR... D&A 4 IR TRANS. REMOVING TRANSMISSION Procedures for removing transmission from units with a loader installed are slightly different than units without loaders. Service Information If a loader is installed. transmission removal may be performed by disconnecting loader from rear axle and splitting between engine and transmission. Transmission (and rear axle) is rolled rearward. then transmission and center housing assemblies are separated. If desired (and suitable equipment is available). loader can be hoisted above unit and secured in this position. Blocks are to be used under loader side frames to maintain their position and side frames may be unbolted from front end. With this method. it is necessary to disconnect hydraulic lines to loader pump... and to disconnect and remove instrument panel as an assembly. Engine is to be disconnected from transmission case... then front axle and engine is rolled forward from transmission. Transmission may then be removed from center housing. This method will make it unnecessary to remove a backhoe (or weight box). If a loader is not installed. removal procedures require only "splitting" at each end of transmission. READ ALL PROCEDURES CAREFULLY AND EXERCISE GOOD JUDGMENT! Separating Between Transmission and Engine NOTE: Detailed procedures are written assuming it is desired to roll transmission rearward from engine. 1. If a backhoe. weight box or other equipment is attached to rear of unit. remove it. 2. Remove both rear side panels from instrument support (see Fig. 1) and disconnect battery "hoc Fig. 1 - Side Panels Removed from Instrument Support Panel- Manual Shuttle Transmission Shown -1- MF 30 - TRANSMISSIONS

8 MASSEY-FERGUSON INSTANT REVERSE TRANSMISSION AND TORQUE CONVERTER TORQUE CONVERTER 2 Disassembly... 2 Inspection... 3 Reassembly... 4 OIL DISTRIBUTOR MANIFOLD..., Disassembly... 7 Inspection... 7 Assembly and Installation... 8 PUMP... 9 Removal... 9 Disassembly... 9 Inspection Assembly and Installation CLUTCH PACKS Removal Disassembly Inspection Assembly Installation TWO-SPEED TRANSMISSION Disassembly Inspection Assembly PLANETARY GEAR ASSEMBLY Removal Disassembly Assembly Installation This text contains the overhaul procedures for the Instant Reverse Transmission and Torque Converter. Procedures for testing, adjusting and trouble-shooting, removal and re-installation of the transmission and torque converter, may be found in the R&I section of this Manual. The Instant Reverse Transmission consists of a torque converter, a pair of hydraulically actuated multiple disc clutches, and a two-speed sliding spur gear-type transmission, with a rear-mounted two-speed planetary reduction assembly. Printed in U.S.A. D&A 4-IR Trans. ~ 1

9 MASSEY-FERGUSON MF 30 AND 30 TURF DRIVE AXLES AND COMPONENTS GENERAL DESCRIPTION AND IDENTIFICATION SPECIFICATIONS... 2 General Fastener Torque Values... 2 Lubrication... 2 DRIVE AXLE ASSEMBLY Removal Installation... 2 AXLE HOUSING ASSEMBLY... 3 Removal... 3 Installation... 3 Left Axle Housing... 3 Right Axle Housing (Includes Differential Bearing Pre-Load)... 4 AXLE PLANETARY ASSEMBLY (MF 30 ONLY).. 6 Removal... 6 Installation... 6 Planetary Bearing Pre-Load... 6 DRIVE PINION ASSEMBLY... 7 Removal... 7 Installation... 9 DIFFERENTIAL ASSEMBLY Removal Installation Ring Gear and Pinion Backlash GENERAL DESCRIPTION AND IDENTIFICATION The drive axle assembly number and the serial number are located on the top, left rear of the center housing P94 TYPICAL ASSEMBLY NUMBER CX 4594 TYPICAL SERIAL NUMBER The engine end of the Unit is the front, the drive axle, the rear. Left and right are determined looking forward from the rear of the tractor. Printed in U.S.A. RM MF in int,,- 1

10 MASSEY-FERGUSON MF 30 AND MF 30 TURF - BRAKE LINKAGE REMOVAL AND INSTALLATION Drum Type Brakes (MF 30 Turf).... Disc Type Brakes (MF 30).... Axle Housing Assembly.... LINKAGE AND PEDALS With Manual Shuttle Transmission... 2 Disassembly... 2 Reassembly... 2 Adjustment... 3 Disc Brakes (M F 30)... 3 Drum Brakes (MF 30T)... 3 With Instant Reverse Transmission... 3 Servicing... 3 Adjustment... 4 REMOVAL AND INSTALLATION DRUM TYPE BRAKES (MF 30 Turf) Refer to D&A 6 for removal, servicing and installation of drum brakes. Adjustment and linkage arrangements are described in headings that follow in this text. DISC TYPE BRAKES (MF 30) Axle Housing Assembly Removal and Installation Differential bearing pre-load procedures are not included here. If a carrier plate is replaced, or if bearing pre-load is questioned, refer to the pre-load procedures under "Axle Housing Assembly Installation" in R&I MF 30, 30T Remove the wheel and securely block the center housing. Drain the center housing lubricant. Detach the brake rod from the brake lever. 2. Remove the fender and attach a hoist to the axle housing assembly. Apply light tension. Detach and support the loader frame. 3. Remove the axle housing retaining nuts. Work the axle housing assembly free of the center housing. Refer to Fig Remove the center housing gasket and clean the housing mating surfaces. Fig. 1 - Axle Housing Assembly Removal or Installation - Planetary Type 5. Install a new center housing-to-axle housing gasket, align the assembly with the differential and the center housing and slide into position. 6. Position the light wire and brake return spring clips, install the axle housing retaining nuts or screws and tighten to 76 to 85 ft.-ibs. torque. Install the brake lever supports, if removed. Connect the brake rod. Printed in U.S.A. R&I MF 30, 30T 6 - I

11 PART 8 FRONT AXLE AND STEERING INDEX STEERING PUMP... 2 Removal... 2 Installation Servicing (Warner-Motive Pump)... 2 Disassembly... 2 Reassembly... 3 Servicing (Parker Hannifin Pump)... 4 Disassembly... 4 Reassembly... 4 CYLINDER AND VALVE... 5 Removal... 5 Installation Control Valve Disassembly... :... 6 Control Valve Reassembly Cylinder Disassembly... 6 Cylinder Reassembly... :... 6 PEDESTAL SHAFT... 7 Removal... 7 Installation STEERING GEAR ASSEMBLY... 7 Removal... 7 Disassembly... 7 Reassembly... 8 Installation... 8 FRONT AXLE... 8 Removal Servicing Axle... 8 Installation Wheel Bearings... 9 Adjustment and Packing... 9 TESTING AND ADJUSTMENTS... 9 System Pressures... 9 Adjusting Relief Valve... 9 Warner-Motive... 9 Parker Hannifin... 9 Adjusting Steering Gear... 9 Adjusting Steering Valve MF 30 - FRONT AXLE AND STEERING

12 TROUBLE-SHOOTING The troubleshooting problem chart is divided into two categories of "symptoms"... one lists OPERATIONAL symptoms while the other lists COMPONENT symptoms. Select the symptom, from the problem chart, most like the malfunction experienced and refer to the "Possible Cause" paragraphs in the sequence order listed. (The references may seem to be listed in a haphazardly manner, but an attempt has been made to refer to the most easily checked, or most likely cause, in logical order.) OPERATIONAL SYMPTOMS SEE POSSIBLE CAUSE! 1. Foaming Oil Fails to Raise Slow or Erratic Lift (Also See # 17) Arms not Lifting Equally Does not have Adequate Lift or Break-Out Capacity Drops with Spool in "Raise" and another spool is Activated Drops with Spool in "Neutral" Position Excessive Breakage of Hoses Low System Pressure (as Determined by Pressure Gauge).... COMPONENT SYMPTOMS A,B,C A,B,D,E,H,T F,A,B,C,H,G,Q,S,T G,I,X J,F,E K Z,L,M,N O,H H,Q SEE POSSIBLE CAUSE CONTROL VALVE 10. External Leakage of Valve "Sticky" Valve Spool(s) Unable to "Push" Valve Spool into Valve Body Spring-Centered Spool does not Return to Neutral "Float" Spool does not Stay in Detent.... Y,V,W S,T S,Y,T S,AA,AB,T R HYDRAULIC PUMP 15. Pump Noisy and/or Overheating Pump Shaft Seal Leaking Pump GPM too Low (as Determined by Tests).... A,B,P,D,E,Q Q F,A,B,P,C,D,Q CYLINDERS 18. Rapid Leak Down Cylinder Rod "Settles" into Barrel Cylinder Rod "Creeps" out of Barrel.... Z,M,U,N,L,Y L,M,N,U L,M,N,U Loaders - 7

13 IMPORTANT: See "Safety Precautions" and "Service Information" preceeding Loader Section. BACKHOES HYDRAULIC SYSTEM INFORMATION - MF 52, MF 54 and MF 54S BACKHOES TROU BLE-SHOOTI NG... 8 TESTS AND ADJUSTMENTS Operational Check of Backhoe Operational Check of Swing Checking and Adjusting Swing Cushioning (MF 54 and MF 54S) Checking System Main Pressure Testing Circuit Reliefs Adjusting Circuit Reliefs Testing "Load Checks"... J Testing for Valve Spool Leakage and Checking Spool Travel Testing for Internal Leakage of Double-Acting Cylinders CONTROL VALVES - SERVICING Service I nformation and Specifications Service Procedures..., 21 DOUBLE-ACTING CYLINDERS Service Information and Specifications Service Procedures SWING CYLINDER REMOVAL AND INSTALLATION Removing Rotary Cylinder I nstalling Rotary Cylinder ROTARY CYLINDERS - MF PART NOS M93 AND M Operation of Cushioning Mechanism - Part No M Servicing Rotary Cylinders in Place Complete Servicing of Rotary Cylinders..., 46 ROTARY CYLINDER - MF PART NO M91., Servicing Rotary Cylinder in Place Complete Servicing of Rotary Cylinder i-

14 MF LOADERS AND BACKHOES SAFETY PRECAUTIONS... 2 SERVICE INFORMATION LOADERS HYDRAULIC SYSTEM INFORMATION - MF 32A MF 34A AND MF 300A LOADERS... 3 System Flow Component Location and Operating Characteristics TROUBLE-SHOOTING Trouble Symptoms... " 1 3 TESTS AND ADJUSTMENTS... 1 a Checking and Adjusting System Main Pressure Testing and Adjusting Circuit Reliefs (Within Valve)... " 17 Testing for Valve Spool Leakage and Checking Spool Travel Testing "Load Checks" Testing for Internal Cylinder Leakage Checking Pump Efficiency (GPM) HYDRAULIC PUMP SERVICING Information Disassembly Inspection Reassembly "Breaking-In" New or Rebuilt Pump... " 22 CONTROL VALVE SERViCiNG Information..., Disassembly Inspection Reassembly DOUBLE-ACTING CYLINDERS Service Information Service Procedures OIL FILTERS Suction Filter - MF 32A and MF 34A Loaders Suction Filter - MF 300A Loader Return Filter BACKHOES (See "Contents" page for Backhoes following Loader section) Form No M3 Printed In U.S.A. -1- MF- LOADERS