Mitsubishi Heavy Industries S4E2 Service manual

SERVICE MANUAL

·.MITSUBISHI

. DIESEL ENGINE

for BD2G/BS3G

CONTENTS

• CONSTRUCTION AND FUNCTION

• SPECIAL TOOLS

• MAINTENANCE STANDARDS

• DISASSEMBLY AND REASSEMBLY

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DEFINITION OF TERMS

In this manual, the following terms are used in the dimensional and other specifications:

NOMINAL VALUE Indicates part. the standard dimension of a

ASSEMBLY STANDARD ...... Indicates the dimension of a part, the dimension to be attained at the time of reassembly or the standard performance. Its value is rounded to the nearest whole number needed for inspection and is different from the design value.

STANDARD CLEARANCE .... Indicates the clearance to be between mating parts at the reassem bly. obtained time of

REPAIR LIMIT ............. A part which has reached this limit must be repaired.

SERVICE LIMIT ............. A part which has reached this limit must be replaced .

General

Special tools

Group

Maintenance standards

Overhaul instructions

Adjustments, bench test,

performance tests

Engine accessory removal and installation

Engine proper

Intake and exhaust systems

Lubrication system

Cooling system

Workshop theory

TABLE OF CONTENTS

Contents

External views, Sectional views, Engine serial number location,

Engine model and application codes, Specifications, Tips on disassembly and reassembly

Group No.

I

Maintenance standards, Tightening torque, Sealants

2

Special tool list

Determining when to overhaul the engine, Testing the

compression pressure

Removal and installation of fuel injection pump, alternator) starter, etc.

Disassembly, inspection and reassembly of engine proper:

Cylinder head, valve mechanism, flywheel, timing gears,

camshaft, pistons, connecting rods, crankshaft, crankcase

Inspection of exhaust manifold

Disassembly, inspection and reassembly of lubrication system:

Oil pump, oil mter, relief valve

Disassembly, inspection and reassembly of cooling system:

Water pump, thermostat. fan, fan belt

Precautions for disassembly and reassembly of general parts.

Oil seals. O-rings, bearings, lock plates, pins

3

4

5

6

7

8

9

10

II

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GENERAL

I. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1.1 S4E2 diesel engine - External views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 S4E2 diesel engine - Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

1.3 Engine serial number location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Engine model and application codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

3. TIPS ON DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

..

GENERAL

1. GENERAL

1.1 S4E2 diesel engine - External views

2

CD

Fuel filter

<V

Fan

®

Water pump

®

Fuel injection pump

®

Fuel feed pump

®

Fan belt

(j)

Intake manifold

®

Stop solenoid

®

Governor

(j])

Flyw heel

(j])

Starter

Left-hand side view

402884

2

®

GENERAL o o~

4

CD

Exhaust manifold

®

Oil filter

®

®

Alternator

P.T.O. Gear

Right-hand side view

402885

3

GENERAL

1.2 S4E2 diesel engine - Sectional views

I

4

CD

Rocker arm

®

Piston

®

Compression ring

@Oil ring

®

Connecting rod

®

Camshaft

(j)

Oil pump

@G!ow plug

®

Fuel injection nozzle

Transverse view

402886

GENERAL

CD

Thermostat

®

Water pump

@Piston

®

Compression ring

®

Oil ring

®Fan

(j)

Camshaft gear

®

Camshaft

®

Connecting rod

(j])

Crankshaft gear

@

Crankshaft

@

Intake valve

®

Exhaust valve

®

Rocker shaft

Longitudinal view

402887

@

Rocker shaft bracket

@ Cylinder head

@

Valve push rod

®

Crankcase

@) Valve pushrod

@

Flywheel

®

Oil strainer

5

6

GENERAL

1.3 Engine serial number location

The engine serial number is stamped on the side face of crankcase.

II Engine

number

s~erial

I u

I

.9/J1

O ...........

""""'+t_

1.4 Engine model and application codes

SO 0 l~_

Series codes

E2: Swirl combustion chamber type

Piston displacement per cylinder:

739 cc (45.1 cu in.)

Bore x stroke:

98 mm x 98 mm (3.86 in. x3.86 in.)

No.-of-cylinders code (2, 3, 4 or 6)

Sagamihara Machinery Works

2. SPECIFICATIONS

Model designation

Type

No. of cylinders - arrangement

Type of combustion chamber

Valve mechanism

Bore x stroke mm (in.)

Piston displacement

Compression ratio

Fuel (ASTM specification)

Ol

~

"

Firing order

"

Direction of rotation

liter (cu in.)

~

"

0

'"

Dimensions

Weight (dry)

Rated output

Overall length

Overall wid th

Overall height

Maximum torque

Compression pressure

Maximum speed

Minimum speed

Type of cylinder sleeves

No. of piston

rings

Compression ring

Oil ring mm (in.) rom (in.) mm (in.) kg (Ib)

PS/rpm kgf·m (lbHt) [N·m1/rpm kgf/ em' (psi) [MPa 1/ rpm rpm rpm

Valve timing

Intake valves

Exhaust valves

Open

Close

Open

Close

Starting system

Starting aid

~t;;E

.aJ!1t;

Air cleaner

Type

0

"

".06

'" "

,...,

Type.

Engine oil

API service classification

Refill capacity

(incl. filter) liter (U.S. gal)

GENERAL

S4E2

Water-cooled, 4-stroke cycle, diesel

. 4-in line

Swirl chamber

Overhead

98 x 98 (3.86 x 3.86)

2.956

(180.3)

20: I

Grade No. 2D diesel fuel

1-34-2

Counterclockwise as viewed from

flywheel side

809 (31.85)

528 (20.79)

750 (29.53)

270 (595)

40/2400

15.5 (112.1) [152.01/1200

27 (384) [2.61/150 - 200

2620

±

20

870 ± 10

Dry) special cast iron

2

1 (w/spring expander)

B.T.D.C.300

A.B.D.C. 50°

B.B.D.C.74°

A.T.D.C. 30°

Electric starter

Glow plugs

Paper element

Pressure feed by gear pump

CC

7 (1.8)

7

8

GENERAL

Oil pump

E

"

Relief valve

~ c

·3

Oil filter

.0

.:l

Oil filter relief valve

Model designation

Type

Speed ratio to crankshaft

Delivery capacity liter (U.S. ga1)/min (at 1800 engine rpm)

Type

Opening pressure kgf/cm2 (psi) [MPa]

Type


Oil jet check

valve


E

"

~

""

'0

0 u

Refill capacity (engine water jacket) liter (U.S. gal)

Type

Water pump

Fan belt

Thermostat

Radiator


Delivery capacity liter (U.S. gal)/min (at 2000 engine rpm)

Type

Manufacturer

Type

Valve opening temperature

°c

(F)

Type

Type

No. of blades

Fan

Diameter

mm (in.)

Injection pump

E

"

»

~

<l

~

Feed pump

Governor


. Type

Manufacturer

Diameter of plunger mm (in.)

Type

Manufacturer

Cam lift mm (in.)

Type

Manufacturer

.

S4E2

Trochoid

0.5

14 (3.7)

Piston valve

3

±

0.3 (43

±

4.3) [0.3

±

0.03]

Paper element

1.0 ± 0.2 (14.2± 2.8) [0.10 ± 0.02]

-

4.6 (1.2)

Centrifugal

1.3

115

(30.4)

Low·edge, cog, B type V·belt

MITSUBOSHI

Wax pellet

76.5 ± 2 (169.7 ± 3.6)

Corrugated fin

Polypropylene·blade, circular-arc type

6

440

(17.32)

1.3

Bosch A

NIPPONDENSO

6.5 (0.256)

Bosch, piston

NIPPONDENSO

6 (0.24)

Bosch RSV, centrifugal

NIPPONDENSO

(

Injection

S

nozzles

'"

~

-.;

Fuel mter

Model designation

Type of nozzle holder

Type of nozzle tip

Manufacturer

No_ of spray holes

Diameter of spray hole mm (in.)

Sprayangle

Valve 0fening pressure kgf/cm (psi) [MPa]

Type

Manufacturer

Voltage - polarity

.

Model

S

'"

>-

00

';;l u

'5

u iii

Starter

Manufacturer

Type

Output V-kW

No. of pinion teeth/No. of ring gear teeth

Type

Manufacturer

Alternator

Output V-A

Rated voltage generating speed

Rated output generating speed

Maximum speed


Type

Rated voltage - current

V-A

Glow plugs

Resistance at nonnal temperature

Type

Air heater

Capacity

Heater relay

Fuse capacity kW

A rpm rpm rpm n

.

GENERAL

S4E2

Bosch, throttle

Bosch ND-DNOSD

NIPPONDENSO

1

1.0 (0.D4)

0°

120

+~o

(1706

+~42)

[11.8

+~.o]

Cartridge, paper element

NIPPON ROKAKI

24V - negative ground

M002T65271 (dry)

MITSUBISHI ELECTRIC

Pinion shift

24 - 3.2

11/110

3-phase, with rectifier

MITSUBISHI ELECTRIC

24-20

1100

5000

13500

1.7

Sheathed

22.5 - 4.8

4.5

±

0.5

-

-

-

9

GENERAL

3. TIPS ON DISASSEMBLY AND

REASSEMBLY

This Service manual deals with

Mitsubishi'srecommended procedures to be followed in servicing the Mitsubishi diesel engines and contains information on the special tools and basic safety precautions.

The safety precautions contained herein, however, are not the whole of work . .It is the responsibility of the service personnel to know that specific requirements, precautions and work hazards exist and to discuss these with his foreman or supervisor. study this manual carefully and observe the following general precautions to help prevent serious injury to the personnel and' damage to the engine.

(

(6) When lifting or carrying a pa'rt too heavy or too awkward for one person to handle, get another person's help and, if necessary, use a jack or chain block.

3.2 Reassembly

(1)

Wash all engine parts, except for oil seals, O-rings, rubber sheets, etc., with cleaning solvent and dry them with pressure air.

(2) Use only right tools and instruments.

(3) Use only good-quaJi ty lubricating oils and greases. Be sure to apply a coat of oil, grease or sealant to parts as specified.

(4) Be sure to use a torque wrench to tighten parts for which tightening torque is specified. (Refer to 2,

Group No.2.)

(5) Replace gaskets and packings with new ones. Apply a proper amount of quick-drying cement to gaskets or packings, if necessary.

3.1 Disassembly

(1)

Use only right tools and instruments.

Serious injury to the personnel and damage to the engine result from the wrong use of tools and instruments.

(2) Use an overhaul stand or work bench if necessary. Also, use assem bly bins to keep the engine parts in order of removal.

(3) Lay down the disassembled and

'cleaned parts in the order in which they were removed to save time for reassembling work.

(4) Pay attention to marks on assemblies, components and parts for their positions or directions. Put on marks, if necessary, to aid reassem bly.

(5) Carefully check each part for any sign of faulty condition' during removal or cleaning. The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning.

10

MAINTENANCE STANDARDS

1. MAINTENANCE STANDARDS ............................................. 12

2. TIGHTENING TORQUE .................................................. 19

2.1 Important bolts and nuts ................................. .... . . . . . . . . . . .. 19

2.2 General bolts and nuts .................................................. 20

3. SEALANTS .............................................................. 21

MAINTENANCE STANDARDS

1.


Unit· mm (in )

Group Inspection point

Nominal Assembly standard

value

[standard clarance}

Repair

Service

limit limit

[clearance} [clearance}

Maximum rpm (no·load)

2620 ± 20

Minimum rpm (no·load)

.


Lube oil pressure

870± 10

Nominal value:

27 kgf/cm' (384 psi)

24 kgf/cm

2

(341 psi)

[2.6 MPa} at ISO - 200 rpm [2.4 MPa}

Nominal value:

3 - 4 kgf/cm

2

2 kgf/cm

(43 - 57 psi) (28 psi)

2

[0.3 - 0.4 MPa} at 1500 rpm [0.2 MPa}

Nominal value:

I kgf/cm

2

(14 psi)

O.5kgf/cm'

(7 psi)

[0.1 MPa}, minimum at idling [0.05 MPa}

-;;;

~

"

Valve timing In. valves open

"

[with 3'mm In. valves close

3° A.B.D.C.

(0. I 2·in.)

Ex. valves open

14° A.T.D.C.

24° B.B.D.C.

clearance on

Ex. valves close

29° B.T.D.C. valve side}

±3 ° (crank angle)

I

Valve clearance (cold)

[ 0.25 }

(0.0098)

Fuel injection timing

B.T.D.C.

22°

Remarks

Adjust governor setting.

Oil and water temp.

20- 30°C

(68 - 86°F)

Oil temRerature

60 _70°C

(140 - 158°F)

Values are only for checking

valve timing and

are different

from actual ones.

Both intake and

exhaust valves

Fan drive belt tension

10 -IS

(3/8 - 5/8)

Measure sag at point indicated by arrows.

~

In.: Intake

Ex.: Exhaust

12



.,:,

"

~

Warpage of gasketed oa

surface

Unit: mm (in.)

Nominal

Assembly standard

value

[standard clarance]

Repair

Service

limit limit

[clearance] [clearance]

0.05 (0.0020),

maximum

0.20

(0.0079)

Remarks

Regrind if warpage

is minor.

"

'"

.!<

"

~

U

'"

.,.

"0

U

~

"

"

~

"

~

Inside

diameter

Out·of·roundness

Taper

~ on

"

'"

."

::E

Clearance on

journals

Thrust journal length

(end play)

~

"

"

~

Inside diameter

" p.

~

Clearance on

tappets

....

~

"'''''

Clearance on

e~ journals·

"

~

"

~~ u.a

Warpage of gasketed

surface

As·installed thickness of gasket

Intake

"0

'"

~

"

.5

>,

U i

~

"

.~

"

"0

Diameter of valves valve stems

Stem

"

"

clearance in guide

Exhaust

valves

Intake

valves

Exhaust

valves

>

As·installed length of

guides

98 98.000 - 98.035

98.200

99.200

(3.86) (3.85826 - 3.85964) (3.86613) (3.90550)

0.Ql5 (0.00059),

maxlmum

0.05 (0.0020),

maximum

Refinish sleeves to

+0.25 (+0.0098) or

+0.50 (+0.0197)

oversize of nominal

value by honing and

use the same oversize pistons and piston rings

75

(2.95)

0.050- 0.115

[(O.OO 197- 0.00453)]

0.200

[(0.00787)J

-0.9

(-0.035)

as journal diameter.

If repair limit is reached, replace bearings.

If service limit is reached, regrind journals and

use undersize bearrings:

Undersize bearings:

-0.25 (-0.0098),

-0.50 (-0.0197) and

-0.75 (-0.0295)

2.45 0.100-0.264

0.300

(0.0965) [(0.00394-0.01039)]

[(0.01l8!)J

22

(0.87)

Replace thrust plate.

22.000 - 22.021

(0.86614 - 0.86697)

[ 0.04 - 0.09

J

[ 0.15 ]

(0.0016-0.0035) (0.0059)

22.100

(0.87008)

0.035 -0.086

0.120

[(0.00138-0.00339)] [(0.00472)J

+0.10

(+0.0039)

as inside diameter

If repair limit is

reached, replace

tappets.

If repair limit is exceeded, replace bushings. Ream if

necessary.

Regrind if warpage is minor.

1.6

(0.063)

0.05 (0.0020),

maximum

±0.15

(±O.0059)

7.955 - 7.940

(0.31319 - 0.31260)

7.940 - 7.920

(0.31260- 0.31181)

0.20

(0.0079)

8

(0.31)

0.055 -0.085

[(0.00217 -0.00335)]

0.070-0.105

[(0.00276-0.00413)]

17

(0.67)

±0.3 (±O.OI2)

7.900

(0.31102)

7.850

(0.30905)

0.150

[(0.00591)J

0.200

[(0.00787)1

13

MAIN"I:ENANCE STANDARDS


Angle

Nominal Assembly standard value [standard clarance]

.

Repair

Service

limit limit


30°

(

Unit: mm (in.)

Remarks

Valve sinkage

~

~;

"

~

Width

Valve margin

"'"

"'"

"'"

;;, u

Free length g), c:

""

~

Squareness

Test force/length under test force kgf (lbl) [N]

~

E

~

Inside diameter of rocker bushings

'"

Diameter of rocker

" shafts

~

Clearance of . bushings on shaft

0.7

(0.028)

±0.2 (±0.008)

1.3

(0.051)

1.2

(0.047)

±0.14 (±0.0055)

2.13 (0.0839)

1.6

(0.063)

Refacing is permissible

up to

1.2

(0.047).

48.85

(1.9232)

1.27 (0.0500),

maximum

19±1(42±2)

[186± 10]/

43 (1.69)

20.000 - 20.021

(0.78740 - 0.78823)

19.984 - 19.966

(0.78677 - 0.78606)

20

0.016-0.055

0.070

(0.79) [(0.00063-0.00217)] 1(0.00276)1

47.60

(1.8740)

15 (33)

[147]

43 (1.69)

~~~~

V

Valve seat angle

~alve

margin

Valve sinkage

14


Group

Inspection points

;1 k

""

0

E

.S k ~

.goo

' 0

".",

~~

U

-

0

" k

~

:>0.

Runout (bend)

Runout

Diameter of

journals

Diameter of crankpins

Parallelism

between journal and crankpin

~

'"

~ k

U

'"

Out·of~roundness of journals and

crankpins

Taper of journals

and crankpins

Fillet radius of

journals and. crankpins

End play

Standard

~

0

"

~ i:C

Outside 0.25 diameter (0.0098)

(at skirt)

.

.

oversize

0.50

(0.0197)

oversize

Unit: mm (in.)


-value

[standard clarance]

Repair

limit

Service

limit


Remarks

0.4 (0.016),

maximum

Rounout measured

with pushrod sup·

ported at centerlines

of its spherical ends

0.02 (0.0008),

maximum

0.05

(0.0020)

75

-0.03 CO.0012)

-0.15

-0.90

(2.95) -0.05 -0.0020 (-0.0059) (-0.0354)

58

-0.035 CO.00138)

-0.20

(2.28) -0.055 -0.00217 (-0.0079)

Runout: 0.0 r

(0.0004), maximum

(over crankpin length)

0.01 (0.0004).

maximum

--~----

...

-- ---c----

0,03

(0.0012)

om

(0.0004),

maximum

0,03

(0.0012)

-

--

-

. -

- - .

-_.

3R

(0.12)

±0.2 (±0.008)

_.

----

.

__

.

I

37

0.100-0.264

0.300

I

I

I

(1.46) [(0.00394-0.01039)1

[(0.01181)1 I

I

97.875 - 97.845

(3.85334 - 3.85216)

..

...

.--~.,.--

97.660

(3.84487)

--

.

- -

~.

If repair limit is

reached, replace thrust plates.

If repair limit is exceeded. use oversize thrust plates.

Oversize thrust plates:

+0.15 (+0.0059).

+0.30 (+0.0118) and

+0.45 (+0.0177)

98

(3.86)

98.125 - 98.095

(3.86318 - 3.86200)

98.375 - 98.345

(3.87302 - 3.87184)

97.910

At right angles to

(3.85472)

piston pin at skirt

.

98.160

(3.86456)

15


Group

Inspection point


value

[standard c1arance J

Repair

Service

limit limit

[clearance J [clearance J

Unit: mm (in.)

Remarks

~

~

~

."

00 e:

0

S

.~

::E

Protrusion

~ e: above

S

crankcase

£

Variance in weight per engine

gj,

'8

e:

0

~

£

No. I ring.

.5

-

0

" e:~

"",

" 0

" ' 0

~

No.2 ring

"'00

~·a

Oil ring

End gap

Outside diameter

~

.5

" , e:

0

~

~ a:

Clearance in piston

Clearance in

bushing

0.35 - 0.75

(0.0138 - 0.0295)

±3 g (±O.I oz)

2.5

0.030-0.070

0.200

(0.098) [(O.oo118-0.00276)J

[(0.00787)1

2.0 . 0.025 -0.060

0.150

(0.079) [(0.00098-0.00236)J

[(0.00591)1

I

4.5

(0.177)

0.025-0.060

0.150

[(0.00098 -0.00236)J

[(0.00591)1

0.35-0.50

(0.0138-0.0197)

28.000 - 27.994

(1.10236 -1.10212)

1.50

(0.0591)

Check bearing

clearance.

I

If repair limit is

reached, replace piston rings.

If repair limit is

exceeded, repJace piston.

28

(1.10)

0-0.016

0.050

[(0 - 0.00063)J [(0.00197)1

.

__

. -

28 0.020-0.051

0.080

(1.10) [(0.00079 -0.0020 I)J

[(0.00315)1

If repair limit is

I reached, replace pin.

If repair limit is ex·

ceeded, replace piston

Replace pin or bushing. Ream if

necessary.

Inside diameter of busWngs

'0 e

""

Twist/bend

0

0

"" u

Clearance of

connecting rod bearings on crankpins

28.045 - 28.020

(1.10413 -1.10315)

0.05/100

(0.0020/3.94),

maximum

0.15

(0.0059)

58 0.035-0.100

0.200

(2.28) [(0.00138 -0.00394)J [(0.00787)1

If repair limit is

. reached, replace bear-

ings.

If repair limit is exceeded, regrind crankpins and use undersize bearings.

16


Group

0

~

""

" f=:

Inspection point

.§

End play

~

~ t;;

0.

.'"

(,)~

0

E

0;


Radial ronout

.S

'"

..

€

Face runcut

RUDout

Intake

Unit: nun (in.)

Nominal

Assembly standard value [standard clarance

1

Repair

Service limit

limit

[clearance J [clearanceJ

40

[ 0.15-0.35 J

(1.57) (0.0059-0.0138)

tS

g

(to.2

oz),

maximum

0.15 (0.0059),

maximum

0.15 (0.0059),

maximum

0.02 (0.0008),

maximum

0.50

(0.020)

0.50

(0.020)

0.05

(0.0020)

Remarks

[ 0.50 J Replace connecting

(0.0197) . rod.

Straighten by cold

working or replace.

D,

46.91(g:~

(1.8nos:g:g?~)

D, - D,

=

6.684

(0.26315)

jDl -D2

1=

6.184

(0.24346)

.:::

'"

E

Cam lift

No.

1,2

Diameters

of journals

No.3

End play

Exhaust

Clearance of shaft in bushing

End play

~

"

Length of thrust journal of shaft and boss

D,

45.94<g:~

11.80881~:g~)

I

D, - D,

=

7.344

(0.28913) iD,-D, f=

6.844

I

(0.26945)

I

I

53.90

, (21.220)

54 53.96 - 53.94

(2.13)

(2.1244 - 2.1236)

53 52.96 - 52.94

(2.Q9) (2.0850 - 2.0842)

[ 0.35 J

(0.0138)

52.90

(2.0827)

5

0.050 - 0.112 . 0.300

(0.20)

[(0.00197 -0.00441)1 [(0.01181)1

.

_-

!-.

36

0.Q25 - 0.D75 0.100

(1.42)

[(0.00098 - 0.00295)1 [(0.00394)1

0-0.10

[(0 - 0.0039)J i

I

Replace thrust

! plates.

Replace bushing.

26

[ 0.05 - 0.20 J [ 0.40 J

(1.02) (0.0020 - 0.0079)

(0.0157)

Replace thrust plates.

Fit of shaft in

crankcase bore

30

0.009T-0.045T

(1.18)

[(O.OO035T-O.OOI77T)

Backlash

[0.07 (0.0028)J

[ 0.15 J

(0.0059)

Replace gears.

17


Group e

~

1;;

G;> c

.9

;;;

"

.c

"

Unit: mm

(in~

Inspection point

Outer rotor to inner rotor clearance

c. e

"

;5

Rotor to cover clearance

Outer rotor to case clearance

Diameter of main

shaft

Clearance of main

shaft in pump case

'"

Opening pressure .

""'

OJ

~ kgf/cm2 (psi) [MPa)


value

[standard clarance

I

Repair

Service

Hmit

[clearance limit

I

[clearance

I

0.013-0.150

[(0.00051-0.00591

)1

0.250

1(0.00984)1

[ 0.04-0.09

I

1 O.IS 1

(0.0016-0.0035)

(0.00S9)

[ 0.20-0.28

(0.0079-0.0110)

I

1 O.SO 1

(0.0197)

13.000 - 12.985

(0.51181 - 0.51122)

0.032 -0 .074

[(0.00126-0.00291

)1

O.ISO

1(0.00s9I)1

3.0

(42.7l

[0.29

±0.2

(±2.8) .

[±0.02)

..

Remarks

Make shim adjust·

ment.

Pressure varies by

0.15 kgf/cm

2

(2.1 psi [O.oIS MPa) per

I mm (0.04 in.) thickness of shim.

Fit of bearing

inner races on

pump shaft

Front

Rear

17

O.OlT -0.017T

(0.67)

1(0.0004T -0.00067T)1

Fit of bearing Front

outer races in pump case

Rear

47

(1.85)

0.0IlL-0.02SL

1(0.00043L-0.00098L)1

40

(1.57)

E

3

~ c. k

»

~

~

00

;§

~

0

0 u c. e

Radial clearance of

17

"

bearings

Inside diameter of spacer for shaft

Clearance of

(0.67)

17

0.5 - 1.0

0.010 - 0.Q25

0.010 - 0.022

t.00039 -

0.00098)

0.00039 - 0.00087

0.001-0.017

(0.67) [(0.00004-0.00067») impeller on both (0.Q20 -

sides

0.039)

Unit seal

Protrusion of carbon

Height

(free state)

0

§

~~

Valve opening temp./valve lift

1.5

(0.059)

21.8

(0.858)

76.S°c;,

(169.7

F)/

9 (0.3S)

±I (±0.Q4)

±2°C (±3.6°F)

1

! or pump assembly.

0.045

Replace bearings if they fail to rotate

(0.00177) smoothly when slowly turned.

0

Replace impeller if any sign of rubbing

contact is noted.

18


2. TIGHTENING TORQUE

2.1 Important bolts and nuts

Secured part or component

Cylinder head bolts

Rocker shaft brackets

Main bearing caps

Connecting rod caps

Flywheel

Camshaft thrust plate

Front plate

Timing gear case bolts

Crankshaft pulley

Idler thrust plate

Oil pan

Oil pan drain plug

Oil pump mounting bolts

Injection pump gear

Thread dia.-pitch

12-1.75

8 - 1.25

Width

across

flats

19

12 ±05

12 kgf·m

Tightening torque

1.5

± 0.5 lbf·ft

N·m

Remarks

87 ±4 118 ±5

[Wet]

11 ±4 15 ± 5

14-2

I 12 - 1.25

12 - 1.25

22 lOA ± 0.5

17

17

8.5 ± 0.5

8.5 ± 0.5

75 ±4

102±5 [Wet]

61 ± 4

83 ± 5

61 ± 4

83 ± 5

8 - 1.25

12

1.8

13

18

10 - 1.5 14 I

7 10

10- 1.5

,

24 - 1.5

14

10 - 1.25 ~14

1

36

40 ±0.5 289 ±4

392 ± 5

3.5

7

25

10

34

8 - 1.25 12

0.7

5 7

12-1.25

12-1.75

19

10 ±0.5

17

5.5 ± 0.5

6-7

72± 4

98 ± 5

40± 4

54 ± 5

43 - 51 59 -69

Remarks: Apply engine oil to threads of parts specified as [Wet] in Remarks column.

19


.

2.2 General bolts and nuts

Screw thread

Diameter

8

10

12

14

16

18

Pitch

1.0

1.25

1.25

1.5

1.25

1.75

1.5

2.0

1.5

2.0

1.5

2.5 kgr·m

1.8

1.8

3.6

3.4

6.5

6.0

10.4

9.8

15.8

15.0

22.9

20.7

Ibf·ft

75

71

114

108

13

13

26

25

47

43

166

150

With spring

washei

N'm

18

18

35

33

64

59

102

96

Tightening torque

155

147

225

203

Wiihoul spring ivasher kgf.m

2.2

2.1

Ibf·ft

16

15

N·m

22

21

4.2

4.0

7.6

7.1

12.2

11.5

18.6

17.6

26.9

24.4

30

29

55

51

88

83

135

127

195

176

41

39

75

70

120

113

182

173

264

239

20


3. SEALANTS

Application point

Oil pan gasket

Mating parts

Front and rear bearing cap seats of crankcase

Sealant

How to use

Apply to front and

ThreeBond 1104 rear lower sicjes

(No.4) (bearing cap seats).

•

Plugs for water and oil holes in crankcase

•

Plug for water hole in cylinder head

Screw plug for crankcase main oil gallery (taper plug)

•

Crankcase

• Cylinder head

Crankcase

Hermeseal H-I

Loctite 271

Apply to holes before installing plugs.

Apply to threads.

Water bypass hose and pipe

Front and rear bearing cap side seals of crankcase

Timing gear case gasket

Thermostat cover, elbow and water pump

Loctite 271

Bearing caps (front and rear side seal contact surfaces)

Timing gear case

Apply to threads.

ThreeBond I 105D

,

Apply to crankcase before installing front and rear

(No.5) bearing caps.

Apply to gasket sur-

ThreeBond I 102 face of timing gear

(NO.2) case.

21

SPECIAL TOOLS

SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

II

24

SPECIAL TOOLS

SPECIAL TOOL LIST

Part No.

Tool name

Valve guide installer

34491·00400

Shape

Use

Valve guide installation

670228.

Valve guide

removal

Valve guide

remover

31391·10500

Valve spring pusher

30691·04500

/

ItJ

Insert caulking tool

31391·13010

(For Intake)

34491·01300

(For exhaust)

:l

670230

Valve spring removal/installa·

tion

401793

Valve seat installation

670232

Cylinder sleeve installation

Sleeve installer 34491·02100

Piston ring pliers 31391·12900

670236

Piston ring

removal/installa.

tion

670240

Piston installation Piston guide . 34491·02200

Tool name

Part No.

Idler shaft puller 34491·02300

Idler bushing puller

30091·07300

Socket 34491·00300

Oil filter wrench 30691·53301

Universal extension

30091·01101

Cranking handle 30691·11800

Shape

SPECIAL· TOOLS

Use

Idler shaft

removal

670237

Idler bushing removal/installa.

tion

670242

Camshaft thrust plate removal/

installation

670235

Cartridge type oil filter removal

401822

PE·A type fuel

injection pump

removal/installa·

tion

670239

Engine cranking

670238

25

26

SPECIAL TOOLS

Tool name

Adaptor

Part No.

30691·21100

Puller assembly 64309-12900

Compression

gauge

33391·02100

Crankshaft

sleeve in·

staller

30691·13010

Shape Use

~

670233

Engine compres-

sion pressure measurement

Crankshaft gear, camshaft gear, crankshaft pulley and water pump pulley removal

670241.

Compression pressure measurement

40t609

Oil seal sleeve on crankshaft

rear side

installation

I

OVERHAUL INSTRUCTIONS

I. DETERMINING WHEN TO OVERHAUL THE ENGINE . . . . . . . . . . . . . . . . . . . . . .. .. 28

2. TESTING THE COMPRESSION PRESSURE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29

II

OVERHAUL INSTRUCTIONS

1.

DETERMINING WHEN TO OVERHA.UL

THE ENGINE

Generally, when to overhaul the engine is to be . determined by taking into consideration a drop in compression

pressure as well as an increase in

lubricating oil consumption and excessive blowby gases.

Low power or loss of power, increase in fuel consumption, drop in lubricating oil pressure, hard starting and excessive abnormal noise are also engine troubles.

These troubles, however, are not always the result of low compression pressure and give no valid reason for overhauling the engine.

The engine develops troubles of widely different varieties when the compression pressure drops in it.

Following are the typical troubles caused by this compression pressure failure:

(a) Low power or loss of power

(b) Increase in fuel consumption

(c) Increase in lubricating oil consumption

(d) Excessive blowby through breather due to worn cylinder sleeves, pistons, etc.

(e)

Excessive seating of valves blow by due to poor worn inlet and exhaust

(f)

Hard starting

(g) Excessive abnormal noise

In most cases, these troubles occur concurrently. Some of them are directly caused by low compression pressure, but others are not. Among the troubles listed above, (b) and (0 are caused by a fuel injection pump improperly adjusted with respect to injection quantity or injection timing, worn injection pump plungers, faulty injection! nozzles, or poor care of the battery, starter and alternator.

The trouble to be considered as the most valid reason for overhauling the engine is (d) Excessive blowby through breather due to worn cylinder sleeves, pistons, etc.; in actually determining when to overhaul the engine, it is reasonable to take this trouble into consideration in conjunction with the other troubles.

.-

...

(

28

.OVERHAUL·INSTRUCTIONS

2. TESTING THE COMPRESSION

PRESSURE

(1) Remove the glow plug from a cylinder on which the compression pressure is to be measured.

(2) Attach the adaptor (30691-21100) to the threaded glow plug hole, and connect compression gauge (33391-

02100) to the adaptor.

(3) Crank the engine by means of the starter, and read the compression gauge indication when the engine begins to run at the specified speed.

(4) If the compression pressure is lower than the Repair limit, overhaul the engine .

J------,

(a) Be sure to measure the compression pressure on all cylinders.

It is not a good practice to measure the compression pressure on two or three cylinders and judge the compression pressure of the remaining cylinders therefrom.

(b) The compression pressure varies with change of engine rpm. This makes it necessary to check engine rpm at the time of measuring pressure. the compression

Item


Unit: kgf/cm2 (psi)[MPa]

Assembly standard

27

(384)

[2.6], min.

Repair limit

24

(341)

[2.4], max .

J-----.

Measure the compression pressure with the engine running at 150 -200 rpm.

~~/

I

..

-~

29

OVERHAUL INSTRUCTIONS

.------.&.1

CAUTION

1----,

(a)

It is important to measure the compression pressure at periodical intervals to obtain the da.ta on the gradual change of the pressure.

(b) The compression pressure would be slightly higher than the

Assembly standard in a new or overhauled engine owing to breaking-in of the piston rings, valve seats, etc.

It drops as the engine parts wear down.

30

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1. ADJUSTMENTS ........................................................ .

32

1.1 Valve clearance ...................................................... .

32

1.2 Fuel system priming .................................................. .

33

1.3 Fuel injection timing inspection and adjustment ............................. .

34

1.4 No-load minimum (idling) speed and maximum speed setting inspection and adjustment ............................................. .

36

1.5 Fan drive belt inspection and adjustment

42

2. BENCH TEST

2.1 Starting up

..................................................

" "

.....

.

. . . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . .

.

. .

.

. . . . . . . . . . .

2.2 Inspection after starting up ............................................. .

43

43

43

2.3 Bench test (dynamometer test) conditions

43

2.4 Inspection and adjustment after bench test ............... : ................. .

43

3. PERFORMANCE TESTS

43

3.1 Standard equipment

43

3.2 Test items

3.3 Test methods

...........................................

"

.........

' "

.

........................................................

43

44

II

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1. ADJUSTMENTS

1.1 Valve clearance

Inspect and . adjust the valve .clearance when the engine is cold or when it is warm in whole.

Unit: mm (in.)

Item

Assembly standard

Valve clearance

(cold)

Intake

Exhaust

0.25 (0.0098)

(1) Inspecting valve clearance

(a) Inspect the valve clearance by the firing order, by turning the crankshaft by the specified crank angle in normal direction at a time to bring the piston to its top dead center on compression stroke.

No. of cylinders Firing order

4 \-3-4-2

Crank angle

180·

(b) The top dead center on compression stroke of the piston is identified by the timing mark "0" (on the crankshaft pulley) being aligned with the pointer on the gear case.

With the piston so located, either intake and exhaust valve rocker arms are not being pushed up by their pushrods.

(c) Insert a feeler gauge into between

~he rocker arm and valve cap, and

Inspect the valve clearance.

32

(

(

(2) Adjusting valve clearance

(a) Loosen the lock nut for adjusting screw, and adjust the clearance by turning the screw in either direction to the 'extent that the gauge is slightly gripped between the rocker arm and valve cap.

(b) After adjusting the clearance, tighten the lock nut, and again inspect the clearance, making sure that it is correct.

1.2 Fuel system priming

(1)

Fuel filter

(a) Loosen air vent plug at the top of the filter (by turning it about 1.5 rotations).

(b) Unlock turning operate priming pump handle by it counterclockwise, and the priming pump.

(c) Tighten the air vent plug when fuel flows from the' vent hole without bubbles.

(2) Fuel injection pump

(a) Loosen air. vent . plug on the injection pump (by turning it about

1.5 rotations). If the pump has two air vent plugs, prime at these plugs.

(b) Operate the priming pump handle.

(c) Tighten the air vent plug when fuel flows from the vent hole without

-bubbles. Lock the priming pump by turning its handle clockwise while pushing it down before tightening the last vent plug.

ADJUSTMENTS. BENCH. TEST, PERFORMANCE TESTS

33


1----------,

(a) If all vent plugs are tightened before the priming pump handle is locked, fuel pressure acts on the feed pump, making it impossible to restore the handle.

(b) Wipe off fuel spilt from the vent holes with cloth •

. 1.3 Fuel injection timing inspection and adjustment

The injection timing for each model of the engine varies according to its output, speed and specification. Be sure to verify the timing by referring to the specifica tions of each model.

(1) Bringing No. 1 piston to top dead center on compression stroke

(a) Using turning bar (30691-11800) at the crankshaft pulley, turn the crankshaft in normal direction

(clockwise as viewed from the fron t side of the engine).

(b) Stop cranking the engine when the timing mark "0" on the crankshaft pulley is aligned with the pointer.

(c) Move the intake and exhaust valve rocker arms for the No. 1 cylinder up and down to make sure that they are not being pushed up by their push rods.

34

(2) Inspecting fuel injection timing

(a) Remove the delivery valve holder from No. 1 pumping element of injection pump. Take delivery valve and spring out of the holder, and restore the holder to the pump.

(b) Turn the crankshaft to bring No. 1 piston to about 60

0 position before top dead center on compression stroke.

(c) While operating the priming pump to allow fuel to flow from the delivery valve holder, crank the engine in normal direction. Reduce cranking speed when the fuel just starts to stop flowing. Stop cranking when the fuel stops flowing.

(d) Make sure that the timing mark on the crankshaft pulley is aligned with the pointer.

(3) Adjusting fuel injection timing

(a) If the timing is retarded, tilt the injection pump toward the crankcase. If it is advanced, tilt the pump away from the crankcase.


...

To advance

To retard

401304

35


(b) One graduation of the scale on the injection pump coupling changes the timing by 6° in terms of crank angle.

1.4 No-load minim urn (idling)· speed and maximum speed setting inspection and adjustment

For details of adjustment, refer to

Fuel System in the separate volume •

.-----,&.[

CAUTION

]-~--,

(a) No-load minimum (idling) speed and maximum speed are set for each engine on the test bench at the factory and the set bolts are

. sealed. These settings are to be inspected and adjusted at

Mitsubishi-authorized service shop only.

(b) W hen inspecting and adjusting these settings, be on standby to operate the engine stop lever manually in the event of engine overrun.

For inspection and adjustment, warm up the engine· thoroughly until the coolant and oil temperature rises to 70°C (158°F).

RSV-type governor

(1) Engine starting

(a) Pull speed control lever to highspeed side. Operate starter switch to crank the engine.

(b) At about 150 rpm of cranking speed, the engine will fire up to pick up speed. Immediately after the engine fires, move back speed control lever to hold the speed anywhere between 800 and 1000 rpm.

36.

Governor

set bolt

Stop lever

Speed control lever

Idle sub-spring

adjusting screw

Rack set bolt

(full-load stopper bolt)

402016

(

(c) W hen the engine is noted to be running with a steady speed, move speed control lever back to low idling speed position.

(2)

Idling set (The setting for keeping the no-load minimum engine speed)

(a) Hold speed control lever at the position for permitting the engine to run at the specified low idling speed, and set the low idling set bolt •

.----&1

CAUTION

l-----.

If a critical speed (the speed at which the engine exhibits excessive vibration due to torsional resonance) might exist, shift the idling set to a lower or higher idling level.

(b) Turning the set bolt clockwise raises the idling speed.

(c) If engine speed tends to fluctuate at a lowest idling speed set as above; turn the idle sub-spring adjusting screw clockwise to push in this spring, making it come in slight contact with tension lever.

With idle sub-spring exerting some force to the lever, the speed will rise slightly but will stop fluctuating •

CAUTION

1

Tightening the idle sub-spring adjusting screw is likely to result in engine speeding when, during duty operation, the load is dumped.

W hen tightening the adjusting screw, be sure to tighten it just enough to elimina te the unstable condition.

ADJUSTMENTS. BENCH TEST. PERFORMANCE TESTS

402017

37


(3) Rack set (The setting for limiting the maximum engine output)

(a) Hold speed control lever at the posi tion for the indicated output and speed (specified for purpose of governor adjustment).

(b) Under this condition, check to be sure that the engine is running in a steady state.

(c) IV ith the engine running in a steady condition, adjust full-load stopper bolt, as follows:

(d) Reposition the full-load stopper bolt by tightening or loosening (to push or pull out the fuel control rack through the levers) in order to find out just where the engine produces the rated output.

(e) Having positioned the stopper bolt properly (for the' rated output), back it off slowly while observing the speed. Stop backing it off just w hen the speed begins to fall from the rated level. Secure the stopper bolt (rack set bolt) in that position with its lock nut.

(f)

At that time, the speed control lever should be at the position mentioned in (a), above.

(g) Turning the full-load stopper bolt clockwise will increase the injection quantity (engine output), and vice versa.

(4) Governor set (The setting for limiting the maximum engine speed)

(a) Hold speed control lever at the indicated maximum speed position while applying full load to the engine.

38

402019

402020


(b) Run in governor set bolt (maximum speed set bolt) slowly until its forward end comes in contact with speed con trol lever held as above.

Secure the bolt right there by tightening its lock nut.

(5) Determination of the speed regulation

(speed droop)

[1]

Speed regulation upon removing load

(a) Run the engine with the speed control lever set for the rated condition (of load and speed).

(b) With the control lever held there, remove the load instantaneously to bring the engine in to no-load condition.

Do

not

move

speed control lever.

(c) The speed will increase once and decrease, as shown and settle at a new steady level. Read the highest speed (N 2) occurring in this transition and the speed (N 3) after settling, and the time (tl) from the moment of removing the load at initial speed (N 1) to the speed settling at the new level (N 3)'

[2) Speed regulation upon applying load

With the engine rimning in no-load condition subsequent to the condition mentioned in

[1]

(b) above, and with the speed control lever left in the same position as above, put the prescribed load instantaneously on the engine: the speed will decrease once and increase, as shown, and settle at a new steady level. Read the lowest speed (N5) occurring in this transition and the speed (N6) after settling, and the time (t2) from N4 to N6'

Speed regulation upon removing load

N2

Instantaneous speed

regulation

(%)

N\it

Nt x 100

Ns

Instantaneous speed

regulation

(%)

N4 - Ns 100

N4

X

I

Steady-state speed

I regulation

(%)

N, Nt

Nt x

100

Nt ~ initial speed, rpm, before load is removed

N2

= highest speed, rpm, during transitional

period " "

N, ~ speed, rpm, at which the engine settles after

load is removed tl

= stabilization time

Speed regulation upon applying "load

_N_4_-,~

'\

~

I

N.

'V--"::":':"

Steady-state speed regulation (%)

N4 N4 N. x

100

N4 ~ initial speed, rpm, before load is applied

Ns ~ lowest speed, rpm, during transtional period

N. ~ speed, rpm, at which the engine settles after load is applied t2

=

stabilization time

39


[3] Computing the speed regulation

From the values obtained in

[1] and [2], above; . compute the speed regulation for each load change. A total of four percent values of speed regulation are to be determined by using the indicated formulas.

If the computed values are at variance with the prescribed values, "governor notch adjustment" must be carried out to eliminate the variance.

(6) Adjustment of speed regulation

(governor notch adjustment)

(a) This adjustment is to be made by turning the adjusting screw for swivel lever· to increase or decrease the pre-tension of governor spring.

(b) To gain access to the adjusting screw, remove the plug at the top of governor housing, and turn speed control lever all the way to the low idling set bolt: this will turn up the swivel lever, pointing the head of the adjusting acrew toward the plug hole. Insert a flat-tip screwdriver through the hole to ca tch the screw head.

(c) Tightening the· adjusting screw increases the pre-tension of governor spring to narrow the speed regula tion; loosening it decreases the governor spring pretension to widen the regula tion.

One notch corresponds to 1/4 turn of adjusting screw and to 3 to 5 rpm change of engine speed.

(d) Changing the setting of this adjusting screw changes the governor set (for limiting the maximum engine speed). After making a governor notch adjustment, be sure to re-adjust the governor set, as explained in

(4), above.

40

(e) Tightening the adjusting screw, mentioned above, will increase the maximum speed, and vice versa .

J------,

The adjustable range is 20-notch (5 rotations) long. Never loosen the screw by more than 20 notches from the fully tightened position or the control action of the governor will become hazardous.

(7) Sealing

(a) The stoppers on the injection pump and its governor are adjusted and set through testing by using an injection pump tester or an engine test bench in the final stage of manufacture prior to shipment from the factory. All these stoppers visible on the injection pump are sealed with wires and punched pellets.

(b) After authorized adjustment of the governor, which has to be effected by breaking the seals, be sure to re-seal all visible stoppers, making them appear as if they were sealed at the factory.

(c) The stoppers to be sealed are specified. Whether the seals are intact or not has important bearing on the validity of claims, if any, under warranty.


41


1.5 Fan drive belt inspection and adjustment

Apply thumb pressure to the belt midway· between the pulleys to inspect the belt tension.

If the tension is incorrect, make an adjustment by means of bolt (1).

Unit: mm (in.)

, Item Assembly standard

Fan drive belt tension

(deflection)

10 -15

(3/8 - 518)

300481

42


2. BENCH TEST

An overhauled engine should be tested for performance on a dynamometer.

This test is also for "breaking-in" of the major running parts of the engine.

To test the engine, proceed as follows:

2.1 Starting up

(1) Check the levels in the radiator, oil pan and fuel tank. Prime the fuel and cooling systems to bleed air out.

(2) Crank the engine with the starter for about 15 seconds to permit lubrica ting oil to circula te through the engine. For this cranking, do not supply fuel to the engine.

(3) Slightly move the speed control lever in the direction of increasing fuel injection, and turn the starter switch to START for starting the engine.

(Do not move the control lever to

"full injection" position.)

(4) After the engine starts, let it idle by operating the speed control lever.

(5) Knocking:

It should die away as the coolant temperature rises. No other defects should be noted.

(6) Exhaust color and abnormal smell

2.3 Bench test (dynamometer test) conditions

Step

I

2

3

4

5

6

7

Speed (rpm)

1000

1500

2000

Rated (varies

according to

specifications)

Load (PS) Time (min.)

No·load

25%

30

25%

25%

30

60

10

50%

75%

100%

10

30

20

2.4 Inspection and adjustment after bench test

(1) Retightening of cylinder head bolts

(2) Adjustment of valve clearance

(3) Adjustment of injection timing

2.2 Inspection after starting up

After starting up the engine, check the following points. Upon discovery of any faulty condition, immediately stop the engine, and investigate for the cause.

(1) Lubricating oil pressure:

It should be

3 to 4 kgf!cm 2 (43 to 57 psi) [0.3 to

0.4 MPa] at rated speed or 1 kgf!cm 2 (14 psi) [0.1 MPa] at idling speed.

(2) Coolant temperature:

It should be

75°C to 85°C (167°F to 185°F).

(3) Lubricating oil temperature:

It should be 60°C to 80°C (140 o

F to 176°F) when measured in oil pan.

(4) Leakage of oil, coolant and fuel.

3. PERFORMANCE TESTS

3.1 Standard equipment

The cooling fan, alterna tor are the of an engine to be air cleaner and standard equipment tested.

3.2 Test items

(1) Fuel consumption test

(2) No-load maximum speed test

(3) No-load minimum speed test

43

.ADJUSTMENTS, B.ENCH TEST, PEHFDRMANCE TESTS

3.3 Test methods

(1) Fuel consumption test

(a) Engine speed (rpm)

(b) Fuel injec tion quan tity

(e) Engine output

(2) No-load maximum speed test

For this test, the governor should be set for no-load maximum speed.

(3) No-load minimum speed test

(a) The control lever should be set to the stable minimum speed position.

By "stable minimum speed" is meant a minim urn speed to which the engine rpm can be quickly dropped from the maximum rpm without stalling,

(b) The no-load minimum speed is specified to be 870

±

10 rpm.

(4) Others

During the performance test, inspect for leakage of gases, coolant, lubl'icating oil and fuel, noise or hunting.

44

(

ENGINE ACCESSORY REMOVAL AND INSTALLATION

1.

PREPARATORY STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2. ENGINE ACCESSORY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3. ENGINE ACCESSORY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

ENGINE ACCESSORY REMOVAL AND INSTALLATION

This section explains the procedures and tips for removal' and. installation of the accessories - the preliminary process to go through for overhauling the engine.

1. PREPARATORY STEPS

(a) Shut off fuel supply, and disconnect the starting system from the engine.

(b) Loosen the drain cock on left rear side of crankcase, and drain coolant.

(c) Loosen the oil pan drain plug, and drain engine· oil.

WARNING

Hot engine oil can cause personal injury if it contacts the skin. Use caution when draining the oil.

2. ENGINE ACCESSORY REMOVAL

(1)

Removing stop solenoid

Disconnect and remove stop solenoid (1) from governor.

(

46

(2) Removing glow plugs

Disconnect wire (2) by loosening nut

(1), and remove glow plug (3) •

.------ ,&[

CAUTION] - - - - - - - ,

After removing each glow plug, cover the opening by taping to prevent dust from getting inside.

(3) Removing fuel injection pipes

(a) Remove pipe clamp (1), and disconnect injection pipes (2).

(b) Unscrew lock nut (3), and remove leak-off pipe

(4) •

.------,&[

CAUTION

j - - - -

Be sure to fit rubber caps to the openings of the injection pumps and nozzle holders to prevent dust from getting inside the fuel system.

(4) Removing fuel injection nozzles

Using a box wrench, loosen nozzle retaining nut, and remove nozzle (1) complete with gasket (2). r--------[

NOTE ] - - - - - - - - .

Remove nozzle gaskets from the cylinder head, using a piece of wire or screwdriver, and discard them if damaged.


47


(5) Removing fuel. filter and intake and exhaust manifolds

(a) Disconnect fuel hose

(1) from fuel filter (1). Remove filter (2) by unscrewing its mounting bolts.

(b) Remove intake manifold (3) and exhaust manifold (4) by unscrewing mounting bolts.

(6) Removing fuel injection pump

Disconnect oil feed pipe

(1) and remove cover (2). Remove injection pump

(4) from the timing gear case by unscrewing two mounting bolts (3).

(7) Removing thermostat

(a) Disconnect bypass hose

(1).

(b) Unscrew elbow attaching bolts, and remove elbow (2), thermostat (3) and gasket (4).

.-----1

NOTE ] - - - - - .

A t reassembly, install thermostat with its air vent hole facing upward.

(8) Removing water pump

(a) Remove fan

(1).

Slacken fan belt

(2), and remove it from water pump

(4).

(b) Disconnect oil pipe (3).

(c) Remove water pump by unscrewing its mounting bolts.

¢"

®

~

48

(9) Removing alternator

(a) Disconnect harness

0), and unscrew belt adjusting plate bolt (2).

(b) Remove alternator (4) by unscrewing munting bolts (3).


401317

(10) Removing

starter

Disconnect harness

(1), and

remove

starter (3) by unscrewing mounting bolts

(2).

3

401318

(11) Removing oil filter·

Remove

oil filter (2) complete with its bracket by unscrewing mounting bolts

(1).

401319

(12) Removing oil pan and oil pump

(a) Remove oil pan (2) by unscrewing mounting bolts

0).

(b) Remove oil pump (4) by unscrewing mounting bolt (3).

Camshaft skew gear might interfere with pump drive gear. Remove pump by turning crankshaft slightly.

49


3. ENGINE ACCESSORY INSTALLATION

To install the engine accessories, use reverse of the removal procedures.

After installing them, take the following steps:

(a) Installing fuel injection pump

When installing the pump, make sure that matching marks on pump drive gear and other gears are aligned with those on idler gear respectively, as shown.

.. -----1

NOTE

l-----·-~

With these matching marks are all aligned, No. 1 cylinder piston is at top dead center on compression stroke.

(b) Refill the engine with recommended oil up to the specified level.

(c) Refill the cooling system with coolant.

(d) Check each pipe connection for oil or coolant leaks.

(e) Prime the fuel system.

(f)

After installing the fuel injection pumps, inspect and adjust the injection timing. (Refer to 1.3,

Group No.5.)

CD

Injection pump drive gear

®

Idler gear

®

Crankshaft gear

®

Camshaft gear

®

P.T.O. idler gear

®

P.T.O. gear

Matching marks on timing gears

(

50

ENGINE PROPER

l. CYLINDER HEAD AND VALVE MECHANISM ............................... 52 l.1 Disassembly .......................................................... 52

1.2 Inspection and repair ................................................... 54

1.3 Reassembly ........................................................... 62

2. FLYWHEEL, TIMING GEARS AND CAMSHAFT ............................... 66

2.1 Disassem bly ........................................................... 66


2.3 Reassembly .......................................................... 75

3. PISTONS, CONNECTING RODS, CRANKSHAFT AND CRANKCASE ............... 78

3.1 Disassembly .......................................................... 78


3.3 Reassembly ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 94

D

ENGINE PROPER

1. CYLINDER HEAD AND VALVE MECHANISM

1.1 Disassembly

Damaged threads, worn pushrod contact face

,

Cracks,

oil leaks

@

I

Worn ends, distortion

I

I

Wear

I

Cracks. damage, carbon and scale deposits

Worn stem or face, damage. weakness

CD

Rocker cover

®

Eye bolt

®

Oil pipe

@ Adjusting screw

®

Bolt (short)

®

Bolt (long)

IJ)

Valve cap

®

Snap ring

®

Washer

QID

Intake rocker arm

®

Rocker shaft bracket

@ Exhaust rocker arm

@ Rocker shaft spring

®

Rocker shaft

@ Valve pushrod

@ Cylinder head bolt

@

Cylinder head

@

Valve cotter

401323

®

Upper retainer

@

Valve spring

@

Valve

@

Valve stem seal

®

Cylinder head gasket

(

52

(1)

Removing rocker shaft assem blies

(a) Loosen the adjusting screw of each rocker about one rotation.

(b) Loosen the rocker bracket short bolt and long bolt in tha t order, and remove the rocker shaft assem bly from the cylinder head. l---~

If these bolts are loosened in reverse order, the rocker shaft bracket might suffer damage.

(2) Disassembling rocker shaft assemblies

Lay the disassembled rockers in the order removed, and install them in that order at the time of reassembly. This is for reproducing the same rocker shaftto-rocker arm clearance as before.

(3) Removing cylinder head·

Unscrew the cylinder head bolts, and lift the head off the crankcase .

(a) W hen removing the gasket from the crankcase, be careful not to damage the mounting face of crankcase.

(b)

If any cylinder head parts are out of order, check the cylinder head bolts for tightening torque wi th a troque wrench before removing the head bolts.

~~

____

ENGINE PROPER i

53

54

ENG I NE PRDPE R

(4) Removing valves and valve springs

Using valve

(30691-04500), . spring squarely, cotters. spring pusher (A) compress the valve and remove the valve r - - - - - [ )----~

If the valves are them for their installation at reassem bly. to be reused, mark locations to aid the time of

1.2 Inspection and repair

Rocker arms, rocker bushings and rocker shaft

(1) Measuring rocker bushing inside diameter and rocker shaft diameter

Compute the clearance between the bushing and shaft on the basis of the measurements.· If the Repair limit is reached, replace the bushing. If it is exceeded, replace both bushing and shaft.

Item

Rocker bushing

inside diameter

Rocker shaft diameter

Rocker shaftto·bushing

clearance

Nominal Assembly

value

standard

20.000

- 20.021

(0.78740

-0.78823)

Unit· mm (in)

Repair limit

19.984

-19.966

(0.78677

- 0.78606)

20

(0.79)

0.016

-·0.055 0.070

(0.00063 (0.00276)

-0.00217)

A

%

®

I

!

401326

401331

Measuring rocker bushing and rocker shaft

(

ENGINE PROPER

(2) Replacing rocker bushings

When installing a replacement bushing, align the oil holes in the bushing and rocker arm.

Replacing rocker bushing

401327

Valves, valve guides and valve seats

(1) Measuring valve stem diameter

If the Service limit is exceeded, or if the stem is abnormally worn excessively, replace the valve.

Item

Valve stem diameter

Intake

Exhaust

Assembly

standard

Unit· mm (in)

Service

limit

7.955

-7.940 7.900

(0.31319 (0.31102)

- 0.31260)

7.940

- 7.920 7.850

(0.31260

(0.30905)

- 0.31181)

(2) Measuring valve stem-to-guide clearance

The valve guide wears more rapidly at its both ends. than at any other parts.

Measure the guide at its ends and in two directions at right angles to each other. If the Service limit is exceeded, replace the guide.

Measuring valve stem diameter

+ l

Measuring valve guide inside diameter

401328

55

ENGINE PROPER

Valve

stem-

Item to·guide

clearance

Intake

Exhaust

As·installed depth

of valve guide

Nominal value

8

(0.31 )

Unit· mm (in)

Assembly standard

Service

limit

0.055

- 0.085 0.150

(0.00217

(0.00591)

- 0.00335)

0.070

- 0.105 0.200

(0.00276

(0.00787)

- 0.00413)

17 ±0.3

(0.67) (±0.012)

(3) Replacing valve guides

(a) Using valve guide remover (A)

(31391-10500), remove the guide

(worn) for replacement.

Removing valve guide

670064

(

(b) To install a replacement guide, use valve guide installer (8)

(34491-00400).

As-installed depth of the valve guide is specified; be sure to use the valve guide installer to insure this depth.

®

Installing valve guide

l

401329

(4) Inspecting valve face

Coa t the valve face lightly wi th red lead and, using valve lapper, check the valve contact with its seat. If the contact is not uniform; or if the valve is defective or' the Repair limit is exceeded, repair or replace the valve and valve seat.

Inspecting valve face

56

ENGINE PROPER r·---'-----[

NOTE

)----~

I

(a) Check the valve face after

I . inspecting or replacing the valve

! guide.

I

(b) ;ress the valve in to the seat

~ithout rotating it.

Item

Angle

;;; Valve

"

sinkage

"

>

Width deg

Valve margin

Assembly standard

30

Unit· mm (in )

Repair limit

0.7 ± 0.2 1.3

(0.028 ± 0.008) (0.051)

1.2±0.14

(0.047 ±

0.0055)

1.6

(0.063)

2.13

(0.0839)

Up to 1.2

(0.047) by

refacing

Good

Bad

Valve contact with its seat

400059

(5)

Refacing valves

If the valve face is badly worn, reface it with a valve refacer .

)----~

(a) Set a valve refacer at an angle of 30

0

•

(b) If the valve margin seems to be less than the Repair limit when ground, replace the valve.

Valve seat angle

400005

Ref acing valve

400060

57

ENGINE PROPER

(6) Refacing valve seats

(a) Using a valve seat cutter or valve seat grinder, cut the valve seat.

After cutting, grind the seat lightly by using a sandpaper of

#

400 grade or so, inserted between the cutter and seat.

(b) Lap the valve in the seat.

1--------.

(a) Cut or grind the valve seat only as necessary for refacing.

(b) If the seat width is in excess of the Repair limit as a result of wear or cutting, replace the valve seat.

(c) If the valve sinkage exceeds the

Repair limit after refacing, replace the valve seat.

(7) Replacing valve seats

(a) Weld a plate of about 5 mm (0.20 in.) thickness to the valve seat.

Insert a shaft into the valve guide hole from the upper side of cylinder head, and drive the seat off the head as shown.

___ &.[

CAUTION ] - - - - - - ,

When welding the plate, be careful not to permit spatters to come in contact with the machined surfaces of cylinder head.

(b) Measure dimensions of valve seat holes in the cylinder head before installing valve seats and make sure that they are as specified.

Refacing valve seat

401332

Shaft [7.8 mm (0.31 in.)]

[5 mm (0.20 in.), approx.] m\;~~:::::::~valve sea t

Weld

670418

Removing valve seat o ,

0-:0.

!

(Doci

O O ! .....

+1+1

('>')<0

o)~1

od

I

~

<0 co

q

I

~

'"

0

-1/

~

JJ2' .....

~

;;';.1 i

';t=:.Unit:mm(in.j]

'g.02~ cia~ft

+1+1 MtD

N~ ol~

1 137 g.~q fi"'~

~'0251,~

..

'==

•

(

Intake

Exhaust

400429

Valve seat dimensions

58

ENGINE PROPER

(c) Chill the valve seat in liquid nitrogen [about -170°C (-274°P)] for more than 4 minutes with the cylinder head kept at normal temperature, or heat the cylinder head to 80°C to 100°C (176°P to

212°P) with the valve seat chilled in ether or alcohol con taining dry ice.

(d) Using valve insert caulking tool (A), install the valve seat by caulking it there.

Valve insert caulking tool

Item

Part No.

Intake

31391·13010

34491·01300

Exhaust

(8) Lapping valves in valve seats

Be sure to lap the seats after the replaced. valves in the valve seats have been

(a) Coat the valve face lightly with a lapping compound.

J--------,

(a) Do not permit the compound to come in contact with the valve stem.

(b) Use the compound of 120 to 150 mesh for initial lapping and the compound of finer than 200 mesh for finish lapping.

(c) Mixing the compound with a small amount of engine oil will facilitate coating.

Installing valve seat

400429

Lapping compound

400065

Coating valve with lapping compound

59

ENGINE PROPER

(b) Using a valve lapper, lap the valve in the seat. To lap, raise the valve off the seat, rotate it only a part of turn to a new position and strike it against the valve seat.

(c) Wash off the compound with diesel fuel.

(d) Coat the valve face with engine oil, and again lap the valve.

(e) Check the valve face for contact.

Valve springs

Measuring squareness and free length

If the squareness or free length exceeds the Service limit, replace the spring.

Item

Free length

Squareness

Test force/length

under test force

kgf(lbf)[NJ/mm

(in.)

Assembly standard

48.85

(1:9232)

Unit: mm (in.)

Service

limit

47.60

(1.8740)

1.27 (0.0500),

maximum

19±1(42±2)

15 (33)

[186 ± IOJ/43

[147J/

(1.69)

43 (1.69)

I

Free

~length

Lapping valve in valve seat

Measuring valve spring

401334

335 (

60

ENGINE PROPER

Cylinder head

Measuring gasketed surface warpage

Measure warpage with a straightedge and a feeler gauge. If the warpage exceeds the Repair limit, reface the gasketed surface with a surface grinder.

Item

Cylinder head gasketed

surface warpage

Assembly standard

0.05

(0.0020),

maximum

Unit· mm (in)

Repair nmit

0.20

(0.0079)

670067

Measuring cylinder head gasketed surface warpage

Combustion jets

Replacing combustion jets

(a) Replace the jets only when they are cracked. To remove, insert a round rod of about 6 mm (0.24 in.) diameter into the glow plug hole, and give light blows to the periphery of the ject through the rod.

(b) To install, align the spray hole of the jet with the center line of cylinder.

402893

Removing combustion jet

Center line of cylinder a~~>t--

Combustion jet

Spray hole

~. ln_t_ak_e ______ E_xh a_u_st ________

6~7~0~07~7

Installing combustion jet

Valve push rods

If the runout exceeds the Assembly standa·rd, replace the pushrods.

Item

Valve pushrod runout

Unit· mm (in)

Assembly standard

0.4 (0.016),

maximum

400069

Measuring pushrod runout

61

ENGINE PROPER

1.3 Reassembly

(

I

Reassembling sequence

I

I

@

(@ r--

~

I I I

<D

I

@ -@

@@@@(@CV

'~"III

®

@)

@

® ® t t

I

®

®

®<-®

'@

62

401336

I.

(1)

Installing valve stem seals

After installing the stem seal to the valve guide, make sure that the seal is properly fitted in the groove of the guide.

,--------.&.1

CAUTION ] - - - - - - - ,

Do not apply any oil or sealant to the mating face of stem seal that comes in contact with the valve guide. When installing the stem seal, coat the seal rubbing surface of the stem with engine oil to insure initial lubrication of the stem seal lip.

(2) Installing valves and valve springs

(a) Install the valve spring and retainer to the valve guide. Using valve spring pusher (A) (30691-04500), install the valve cotters. r------I

NOTE ] - - - - - - - - ,

In case of the double spring

(comprising inner and outer springs), install the outer spring with its smaller-coil-pi tch end on the cylinder head side.

(b) Using a soft hammer, give light blows to the valve stem top several times to make sure that the spring and valve co tter are properly installed.

Stem seal

Valve guide

A

ENGINE PROPER

670080

401326

63

ENGINE PROPER

(3) Installing cylinder head

(a) Screw tW{) guide bolts into the crankcase to hold the gasket in place.

(b) Place the cylinder head on the crankcase as guided by the two guide bolts. Apply engine oil to the threads of cylinder head bolts, and insert the bolts into the head .

.-----Lt,.[

CAUTION

J-----,

Do not apply any sealant to the cylinder head bolts. r - - - - - - - - - - - - - - - - - - , (

(c) Tighten the cylinder head bolts to the specified torque in the sequence shown.

Front side

¢::l

Tightening

torque

Unit: kgf·m (lbf·ft) [N.m]

12 ± 0.5

(87 ± 3.6)

[118 ± 4.9]

402894

64

(4) Reassembling rocker shafts

The rocker arms for intake valves are different in dimension from those for exhaust valves. After installing the arms, make sure that they move freely.

24.5 mm

(0.965 in.)

ENGINE PROPER

22.5. mm

(0.886 in.)

(5) Installing rocker shaft assemblies

Tighten the long bolt and short bolt in tha t order (by following reverse of loosening order).

Exhaust

Intake

~~~~~~~_~~~~_~~~670364

1.5

±

0.5 kgf·m

(10.8 ± 3.6Ibf.ft

[14.7

±

4.9 N·m]

(6) Adjusting valve clearance

Refer to 1.1, Group No.5.

65

ENGINE PROPER

2. FLYWHEEL, TIMING GEARS AND CAMSHAFT

2.1 Disassembly

402891

66

CD

Flyw heel

®

Flywheel housing

®

Oil seal

@Oil pan

®

Oil pump

®

Crankshaft pulley

(J)

Timing gear case

®

Oil seal

®

Baffle plate

:@

P.T.O. gear

@ Idler gear (P.T.O.)

'@

Bearing case

@ Thrust plate

.®

Idler gear

@ Camshaft gear

@ Thrust plate

@

Camshaft

@

Tappet

®

Front plate

402897

ENGINE PROPER

(1) Removing flywheel

(a) Unscrew the flywheel mounting bolts.

(b) Screw the jacking bolts into the holes provided in the flywheel uniformlY, and remove the flywheel.

(2) Removing flywheel housing

Unscrew the housing mounting and remove the housing. bolts,

(3) Removing oil pan and oil pump

Unscrew the oil pan mounting bolts, and remove the oil pan. Then, remove the oil pump by unscrewing its bolt. (Refer to 2, Group No.6.)

(4) Removing timing gear case

Remove the crankshaft pulley and timing gear case.

401344

fJJ

jJ;1

/?,r

1

jt--@"ll)

401345

67

ENGINE PROPER

(5) Measuring backlash and end play

Measure the backlash and end play on each -gear to obtain the data for parts replacement. (Refer to 2.2, .Group No.

7.)

(6) Removing timing gears

Be sure to align the timing marks for each pair of gears before removing or installing the gears.

(7) Removing camshaft

Position the camshaft gear so that its two jacking bolt holes come to top and bottom. Using socket A (34491-00300), unscrew the thrust plate bolts, and remove the camshaft from the crankcase.

After removing the camshaft, remove the tappets.

(8) Removing camshaft gear

Using a puller, remove the gear from the camshaft. Now·,. the thrust plate can be removed.

~-------II~N~OT~El--------~

It is not necessary to remove camshaft gear !II1less camshaft gear or thrust plate is detective.

68

401520

402899 r

ENGINE PROPER


Camshaft and camshaft bushings

(1)

Measuring camshaft end play

If the end play exceeds the Repair limit, replace the thrust plate.

Item

Camshaft end play

Unit· mm (in)

Assembly standard

Repair limit

0.050 ~ 0.112

0.300

(0.00197 - 0.00441) (0.01181)

(2) Measuring cam lift

Using a micrometer, measure the cam. lift. If it exceeds the Service limit, replace the camshaft.

Unit· mm (in)

Cam lift

Item

Nominal

value

Assembly standard

Service

limit

Intake

D,

46.916~gj

D, -D,· D, -D,

(I

.

=

6.684

=

6.184

-0.012 (0.26315) (0.24346)

Exhaust

D,

45.944~g:~

D, - D,

Dl

~D2

=

7.344

=

6.844

(3) Measuring camshaft runout

If the runout exceeds the Repair limit, straighten the camshaft by means of a press, or 'replace it with a new one.

1-------.

Set up a dial gauge on the camshaft, and turn the camshaft. Take one half (1/2) of the gauge indication as the runout.

Item

Camshaft runout

Assembly

standard

0.Q2

(0.0008),

maximum

Unit·: mm (in.)

Repair limit

0.05

(0.0020)

Measuring camshaft end play

Measuring cam lift

670438

Measuring camshaft runout

69

ENGINE PROPER

(4) Measuring camshaft journal diameter

If the journals exceed the Service limit, replace the camshaft bushings.

Item

Assembly standard

Unit· mm (in)

Service limit

No. I, 53.96 - 53.94

2 (2.1 244 - 2.1 236)

53.90

(2.1220)

Camshaft journal

diameter

No.3

52.96 - 52.94 52.90

(2.0850 - 2.0842) (2.0827)

Camshaft journal·to· bushing clearance

0.15

0.04 - 0.09 (0.0059)

(0.0016 - 0.0035) (Repair limit)

Measuring camshaft journal diameter

670439

70

(5) Replacin!i camshaft bushings

To install bushings, align their oil holes with those from oil gallery and drive bushings in.

S>

.

Removal

~

--

W

~~

S>

Installation

~"''\:

401754

Replacing camshaft bushing

Tappets

(1) Inspection

Check the cam contact face of each tappet for abnormal wear, and replace it if necessary.

OOe]

Good Bad

Bad

400068 \

Cam contact face of tappet

ENGINE PROPER

(

(2) Measuring tappet-to-guide clearance

If the clearance exceeds the Assembly standard, replace the tappet.

Item

Tappet guide inside diameter

Tappet·to·guide

clearance

Assembly standard

22.000

- 22.021

(0.86614

- 0.86697)

Unit: mm

(in )

Repair limit

0.Q35

- 0.086 0.120

(0.00138 (0.00472)

- 0.00339)

Service

limit

22.100

(0.87008)

Timing gears

Measuring backlash

Set up a dial gauge so that it contacts the pitch circle of the gear, and move one gear back and forth to· measure the backlash between the gears. If the backlash exceedS the Repair limit, replace the gears.

Item

Timing gear backlash

Assembly standard

0.07 (0.0028)

Unit· mm (in )

Repair limit

0.15

(0.0059)

Idler, idler bushing and idler shaft

(I)

Measuring idler end play

Measure the end play with a feeler gauge or dial gauge. If the end play exceeds the Repair limit, replace the thrust plate.

Item

Idler end play

Assembly standard

Unit· mm (in)

Repair limit

0-0.10 0.35

(0 - 0.0039) (0.0138)

401200

Measuring tappet and guide

401532 .

Measuring timing gear backlash

402899

Measuring idler end play

71

ENGINE PROPER

(2) Measuring idler bushing inside diameter and idler shaft diameter

If the idler shaft-to-bushing clearance exceeds the Standard clearance, -replacethe bushing.

Item

Idler shaft·to· bushing clearance

- Unit· mm (in)

Nominal

Standard value

clearance

Repair limit

36

(1.42)

(Diam.]

0.Q25

- 0.D75

0.100

(0.00098 (0.00394)

- 0.00295)

(3) Replacing idler bushing

W hen installing the bushing, press it in until its end face is flush with that of gear boss.

401521

Measuring idler shaft and bushing

401756

Removal

Installation 401757

Replacing idler bushing

(

(4) Replacing idler shaft

To remove the idler shaft for replacement, use idler shaft puller (A)

(34491-02300).

Removing idler shaft

670089

Flyw heel and ring gear

(1)

Measuring flywheel radial runout

Set the flywheel on the surface plate and, measure the radial runout of the friction surface by moving a dial gauge on and along tha tsurface·. If the radial runout exceeds the Repair limit, refinish the friction surface.

Measuring flywheel radial runout

72

ENGINE PROPER

· (2) Measuring flywheel face runout

With the flywheel installed on the engine, measure its face runout. If the face runout exceeds the Assembly standard, check for im proper installation or foreign matter lodged in the mounting face.

Item

Radial runout

Face runout

Assembly standard

Unit· mm (in)

Repair limit

0.15 (0.0059),

maximum

0.50

(0.020)

(3) Replacing ring gear

Check the ring gear for broken teeth, corrosive wear or other defects, and replace the gear if defective. To remove, proceed as follows:

(Removal)

(a) Heat the ring gear uniformly with an acetylene torch.

(b) Using a bar, give light hammer blows to the periphery of ring gear.

(Installa tion)

Heat a replacement ring gear up to about 100°C (212°F) in a piston heater, and press the gear onto the flywheel with its unchamfered teeth foremost.

Crankshaft pulley

Inspecting V-belt groove

Inspect the groove for wear. W rap a new belt around the pulley, pressing it in the groove as far as it goes, and see if the top surface of the belt is above the top of the pulley.

Measuring flywheel face runout

Replacing ring gear

t

1.6 mm (1/16 in.),

minimum

400150

Inspecting V -belt groove in crankshaft pulley.

73

ENGINE PROPER

If the top surface of the belt is uniformly above the top of the pulley all the way around, it is not necessary to replace the pulley.

If the top surface of the belt sinks into the groove more than 1.6 mm (1/16 in.), replace the pulley.

(

(

74

ENGINE PROPER

2.3 Reassembly

B

402892

Section A-A

402906

5

Section B-B

402903

I


@

, I , , , , I I I 1 I I I

® r

® ®

@ @ @)

@®CV®®®@CD@

,r

@

r

® i

®

Crankcase

I

402887

75

ENGINE PROPER

(1) Installing camshaft -gear and thrust plate

Heat the gear for installation. Have the thrust plate installed in advance.

(2)

Installing camshaft

Carefully insert the camshaft into the crankcase.

Camshaft gear

(3)

Installing idler

Install timing install the idler while aligning marks each pair of gears, the thrust plate with bolt. the and

(4) Installing oil seal

To install the oil seal, use the installer.

(

400456 \

76

ENGINE .PROPER

(5) Inspecting and adjusting timing g~ars after installation.

After installing the timing gears, be sure to inspect and adjust them as follows:

(Inspecting timing gear backlash and end

. play)

After installing the timing gears, inspect the backlash between the gears in mesh and the end play of each gear.

(Refer to 2.2, Group No.7.)

(Inspecting valve timing)

It is not necessary to inspect the valve timing, provided that all matching marks on the timing gears are aligned.

Inspect the timing for verification as follows:

Using a 3 mm (0.12 in.) thick smooth steel plate, add 3 mm (0.12 in.) clearance to the intake and exhaust valves of No. 1 cylinder. Then, insert a

0.05 mm (0.0020 in.) feeler gauge into between the top of valve cap and rocker, and slowly turn the crankshaft, trying to find a position where the feeler gauge is firmly gripped (the valve starts opening) and a position where the gauge is just ungripped (the valve starts closing). Check to make sure that these positions coincide with the angular positions shown in the

'valve timing diagram with 3 mm (0.12 in.) clearance added to valves.

BD,C.

Valve timing diagram

T.D.C.

Intake

402899

401762

401763

Valve timing diagram with 3 mm (0.12 in.) clearance added to valves

77

ENGINE PROPER

3. PISTONS, CONNECTING RODS, CRANKSHAFT AND CRANKCASE

3.1 Disassembly

Scratches, cracks, wear, carbon deposit on outside

WeaJ., scratches, rust

Scale deposit, corrosion, damage

I

Wear

I

I

Wear

J clogged oil hole

I

.---,~ i

Scratches> flaking metal·to-metal

@ contact

®

®

Scratches, cracks, pitting, clogged oil hole, wear

Chipping, abnormal wear

Scratches, flaking metal-to-metal contact

CD

Nut

®

Connecting rod cap

®

Connecting rod bearing

@

Top compression ring

®

Second compression ring

®

Oil ring

(j)

Snap ring

®

Piston pin

®

Piston

®>

Connecting rod

@

Bearing cap bolt

®

Main bearing cap

@

Side seal

®

Thrust plate

401766

@ Main bearing (lower shell)

@

Crankshaft

@ Main bearing (upper shell)

®

Crankcase

78

(1) Removing connecting rod caps

(a) Unscrew the nuts securing the cap.

Give hammer blows to the bolts squarely and evenly· and, after the cap comes off the reamer bolt, take off the cap.

(b) Mark the removed connecting. rod bearings for identification of cylinder numbers and kinds, upper shells and lower shells.

(2) Preparatory step for removing pistons

(a) Lay the crankcase on its side .

. (b) Remove all carljon deposits from the upper areas of cylinder sleeves with cloth or oil paper. Carbon deposits, if any, will make it difficult to pull the pistons upward.

(3) Removing pistons

Bring the piston assembly (from which the connecting rod cap has been removed) to top dead center position.

Put the hammer handle to the big end of the rod, and push the ass em bly off the crankcase.

(4) Removing piston rings

To remove the rings, use piston ring pliers (A) (31391-12900).

ENGINE PROPER

401767

401769

79

ENGINE PROPER

(5) Removing piston pin

(a) Using snap ring pliers, remove the snap rings ..

(b) Remove the piston pin, and separate .. the piston from the connecting rod.

(c) If it is difficult to pull out the pin, heat the piston in a piston heater or hot water to expand the pin bore.

(6) Removing main bearing caps

Unscrew the bolts securing the cap, and remove the cap complete with main bearing. To remove the front and rear main. bearings, use a puller.

r-----.&J

CAUTION

l---~

When removing the caps, be careful not to damage the bearings. After removing the caps and bearings, mark each com bina tion for its location so that it is installed to the same crankshaft journal as before at the time of reassembly.

(7)

Removing crankshaft

Slowly lift· the crankshaft off the crankcase.


Crankcase and cylinder sleeves

(1) Measuring warpage of crankcase gasketed surface

M eas!1re the warpage wi th a straightedge and fee.ler ga"tige. If the warpage exceeds :the Assembly standard, grind the. surface'. with a surface grinder. Grind'>the" crankcase only enough ·to remove ·the warp.age.

,

..

Unit· rom (in)

Item

Warpage of crankcase gasketed surface

Assembly standard

0.05 (0.0020).

maximum

Repair limit

0.20

(0.0079)

80

401770

401772

670102

Measuring crankcase gasketed surface

(

(2) Measuring cylinder sleeve insiqe diameter

(a) Measure the sleeve in two directions, paraliel and transverse to the crankshaft, at three

. positions, top (ridged area), middle and bottom as shown.

Item

Cylinder sleeve

inside

diameter

Out of round

Taper

Assembly standard

98.000

- 98.035

(3.85826

- 3.85964)

Om5

(0.00059),

maximum

0.05

(0.0020),

maximum

Unit· mm (in )

Repair limit

Service

limit

98.200 99.200

(3.86613) (3.90550)

(b) If the inside diameter reaches the

Repair limit within the Service limit, bore the sleeve to the specified oversize.

(c) Hone the sleeve to

+0.25 mm

(+0.0098 in.) or

+0.5 mm

(+0.0197 in:) oversize accurate within 0 to

0.035 mm (0.00138 in.). Use the piston and pis tori rings of the same oversize. .

(d)

If any sleeve is unevenly worn, determine the oversize on the basis of the maximum wear noted to ensure perfe.ct roundness in the oversized bore.

ENGINE PROPER

11 mm (0.43 in.)

60 mm

(2.36 in.)

105 mm (4.13 in.)

670103

Measuring cylinder sleeve inside diameter

81

ENGINE PROPER

1-------.

(a) Refinish all sleeves to the same oversize.

(b) If the . sleeve is found in good condition, with the wear far less than the Repair limit, replace the piston rings, and ream off

"ridge" at the top of the sleeve.

Hone the bore if necessary.

(3) Replacing cylinder sleeve

If one sleeve exceeds the Service limit in inside diameter or it is defective, with the other sleeves in good condition, replace that sleeve only.

(Removing cylinder sleeve)

(a) Set up a boring machine on the crankcase by aligning it with the center of the less-worn area of the sleeve at the bottom.

(b) Bore the sleeve un til its stock thickness is about

0.5 mm

(0.02 in.) •.

(c) Break and remove the sleeve, being careful not to damage the inside surface of the crankcase.

670104

Ridge-reamin~ cylinder sleeve

0.5 mm (0.020 i~.)t<-

"

,

'----

~

,

/ '

I

,

(;/

~401197(

Removmg cylinder sleeve

(I)

(Installing a new cylinder sleeve)

(a) Use cylinder sleeve installer

(34491-02100 ).

(b) Press the sleeve into the crankcase, leaving a protrusion of

0.3 to

0.5 mm (0.012 to 0.020 in.) at the top.

Then make it flush with the crankcase top.

(c) Bore and hone the sleeve to

98

~.035 mm

(3.86

~.OOI38 in.).

Removing cylinder sleeve

(2)

401198

401773 \

Installing cylinder sleeve

82

ENGINE PROPER

Pistons and piston rings

(1)

Measuring piston diameter

(a) Using a micrQmeter, measure each piston in the direction transverse to the piston pin.

If the diameter exceeds the Service limit, replace the piston. If any pistons have to be replaced, select new pistons so that the variance in weight among pistons per engine is within the

Assembly standard.

Item

Assembly standard

Unit· mm (in )

Service

limit

Standard

97.875 - 97.845 97.660

(3.85334 - 3.85216) (3.84487)

0.25

Piston

(0.0098)

diameter oversize

98.125 - 98.095 97.910

(3.86318 - 3.86200) (3.85472)

0.50

(0.0197)

oversize

98.375 - 98.345 98.160

(3.87302 - 3.87184) (3.86456)

Variance in weight per engine gram (oz)

±3 (±O.l)

(b) Piston weight is stamped on the top of each piston.

/

Measuring piston diameter

401774

@

Piston weight m

Piston weight marking

401775

83

ENGINE PROPER

(2) Measuring piston ring end gap

Place the ring in a new or master sleeve, .and measure. the gap. If the gap exceeds the Service limit, replace all rings as ·a se t.

Inside diameter of master cylinder sleeve:

981.035 mm

(3.861.00138 in.) o

0 0 o

(0~O'"°9~~~~~

Measuring piston ring end gap

401776

r--------LI~NO~T~El--------~

Place the piston ring in the master sleeve by pushing it squarely with the use of piston.

Item

Piston ring end gap

Unit· mm (in )

Assembly standard

Service limit

0.30 - 0.50 1.50

(0.0118 - 0.0197) (0.0591)

(3) Measuring piston ring side clearance

Insert new piston rings into the ring grooves in the piston, and measure the clearance of each ring with a feeler gauge and straightedge as shown.

M

0

"

'"

'"

Item

No. I ring

"

No.2 ring

00

'"

0

'"

Oil

~ ring

Unit: mm (in )

Nominal Assembly

value

standard

Repair limit

2.5

0.030

- 0.070 0.200

(0.098) (0.00118 (0.00787)

- 0.00276)

2.0

(0.079)

4.5

(0.177)

0.Q25

- 0.060 0.150

(0.00098

(0.00591)

- 0.00236)

Measuring piston ring side clearance

400050

(

84

ENGINE· PROPER

(4) Measuring piston pin and hole diameters

If the Repair limit is reached, replace the piston pin.

If it is exceeded, replace the piston.

Item

Piston pin diameter

Piston pin·to·hole

clearance

Assembly standard

Unit: mm (in.)

Repair limit

28.000 - 27.994

(1.10236 - 1.10212)

0-0.016 0.050

(0 - 0.00063) (0.00197)

(5) Measuring piston protrusion

Measure protrusion of each piston and, if it is not within the Assembly standard, inspect the various parts for clearance.

(a) Determine the top dead center of piston with a dial gauge.

(b) Set up the dial gauge at the top of crankcase, and set the gauge pointer to zero (0).

(c) Measure the protrusion at three places on the piston head, and average the three measurements to determine the protrusion. Subtract the protrusion from the

"as-installed" thickness of cylinder head gasket to determine the clearance between the piston top and cylinder head.

Item

Piston protrusion

"As·installed" thickness of cylinder head gasket

Unit: mm (in.)

Assembly standard

0.35 - 0.75

(0.0138 - 0.0295)

1.6±0.15

(0.063 ± 0.0059)

Measuring piston pin and hole

401206

Measuring piston protrusion

85

ENGINE PROPER

]---~

Keeping the piston protrusion within the Assembly standard is important not only for engine performance but also for prevention of interference of the valve with the piston.

Connecting rods, connecting rod bearings and small-end bushings

(1)

Measuring connecting rod bearing-tocrank pin clearance

Measure the crank pin diameter and bearing inside diameter to determine the clearance between the two. If the clearance exceeds the Repair limit, replace the bearing. If the crank pin is worn excessively or unevenly, grind the crankpin, and use undersize bearing.

The two bearing undersizes are -0.25 mm (-0.0098 in.) and -0.50 mm (-0.0197 in.).

To measure the bearing inside diameter, install upper and lower shells to the connecting rod properly, and tighten the cap bolts to the specified torque.

Item

Crankpin diameter

Connecting rod bearing·to·crankpin

clearance

Assembly standard

Unit· mm (in)

Repair limit

58 -0.035

-0.055 -0.20

(2 28 -0.00138) (-0.0079)

. -0.00217

0.Q35 - 0.100

0.200

(0.00138 - 0.00394) (0.00787)

Measuring connecting rod bearing inside diameter

401778

86

(

ENGINE PROPER

(2) Measuring connecting rod bushing-topiston pin clearance

Measure the piston pin diameter and bushing inside diameter to determine the clearance between the two. If the clearance exceeds the Repair limit, replace the pin or bushing whichever is badly worn.

Item

Assembly standard

Unit· mm (in)

Repair limit

Piston pin bushing inside

diameter

28.045 - 28.020

(1.10413 - 1.10315)

Connecting rod bushing·to.piston

pin clearance

0.020 - 0.051 0.080

(0.00079 - 0.00201) (0.00315)

(3) Replacing connecting rod bushing

(a) To remove the bushing for replacement, use a connecting rod bushing puller as shown.

(b) Align the oil holes in the bushing and connecting rod.

(c) Press the bushing from the chamfered side of connecting rod.

(d) After installing the bushing, insert the piston pin to make sure that the pin rotates freely.

(4) Inspecting connecting rods for bend and twist

(a) Measure

"e"· and "V' If the measurement at

"e" is larger than

0.05 mm (0.0020 in.) per 100 mm

(3.94 in.) of "!," straighten the rod with a press.

Item

Connecting rod bend and twist

Assembly standard

0.05/100

(0.0020/3.94),

maximum

Unit: mm (in.)

Repair limit

0.15

(0.0059) c

E9

IHI

Measuring connecting rod bushing inside diameter

401779

Installing connecting rod bushing

670129

Piston pin

Bend

Twist

Inspecting connecting rod

400110

87

88

ENGINE PROPER

(b) For inspecting connecting rod for bend and twist, the connecting rod aligner is generally used.

~---~INOTE1----~

To inspect for bend, install . the bearing cap to connecting rod, and tighten the cap bolts to the specified torque. r - - - - - - - - - - - - - - - - . (

Checking connecting rod on aligner

(c) To inspect the rod installed to the piston, place the piston on a surface plate, insert a round bar corresponding to the crank pin in diameter into the big end bore, and measure the heights "A" and

"B"

of the bar.

.. cr~

0··

.-

/,,:-', ..

L'T~

~~

J

.,

A

B

=~

II ;

=

: II

401781

Inspectmg connectmg rod mstalled to pIston

(5) Inspecting connecting rod bearings

Inspect each bearing shell for wiped overlay, scratching, burning, pitting and other defects. If any of these defects is present, replace the shell •. ·

Wiped overlay

400112

ENGINE PROPER

(6) Measuring connecting rod end paly

Install the connecting rod to the mating crankpin, and tighten its cap to the specified torque. Then, using a feeler gauge, measure the end play. If the end play exceeds the Service limit, replace the connecting rod.

Unit· mm (in )

Item

Nominal Standard Service value

clearance

limit

Connecting rod end play [widths 40

0.15

- 0.35

of connecting rod

(1.57) (0.0059 and crankpin

1

- 0.0138)

0.50

(0.0197)

(7) Variance in weight among connecting rods per engine

When replacing connecting rods, make sure that the variance in weight among connecting rods per engine is within the Assembly standard shown below.

Item


Assembly standard

±5 g (±0.2 oz),

maximum

Crankshaft

(1) Measuring journal diameter

Using a micrometer, measure the journal in two positions, 1 and 2, and in two directions, A and B, to determine the wear, out of round and taper. If any of the Repair limits is exceeded, regrind the journal to the undersize or replace the crankshaft.

Item

Assembly standard limit

Unit· mm (in.)

Repair

Service limit

Dia·

Out of

-0.15 -0.90

Crank· shaft

meter

(2 95 -0.0012) (-0.0059) (-0.0354)

jour-

75 -0.03

-0.05

nals round

0.01

(0.0004),

0.03

(0.0012)

Taper

maximum

Measuring connecting rod end play

670429

Matching marks

Stamped weight .rank letter

401782

Measuring crankshaft journals

670112 '.

89

ENGINE PROPER

(2) Measuring crankpin diameter

Using a micrometer, measure the crank pin ·in two positions, 1 and 2, and in two directions,

A and

B, to determine the war, out of round and taper. If any of the Repair limits is exceeded, regrind the crank pin to the undersize or replace the crankshaft.

Crankpins

Item

Diameter

Out of round

Taper

Assembly standard

Unii: nun (in.)

Repair limit

58 -0.035

-0.055

. -0.00217

-0.20

(228 -0.00138)

(-0.0079) om

(0.0004),

maximum

0.Q3

(0.0012)

(3)

Grinding crankshaft

If the crankshaft is ground to any of the undersizes and refinished to a dimension which is

0.100 to

0.120 mm

(0.00394 to

0.00472 in.) smaller than the undersize, it is not necessary to check the bearing contact pattern.

-----------

Crankshaft journal

Crankshaft grinding dimensions

Undersize

Unit· mm

(in)

Refinishing dimension

0.25

(0.0098)

0.50

(0.0197)

74.65 - 74.63

(2.9390 - 2.9382)

74.40 - 74.38

(2.9291 - 2.9283)

Crankpin

0.25

(0.0098)

0.50

(0.0197)

57.65 - 57.63

(2.2697 - 2.2689)

57.40 - 57.38

(2.2598 - 2.2591)

Measuring crankpins

670113

90

ENGINE PROPER

W hen grinding the journals and crank pins, be sure to produce the same fillet radius as the original one. They should have a hardness of 620 or more in terms of Vickers Hardness Number.

If necessary, reharden the journals and crank pins, and inspect them foor cracks by conducting a magnaflux (magnetic particle) test.

(4) Measuring crankshaft end play

Install the thrust plates in position, and secure the main bearing caps. Under this condition, measure the end play

(the end clearance of thrust plates in the journal). If the end play exceeds the Assembly standard, replace the thrust plates.

Item

Crankshaft end play

Nominal Assembly value standard

Unit· mm (in)

Repair limit

37

0.100

- 0.264

(1.46) (0.00394

- 0.01039)

0.300

(0.01181)

(5) Measuring crankshaft runout

Support the crankshaft on its front and rear journals in V-blocks, and ineasure the runout at the center journal, using a dial gauge. Depending on the amount of runout, repair the crankshaft by grinding or straightening with a press.

If the runout exceeds the Repair limit, replace the crankshaft.

Item

Crankshaft runout

Assembly standard

0.02 (0.0008),

maximum

Unit· mm (in )

Repair limit

0.05

(0.0020)

(6) Replacing crankshaft gear

(a) Using gear puller, rem ove the gear from the crankshaft.

Measuring crankshaft end play

401783 o o o

0

0

0

Measuring crankshaft runout

Replacing crankshaft gear

91

· ENGINE PROPER

Do not remove tile gear by driving with a hammer.

(b) To install, heat the gear up to about 100°C (212°F) with the heater. Place the new gear on the crankshaft by aligning the key with the notch of the gear and give light blows of a copper hammer to the end face of the gear.

Key and notch to be aligned

(7)

Replacing rear oil seal

If the seal shows a sign of oil leaks, replace it with a replacement oil seal wi th sleeve.

To install the sleeve, apply oil to the inside surface of the sleeve, and drive it on to the crankshaft, using crankshaft sleeve installer (A) (30691-13010), as shown.

Main bearings

(1) Inspection

Inspect each bearing shell for abnormal contact, . scratching, corrosion, wiped overlay and other defects. Also check for a sign of 'poor seating in the bore of the crankcase or bearing cap.

401785

®

Replacing rear oil seal

401786

(

\

92

ENGINE PROPER

(2) Measuring main bearing clearance

Fit the bearing shells to the crankcase and bearing cap, and tighten the cap bolts to the specified torque. Measure the inside diameter of the bearing in two positions, front and back along the longitudinal axis of crankshaft, in the criss-cross directions to take an average. Obtain the difference between the journal diameter and this inside diameter to determine the clearance.

Unit· mm (in )

Item

Main bearing·to· journal clearance

Assembly standard

Repair limit

0.050 - 0.115

0.200

(0.00197 - 0.00453) (0.00787)

(3) Replacing main bearings

If the clearance exceeds the Repair limit, . replace the bearings, or refinish the crankshaft and use undersize bearings. If the crankshaft is refinished in compiance wi th any of. the undersizes, it is not necessary to inspect the bearing contact pattern. o

401789

Measuring main bearing inside diameter

93

ENGINE PROPER

3.3 Reassembly

I


I

~ ~

1 l

~

' I

, <P

(@@®(upper)(@@@)------>l®III®<-®(Iower) r r r

®@®

1 l

~ ~

@Oower) @ @

I

(j)

®

®

®(upper)

(1)

Installing main bearings

(a) Install each upper shell in the crankcase by fitting its locking lip in the recess. Tlie oil holes in the shell and crankcase will be aligned when the shell is so installed.

(b) Apply a thin coat of engine oil to the inside surface of each shell.

(c) Install the thrust plate in position.

Installing main bearing upper shell

401788

(

94

ENGINE PROPER

(2) Installing crankshaft

(a) Wash the crankshaft with cleaning solvent, and dry it by directing pressure air.

(b) Hold the crankshaft in horizontal position, and carefully put it on the crankcase.

(c) Apply a thin coat of engine oil to the journals of crankshaft.

(3) Installing main bearing caps

(a) Apply engine oil to each lower shell, and fit it to the bearing cap.

(b) Apply ThreeBond 1l05D to the mating face of the front and rear caps.

,------1

NOTE

1--------,

Apply ThreeBond 1l05D to only front and rear caps to which side seals are to be installed.

(c) Install the bearing caps to the crankcase, making sure that they are flush with the crankcase walls on the front and rear sides.

(d) Coat the side seals with potash soapy water, and insert them in to the grooves in each bearing cap.

Using the face of a screwdriver, push in the seals, bringing their rounded corners on the outer side and taking care not to twist the seals.

(e) Apply ThreeBond 1104 (grey in color) to the vicinity of the side seal joint.

Crankcase Bearing cap Side seal t!

401772

Rmark

670138

Coat with potash

,

I

Q(

\

.

soapy water.

t!" ,

~

¢ .

~.

~

::>

~~<!O I~ i

Apply ThreeBond 1104. ( / I i'"

~

401552

95

ENGINE PROPER

(4) Installing bearing cap bolts

Apply engine oil to the bolts, and tighten them to the specified torque.

, - - - - - - - - - - - - - - - - - - - , (

(5) Meas.uring crankshaft end play

Install the thrust plates in position, and secure the main bearing caps. Under this. condition, measure the end play

(the end clearance of thrust plates in the journal). If the end play exceeds the Assembly standard, replace the thrust plates.

Unit: mm (in)

Item

Crankshaft end play

Assembly standard

0.100

- 0.264

(0.00394

- 0.01039)

Repair limit

0.300

(0.01181)

(6) Lay the crankcase on its side

1O.4±O.S kgf·m

(75.2±3.6Ibf·ft)

(102±4.9

N.m)

401790

-

~ n

1-

E~d p'lay

®

/

""

H t-

~lu

' -

["

01

-~

---...

---'

401791

(

401792

(7) Installing piston rings

(a) Using piston ring

(31391-12900), install the rings on the piston. pliers piston

1------,

Each piston ring is marked "R" on the side to be up when installed on the piston.

Up mark

; 0

~~

/~o.

1

compression /' .......

J

nng

---~

' - - - - - - - 1 i=='=:::j

~2~reSSion ring

No.3 oil ring

670131

Piston rings

96

(b) Install the oil ring with its end gap positioned at 180· to that of spring expander. Attach teflon tube to the expander close to the oil ring end gap.

ENGINE P.ROPER

,~ing

' gap expander ' "

~

. r, .

Spring expander )

p

...

~..., Dilring

670133

(8) Preparatory steps for installing pistons

Clean the cylinder sleeve bore surface with a clean .cloth, and apply engine oil to that surface.

401795

(9) Installing connecting rod bearings and caps

(a) Insert the bolts in to the cap by settling the flat of bolt head in place on the. cap.

(b) Install the upper shell of the bearing in the rod by fitting its locking lip in the groove, and apply engine oil to the inside surface of the shell. 401796

97

ENGINE PROpER

(10) Installing pistons

(a) Apply engine oil to the piston rings, and reposition the rings by keeping their end gaps away from the direction of piston pin and thrust side.

. Camshaft side .End gap of No. 1

canpression ring

~

~

v

End gap

~

?fN~.

2

60.~~~~

compressIOn nng

Combustion chamber side

670139

(b) Bring the crankpin to which the piston is to be installed to top dead center position. Using piston guide (A) (34491-02200), insert the piston assembly into the crankcase, with the matching mark of the connecting rod on the camshaft side.

670140

(c) After resting the big end of connecting rod on the crankpin, turn crankshaft by 180°, and install the cap.

~.~ ~

...

~

'\

II

40179B

(11) Installing connecting rod caps

(a) Install the lower shell of the bearing in the cap, apply engine oil to the inside surface of the shell.

(b) Install the cap by tightening the nuts to the specified torque.

401799 \

98

INTAKE & EXHAUST SYSTEMS

I.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

2. EXHAUST MANIFOLD ..................................................... 100

INTAKE & EXHAUST SYSTEMS

1.

DESCRIPTION

Muffler

-

Cylinder

Air cleaner

401800

2. EXHAUST MANIFOLD

Inspection

(a) Inspect flanges for cracks.

(b) Inspect flanges for warpage. If the warpage exceeds the Assembly standard, repair the flanges.

Item

Warpage of exhaust manifold flanges

Unit· mm

Assembly standard

0.2 (0.008),

maximum

Inspecting exhaust manifold flanges for warpage

100

LUBRICATION SYSTEM

1. DESCRIPTION ............................................................ 102

2. OIL PUMP ............................................................... 103

2.1 Disassembly .......................................................... 103


2.3 Reassembly .......................................................... 106

3. OIL FILTER ............................................................. 107

Disassembly and inspection .................................................. 107

4. RELIEF VALVE ......................................................... 107

Inspection ............................................................... 107

LUBRICATION SYSTEM

1. DESCRIPTION

Fuel injection pump-

Water pump

Crankshaft-

Valve mechanism

Piston

Oil filter

Relief valve

Oil pump

Oil strainer

402910

102

2. OIL PUMP

2.1 Qisassembly

,--_-----,

~G)

Worn or broken gear teeth

,

U

......

~

®

( 2 1 r - ' - - - - ( 8

LUBRICATION SYSTEM

<D

Oil pump case cover

®

Outer rotor

®

Taper pin

@) Pump drive gear

@Pin

®

Inner rotor

(J)

Main shaft

®

Oil pump case

401803

103

LUBRICATION SYSTEM

(1)

Removing main shaft

Take off the taper pin, and remove the drive gear from the main shaft. Then, pull the main shaft complete with the inner rotor from the pump case.

(2) Removing inner rotor

Take off the pin, and separate the inner rotor from the main shaft.

670144

(


(1)

Measuring outer rotor-to-inner rotor clearance

If the clearance exceeds limit, replace the outer rotors as an assem bly. the Service and inner

Item

Outer rotor-to-

inner rotor clearance

Assembly standard

0.013

- 0.150

(0.00051

- 0.00591)

Unit: mm (in)

Service

limit

0.250

(0.00984)

670148

Measuring ouler rolor-la-inner ralor clearance

(

104

LL!BRICATION SYSTEM

(2) Measuring rotor-to-cover clearance

(end play of rotors)

If the clearance exceeds the Repair limit, replace the rotors or grind the mating faces of the case and cover.

Item

Rotor·to-cover

clearance (end play of rotors)

Assembly standard

Unit: mm (in.)

Repair limit

0.04

-0.09

(0.0016

- 0.0035)

.

0.15 .

(0.0059)

(3) Measuring outer rotor-to-pump case clearance

If the clearance exceeds the Service limit, replace the rotor or case whichever is badly worn.

Item

Outer rotor·to·pump

case clearance

Assembly standard

0.20

-0.28

(0.0079

- 0,0110)

Unit: mm (in.)

Service

limit

0.50

(0.0197)

(4) Measuring main shaft-to-pump case clearance

Measure the diameter of main shaft and the inside diameter of pump case to determine the clearance between the two. If the clearance exceeds the

Service limit, replace the main shaft or the pump assembly.

Item

Diameter of main shaft

.

Unit: mm (in.)

Assembly·

·"8'ervice standard limit

. .

13.000

12.985

(0.51181

- 0.51122)

Main shaft·to·pump

case clearance

0.032

- 0.074

(0.00126

- 0.00291)

0.150

(0.00591)

Measuring rotor-to-cover clearance

670146

Measuring outer rotor-to-pump case clearance

..c;Ff

JI Il

.. n~l

UOLJ

670147

670149

Measuring main shaft-tp-pump case clearance

105

LUBRICATION SYSTEM

2.3 Reassembly

7

8

4

3

402907 (

I


I

<PI r t II®

@+(l) @@

®

CD

.-----1

NOTE

1---------,

(a) When using replacement (new) main shaft and drive gear at the time of reassem bling the pump, drill dowel pin hole in and through the shaft and gear.

(b) W hen tightening the cover bolts, be sure to make sure that the rna tching marks on the cover and case are aligned. A failure to match the marks will result in malfunction.

401219

Matching marks on pump case and cover

106

LUBRICATION SYSTEM

3. OIL FILTER

Disassembly and inspection ill

Dogged

01 torn element

Replace element every 500 hours.

•

••

Apply engine oil- to

O-ring when installing element.

Cracks. distortion

670476

CD

Filter element

®

Center screw

4. RELIEF VALVE

Inspection

(1)

Check the valve seat for abnormal contact. Also check the spring for weakness and breakage.

(2) Measure the relief valve opening pressure. If it exceeds the Assembly standard, make an adjustment by tightening or loosening the adjusting screw (varying the se tting of the spring).

Item

Relief valve opening

pressure

Unit: kgf/cm' (psi) [MPa]

Assembly standard

3.0 ±0.2

(42.7 ± 2.8)

[0.29 ± 0.02]

®

Filter case

®

Relief valve

670379

Hydraulic pressure outlet

Adjusting screw

401806

107

\

...

COOLING SYSTEM

1. DESCRIPTION ....................................... ; ..................... 110

2. WATER PUMP ........................................................... 110

2.1 Disassembly .......................................................... 110

2.2 Inspection ........................................................... 111

2.3 Reassembly .......................................................... 112

3. THERMOSTAT .... , .........•............................................ 113

Inspection ............................................................... 113

4. FAN AND FAN BELT

........................................... 114

Inspection ............................................................... 114

COOLING SYSTEM

1. . DESCRIPITION

Radiator

Thennostat

Bypass pipe

(

2. WATER PUMP

2.1 Disassembly

Cooling fan

®

@

@

Water pump

®

CD

Corrosion. feathering due to rubbing contact. damaged threads

402911

110

CD

Cover

®

Impeller

@Nut

@ Pump pulley

@Spacer

I

Rotation

I

®

Oil seal

(J)

Snap ring

®

Shaft

®

Bearing

@>

Bearing

@

Oil seal

@ Unit seal

@ Case

670196

COOLING SYSTEM

(1) Removing impeller

The impeller is right hand-threaded.

To remove the impeller, turn it counterclockwise (in the direction of arrow).

400136

(2) Removing shaft

Remove the oil pull out the bearings to the seal and snap ring, and shaft complete with pulley side.

2.2 Inspection

(a) Inspect the pump operation by slowly rotating it. If it is erratic in rotation, replace the bearings.

(b) Visually inspect the impeller for corrosion or broken blade. Replace the impeller if defective. Also check the impeller for sign of rubbing cont!lct with the pump case and regr cover: If such a. contact is evident, replace the impeller and bearings.

(c) Inspect the unit seal for condition.

Replace the seal if any sign of leakage is noted during operation.

Item

Carbon protrusion

Free~staie height

Assembly standard

1.5

(0.059)

21.8 ± I

(0.858 ± 0.04)

Unit: mm (in )

Service

limit

..

0

Floating

Unit seal

400139

111

COOLING SYSTEM

2.3 Reassembly

4

(j)

®

3.5 kgf-m

(25.3 Ibf.ft)

[34.3 N-m]

®

®

I


I-

®

.I r r l 'I 'rrrrrr@

®

@ @Floating seat (g:l<-@(seal ring)

CD ®

(J)

®

®

CD

,J

@) r------I

NOTE

l----~

After reassembling the pump, operate it by means of the pulley and belt, making sure that it runs smoothly wi thout any sign of rubbing contact with the pump case or cover.

(1) Installing unit seal

To install the seal, use a unit seal installer.

Do not reuse a unit seal which has been removed from the pump case.

(2) Installing oil seal

To install the seal, use an oil seal installer.

670197

400475

(

112

WORKSHOP THEORY

I.

PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .

116

1.1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

1.2 O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.3 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.4 Lockplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

1.5 Split pins and spring pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

II

WORKSHOP THEORY

1.

PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY

1.1 Oil seals

W installing oil seals, carefully observe the following points:

(1)

Driving oil seals into housings

(a) Make sure that seal lip is not damaged, and position it correctly with respect to oil compartment.

(b) Apply a small amount of grease to the surface of oil seal to be fitted in to housing bore.

(c) Using a tool of the type shown to guide seal lip, drive oil seal squarely. Never give any hammer blows directly to oil seal since this will damage the seal, resulting in oil leakage.

Oil seal driver

400247

(2)

Driving oil seals onto shafts

(a) Apply a thin coat of grease to oil seal lip.

(b) Use an oil seal guide of the type shown when driving oil seal over stepped portion, splines, threads or keyway to prevent damage to seal lip.

Oil seal guide

400248

116

WORKSHOP THEORY

1.2 O-rings

Use an O-ring guide of the type shown when installing O-ring over stepped portion, splines, threads or keyway to prevent damage to the ring. Apply a thin coat of grease to O-ring.

1.3 Bearings

(1)

When installing a rolling bearing, be sure to give a push to the race, inner

qr

outer, by which the bearing is fitted. Be sure to use a bearing driver of the type shown.

(

(2) Use a press whenever possible to minimize shock to bearing and to assure proper installation.

400249

O-ring guide

-

~q~

400250

Bearing installation by a press

400251

117

WORKSHOP THEORY

1.4 Lock plates

Bend lock plate against one of the flats of nut or bolt head as shown. m

Right

I -

rrp-, fIlS

•

Right

Wrong

1.5 Split pins and spring pins

Generally, split pins are to be replaced at the time of disassembly. Be sure to insert the split pin fully and spread it properly. Drive each spring pin into position so that it may not get out of place after subsequent installation of parts has been completed.

Bending lock plates

(

118

3. THERMOSTAT

Inspection

Immerse the thermostat in a water ba th, and test it for thermostatic action by heating the bath to raise the water temperature. If the valve fails to operate properly, replace the thermosta t.

Item

Temperature at which

valve starts opening

Temperature at which valve opens fully

Valve stroke

Unit· mm (in)

Assembly standard

76.5 ±2°C

(169.1 ± 3.6°F)

90 ±2°C

(194 ± 3.6°F)

9 (0.35)

, - - - - - [NOTE l----~

(a) Stir the water in the bath with a stick to maintain its temperature uniform during test.

(b) At reassembly, install thermostat wi th its air ven t hole facing upward.

COOLING SYlnEM

mm

(in.)

9(O.35)~

o

76.5 ±2 90 ±2

US9.7 :!:3.6)(194 :!:3.6)

Tempefalutt °c

('To)

401810

. 113

COOLING SYSTEM

4.

FAN AND FAN BELT

Inspection

Distorted or cracked blade

in length,

detenoration, cracks

401811

(

114

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DEC .. '86

Printed in Japan

Pub. No.

99879-00120-

1

/

SERVICE MANUAL

MITSUBISHI

DIESEL ENGINE

for BD2G/BS3G

CONTENTS

• FUEL SYSTEM

• ELECTRICAL SYSTEM

j j

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INTRODUCTION

This Service Manual is written to familiarize you with the maintenance of the fuel system and electrical system of your Mitsubishi S4E2 Diesel Engine. This is edited as a separate volume to supplement the Service Manual of Mitsubishi

S4E2 Diesel Engine (Pub. No. 99159-01110-1/). For groups other than those in this Manual, refer to that Service Manual.

Major equipment specifications

Equipment

S4E2(BD2G,BS3G)

Injection nozzle

Type of nozzle holder ND-DNOSD

Type of nozzle tip

Fuel system

Feed pump ND-EP/KS22A

Injection pump

PES4A65B

Electrical system

Governor

Starter

Alternator

ND-EP/RSV

M002T65271

AOOlT70770

Fuel system

Group

Electrical system

TABLE OF CONTENTS

Contents

Disassembly) inspection, reassembly and maintenance

standards of fuel system:

Fuel fIlter, fuel injection nozzles, fuel feed pump,

fuel injection pump, governor

Disassembly. inspection, reassembly and maintenance

standards of electrical system:

Starter, alternator, glow plugs

Group No.

I

I

2

FUEL SYSTEM

1.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. FUEL FILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Disassembly and inspection 2

3. FUEL INJECTION NOZZLES

3.1 Disassembly

3.2 Inspection and adjustment

3.3 Reassembly

............................................. .

........................................................ .

3

3

3

6

4. FUEL FEED PUMP

4.1 Disassembly


5. FUEL INJECTION PUMP

5.1 Disassembly

5.2 Inspection

9

9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11

5.3 Reassembly

13

5.4 Testing and adjustment . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15

7

7

8

6. RSV GOVERNOR ........................................................ 20

6.1 Disassembly ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20

6.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22

6.3 Testing and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23

7. MAINTENANCE STANDARDS ............................................ , 29

7.1 Maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29

7.2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31

I

FUEL SYSTEM

1.

DESCRIPTION

Fuel filter

Fuel injection nozzle

Fuel leak-off pipe

_ To fuel tank

Fuel injection pump

Fuel feed pump

2. FUEL FILTER

Disassembly and inspection

Cartridge type paper-element filter

2'

~\;f'------Air vent plug

Clacks, damaged threads

Apply engine oil when installing.

_ From fuel tank

401812

2

CD

Element assembly

®

Bracket

Clogged or torn element

Replace every 500 hours.

401814

FUEL SYSTEM

FUEL INJECTION NOZZLES

3.1 Disassembly

====1--~1

@-'

I

Carbon deposit, clogged spray hole

401816

Q) Retaining nut

®

Nozzle tip

®

Distance piece

®

Pressure pin

3.2 lnspection and adjustment

(1) Injection pressure

(a) Set up the nozzle on the tester.

Operate the tester handle several times to prime the pipe and nozzle.

(b) Slowly operate the handle all the way up and down, completing each cycle in about a second, while observing the pressure gauge indication.

(c) As the nozzle beings to spray fuel, the needle of the gauge. being deflected will start oscillating.

Read the pressure right then as the injection pressure.

®

Spring

®

Washer

(J)

Nozzle holder

Testing injection nozzle

Item

Valve opening pressure

300542

Unit: kgf/cm

2

(psi) [MPa]

Assembly standard

120 +10

0

(1706

+6

42

)

[11.8+6-

0 ]

3

FUEL SYSTEM

.----&

WARNING

Never expose the hand or other part of the body to fuel spray nor touch the spray hole during the test.

(d) If the pressure is out of specification, make a shim adjustment.

Increasing or decreasing shim thickness by 0.1 mm (0.004 in.) raises or drops injection pressure by about

10 kgf!cm 2 (142 psi) [1.0 MPa]. Shims for this adjustment are available in

20 sizes, from 1.0 mm (0.039 in.) up to 1.95 mm (0.0768 in.) in an increment of 0.05 mm (0.0020 in.)

(2)

Spray pattern

(a) At the time of testing the injection pressure, inspect each nozzle for clogged spray hole and fuel leaks from the hole. Also examine spray pattern.

(b) To test the nozzles move the tester handle at it rate of about 1 stroke per second- to make sure that it sprays fuel in good straight pattern.

(3) Washing or replacing nozzle tip

(a) Loosen the re taining remove the nozzle tip. needle valve and body . nut, and

Wash the

.-----Lt,.l

CAUTION) - - - - - - ,

When pulling out the nozzle tip, be careful not to damage it. Never strike the nozzle tip.

G<Jod Large-angle

spray spray

Mte!-

dribble

Skew

spray

Twiggy

spray

401818

Spray patterns of throttle type nozzle

(

4

(b) Wash the nozzle tip in clean gasoline. After washing, assemble the needle valve and body in clean diesel fuel.

I

~~----,

The needle valve and body are finely finished. Do not change the combination or set of the valve and body.

(c) Tighten the retaining nut to the specified torque.

(d) If the spray pattern is still bad after the nozzle has been adjusted and cleaned, replace the nozzle tip.

J-------.

Never attempt to touch the sliding surface of needle valve •

.------1

NOTE ] - - - - - - - ,

To replace the nozzle tip, remove the sealpeel (plastic covering) and wash the new tip in clean gasoline by sliding the needle valve in the nozzle to remove the rust preventive oil completely.

FUEL SYSTEM

~O:j

Needle valve Body

402912

5

FUEL SYSTEM

3.3 Reassembly

5

±

0.5 kgf.m

(36 ± 4 lbf·ft)

[49 ± 5 N·m]

- ! - - - - ( 2 fR~~ssembling sequence

I

670038

(

(

6

4. FUEL FEED PUMP

4.1 Disassembly

CD

®

~

0

II

",

©

•

®

I

®

II

FUEL SYSTEM

401543

CD

Priming pump

®

Check valve spring

®

Check valve (inlet)

®

Hollow screw

@ Valve support

®

Check valve spring

(j) Check valve (outlet)

®

Piston chamber plug

®

Piston spring

@) Piston

@

Ring

@

Tappet

@ Pushrod

®

Hollow screw

@ Filter gauze

@ Nipple

@ Pump housing

(Remove the parts in the order numbered for disassembly.

To reassemble, follow the reverse of disassembling order.)

7

FUEL SYSTEM


Airtightness

Immerse the feed pump in a pool of fuel, with its discharge side plugged up. Apply an air pressure of 2' kgf/ cm 2 (28 psi)

[0.2 MPa] to its suction to see if any bubbles come out of the pump. Some air, how eyer , will leak out through the clearance between its push rod and housing. The pump is sufficiently airtight if the amount of this leakage (with no leakage from any other part of the pump) is not greater than the value specified.

Item

Specification

Feed pump airtightness

Standard

Not greater than

50 cc

(3.1 cu in.)!minute (with bubbles not larger than

2 mm (0.08 in.) in size) at an air pressure of 2 kgf/cm'

(28 psi) [0.2 MPa]

If the airtightness is poor, repair the pushrod bore in pump housing wi th a burnishing broach and install an oversize pushrod.

®

• t - - - - - - i 6l----i

- - - - 6

•

CD

Measuring cylinder

®Tappet

@Plug

@Diesel fuel oil

2 kgf/cm'

(28 psi)

[0.2 MPa]

@

670159

8

5. FUEL INJECTION PUMP

5.1 Disassembly

FUEL SYSTEM

CD

Screw plug

®

Bearing cover

®

Camshaft

®

Bearing

®

Bearing

®

Shim

(J) Tappet

®

Circlip

®

Roller pin

@) Tappet roller

@

Roller bushing

@ Shim

@ Lower spring seat

®

Plunger

®

Plunger spring

@ Upper spring seat

@

Control sleeve

@ Control pinion

®

Lock plate

®

Delivery valve holder

@ Delivery valve spring

@ Delivery valve

@ Pump cylinder

®

Rack guide screw

®

Control rack

@ Pump body

Fuel injection pump - Disassembled view

(Remove the parts in the order numbered for disassembly.)

670191

9

FUEL SYSTEM

(1) To remove camshaft (3), turn the camshaft by hand to raise each tappet

(7) to its top dead center, and insert tappet insert (a) into tappet hole to make each tappet free of cam.

(2)

To remove tappet insert (a), insert roller clamp (b) through the screw plug hole to pinch the tappet roller

(10), give a push to tappet

(7), and remove the tappet insert.

(3)

To remove tappet

(7), insert the tappet clamp (c) through bearing hole to pinch the tappet, take off the roller clamp (b), and remove the tappet.

.-----1

NOTE ) - - - - - - - .

Tilt down the top (delivery valve holder side) of the pump so that the plungers and springs will not come off.

(4) To remove plunger (14), pinch the lower portion of the plunger with plunger clamp (d), and draw out the plunger together with its lower spring seat (13) .

.----&1

CAUTION ) - - - - - - .

W hen removing the plunger, be careful not to scratch the plunger: pull the plunger straight out.

10

5.2 Inspection

(1) Measure the width of plunger flange.

If this flange is worn down to exceed the assembly standard, replace the pump element assembly (plunger and

. bat'reI).

Unit: mOl (in.) lIem

Assembly standard

Widih of pump element plunger flange

7 -0.05

0

(0.2756 ;:.0020)

(2) Measure the width of the slot provided in the control sleeve. If this slot is worn down to exceed the assembly standard, replace the sleeve. lIem

Unit:

111m

(in.)

Assembly standard

Width of control sleeve slol

(0.2764 +g.004)

(3) Pull out the plunger from the barrel about two-thirds of the way, while holding the barrel horizontal; then angle up the barrel slowly by about

60°. This should cause the plunger to slide out all the way by its own weight to evidence a proper fit. If the plunger goes outward· in a freefalling manner or becomes stuck on the way, then the pump element assembly must be replaced.

(4) Pull up the delivery valve piston, cover the bottom of the valve seat with thumb as shown and give finger pressure to the piston on its top lightly. If piston is not worn down, it should be pushed back when finger pressure is relieved.

If it is seated without responding to the finger pressure relieved, it is worn down excessively.

FUEL SYSTEM

670175

11

FUEL SYSTEM

(5) Using a spring balance, check the force necessary to set the control rack in sliding motion. Repair or replace the control rack if it offers a resistance requiring a greater force to overcome than the assembly standard.

, Item

Sliding resistance of control rack

Unit: gf(ozf) (N)

Assembly standard

Not more than 120 (4.2) (1.2) as starting pull

, - - - - - - - - - - - - - - -

(

670176

(6) Measure the overall radial play of tappet roller (10), roller bushing (11) and pin (9) with a dial gauge as shown. If it exceeds the assembly standard, replace the whole tappet sub-assembly (8).

401584

12

5.3 Reassembly

FUEL SYSTEM

Tightening torque:

3.0 ± 0.5 kgf·m

(21.7 ± 3.61bf·ft)

[29.4

±

4.9 N·m]

IReassembling sequence

I

Tightening torque:

6.5 ± 1.0 kgf·m

(47.0

±

7.21bf·ft)

[63.7

±

9.8 N·m]

670194

13

FUEL SYSTEM

(1) When installing plunger (14), position it with the stamped figure on its driving face coming on top (cover plate side). If reversed, its lead and feed hole are not aligned and it cannot control fuel injection quantity.

(2) To install tappet (7), pick up the tappet with tappet clamp (c), feed the tappet in to the camshaft chamber, and insert it into the bore with roller clamp (b).

(3) To install· camshaft (3), match the driving face of plunger and the slot in pump cylinder, push the tappets, and hold them with tappet inserts (a). r--------[

NOTE ] - - - - - .

Each time when the above step is completed on one cylinder, check the control rack if it slides smoothly.

(4) Check the sliding resistance of control rack (25). The rack is required to slide with a push or pull of not greater than 120 gf (4.2 ozf) [1.2 N].

14

(5) Install the governor housing temporarily i and check the axial play of camshaft

(3) by using camshaft clearance gauge (e).

Unit: mm (in.)

1 Assembly standard 1 0.Q3 - 0.05 (0.0012 - 0.0020)1

If the play noted is off the assembly standard indicated above, reduce or increase it by shimming: shim stock for thi~ purpose is available in six thicknesses, 0.10 mm (0.0039 in.),

0.12 mm (0.0047 in.), 0.14 mm

(0.0055 in:), 0.16 mm (0.0063 in.), 0.18 mm

(0.0071 in.) and 0.50 min (0.0197 in.) •

So that the camshaft will not be so displaced by shimming to one side as to offset the cams from the tappets, try to use equal amounts of shim on both sides.

5.4 Testing and adjustment o Control rack sliding resistance test o Injection timing adjustment a. Pre-stroke adjustment b. Checking position injection and adjusting the angular of the beginning of c. Tappet clearance measurement o Injection quantity adjustment

Before installing the reassembled fuel injection pump to the engine, be sure, in addi tion to the above tests, to carry out required tests on the governor, too.

FUEL SYSTEM

15

FUEL SYSTEM

(1) Preparation

(a) Attach the rack position measure.

Remove from the governor these parts: maximum speed stopper, stop adjusting screw, idling spring, torque spring and adaptor spring.

Push in the control rack toward the governor side as far as it will go, and set the rack position measure at the starting position

(zero mm).

(b) Bleed air out of the injection pump, as follows:

First, move the selector lever of

. the pump tester into "injection quantity" position and turn on the motor switch to start up the motor.

Next, .produce the prescribed delivery pressure by means of the pressure adjusting valve. Loosen the air bleeder screw on the pump to let out the trapped air, if any •

.------1

NOTE ] - - - - - - - ,

It is not necessary to "run" the pump in order to bleed air out.

(2) Control rack sliding resistance test

Run the pump at 1000 rpm and measure the resistance with the hand spring balance. The control rack should be capable of sliding without offering any resistance greater than 50 gf (1.8 ozf)

[0.5 N].

16

670183

(

(3) Injection timing adjustment

(a) Pre-stroke adjustment

Loosen the nozzle holder overflow valve; move the selector lever of the tester to "injection timing" position; and start running the high-pressure pump of the tester by engaging the clutch; and, with the tappet clearance measuring device securely installed, turn the camshaft to bring No. 1 plunger to bottom dead center (lowest) position.

From this position of camshaft, rotate it gently in normal direction to raise the tappet (and hence the plunger). In the meantime, fuel will be overflowing. Stop turning the camshaft just when the fuel ceases to overflow, and read the distance traversed by the tappet from its lowest position.

Unit: mm (in.)

Item

Standard

1.9 - 2.0 (0.Q75 - 0.079)

If the pre-stroke is out of standard, bring the tappet to its top dead center position, insert spring holder into between the lower spring seat and tappet, and turn the camshaft in normal direction. Now there will be a clearance between the spring seat and tappet. Vary the thickness of shim plates by utilizing this clearance to adjust the pre-stroke.

(b) Checking and adjusting the angular position of the beginning of injection

The end of pre-stroke corresponds to the beginning of injection: the plunger begins to pressurize the fuel in the barrel when it has just closed the feed hole.

FUEL SYSTEM

17

FUEL SYSTEM

Take the position of No. 1 plunger at its beginning of injection as the reference angular position

(0 deg.), and check the angular position at which each of the rest of the plunger begins to inject. Make sure that the beginning of injection comes within the

1 deg. tolerance of the angular value·. prescribed:

Cylinder No.

Angular

position of

beginning of

injecti?fl

I 3

4 2

0

89°30' 179°30' 269°30'

- 90°30' - 180°30' _ 270°30'

If the angular the prescribed shimming as adjustment. position is out of range, adjust it by in (a) Pre-stroke

(c) Tappet clearance measurement

Turn the camshaft and bring the tappet to its top dead center position. Keeping the tappet in this position, lever up the tappet with a screwdriver and measure the clearance.

Item

Tappet clearance

Unit· mm (in.)

Standard

0.2 (0.008), min.

This clearance is prescribed to be not less than the value specified above, and normally should not require any adjustment. Thus, the purpose of this measurement just for making sure that some clearance greater than the specified minimum is available.

If the reading happens to be less than the minim um, increase it by means of the tappet adjusting bolt, without causing the injection timing

(beginning of injection) to deviate from the I-deg. tolerance.

Increasing the tappet clearance will increase the pre-stroke: be sure not to exceed the upper limit

[2.0 mm

(0.0787 in.)].

18

(

(4) Measurement of injection quantity

The injection quantity varies according to the position of the control rack and the pump rpm. The injection quantity should be measured under the condi tions where the pump is set to a certain rpm.

(a) Attach the injection pump on the tester and connect the injection pipes to the tester. Remove the control rack cover. Attach the rack position measuring device in place.

(b) Bleed air from the fuel system by operating the tester handle.

(c) Keep the fuel supply pressure at

2.0 kgf!cm

2 (28.4 psi)

[0.2

MPa] on tester gauge, run the injection pump at the specified speed by the tester, keep the control rack at the standard position, and measure the injection quantity by a measuring cylinder for each pump element.

Adjust it to bring its injection quantity into the specified range.

For specified injection quantity, refer to the Maintenance standards.

If injection quantity of any cylinder is out of the specified range, adjust it by loosening the pInion clamp screw and slightly turning the control sleeve.

Turning the control sleeve toward the governor" side will increase the injection quantity, and vice versa.

After tighten pinion. adjustment, the clamp be sure screw on to the

FUEL SYSTEM

19

FUEL SYSTEM

6. RSV GOVERNOR

6.1 Disassembly

20

402914

CD

Bolt

@

Shackle

®

Start spring

®

Round nut

®

Flyweight

®

Screw plug

(j)

Governor housing

®

Adjusting screw set

®

Adjusting screw set

@) Adjusting nut set

@ Full-load stopper

@ Screw plug

@

Lever supporting shaft

®

Adjusting lever

@ Snap ring

@ Lever bushing

©

Control spring

@

Swiveling lever

®

Guide lever

®

Sleeve

®

Ball bearing

@ Plate washer

@

Tension lever

®

Adjusting set assembly

@ Stop lever

®

Spring cover

©

Return spring

@ Bearing bushing

@ Governor shaft assembly

@ Control lever

®

Cover plate

@ Governor cover

Governor - Disassem bled view


(1)

Detach the cover by pulling it a little backward. Insert the screwdriver, move the shackle clasp downward with the tip of screwdriver and undo the pinned connection between control rack and shackle (2).

(2) Unhook the start spring (3). Remove the governor cover complete with the lever mechanism.

(3) Remove round flyweight (5) by round nut wrench nut (4) loosening

(A). securing it with

(4) Run the flyweight extractor (B) into the threaded hole, as shown, and force the flyweights (5) off the camshaft by jacking action.

FUEL SYSTEM

402915

402916

21

FUEL SYSTEM

6.2 Reassembly

Governor - Sectional view

(For the parts not numbered, refer to the disassembled view.)

I


I

402917

22

(

(J \

After positioning the flyweights (5) on camshaft, secure it by tightening the round nut to the specified torque wi thround nut wrench (A).

Tightening torque

5- 6 kgf.m

(36 - 43 Ibf·ft)

[49-59N·ml

(2) Install the control spring with its opening facing the shackle.

Install with its opening facing the shackle.

FUEL SYSTEM

402918

6.3 Testing and adjustment

After assembling the governor properly, the adjustments described below should be effected on the test bench.

(1) Fuel injection pump injection quantity adjustment

Before adjusting the governor, be sure to carry out the required injection timing and injection quantity adjustments on the fuel injection pump.

For the adjustments, refer to 5.4

Testing and adjustment, Fuel Injection

Pump.

670164

23

FUEL SYSTEM

(2) Governor adjustments

After checking the governor for the various linkage and sliding part conditions, make the following adjustments in that order.

1 Medium-speed control adjustment

2 Angleich control adjustment

3 Low-speed control adjustment

4 High-speed control adjustment

5 Torque spring setting

6 Matching to engine

(a) Install the angular scale pIa te

(protractor) on the governor housing to read the angular position of the adjusting lever.

(b) Carry out each reference to the curves. adjustment in characteristic

(

I

!

,

!

"

12-7

~

0

"'

'"

~

§

~

0 u

12

"

•

'"

••

U

..

,1.2

•

SJ

•

,

Medium-speed control range

~

.spring setting

"-

Angleich o\Jter spring

~ting

FUll-load stopper

. . ...L,setting .

",y

Torque spring setting

~

200

\Low-spee control range

\

~ ~

[\

~

~

control ran

ge

~ ~

~

~

E

~

~

UO 600 aoo

1000

Pump speed (rpm)

1200

1400

402920

I

Governor characteristic curves

(

Medium-speed control adjustment

Setting the full-load stopper

Run the injection pump at the speed corresponding to "Nc," turn the adjusting lever to give the control spring a fairly tight tension, and secure the adjusting lever there temporarily. Turn the full-load stopper with the screwdriver until the rack comes to the position corresponding to "Rc," and secure the stopper there with lock nut. Turning the full-load stopper clockwise as seen from the rear of the governor increases the rack position, and turning it counterclockwise decreases the rack posi tion.

Nc (rpm)

850

Rc(mm)

9.0

24

670166

FUEL SYSTEM

Angleich control adjustment

For the governor with the adaptor spring, adjust it as follows:

(1) Move the adjusting lever to make it bear against the maximum-speed stopper, and secure it there, and install the adaptor complete to the lower portion of the tension lever.

(2) Raise the pump speed from "Na" to

"Nd." This should move the control rack from "Ra" to "Rd"; if not, tighten or loosen adaptor screw (4).

The rack movement from "Ra" to

"Rd" corresponds to the amount of compression of adaptor spring (5), which is referred to as "adaptor stroke." Tightening (or driving inward) adaptor screw (4) elongates this spring to increase the stroke, and vice versa.

(3) Run the pump at "Na." This should move the control rack to "Ra"; if not, change the thickness of shim plate (3) indicated in this illustration

(preload adjustment of adaptor spring).

CD

Tension lever

~Lock nut

®Shim plate

Inner

spring

Outer spring

Na (rpm)

Ra (mm) Nd (rpm) Rd(mm)

250 12.7 400

11.2

500 10.4

700 9.8

Low-speed control adjustment

(1)

Run the pump at "Ni," with the adjusting lever bearing against the maximum-speed stopper; turn back the adjusting lever until the control rack comes to "Ri"; and secure the adjusting lever there.

CD

®

4

670190

®

Adaptor screw

@Adaptor spring

670168

25

FUEL SYSTEM

(2) Lower the speed, and make sure that the control rack is at above "Rg" when pump speed is at "Ng."

(3)

After completing the foregoing adjustments, stop running the pump and turn the adjusting lever all the way in the stopping direction and turn tlie stop adjusting screw until the control rack comes to

1 mm

(0.0394 in.) "position. Set the stop adjusting screw to limit the stopping end of adjusting lever stroke, and secure the screw by tightening its lock nut.

Ni (rpm)

300

Ri(mm)

83

Ng(rpm) Rg(mm)

200 11

High-speed control adjustment

(1)

Setting the maximum-speed stopper

Turn back the adjusting lever to determine the maximum speed to be controled by the governor. The maximum speed stopper sets this position of the adjusting lever. Slowly raise the speed from "Nc." Upon locating that position of adjusting lever at which the control rack begins to move in from "Re" at "Ne" speed, bring the maximum-speed stopper into contact with the lever, thereby setting the maximum-speed position of adjusting lever. Secure the stopper there with lock nut.

(2)

Speed regulation adjustment

What "speed regulation" signifies was explained previously: it refers to the difference between two governed speeds: no-load speed and full-load speed for a given position of the adjusting lever.

It is expressed" as a percentage of full-load speed:

Speed regulation

=

Nh - Ng x 100

(%)

Ng

Nh

=

No-load maximum speed at a certain position of the adjusting lever

26

Ng = FulFload ma·ximum speed at the same position of the adjusting lever

As an example, where full-load maximum speed is 1300 rpm and noload maximum speed is 1360 rpm,

Speed t'egulation

=

1360 - 1300 x 100

=

4.6

(%)

1300

Generally speaking, the smaller the speed regulation, the better is the engine control; but some regulation is necessary for the sake of running stability and the smallest regulation for the type of all-speed governor as the present one is limited by the governor mechanism. Moreover, each engine runs best when the governor is set to provide the regulation specified for the engine.

For the maximum speed position of adjusting lever, speed regulation is represented by that portion of the characteristic curve from point "Re" to point "Rf" for the differential speed from "Ne" to "Nf."

In the present governor, the regulation can be changed· by means of the adjusting screw provided in the swiveling lever. Tightening this screw increases the tension of control spring to reduces the value of regulation, and vice versa.

"X" in the standard adjustment data in the Maintenance standards means the number of rotations of the adjusting screw to be turned back from the fully driven position.

"X=l" is the position of the adjusting screw turned back one (1) rotation.

Four notches of this screw correspond to one (1) rotation.

Nc (rpm) Re(mm) Ne (rpm) Nf (rpm) Rf(mm)

850

7.1

1200 1225

6.5

FUEL SYSTEM

27

FUEL SYSTEM

.-----.&,.!

CAUTION ] - - - - - ,

Never back away the screw by more than 24 notches (6 rotations), or the threaded engagement of the screw will be so small as to invite a hazardous condition.

(3) Re-adjustment of maximum-speed stopper setting

Changing the speed regulation by tightening or loosening the adjusting screw is, in substance, changing the tension of the control spring. For this reason, after each repositioning of the adjusting screw, the positin of maximumspeed stopper for determining "Ne" must be changed to raise or lower "Ne" to a proper level by repeating the process described in (1) above .

.------!

NOTE ] - - - - - - ,

In the table of standard adjustment data, the angular position of the adjusting lever assumes that 40

0 is vertical. Turning the adjusting lever from this position to the maximumspeed stopper side increases degree and vice versa.

Matching the pump to the engine

After adjusting the governor according to the procedures set forth above, check the injection quantity by running the injection pump at the same angular position of the adjusting lever as that for the high-speed con trol according to the standard adjustment data. Use a 100-cm 3 (6.1-cu in.) measuring cylinder to receive and collect the fuel delivered by the four pumping elements.

28

(

670167

(

FUEL SYSTEM

7. MAINTENANCE STANDARDS

7.1 Maintenance standards

Group

E

3

~

>.

~

0;

"-

'"

~

N

N

0

'"

0

.,


Valve opening

pressure

kgf/cm' (psi) [MPa]

Sprayangle

Oil-tightness of

needle valve seat

Outside diameter of

tappets

Inside diameter of

tappet holes

Outside diameter of tappet roller

7

(0.276)

15 o

0

(0.591)

-0.027 <-0.00106)

1.8 - 2.2

(25.6 - 31.3)

(0.18 - O.22J

Po

E

'"

'"

0;

"-

'"

Deliverr pressure kgf/cm (psi) [MPa]

Delivery capacity

900 cm' (55 cu in.)/

min,min

Airtightness

Nominal

value

120

(1706)

[1l.8]

0°

Assembly standard

[standard clearance]

Repair limit

Service

limit


0-+10

(0 -+142)

[0 - +1.0]

Remarks

Make shim adjust-

ment. Pressure varies

by 10 kgf/cm'

(142 psi) [1.0 MPa] per

0.1 mm (0.004 in.) thickness of shim.

Test by means of hand tester, usiIi§ diesel fuel, at 20 C

(68°F). If spray pat-

tern is poor even after nozz1e is wash-

ed in clean diesel fuel, replace nozzle tip.

Seat shall hold a test pressure

20 kff/cm' (284 psi) [2.0

MPa lower than valve open-

ing pressure for

10 seconds.

Wash or replace

nozzle tip.

600

(37 em' ell in.)/

min, min

No parts shall show any evidence of

air leaks.

0.1

(0.004)

-0.075

(-0.00295)

Injection pump speed: 600 rpm

Check displacement with injection pump operated at 1000 .rpm with a dis-

charge pressure of

1.5 kgf/cm' (21 psi) [0.15 MPa].

Close pump discharge port with a plug. Apply an air pressure of 2 kgf/ cm' (28 psi) [0.2

MPa] to the pump, and keep the pump

immersed in diesel

fuel longer than

1 minute.

29

FUEL SYSTEM

Group


Delivery valve seating tightness

Backlash between

pinion and rack

Rack sliding

resistance

Fit of tappets in pump housing

Outside diameter of tappet rollers

Plunger

8 t>..

"-

Free

8 length

"

2 c:

~

>.

~

.8

-.;

~

"

"-

-.;

"

" tappet holes in pump housing spring

Delivery valve spring

Cam height

(major diam)

Inside diameter of

Nominal value

Plunger oU·

tightness kgf/cm' (psi) [MPa]

150 - 200

(2133 - 2844)

114.7 - 19.6].

min

120 gf(4.2 ozf) [1.2 NJ, max with pump at stand-still; 50 gf

(1.8 ozf) [0.5 N], max with pump running at 1000 rpm

[ 0.03 - 0.07 ]

(0.0012 - 0.0028)

17 o

0

(0.669)

-0.027 <-0.00106)

49

(1.929)

32

(1.260)

32

(1.260)

+1 (0.039) o

0

±0.5 (±0.020)

+g.1

tg.0039)

24

(0.945)

Assembly standard


Repair limit

Service

limit


150

(2133)

114.7]. max

Remarks

Pump speed:

200 rpm

.

See

10 kgf/cm' (142 psi) [1.0 MPa]

Remarks. pressure drop should not exceed 5 seconds .

[0.15 (0.0059)]

[ 0.25 ]

(0.0098)

[ 0.2 ]

(0.0079)

-0.075

(-0.00295)

-0.5

(-0.020)

-I

(-0.039)

-0.2

(-0.0078)

0.15

(0.0059)

\

,

Pre-stroke

1.95

(0.0768)

±0.05 (±0.0020)

Beginning of injection

Tappet clearance

90° ± 30'

[0.2 (0.008)] , min

I

Injection quantity adjustment:

Pump speed

rpm

1000

1000

200

Rack position mm (in.)

8.5 (0.335)

8.0 (0.315)

5.7 (0.224)

Plunger strokes

1000

1000

1000

Injection quantity cm

3

(Cll in.)

¥ariancc em (ell in.)

37 ± 1.5 (2.26 ± 0.09) 2 (0.12), max

33 ±

1.5

(2.01 ±0.09)

2 (0.12), max

13 ±3 (0.79 ±0.18)

2 (0.12), max

Test conditions

Nozzle tip:

Injection pressure:

093400-0090 (ND-DN40SDND32)

120 kgf/cm' (1706 psi) (l1.8

MPa]

Test oil:

Delivery pressure:

ASTM Diesel fuel No. 2D

2.0 kgf/cm' (28.4 psi) 10.2

MPa]

Injection pipe:

2 x 6 x 600 mm (1/16 x 1/4 x 23-5/8 in.)

Test oil temperature:

40 - 45°C (104 _ 113°F)

30

FUEL SYSTEM

Group

E

2

~

>,

~

"


Governor:

Item

i

I

Nominal value

Assembly standard

[standard clearance

1

Repair

Service

limit

[clearance limit

1

[clearance

1

Remarks

Speed control range: 325 - 1200 rpm

Adjusting lever angle

Pump speed

rpm

Speed regulation", 5.0

Control rack position mm (in.)

Total injection quantity

em' (eu in.)/I 000

strokes, 1 cyt

High-speed control

.

~

0

~

0

"

~

Medium-speed control

"

Low-speed control

53°

±

SO

53° ± SO

25° ± 5°

1400

1300

1225

1200

850

300

200

400

1.5 (0.059). max

3 ± 1.0 (0.118 ±0.O39)

6.5 ±O.I (0.256 ±0.004)

tl

±O.I (0.280 ±0.004))

8.9 ±0.2 (0.351 ±0.008)

(Set by torque spring)

9.0 ±O.I (0.354 ±0.004)

(Set by full-load stopper)

8.3 ± 0.1 (0.354 ± 0.004)

11.0 (0.433). min

5.3 ±O.I (0.209 ±0.004)

(Set by idle sub-spring)

Matching to engine

53°

±so

400

500

900

1200

52 ±2 (3.17 ±0.12)}

47 ± I (2.87 ± 0.06)

(by means of Angleich spring)

39 ±2 (2.38 ±0.12)}

29 ± 1(1.77 ±0.06)

(by means of torque spring)

7.2 Tightening torque

Important bolts and nuts

Securred part of component

Nozzle retaining nut

Injection pump delivery valve holder

Injection pump delivery valve clamp bolt kgf·m

Tightening torque

Ibf·ft N·m

5

±

0.5

2.5 - 3.5

O.S J.I

36 ± 4 49

±5

IS - 25 25 -34

5.8 - 8.0 7.8 - 10.8

Remarks

31

(

ELECTRICAL SYSTEM

I. STARTER .............................................................. 34

1.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34

1.2 Inspection and repair .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35

1.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39

2. ALTERNATOR .......................................................... 42

2.1 Disassembly .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42

2.2 Inspection and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42

2.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44

3. GLOW PLUGS .......................................................... 44

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44

4. MAINTENANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45

4.1 Maintenance standards ........................................... . . . . .. 45

4.2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45

I

ELECTRICAL SYSTEM

1. STARTER

1.1 Disassembly

Roughness, burning, grooved wear, worn or damaged gear

CD

Switch

®

Rear bracket

®

Brush holder

@Yoke

®

Armature

®

Ball bearing

Pole and field coil installation

(J)

Ball bearing

®

Cover set

®

Center bracket

@Gear

(jJ)

Spring set

©

Lever

Brush dust buildup, uneven wear, brush movement in holder

@

Pinion set

®

Pinion shaft

@

Oil seal

@

Ball bearing

QD

Front bracket

670248

(

34


(1) Armature

(a) Testing armature for short circuits

Place the armature on a growler, and slowly revolve it with a hacksaw blade held above the armature core.

The hacksaw blade vibrates against the core when it is above a slot containing a shorted winding. Replace the armature if shorted.

(b) Testing armature for grounded circuits

If there is continuity between the commutator and shaft (or core), the armature is grounded and should be replaced.

(c) Inspecting commutator

1) Support the armature in V-blocks, and measure the runout of commutator with a dial gauge. If the runout exceeds the Repair limit, repair the commutator by turning it in a lathe within

Service limit for the outside diameter. If the commutator surface is rough, smoothen it with a sandpaper pf #300 to #500.

Item

Commutator runout

Unit: mm (in.)

Assembly

standard

Repair Service

limit limit

0.03

0.05 0.05

(0.0012)

(0.0020) (0.0020)

2) Measure the outside diameter of commutator. If it is smaller than the Service limit, replace the armature.

Item

Outside diameter of commutator

Assembly

standard

32 (1.26)

Unit: mm fin.)

Service

limit

31 (1.22)

ELECTRICAL SYSTEM

401826

I

401827

35

ELECTRICAL SYSTEM

3) Measure the depth of each mica between segments with a depth gauge. If the depth exceeds the

Repair limit, recondition the mica.

Item

Commutator mica depth

Unit: nun (in.)

Reapir limit

0.2 (0.008), maximum

(

,------------------------------,

~ent

Mica depth Good

~

401828

I

(2) Field coil

(a) Testing for open circuits

If there is no continuity between the lead wire and positive

(+) brush, the field coil is open and the yoke assembly should be replaced.

401829 (

(b) Testing for grounded circuits

If there is continuity between the yoke and positive

(+) brush, check the insulation, and repair or replace the yoke assembly.

(3) Brushes and holders

(a) Wear of brushes

Measure the brush length and, if it is less than the Service lim it, replace the brushes. If the brushes are unevenly worn or rough, recondition them with a sandpaper of

#

300 to

#500.

Item

Brush length

Assembly standard

18(0.71)

Unit· mm (in)

Service

limit

II (0.43)

36

Brush

401830

401831

(b) Brush spring tension

Test the spring tension (test force) using a new brush. In this test, read the load at the moment that the spring moves off the brush. If the tension is below the Service limit, replace the spring.

Item

Assembly standard kgf (lbl) [N]

Service

limit

Brush spring

tension

3.5 (7.7) [34.3] 2.3 (5.1) [22.6]

(c) Testing brush holders for insulation

If there is continuity between the positive

(+) brush holder and negative

(-) holder plate, replace the brush holder assembly.

(4) Overrunning clutch

Make sure that the pinion shaft turns smoothly when turned in the direction of driving (clockwise) and that it locks when turned in the opposite direction.

If not, replace the overrunning clutch.

ELECTRICAL SYSTEM

401832

401833

401834

37

ELECTRICAL SYSTEM

(5) Pinion thrust gap

The pinion shaft thrust gap is the play exhibited by the pinion shaft when it is moved in the thrust direction. Measure the thrust gap in the following manner.

If it is out of specification, select the adjusting washer and adjust the gap.

(a) W hen the pinion is removed:

Install the gear on the pinion shaft, insert the shaft into the center bracket, and lock the shaft with the washer and ring. Under this condition, move the shaft in the axial direction, and measure the thrust gap.

(b) When the pinion is installed:

Install the pinion shaft and gear between the front and center brackets, and temporarily tighten the bolt. Under this condition, move the shaft in the axial direction, and measure the thrust gap.

Item

Pinion thrust gap

Unit· mm

(in )

Assembly standard

0.5 (0.020), maximum

[Below 0 not permissible

1

Center bracket

Thrust gap

-

Stop ring

Washer

Pinion shaft

Adjusting washer

401835

38

(

ELECTRICAL SYSTEM

1.3 Reassembly

,-------------------~----------------------------------------~-.

Apply grease to sliding surface of lever.

I


I

Replace packing.

Apply grease.

.670044

39

ELECTRICAL SYSTEM

Inspection and testing after reassembly

(1)

Pinion gap adjustment

(a)

If

the assembled starter is wired as shown, the pinion will shift and turn slowly. Remove the connector from the M terminal to stop the pinion.

(b) Under this condition, lightly push in the pinion toward the armature, and measure the movement (gap) of the pinion.

(c) To adjust the gap, increase or decrease the pac kings fitted to the magnetic switch. Increasing the packings decreases the pinion gap.

Item

Pinion gap

Unit: mm (in.)

Assembly standard

O.S - 2.0

(0.020 - 0.079)

.------Lt,[

CAUTION] - - - - - - - - - ,

Do not test the starter continuously for more than 20 seconds to prevent the switch coil from overheating.

(2) No-load test

After adjusting the pinion gap, hook up the starter as shown, and test it for no-load characteristics.

Use wires as thick as possible and tighten each terminal securely.

Voltage

(V)

23

Current

(A)

80, maximum

Speed

(rpm)

3400

Battery

~<"'le!f!!'l--'

S terminal

401836

Pinion gap

400191

Ammeter

~ i

Battery

1

_1-

v

Voltmeter

Switch

I

670211

I

40

(

ELECTRICAL SYSTEM

(3) Magnetic switch

(a) Testing coil for open circuits

If there is no continuity between S and M terminals and between S terminal and body (ground), replace the switch.

(b) lnspecting contactors for fusion

If there is continuity between Band

M terminals, replace the switch.

(c) lnspecting contactors for poor contact action

Inspect for contactors.

excessive,

defective. voltage drop between

If voltage drop is the contactors are

B leonina!

L

401837

- - - - - - - - - '

41

ELECTRICAL SYSTEM

2. ALTERNATOR

2.1 Disassembly

Bearing rotation

®

.®

Bearing rotation

Dirty or burned slip rings, worn oil seal contact surface of shaft.

42

Brush movement

670213

CD

Screw

®Nut

®

Pulley (wi th fan)

®

Spacer

®

Rotor


(1)

Brushes

®

Bearing

(j)

Screw

®

Bearing

®

Front bracket

@

Stator

Replace the brushes if they are worn down to the wear limit line.

Item

Brush length

Assembly standard

18 (0.71)

Unit: mm (in.)

Service

limit

8(031)

(jJ)

Brush holder set

@ Rectifier assembly

@

Plate

®

Rear bracket r r -

Service IimJiJ 8 mm (0.31 in.)

18 rom

(0.71 in.)

L"-

670216

ELECTRICAL SYSTEM

(2) Field coil

Measure the resistance between the slip rings. If the resistance is out of specification, replace the rotor.

(3) Stator coil

Inspect for continuity between the lead wires. If no continuity is noted, the coil is open-circuited. Also check for continuity between the l<~ad wire and coil. If any continuity is noted, the coil is grounded.

(4)

Rectifier

Inspect the resistance between the lead wire and heat sink on each diode by connecting the positive

(+) side lead wire and negative' (-) side lead wire of the tester to,' the diode. If the resistance is infinite in both cases, the diode is open-circuited. If it is nearly zero in both cases, the diode is shortcircuited. If the diode is openor short-circuited, replace the rectifier.

Heat sink

(+) o

. L terminal

Trio diode lead o

400174

43

ELECTRICAL SYSTEM

2.3 Reassembly

I


I

I I j:'®

@-+@

®

@

I I I I

@(l)@ @l

L r

III®

CD®®@

Push the brush into the holder, and hold it there by inserting a 2 mm (0.08 in.) diameter wire into the hole in the brush.

Then, install the rotor. Remove the wire after installing the rotor.

3. GLOW PLUGS

Inspection

If the glow plug glows red when the positive

(+) wire is connected to the portion (A) with the portion (B) grounded, the plug is in satisfactory condition.

670054

Wire

\

ff

Brush

rrnt:

lli~~

,...l-...

Rotor

~

670220

I

Testing glow plug

44

(

ELECTRICAL SYSTEM

4. MAINTENANCE STANDARDS

4.1 Maintenance standards


Diameter of

commutator

Nominal

Assembly standard

value


32

(1.26)

Repair

Service

limit limit


31

(1.22)

18

Length

~

'"

-

(0.71) t

-

-"

~

,;;

Spring

pressure

kgf(lbf) [N]

3.5

(7.7)

[34.3]

Thrust gap of pinion shaft

0.5

(0.Q20)

O,minimum

11

(0.43)

2.3

(5.1)

[22.6]

-

~

,.,

~

Pinion gap

0.5 - 2.0

(0.Q20

- 0.079)

~

No-load characteristics

., iil

Locked characteristics

Voltage Current Speed Voltage Current

Magnetic switch operating voltage

Torque

Switch-in

kgf.m (lbf·f!) voltage Switching off

V

A rpm

V A

[N·m] V

23

80,

max.

3400

8

730, 4.5 (32.5)

max.

[44.1], min.

Shall turn off upon

16, max. lurning off of slarter

switch.

Remarks

Brush spring

~

0

-

tension

gf(lbf) [N]

"

~

Outside diameter

of slip ring

Brush length

33

(1.30)

18

(0.71)

210

(0.5)

[2.1]

32.4

(1.276)

8

(0.31 )

4.2 Tightening torque

Important nut

Securred part of component

Starter B terminal

Thread dia. - pitch

8 - 1.25

Widlh

across

flats

12

Tighlening torque kgf·m

1.0 - 1.2 lbf·f! N·m

7-9

10 -12

Remarks

45

BD2G, BS3G WilliNG DIAGRAM

EngineOilP"~'-'" ~l~~ _~~, ~

Stater switch connection

Fuse

Combination meter {OK monitor}

(

Engine oil pressure warning lamp Air

.

,__ - ,

. . ,Alternator not charging Battery electrolyte level

Workmg lamp md,cator :waming lamp warning lamp

ct

mer element warning lamp OK monitor test switch I

"

,

Service meter

Lighting switch

~b p~11

(

~ 8 c

Glow plug

II III

;odioo'"

3~31"~313~3i

.., .., ..,,,,, .,.,..,

G, 8 GJA S

3

OFF

2

HEAT

ON

STAAT tim"'r~or iuel cut soleno,d .

------l

EJ

~

8

•

;Y w ro ' "

"., '"

2R 2R

0.75 G ON

!

2l

L __

~

9

BTT

SOL

J

, l

I

,J

' . -

I

[81

HHhlel

1 I I I I

1.25BR

' S B R ) :

~

0.858

-Water temp

) gauge .

Reoul ator

Fuel gauge

! lrTil

T

I

"""""""

F

1

1.25G

!FGiJ

1 3412TI36

1

~--~ l .

--~

~

'

G,OWP'"' f

1 f

I

--l.

4w

~

~"Old

gine '

Head lamps

'i;:'

I

-c&

'L ;;;

, 0

I

Engine thermo 5witch

C g>_ i

: L

1

: S

I

..J

• w

,

,

,I,,,,,,,,,"",," , , -

_"~.

,

-[1217111141171'

---'

"

I

I hol"l

O.85WR

-~,

, ___ '0" ;,, "'" I",

T:-r.:Tl

.

L

011315 - -

0 . 8 5 G 8 ' o>5RL

[ .

,,","

C~ ci .

O . 8 5 W ·

! ; ; '

,

_

, '

~-

'

Q

J'

r

;! i ;"""""

I

8

~ l i

58 -w

Cl

'

- , ci

~ ~ l

~ ~~

·1

!

, J

Y

'-

"'

8 y e l

408 sensor

" . , 1

, , " e o

A(rc\eanerindicator

__

L

.

--

. 0 0 ' ' ' . " ' " " ' ' ' '

O.5Y::il-J-. .

~asRl

Hom

'0

'

15-

Working lamp

_ _

"

~Q.

,

II

. c-;

.

.

. ' :

~ ,~.

___:J

'Neutral SWitch

~ l

408";:

8

8 l

S"rt" atte~y

Pub. No,

1 i

12V60Ah

I'

:

I

Battery switch

1

---

~

99879-00120-

9j

DEC. '86


Pub. No.

99879-00120-

2

/

SERVICE MANUAL

MITSUBISHI

. TRACTOR··

··BD2Gi········ .. ····················

TRACTOR

SHOVEL

HSaG

CONTENTS

POWER TRAIN/HYDRAULIC SYSTEM


j j

I

I

I

I

I

I

I

I

I

I

I

TABLE OF CONTENTS

Flywheel clutch

Direct drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I

3

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering clutches and final drives

Steering valve

5

6

8

Frame .................. , ................................. . 9

Front idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10

Hydraulic adjuster cylinders and recoil springs ...................... 11

Track carrier rollers . . . . . . . . . •. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 .

. Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13

Tracks 14

Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16

Control valve . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

BD2G with power angling/tilt blade ............................. 17

BD2G with power tilt blade ................................... 19

BS3G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . " ........ '" 25

Lift cylinders (BD2G with power angling/tilt blade and power tilt blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25

Angling cylinders (BD2G with power angling/tilt blade) .. .'........... 26

Tilt cylinder (BD2G with power angling/tilt blade) . . . . . . . . . . . . . . . .. 27

Tilt cylinder (BD2G with power tilt blade) . . . . . . . . . . . . . . . . . . . . . .. 28

Lift cylinders (BS3G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29

Dump cylinders (BS3G) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30

Power angling/tilt blade (BD2G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31

Power tilt blade (BD2G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32

Bucket and linkage (BS3G) ..................................... 33

Tightening torques

34

(

\

FLYWHEEL CLUTCH

Unit· mm (in )

Group Ref.

No.

Item

Assembly standard

Service limit

Remarks

8

12

13

I Clutch discs

Facing tbickness~

....

,'::

..

Tightening torque kgf·m (Ibf·ft) [N·m}

5.7 - 6.3

(0.224::=- 0.248)

Run;;tit

.

:."::.

0.7(O.028~,.max.

0.7 (0.028), min .

2 Hub splines

3

4

5

6

.

Minor diameier

•

Fit

~of ~u~,.splines

.

< .

26·.6i-26.70 .

(1.0500::- 1.0512) . o • • • •

0.05."- Q. I 5 .

(0.0020- 0:U059) :

0.30

(0.0118)

• 0

Friction surface

thickn'ess ... ':: .

·20.2(0.795)

0

19.7 (0:776), max.

FrlCtion';urface _. flatness

Strut bolt holes

0.05 - 0.15

(0.0020 - 0.0059)

10,20 ..c 10.25

. (0.4016 - 0.4(35)

0.30

(0.01l8)

10.50

(0.4134)

Pressure plate

Mating plate

Pressure springs

Release levers

Release lever pin

·:bushingS·. o

See Remarks.

Bushing are said to have reached tbe

service limit if

"teflon" overlay coating is worn away.

Friction surface -. tbickness

Friction

-surface

flatness

Free lengtb .

Test force/length under test force· kgf{lbf)[N}/mm (in.)

Squareness

Stroke

13.0 (0.5 I 2)

0.05 - 0.10

(0.0020 - 0.0039)

70.6 (2.780)

43.5±2.2{95.9±4.9)

[426.6 ± 21.6} /48.2

(1.898)

12.5 (0.492), max.

0.20

(0.0079)

68.5 (2.697)

39.2 (86.4)

[384.4)/

48.2 (1.898)

3°, min.

~------I-.9------~~O

A-B

= 0.5 10.020),

18 (3/4)

min.

7 Strut bolts

4-6

(28.9 - 43.4)

(39.2 - 58.8)

One side: -0.4

(-0.016)

Botb sides:-O.&

. (-0.031)

9

10

II

Clutch cover mounting bolts

Lock plate mounting bolts

Seal ring

Tightening torque

0 • • kgf·m (Ibf·ft) [N·m}

Tigh tening torque . kgf·m (Ibf·ft) [N.m]

Cover

Brake band

Pump drive gear

Surface

Surface making

contact with seal ring

Lining thickness

BackJash with mating

gear

·1.7 (12.3) [16.7}

1.7 {I 2.3) [16.7}

5.0 (0.197)

0.35 - 0.42

(0.0138 - 0.0165)

Cuts or breakage

Grooves or scratches

3.0 (0.118), max.

0.70 (0.0276),

min.

1

FLYWHEEL CLUTCH

8

2

4

2

000

00

-'.

7

602279

602165

(

DIRECT DRIVE TRANSMISSION

Unit: mm (in)

Group Ref.

No.

Item Assembly standard

Service limit Remarks

3

-

4

5

-

6

7

8

9

10

Bacl>liish ,\lith

1

gear

0.12 - 0.28

(0,004? - 0.0110)

0.60

(0.0236)

. 0..J2~ 0.28

- (0.0047 - 0.0110)

0.60

(0-0236)

_ . 0.12 -0.28

0.60

2nd-reverse gear

Backlash with

'. (0.0047 - 0.0110)

0.12 - 0.28

(0.0236)

2nd-sliding gear I'-"-"'-'-:-='-"'-'-'----+-'-=-=-'-'---'-:-'-:--'-+--==~-_I~----_l

0.60

__ . 2nd-drive gear. . (0.0047 - 0.0110)

(0.0236)

' .

"-,Backl:ishWithlnput'

Counter gear

.. "

Backlash with

3rd~sliding

. gear

0.12-0.28

(0.0047 - 0.011 0)

0.12 - 0.30

(0.0047 - 0.0118)

0.60-

(0.0236)

0.60

(0.0236)

..

-

-

0.500

(0.01969)

Shift rails

(shifter shafts)

.

.

'

.

Fit in forks

.Bend

0.020 - 0.062

(0.00079 - 0.00244)

Shift forks

Sliding gears

Clearance of shift fork

in groove

Width of shifter fork

gr-ooves

0.1 - 0.3

(0.004 - 0.012)

Free length 62 (2.44)

Detent springs

(poppet springs)

Test force/length under

test force

kgf (lbf)[N]/min.

9.80±0.49(21.6±1.08)

[96.11 ± 4.81 J155

(2.17)

7.1 - 7.2

(0.280 - 0.283)

0.5

(0.020)

60.5 (2.382)

7.5 (16.5)

[73.5]1

55 (2.17)

7.7

(0.303)

Should slide smoothly .

Countershaft

end securing

II bolts/bevel pinion shaft securing bolts

Tightening torque kgf·m (lbf.ft) [N·m]

2.7 0.3

(i 9.5 2.2)

[26.5 2.9]

3

DIRECT DRIVE TRANSMISSION

9

60Z242 o

602167

602243

4

Group

Ref.

No.

~

~

""

I Drum

2 Linings

Item

Outside diameter

Clearance in linings

Thickness

BRAKE

Assembly standard

252 (9.92)

0.8 (0.031)

6.5 (0.256)

Service limit

250 (9.84)

Unit: mm (in.)

. .

Remarks

4.5 (0.177)

2

602244

5

6

STEERING CLUTCHES AND FINAL DRIVES

Group

Ref.

No ..

-

[(j

'5

-5

-

V)

[(j

.i:i

."

O!

J:


1

2

Bevel gear

Backlash with pinion'

Tapered roller Preload (bevel gear)

beariilgs

kgf·m (Ibf·ft) [N·m)

Free length

0.15 - 0.20

(0.0059 - 0.0079)

0.7-0.9 (5.1-6.5)

[6.9 - 8.8)

77.5 (3.051)

3

Clutch springs

Test force/length under 66.5 ± 5 (l46.6± 11.0) test force

[652.1 ± 49.0)/ kgf (lbl) [N)/mm (in.) 63 (2,48)

8.7 (0.343)

4

Friction plates

Thickness

Fit in outer drum

splines

Thickness

0.16 - 0.52

(0.0063 - 0,0205)

2.8 (0.110)

5 Disc plates

Fit in inner drum

splines

Total thickness of friction plates (6 pes) and disc plates (6 pes)

0.14 ~ 0.30

(0.0055 O.oJ 18)

69

(2.72)

6

Shlfter . Fit in flange

0.200 - 0.324

(0.00787 - 0.01276)

7

Inner drum

Tightening torque

securing bolts

kgf·m (lbf·ft) [N'm)

3.5 ± 0.3

(25.3

±

2.2)

[34.3

±

2.9)

3.5 ± 0.3

(25.3

±

2.2)

[34.3 ± 2.9)

Outer drum and

8

pinion securing

bolts

Tightening torque kgf·m (Ibf·ft) [N·m)

9

10

11

Drive shaft/ clutch shaft Tightening torque securing bolts kgf·m (Ibf.ft) [N·m)

(16·mm diam)

Pinons

Sprockets

Backlash with driven gear

Tooth width

12

Tapered roller

Preload bearings kgf·m (Ibf.ft) [N·m)

Final drive

13

case mounting

bolts

Tightening torque kgf·m (Ibf.ft) [N·m)

16 - 19

(115.7 - 137.4)

[I57 - 186)

0.17 - 0.37

(0.0067 - 0.0146)

40 (1.57)

0.29 - 0.37

(2.10 - 2.681

[2.84 - 3.63

7.6 - 9.2

(55.0 - 66.5)

[74.5 - 90.2)

Service limit

0.50

(0.0197)

6.0 (0.236)

0.80

(0.0315)

2.3 (0,091)

0.60

(0.0236)

66

(2.60)

1.00

(0.0394)

36 (1.42)

Unit· mm (in )

Remarks

(

STEERING CLUTCHES AND FINAL DRIVES

602177

7

8

STEERING VALVE

Group

Ref.

No.

-

~

~

.c:

" en



I

Valve springs

Test force/length under 9.8 ±l (21.6 ±2.2) test force [96.1 ± 9.8J/56 kgf (Ibl) [Nl/mni (in.) (2.20) .

2 Return springs

Free length 36.5 (1:44)

Test force/length under test force .

0.9

±

0.1

~2.0

± 0.2)

[8.8 ± 1.0 /32.9 kgf (Ibl) [Nl/mm (in.)

(1.30)

Service limit

Unit· mm (in )

Remarks

(

2

(

602278

FRAME

..

---_

..

__

.

....

-.

-

Group

Ref.

No.


1

Steering clutch

-

. case/frame/rigid Tightening torque

bar mounting

kgf·m (lbf.ft) [N·m) bolts

26 ±2

(188 ± 14)

[255 ± 20)

2

Engine front mount/flywheel Bracket-to-stopper housing

mount clearance

Upper: 1.2 - 2.2

(0.047 - 0.087)

Lower: 1.8 - 2.8

(0.071 - 0.110) f«

Engine front 15.9 ± 1.6

"

3

mount

attach~

Tightening torque

(I15.0± 11.6l e ing bolts kgf·m (lbf·ft) [N·m)

[155.9 ± 15.7

Flywheel hous15.9 ± 1.6

Tightening torque

4 ing mounting kgf·m (lbf·ft) [N·m]

(115.0 ± 11.6l

[155.9

+

15.7 bolts

Standard models 1200 (47-1/4)

1400 (55.1/8)

5

Center to center

of tracks

Swamp models

Super-swamp models

Ultra super-swamp

models

1590 (62-5/8)

1880 (74)

.

-

-

-

.

Service limit

1.0

(0.039)

10 (3/8)

I)lt: ml)1 .. m.

Remarks

Difference

between" AD and "B"

2

2

602246

A

5

602245

J

B

602247

9

FRONT IDLERS

Group

Ref.

No.

-

1

2

Idlers

-

3

4

5

.,.

5

Shafts

0

It

6 Filler plugs

Item

Diameter

Diameter

Width

Axial play

Fit in bushing

Tightening torque kgf·m (lbf·ft) [N.m]

Bearing·shaft

7

securing taper

pin bolts

8

I-----

9

Guides/track

frames

Tightening torque kgf'm (lbHt) [N.m]

Lateral clearance

Vertical clearance

Assembly standard

448 (17.64)

420 (16.54) .

42 (1.65)

0.20 -0.25

(0.0079 - 0.0098)

0.155 - 0.235

(0.00610 - 0.00945)

7.6 ± 0.8

{55 ±

5.8~

[74.5 ± 7.8

6.5 ±0.7

{47 ±

5.1~

[63.7 ± 6.9

I (0.04)

I (0.04)

3

Service limit

Unit· mm (in )

Remarks

411 (16.18)

35 (1.38)

1.40

(0.0551)

1.000

(0.03937)

Repair limit:

413 (l6.26)

3 (0.12)

3 (0.12)

(

10

2

8

9

602187

\,

HYDRAULIC ADJUSTER CYLINDERS AND RECOIL SPRINGS

Group

Ref.

No.


~

'0

'"

'"

I Recoil springs

2 Cylinders

Free length

Test force/length under test force kgf(lbf) [kN)/nlin (in.)

Fit on piston

381.5 (15.020)

2610 ± 210

(5755 ± 463)

[25.6 ±2.I)/

. 326 (12.83)

0.075 - 0.164

(0.00295 - 0.00646)

26 ±2

(188 ± 14)

[255 ± 20)

~

"'" iJ

3

Track carrier

roller bracket mounting bolts

~

$

:g

'5'

"

~

4 Filler valves

5

Track adjuster cylin!!ers

Roller shaft and

6

bracket securing

bolts

Tightening torque kgf·m (lbHt) [N·m)

Tightening torque kgf·m (lbf·ft) [N·m)

Adjustment limit

.

--

..

-

Tightening torque kgf·m (lbf.ft) [N·m)

3.5 ± 0.5

(25.3 ± 3.61

[34.3± 4.9

370 (14.57)

14.7 ± 2.2

(106.3 ± 15.9)

[144.1 ± 21.6)

Service limit

2300 (5072)

[22.6) /

326 (12.83)

0.800

(0.03150)

450(17.7)

..

Remarks

..

.

,

..

~

:::::1.,

'---

.

;.:=r

~L-

F

••

..

..

..

..

,

.'

I 6

:

: iO

L-..

-::o r' ..

..J

.. a

.L1J

I ,I I

~

•

:

~::

I

G

,.~----,

1:0 CIt

IL:::. .- --:: ..

'''-1

..

J

0

. .

"" d)

I

--

0

..

--

I

..

1

0

'r;:)

0

/

--

3

.. r

.. l

602248

602249

11

TRACK CARRIER ROLlERS

..

Group

Ref.

No.

I

r-----

2

Item

Diameter

Diameter .. i:l

::ll

3 r-e

4

II

.~

5

Roller shafts

<.>

-a

~

6 Filler plugs

7

Width

Axial play

Fit in bushings

Tightening torque . kgf·m (lbf·ft) [N·m)

.

Roller shaft

Tightening torque securing bolts kgf·m (lbHt) [N·m)

Assembly standard

140 (5.51)

120 (4.72)

30 (1.18)

0.2

0.5

(0.008 - 0.020)

. 0.185 0.226

(0.00728 - 0.00890)

4.2 + 0.4

(30.4 ±

2.9~

[41.2 + 3.9

12.2 + 1.2

~88.2

± 8.7)

[119.6 ± 11.8)

Unit: mm (in.)

Remarks Service limit

118 (4.65)

98 (3.86)

35 (1.38)

1.0

(0.039) .

1.600

(0.06299)

Repair limit:

104 (4.Q9)

(

(

12

TRACK ROLLER'S

Group

Ref.

No.

Item

I r--

2

r-;-

Rollers

Diameter

Diameter

Flange width

~

4

::I

...

e

Axial play

5

Roller shafts .

Fit in bushings

6 Filler plugs

Tightening torque kgf·m (Ibf.ft) [N·m]

7

Roller mount· ing bolts

Tightening torque kgf·m (Ibf·ft) [N·m]

Assembly standard

164 (6.46)

140 (5.51)

9 (0.35)

0.30 - 0.90

(0.0118 - 0.0354)

0.20 0.25

(0.0079 - 0.0098)

7.6

±

O.S

(55.0

±

5~Sl

[74.5 ± 7.S

6+ 0.6

(43.4 ± 4.3)

[5S.5

±

5.9]

·Unit: mm (in.)

Remarks

Service limit

152 (5.98)

128 (5.04)

4 (0.16)

1.40

(0.0551)

1.60

(0.0630)

Repair limit:

132 (5.20)

3

4

2

7

5

602250

602188

13

TRACKS

Group

Ref.

No.

~

11

~

I

Bushings

Item

Outside diameter

Assembly standard

41 (1.61)

(Limit for reversing

38 (1.50»

2

Links a Height b

Link pitch

(for 4 links)

75 (2.95)

540 (21.3)

3

Track pins Fit in bushings

Standard models

Standard models

0.450 - 0.734

(0.01772 - 0.02890)

38.5 (1.516)(BD2G)

30 (1.18) (BS3G)

4

Shoes

5 Tracks

Grouser

Swamp models height

Super-swamp models

Ultra super-swamp

models

'.

, 67.5 (2.657)

57.5 (2.264)

57.5 (2.264)

6

Sho~ bolts

Sag

Tightening torque kgf·m (Ibf.ft) [N·m]

20-30

(3/4 - 1·1/8)

17 - 20

(123 - 145)

[167-196]

Service. limit

37.2

(1.465)

68 (2.68)

Unit· mm (in )

Remarks

Limit for revers· ing: 38 (1.50)

(maximum wear)

Repair limit:

70 (2.76)

Limit for revers-

ing: 552 (2U3)

550 (21.65)

2.5

(0.098)

II (0.43)

10 (0.39)

55.5 (2.185)

52.5 (2.067)

52.5 (2.067)

Repair limit:

57.5 (2.264)

Repair limit not specified

Standard/swamp model track 602184

4

14

Super-swamp/ultra super-swamp model track

602185

5

602252

I,

2-b

2-a

2-a

6 4

Standard model track

2-b

602253

TRACKS

4 6

Swamp model/super-swamp model/ultra super-swamp model track

15

16

HYDRALJLlC PUMP

Group

Ref.

No.

Item

Rpm

'"

1

Pump

performance

Delivery pressure kg/eI11'(psi) .IMPa)

'"

-

.

Capacity liter (eu in.)/min

.a

Tightening torque

&' 2

Through bolts

.kgf·m (lbFft) [N·m)

~

_.

3

Pump mountTightening torque ing bolts kgf-m

(lbf-ft)~[N·m)

Assembly standard

2400

180 (2560) [17.7)

.

-

~~

54 (3295)

4.7 - 5.0

(34.0 -

36.2~

[46.1 - 49.0

4.2 (30.4) [41.2)

Service limit

Unit· mm

Remarks

1

2

r /

~

~I/

t

F.n

t=J1

.....

I -

L

3

I f--::-

~r-

~

601501

..

Group

Ref.

No.

..


I

2

Main relief valve

Check valve springs

Pressure

tha~ ~~kes relief valve Ilpen kgf/cm' (psi) [MPaJ

.

Flow rate liter (cu in.)/min.

Valve tightening torque kgf·m (lbHt) [N·mJ

Free length


test force

kgf (lbf)[NJ /mm (in.)

180±3

(2560 ± 43)

[17.7 ± 0:3]'

50± 2

(3051

+

122)

IO± I

(72.3 ± 7.2)

[98.1

+

9.8J

20 (0.79)

0.2 ± 0.Q2

(0.44 ± 0.04)

[2.0

±

0.2J

10.5 (00413)

I


g,o

'-'

N

Q

11.0 ± 1.1

-

~

'"

., i

"

~

'"

.~

3

Plunger

centering

springs ib

«:


" test force kgf (Ibf)[NJ /mm (in.)

~

Free length

Test force/length under test force kgf (Ibf)[NJ /mm (in.)

Free length

§


test force

(24.3

±

2.4)

[107.9 ± 10.8J/

10.5 (0.413)

51 (2.01)

11.0 ± 1.1

(24.3 ± 2.4)

[107.9 ± 1 0.8J /

10.5 (00413)

57 (2.24)

13.8 ± 1.0

(30.4 ± 2.2l

[!35.3±9.8/ kgf (lbf)[NJ /mm

(in.)

10.5 (0.413)

'"

"

~


Plunger


7 ±0.7

'0

~

4 detent

(1504

± l.5l

[68.6 ± 6.9 /

0 u

" spring test force kgf (lbf)[NJ /mm

(in.)

27 (1.06)

. Free length 26 (1.02)

5

Relief valve

outer spring

Test force/length under test force kgf (lbf)[NJ /mm (in.)

11.0±1.I

(24.3 ± 2.4)

[107.9

± I

0.8J /

22 (0.87)

6

7

8

Relief valve'

inner spring

Check valve plugs

Makeup

valves

Free length


test force

kgf (Ibf)[NJ /mm (in.)

Tightening torque kgf·m (lbHt) [N·mJ

Tightening torque

kgf·m (lbf·ft) [N·mJ

23 (0.91)

1.4 ± 0.1

(3.1 ±0.2l

[13.7 ± 1.0 /

18.4 (0.724)

3.5 ±

004

(25.3 ±.2.9l

[34.3

+

3.9

5.0 ± 0.5

(36.2 ± 3.6)

[49.0 + 4.9}

.

CPNTROL VALVE

Service limit

Unit: mm (in.)

Remarks

.

"

..

17

18

CONTROL VALVE

Remarks


Group

Ref.

No.

-

E1

""

1>'

OJ

". i

,.

~

0

"

"

~

N

Q

"

~

"

:0

9 plunger detent

'"

10

(14.5

±1.4~

[19.6 ± 2.0 plug kgf·m (lbf.ft) [N.m]

-

Seal cover

Tigbtening torque

1.1 ± 0.1 plates & cap securing bolts kgf·m (lbf.ft) [N.m]

(8.0 ± 0.7)

[10.8± 1.0]

11

Plunger plug &

Tie rods

Tigbtening torque

Tigbtening torque kgf·m (lbf·ft) [N·m]

2.0 ±0.2

2.7 ± 0.3

(19.5 ± 2.2)

[26.5 ± 2.9]

Control lever

Operating

N ~ Raise

1.5 - 3.0 (3.3 - 6.6)

force

[14.7 - 29.4] kgf (lbl) [N]

N ~

Lower

1.0 - 2.0 (2.2 - 4.4)

[9.8 - 19.6]

Lower

"*

4.5 - 5.0 (9.9 - 11.0)

Float

Float ~

Lower

[24.5 - 29.4]

N~RH

[44.1 - 49.0]

2.5 - 3.0 (5.5 - 6.6) angling }2.0 - 3.0 (4.4 - 6.6)

N~LH [19.6 - 29.4] angling

·N

~

RH tilt F.5 -3.5 (5.5 -7.7)

N ~ LH tilt

[24.5 - 34.3]

Service limit

.

With engine shut off

11

2

602199

\

CONTROL VALVE

Group

Ref.

No.

I

Main relief valve

2 Safety valve

6

Relief valve

outer- spring

7

Relief valve

inner spring

8

Safety valve spring

Item

Pressure that makes relief valve open kgf/cm

2

(psi)[MPa]

-

Flow rate liter (cu in.)/min

Valve tightening torque kgf·m (Ibf·ft) [N.m]

Pressure that makes relief valve open kgf/em2 (psi)[MPa]


V~lve tightening torque kgf.m {Ibf.ft)[N.m]

Free length

~

'"

.0

3

Check valve

springs


test force

kgf (Ibf) [N]/mm (in.)

0 u

'"

-

S

~

"

0 c.

:€

"

i

"

'"

'0

~

4

Plunger

centering springs

Plunger detent

5

,::;

;.:j

Free length


test force

kgf (lbf)[N] /mm (in.)

~

Free length

-


test force

kgf {Ibf)[N] /mm (in.)

Free length spring

Test force/length under test force kgf (lbf)[N] /mm (in.)

Free length

Test force/length under test force kgf {Ibf)[N] /mm (in.)

Free length


test force

kgf {Ibf)[N] /mm (in.)

Free length

Test force/length under test force kgf {Ibf)[N] /mm (in.)

Assembly standard

51 (2.01)

11.0±J.]

(24.3 ± 2.4)

[107.9 ± 10.8]/

27.6 (1.09)

35 (1.38)

7.0

±

0.7

(15.4 ± 1.5)

[68.6 ± 6.9l/

27.6 (1.09)

26 (1.02)

11.0 + J.]

(24.3 ± 2.4)

[107.9 ± 10.8]/

22 (0.87)

23 (0.91)

1.4 + 0.1

(3.1 ± 0.2)

[13.7± 1.0]/

18.4 (0.72)

39.5 (1.56)

20.8 ± 1.5

(45.9 ± 3.3)

[204 ± ISl/

34.5 (1.36)

180 + 3

(2560 ± 43)

[17.6 ± 0.3]

50 ± 2

(3051 + 122)

010+ I

(72 ± 7)

[98 ± 10]

200+2

(2844 ± 28)

[19.6 ± 0.2]

15 ± 2

(915 + 122)

5.0 ± 0.5

(36.2 ± 3.6)

[49 + 4.9]

20 (0.79)

0.20 + 0.02

(0.44 ± 0.04)

[2.0 ± 0.2] /

10.5 (0.41)

57 (2.24)

13.8 + 1.0

(30.4 ± 2.21

[135.3 ± 9.8 /

27.6 (1.09)

Service limit

..

Remarks

19

20

CONTROL VALVE

Group

Ref.

No.

-


9

Check valve plugs

Tightening torque kgf·m (lbf.ft)[N·mJ

3.5 + 0.4

(25.3 ±

2.9i

[34.3 + 3.9

'4i'

~

$

-

0

~

""

'1<

D

M

Q

'" i

'£

0

= u

10

Plunger plug &

11 plunger detent

12

Plugs

13 plates & cap

14

Makeup valve plug

Seal cover securing bolts

Tie rods

Control lever

Tightening torque kgf·m (lbf·ft)[N·m]

Tightening torque kgf·m (lbf·ft) [N.m]

Tightening torque kgf·m (lbf·ft) [N·m]

Tightening torque kgf·m (lbf.ft)[N.m]

Tightening torque kgf·m (lbf·ft)[N·m]

Operating force kgf (lbf)

[N]

N

+

Raise

N

+

Lower

Lower

0)-

Float

5.0 + 0.5

(36.2 ± 3.6)

[49.0 + 4.9]

2.0+ 0.2

(14.5 ± 1.4)

[19.6 ± 2.0]

10

±

I

(72.3 ± 7.21

[98.1 + 9.8

1.1

+ 0.1

(8.0

±

0.7)

[10.8 + 1.0]

2.7 + 0.3

(19.5

±

2.2l

[26.5 + 2.9

1.5 3.0 (3.3 6.6)

[14.7 - 29.4]

1.0 - 2.0 (2.2 - 4.4)

[9.8 - 19.6]

4.5 - 5.0 (9.9 - 11.0)

[44.1 - 49.0]

Float

+

2.5 - 3.0 (5.5 - 6.6)

Lower

[24.5 - 29.4]

N

+

RH tilt p.5 - 3.5 (5.5 - 7.7)

N

+

LH tilt

[24.5 34.3]

Service limit

Unit· mm (in.)

Remarks


14

·602206

CONTROL VAlVE

602207

602208

2.1

CONTROL VALVE

~

C> e

"

~

"8

~

0

= u

Group

Ref.

No.


I

2

3

Main relief

valve

Safety

valves

Check valve springs·

Plunger

4

centering springs

"

"'"

Pressure that makes

relief valve open kgf/cm' (psi)[MPa]

.

Flow rate. liter (cu in.)/min

Valve tightening torque kgf·m (lbf·ft)[N.m]

Pressure that makes relief valve open. kgf/cm' (psi)[MPa]


"'"

Pressure that makes

relief valve open kgf/cm' (psi)[MPa]

"'"

0<: Flow rate liter (cu in.)/min

160

+

3

(2275 ± 43)

[15.7 + 0.3]

50 ±2

(3051 + 122)

10 ± I

~72

± 7)

98 + 10]

200±2

(2844 ± 28)

[19.6 + 0.2]

23 ±2

. . (1404+ 122)

160±2

(2275 ± 28)

[15.7 + 0.2]

23 ±2

(1404 + 122)

Free length

Test force/length under test force kgf(lbf)[N]/mm (in.)

Free length

§

Test force/length under test force· kgf(lbf)[N]/mm (in.)

20 (0.79)

0.20 ±0.02

(0.44 ± 6.04)

[2.0 ± 0.2]/

10.5 (O.4i3)

57 (2.24)

13.8 ± I

(30.4 ± 2.21

[135.8 ± 9.8 /

27.6(1.09) .

5

Makeup valve springs

Free length p.

S Test force/length under

" test force kgf (lbf) [NJlmm (in.)

Free length

Test force/length under test force kgf (lbf) [N]/mm (in.)

51 (2.01)

11.0 ± 1.1

(24.3 ± 2.4)

[107.9 ±

10.8]1

27.6 (1.09)

21 (0.83)

.0.16 ±0.02.

(0.35 ± 0.04)

[1.6 ±

0.2]1

17.5 (0.69)

6

7

Relief valve

outer spring

Relief valve

inner spring

Free length

Test force/length under test force kgf (lbf)[N]/mm (in.)

Free length


test force

kgf(lbf)[N]/mm (in.)

26 (1.02)

11.0 ±

1.I

(24.3 ± 2.4)

[lO7.9 ± 10.8]/

22 (0.87)

23 (0.91)

1.4 ± 0.1

"(3.09 ± 0.2)

[13.7 ± 1.0]/

18.4 (0.72)

Service limit

Unit: mm

(in.)

Remarks

. .

I

I

(

22·

cCONTROL VALVE

Group

Ref.

No.


8

Safety valve

springs

Free length

Test force/length under test force kgf (lbf)[N]/mm (in.)

-

39.5 (1.56)

20.8

+

1.5

(45.9

±

3.3)

[204.0

±

14.7J/

34 (1.34)

9

Check valve plugs

Tightening torque kgf· (lbf·ft)[N.m] .

3.5

±

0.4

(25.3

±

2.91

[34.3

+

3.9

Makeup valves

10

-

-

G'

M e-

~

1l

"0 li

Plunger plug & plunger detent plug

Seal cover

12 plates & cap securing bolts

13

Tightening torque kgf·m (lbf·ft) [N·mJ .

Tightening torque· kgf·m (lbf·ft)[N·m]

Tightening torque kgf·m (lbf·ft) [N·mJ

5.0 + 0.5

(36.2

±

3.6)

[49.0

±

4.9]

2.0

±

0.2

(14.5

±

1.4)

[19.6

+

2.0J

1.1 + 0.1

(8.0

±

0.7)

[10.8 + 1.0]

Tie rods


2.7

+

0.3

(19.5

±

2.21

[26.5 + 2.9

Control valve Operating N

+

Raise force kgf (lbf)

[N]

N

'*

Lower

Lower

+

Float

Float

+

1.5 3.0 (3.3 6.6)

[14.7 - 29.4]

1.0

~.2.0

(2.2 -,. 4.4)

[9.8 - 19.6] .

4.5 - 5.0 (9.9.- 11.0)

[44.1 - 49.0] .

2.5 - 3.0 (5.5 - 6.6)

Lower

[24.5 - 29.4J

N

+

Tilt

} 2.5 - 3.5 (5.5 -7.7)

N

+

Dump

[24.5 - 34.3J

Service limit

-

Unit: mm (in.)

Remarks


23

CONTROL VALVE

6

7

3

9

' 1 ' 2

13

602214

602199

11

602215

24

CYLINDERS

Item Assembly standard , Service limit Group

Ref.

No.

~

-;;-

-'"

2 Guide bushing

Fit of guide bushing on 0.Q75.- 0.139

".0

~S

" k

"'k

"

;. 0

3

Piston securing

"

;. nut

'"0 ....

;.,,,

..

~

0 " "

""",

C

tI:$

" o~::o

4::Q..,

:.:Jes

I

Cylinder and

piston

4 Gland screw

5 r--

6

Piston rod

Fit of cylinder on piston piston rod . _

Tightening torque kgf·m (Ibf.ft)[N.m]

Tightening torque kgf-m (Ibf·ft)[N.m]

Center to center of

pins with cylinder fully retracted

Stroke

(0.00295 - 0.00547)

50.0 ± 2.5

(361.7 ±lS.I)

[490.3± 24.5)

15.0 ± 1.5

(108.5 ± 10.8)

[147.1 ± PI.7]

640 (25.20)

370 (14.57)

0.350

(0.01378)

0.350

(0.01378)

Unit· mm (in )

....

Remarks.

-

3

602256

.25

CYLINDERS

Group

Ref.

No.

Item

.-

I l "

" :<

'" gp0

:.=

M gpo

..:e

~ k

""

~

on

.5

Ch

1

Cylinder and piston

2 Guide bushing

Fit of cylinder on piston

Fit of guide bushing on piston rod a

3

Piston securing

Tightening torque nut kgf.m (Ibf.ft)[N·m)

4 Gland screw

5

Piston rod

-

Tightening torque kgf·m (Ibf.ft) [N.m)

Center to center of pins with cylinder fully retracted

6

Stroke

Assembly standard

om5 -

0.139

(0.00295 - 0.00547)

50.0 ± 2.5

(361.7

±

18.11

[490.3 ± 24.5

15.0 ± 1.5

(108.5 ± 10.81

(147.1 ± 14.7

579.5

(22.815)

321 (12.64)

Service limit

0.350

(0.01378)

0.350

(0.01378)

Unit: mm

(in.)

Remarks

602255

\

26

CYLINDERS

Group

Ref.

No.

Item

-;;-

'0

:a

~

'"

'"

" i<

0

'"

.5 ::t

>'.0

UN

~~

7

5

I

Cylinder and piston

2

Guide bushing

3

Piston securing

Tightening torque nut kgf·m (lbf·ft)[N·m)

4 Gland screw

Piston rod


Fit of gUide bushing on piston rod

Tightening torque kgf.m (lbf.ft)[N.m)

Center to center of

pins with cylinder fully retracted

Stroke

Assembly standard

0.075 - .0.139

(0.00295 - 0.00547)

70.0 ± 3.5

(506.3

±

25.3)

[686.5

±

34.3

24.0

±

2.4

(173.6

±

17.4)

[235.4 ± 23.5

390 (15.35)

110 (4.33)

'.

Service limit

0.350

(0.01378)

0.350

(0.01378)

Unit: mm

(in.)

Remarks

4

2

3

6

~---------------5----------------~

602257

27

CYLINDERS

Group

Ref,

No.

Item

1

Cylinder and piston


~

~

2 Guide bushing

S

3

~

Piston securing

Tightening torque nut

Fit of guide bushing on piston rod kgf·m (lbf.ft)[N.m]

'"

'"

.~

4

Gland screw

.S ;.

;;:."

;t:Q

Tightening torque kgf·m (lbf.ft)[N.m]

Center to center of

5 pins with cylinder

Piston rod fully retracted r-;-

_

..

Stroke

Assembly standard

0.075 ...: 0.1 39

(0.00295 - 0.00547)

50.0.± 2.5

(361.7 ±18.11

[490.3

±

24.5

45.0±4.5

(325.5 ± 32.51

[441,3 ± 44.1

"

500 (19.69)

115 (4.53)

Service limit

0.350

(0.01378)

0.350

(0.01378)

Unit" mm (in)

Remarks

4 2

3 o

~-------------------5----------------------~

602258

28

(

CYLlNQERS

Group

Ref.

No.

Item

~

(,!)

'"

~

~

OJ

""

"

....l

I

Cylinder and piston

2 Guide busbing

3

4 Gland screw

5

Piston rod

~

6

Fit of guide busbing

on piston

Fit of guide bushing on piston rod

Piston securing

Tightening torque nut kgf·m (Ibf·ft) [N.m)

Tightening torque kgf·m (Ibf.ft) [N·m)

Center to center of pins with cylinder fully retracted

Stroke

Assembly standard

0.075 - 0.139

(0.00295 - 0.00547)

95.0 ± 5.0

(687.1

±

36.2~

[931.6 ± 49.0

75.0

±

8.0

(542.5

±

57

.9~

[735.5

±

78.5

-

Service limit

0.350

(0.01378)

0.350

(0.01378)

700 (27.56)

386 (15.20)

Unit: mm (in)

Remarks

4

602259

29

CYLINDERS

Group

Ref.

No.

Item

I

Cylinder and piston


Fit of guide bushing

~

"

2 Guide bushing on piston rod

'"

!1

~

0

""

"

3

Piston securing

nut

4 Gland screw

Tightening torque kgf·m (Ibf·ft)[N.ml

Tightening torque kgf·m (Ibf·ft) [N.ml

Center to center of

5 pins witil cylinder

Piston rod fully retracted t---

6 Stroke

Assembly standard

0.075 - 0.139

(0.00295 - 0.00547)

50.0 ±2.5

(361.7 ± 18.1l

[490.3 ± 24.5

45.0 ± 4.5

(325.5 ± 32.5)

[441.3 ± 44.1

866.5 (34.11)

423.5 (16.67)

Service limit

0.350

(0.01378)

0.350

(0.01378)

Unit: mm (in)

Remarks

(

602260

30

(

POWER ANGLINGITILT BLADE (BD2G)

Group

Ref.

No.

~.

'-'

N

CI e

<>

'"

.<>

~

~

~

Item

I

Cutting edges/ end bits

Distance from center

of bolt hole to edge tip/bit tip

Cutting edge

2 mounting plow bolts

Tightening torque kgf·m (lbf·ft)[N.m]

3

Cap mounting

Tightening torque bolts kgf·m (lbf·ft)[N·m]

Outer and

4 inner plates mounting bolts


"

<> i<

0

'"

5

Swing bracket

Tightening torque mounting bolts kgf·m (lbf.ft)[N·m]

6

Plate mounting Tightening torque bolts kgf·m (lbf·ft) [N·m]

Assembly standard

"

75 (2.95)

6.5 ± 0.7

(47.0 ± 5.11

[63.7± 6.9

38 -43

(274 - 311)

[373 - 422]

12 -.14

(87 -lOll

[118 - 137

12.2 - 14.8

(88.2 - 107.0)

[119.6 - 145.1]

7.6 9.2

(55.0 - 66.5l

[74.5 - 90.2

Service limit

Unit: mm (in.)

Remarks

45 (1.77)

602264

3

6

602266

602267

31

POWER TILT BLADE (BD2G)

Group

Ref.

No.

-item

-

Cutting edges/

I end bits

~

"

~

~

~

.0

2

Cutting edge mounting plow bolts

:=

-

3

Trunnion

Distance from center

of bolt hole to edge tip/bit tip

Tightening torque kgf·m (Ibf.ft)[N·m]

Tightening torque mounting bolts kgf·m (Ibf·ft) [N·m]

~

~

0

'"

4

Trunnion cap

Tightening torque mounting b.olts kgf·m (IbHt) [N·m]

Assembly standard

75 (2.95)

6.5 ± 0.7

(47.0 ± 5.11

[63.7

+

6.9

lOA

± 1.0

(75.2 ± 7.21

[102.0 ± 9.8

15.8 ± 1.6

fI14.3±11.6~

154.9 ± 15.7

Service limit

Unit: mm (in.)

Remarks

(

45 (1.77)

(

602264

602268

(

32

BUCKET AND LINKAGE (BS3G)

Group

Ref.

No.

Item

Assembly standard

G'

'"

"

-g

..

j

~

"

-

-

-

I

2

3

Cutting edges Width

4

5

Tooth

Lock plate mounting bolts kgf·m {lbf.ft)[N.m]

6

each pin in

7

Clearance of bushing

Length

Tightening torque for securing bolts kgf·m {lbf.ft)[N·m]

Tightening torque

35 (1.38)

45 (1.77)

.

50 (1.97)

.

160 (6.30)

29 -32

(210 - 2311

[284 - 314

159 (6.26)

3.5 ± 0.3

(25.3 ± 2.2) .

[34.3

±

2.9]

0.100-0.175

(0.00394 - 0.00(89)

0.200 - 0.275

(0.00787 - 0.01083)

0.130 - 0.219

(0.00512 - 0.00862)

Service limit

100 (3.94)

120 (4.72)

0.600

(0.02362)

0.600

(0.02362)

0.600

(0.02362)

Unit: mm (in.)

Remarks

2

3

602262

602261

33

34

TIGHTENING TORQUE FOR STANDARD BOLTS

TIGiUEf.UNG TORQUE FOR STANDARD BOLTS

Unit: kgt·m

\

Nominal size

(mm)

6

8

10

12

14

Pitch

(mm)

I

1.25

1.25

1.25

1.5

. With spring washer

@Iw.

@IDW

..

~

Without spring washer

@JOOil

Remarks:

~ torques for standard

. bolts and nuts.

0.75 0.98 1.3 0.88 1.1 1.5

.1.7

3.5

6.5

10.4

15.8

2.3

4.6

8.4

13.5

20.6

3.1

7.1

12.5

19.6

29.3

2.0

4.2

7.6

12.2

18.6

2.7

5.4

9.9

15.9

24.2

3.7

2. The tolerance for these torques is ±IO%.

8.3

14.7 .

. 3. Unless otherwise speci·

fied, use these torques.

23.1

4. These torques are for

'''dry'' condition.

34.S

"d k

'" o£i

16

18

1.5

1.5 22.9

29.8 42.2 26.9 35.0 49.7

::s

-

"

'"

20 1.5 31.7

41.2 58.5 37.3 48.5 68.8

"

22 1.5

42.2 .

54.8 77.8 49.6 64.5 91.5

24 1.5 55.8 72.5 102.6 65.6 85.3 120.7

27 1.5

81.0

105.3 148.0 95.3 123.9 174.1

30 112.2 145.9 205.2 132.0

33

36

39

1.5

1.5

1.5

1.5

149.6 194.5

195.6 254.3

273.3 176.0

356.6 . 230.1

251.0 326.2 455.8 295.3

171.6 241.4

228.8

321.6

299.2

419.6

383.8

536.2

!\

Nominal size

(mm)

10

12

14

Pitch

(mm)

1.5

1.75

2

With spring washer Without spring washer

@lw @IW @)lW

@lw

@)nw

@)lW

3.4

6.0

9.8

4.4

7.8

12.7

6.9

11.8

18.6

4.0

7.1

11.5

5.2

9.2

14.9

8.1

13.8

22.0

16 2 15.0 19.5 28.0 17.6 22.9 33.0

-

18

2.5 20.7 27.0 39.1 24.4 31.8 46.0

"d k

'"

20

2.5

29.2 37.9

54.7 343 44.6 64.3

0

" 22 2.5

'"

"

24

27

3

3

39.1

50.2

50.9

65.3

73.0

94.3

40.0

'59.0

59.9 85.9

76.8 111.0

73.9 96.1 137.7 86.9

113.0

162.0

::s

30 3.5

98.9

128.4 188.0 116.3 151.1 221.1

33 135.5 176.1 252.6 159.4

3.5

4

207.2 297.3

261.5

384.0 36 170.9 222.3 326.3 201.1

39

42

4

4.5

226.3 294.1 420.0 266.2

280.9 365.2

523.9 330.5

346.0 494.1

429.6 616.4

(

(

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DEC. 86


Pub. No.

99879-00120-

3

/

SERVICE MANUAL

MITSUBISHI

TRACTOR··

B

TRACTOR SHOVEL

BS3G

(DIRECT DRIVE MODEL)

CONTENTS

POWER TRAIN

• OPERATING PRINCIPLE

• TESTING AND ADJUSTMENTS

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FOREWORD

This service manual has instructions and procedures for the subject on the front cover. The information, specifications, and illustrations used in this manual are based on information that was current at the time this issue was written.

Correct servICing will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.

Safety is not only your concern but everybody's concern. Safe working habits cannot be bought or manufactured; they must be learned through the job you do. By learning what CAUTION or WARNING symbol emphasizes, know what is safe - what is not safe. Consult your forem'an, if necessary, for specific instructions on a job, and the safety equipment required.

NOTES, CAUTIONS and WARNINGS

NOTES, CAUTIONS and WARNINGS are used in this manual to emphasize important and critical instructions. They are used for the following conditions:

I

NOTE] ..............

An operating procedure, condition, etc., which is essential to highlight.

&1

CAUTION]

....... Operating procedures, practices, etc., which if not strictly observed, will result in damage to or destruction of machine.

Operating procedures, practices, etc., which if not correctly followed, will result in personal injury or loss of life.

;;',

\.

TABLE OF CONTENTS

OPERATING PRINCIPLE

General description

2

Flywheel clutch

5

Clutch oil line

6

Direct-drive (DD) transmission

Transmission control

7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Steering clutches, brakes and final drives . . . . . . . . . . . . . . . . . . . . . . . .. 10

Steering clutch and brake controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .. I I

Undercarriage .. '" ........................................ J3

TESTING AND ADJUSTMENT

Adjusting the steering clutches and brakes

Adjusting the brake pedal

..................... " 18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19

Adjusting the clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19

Adjusting the clutch brake

Adjusting the tracks

................................... 20

....................................... w

Troubleshooting guide

21

OPERATING

PRINCIPLE.

OPERATING PRINCIPLE

Direct-drive (DO) model

GENERAL DESCRIPTION

(

1 2

4

<I

602163

I>

(

602164

1 Engine

2 Flywheel clutch

3 Universal joint

4 Transmission

5 Bevel gear dri ve

6 Steering clutch

7 Final drive

Major components of this power train are, from engine "I" to the tracks, flywheel clutch "2," universal joint "3," transmission "4," bevel gear drive "5," steering clutches "6" and final drives "7" including sprockets.

The engine and flywheel clutch are bolted together and are mounted on the frame by a total of four mounts fitted with barrel-shaped vibration-insulating rubber pads.

The transmission

. selection of three reverse speeds is which provides a forward and two independen t case bolted housed in an to the front face of steering clutch case.

2

i=

«

OC

W

~

0

W

-'

"0. u

"

~

N

N

0

"

'"

-,

1

, p j

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FLYWHEEL

CLUTCH

OPERATING PRINCIPLE

602165

1

Flywheel

2 Clutch disc

3

Ma ting plate

4

Pressure plate

5

Clutch cover

6

Release lever

7 Release hub

8

Release spring

9 Fork

10

Main shaft

This flywheel clutch is of wet

(oil-cooled), multi-disc type and is housed in the clutch case which also serves as a flywheel housing.

The clutch is normally kept in engaged condition and is disengaged by the clutch pedal connected through a linkage to the release lever.

Clutch discs (driven members) "2" have checkered oil grooves to increase the torque capacity of the clutch in oiJsprayed condi tion.

This wet clutch, unlike a dry clutch, tends to grab in disengagement due to presence of oil film between the driving and driven members. To prevent this

11

Oil pump

12

Oil strainer

13

Clutch brake grabbing and to facilitate smooth engagement, the discs . are slightly

"dished." When in engaged position, the discs are pressed ·flat and act as cushion sp·rings to serve the purpose.

Clutch disc assembly

Ordinary disc (not "dished") "Dished"

Facing

Driven plate

Splined hub

Flywheel

side

Flywheel side

Amount of dishing

602183

5

OPERATING PRINCIPLE

CLUTCH OIL LINE

5

1 Oil strainer

2 Gear pump

3 Relief valve

This oil Jineis for actuating the steering valve and for cooling and lubricating the clutch discs and related parts.

Oil drawn by gear pump "2" through strainer "1" flows through relief valve "3" into oil cooler "4" where it is cooled, and then into the oil bypass drilled in clutch main shaft "5." From this bypass the oil is sprayed over the friction surfaces of clutch discs.

4 Oil eooler

5 Clutch main shaft

6 To and from steering valve

602166 (

6

DIRECT-DRIVE (DO) TRANSMISSION.

OPERATING PRINCIPLE

I,

602167

1 Input shaft

21st-speed reverse gear

3 2nd-speed reverse gear

4 Input gear

5 2nd-speed drive gear

6 Coun tershaft

This transmission is of manual-shift, sliding gear countershaft type, and provides a selection of three forward and two reverse speeds.

The arrangement of its shifting and gearing is as shown above. The bevel pinion shaft (third) carries three sliding gears. These gears are shifted into mesh with three gears mounted on the countershaft (second) for forward ratio selection, or with two gears on the input shaft (first) for reverse ratio selection.

7 1st-speed drive gear

8 1st-speed sliding gear

9 2nd-speed sliding gear

10 Counter gear

11 3rd-speed sliding gear

12 Bevel pinion shaft

602168

7

OPERATING PRINCIPLE

Power flow in transmission

Forward 1st-speed position

Reverse 1st-speed position

1

.2. o

T

.:0·-

Counlershaft 6

1 sl -speed drive gear 7 lsi-speed slidinXf gearS

-I

£

J lIt.

1

1 T

Bevel pinion

I

shaft 12

602169

Forward 2nd-speed position

Inpul sh~ I--L;!1i..;;:...;.It---tI-rtl--'~;;;

Input gear 4

···1

-"

+

Counter g, gear 10 o

2nd-speed drive gear 5

2nd-speed sliding gear 9

.Q.Q. tH

~'!-+Counlershaft

6

I:l l ...

1 i5 ' \

T

Bevel pinion shaft 12

602172

.

Rev",,rse 2nd-speed, posi tion ..

..

:

'.

-.. ----.:- I

~

O

OOT

_ o r

I

Iii

U

I

I

0

1

.1-2nd-speed

~ ~. lliding gear 9 r

1

1 T.o

B:el pinion

:1 shaft 12

8

. 602170

Forward 3rd-speed position

I

Inputsha~L

I

I ftInpUI gear 4 o

1

I

I

I hi gear 10

II

J

00

_ r

1"1

0 " \ _ I

T

JLt

T

;~:e;:ar

Bevel pinion shaft 12

II

I

I

1>4>10>11>12

602171

!

602173

TRANSMISSION CONTROL

OPERATING PRINCIPLE

5

602174

4

R2

9

10

Rl

8

10

7

1 1st-speed shift fork

2 2nd-speed shift fork

3 3rd-speed shift fork

41st-speed sliding gear

9

•

602175

5 2nd-speed sliding gear

6 3rd-speed sliding gear

7 1st-speed shift rail

8 2nd-speed shift rail

When the gearshift lever is moved into the desired speed position, one of the three forks is moved to shift the desired sliding gear on the third shaft into mesh wi th the gear on the countershaft or input shaft.

The control is provided with an interlocking mechanism involving springloaded steel (detent) balls. Because of this interlocking mechanism, it is only possible to engage one gear reduction at a time. For instance, when 1st-speed shift rail "7" is moved, 2nd-speed shift rail "S" and 3rd-speed shift rail "9" are locked by steel balls "10."

2

1

602176

9 3rd-speed shift rail

10 Steel (detent) ball

9

OPERATING PRINCIPLE

STEERING CLUTCHES, BRAKES AND FINAL DRIVES

1 Bevel pinion

2 Bevel gear

3 Dri ve shaft

4 Bearing cage

5 Steering clutch cylinder

(; Inner drum

7 Disc plate

8 Friction plate

9 Outer drum

10 Pressure plate

11 Final drive pinion

12 Final driven gear

602177

13 Shaft

14 Floating seal

15 Sprocket

16 Track

The steering clutch is type controlled from lever. of dry multi-disc steering clutch outer (driven) drum "9" is bolted to the flange of final drive pinIOn. Inner

(driving) drum "6" to the flange of drive sha:ft "3." Friction plates "8" are engaged with the outer drum and disc plates "7" with the inner drum. The stack of these plates is normally kept compressed by spring-loaded pressure transmit the power to involving pinion "11" and disengaged, the pressure away from the stack. plate

"10'"

to the final drive gear "12." When pIa te is moved

The outer drum is surrounded by a brake band which is actuated (contracted) from the steering clutch lever to brake the drum.

10

10

STEERING CLUTCH AND BRAKE CONTROLS

OPERATING"PRINCIPLE

7

602178

Steering clutch in engaged position

602179

1 Steering clutch lever

2

Steering valve

3 Steering clutch" cylinder

4

Pressure plate

5

Disc plate

As steering clutch lever piston of steering valve

"I"

is pulled, the

"2"

is moved in such a direction as to apply hydraulic pressure to steering clutch cylinder

"3."

By this hydraulic pressure, pressure plate

"4"

is moved away from the stack of disc plates

"5"

and friction plates

"6"

to disengage the clutch.

When the lever is further pulled, brake band

"7"

is contracted to brake outer drum

"8" to interrupt the flow of power to the final drive.

Steering clutch in disengaged position

6

7

Friction plate

Brake band

8

9

Outer drum

Brake pedal

10 Ratchet (brake lock)

602180

It is possible to disengage the steering clutch without braking for gradual turn or to disengage jt with braking for sharp turn.

As brake pedal

"9"

is depressed, the brake bands of right-hand and left-hand clutches are simultaneously contracted for braking independently of the clutch con trol. This pedal can be used as a parking brake if locked in fully depressed position by means of ratchet "10."

11

OPERATING PRINCIPLE

Steering clutch control hydraulic circuit

4

2

602181

(

12

6

1 Relief valve

2 Steering valve

3 Steering clutch cylinder

7

4 Oil cooler hose

5 Steering clutch lever

602182

6 Oil pump

7 Steering clutch

OPERATING PRINCIPLE

UNDERCARRIAGE

Tracks

The track consists of shoes, pins, links and bushings. Each link "8" overlaps the preceding link, thus forming a continuous or endless chain.

Master pin "1" is to be positioned in front of the front idler for removal of the entire track from the tractor.

The shoes are available in two types, standard shoe "9" for the standard specifica tion model and curved apex shoe

"12" for the swamp, super-swamp and ultra-super-swamp specification models.

The swampier the conditions under which the tractor may be operating, the shoes are longer, that is, the ground pressure is lower.

Links "8" are fitted with seal washers "5" for the standard and swamp specification models; they are fitted with rubber seals

"11" for the super-awamp and ultrasuper-swamp specification models.

Track rollers

The track rollers are mounted on the lower side of track frame to support the tractor and distribute its weight along the track.

A total of· five track rollers are used; they are unequally pitched to reduce vibration occurring during operation.

Each track roller is factory-filled with gear oil. Floating seal "2" keeps this oil in and dirt out under all operating conditions.

Front idlers

Front idler "9" guides the track into position in front of the track rollers.

It rolls around and on shaft "3" which is rigidly held at both ends by bearings "4."

Wear strips "7" are welded are worn down to the limit. strips on the top of track frame. kept in by the floating seal. to the bearings; they can be replaced when they

The whole idler assembly is capable of sliding forward and backward on the rail

The idler is filled with gear oil which is

Carrier rollers

The carrier roller supports the weight of track between the sprocket and front idler.

Roller "3" is supported through bushing "4." supporting the shaft is of by shaft "5"

The bracket cantilever type.

Like the track rollers and front idlers, the carrier rollers are filled with gear oil and are fitted with floating seals.

Recoil springs and hydraulic adjuster cylinders

Cylinder "3" is rigidly connected to the front idler and is secured to the track frame by carrier roller bracket "7."

The space inside the cylinder is filled with grease; the grease is pumped into or released from the cylinder through fill valve

"1."

The recoil spring is compressed and held to a definite length. Normally, the pressure of the spring is not exerted against the track. However, should rocks or other obstructions get between the track and rollers, idler or sprocket, cylinder "3" and shaft "4" will move backward and spring "6" will recoil still farther to avoid overstressing the track.

13

j j

I

I

I

I

I

I

I

I

I

I

I

OPERATING PRINCIPLE

Carrier roller

Tracks

Standard type

7

6 B

9 o

0·...--.--11 n - - - l l o~

3

5

2 idler

1 Master pin

2 Spacer

3 Master pushing

4 Master link

5 Seal washer

6 Pin

7 Bushing

8 Link

9

10

Standard shoe

Master seal

11 Seal

12 Curved apex shoe ..

1 Cover

~

6021

5 Shaft

6' Floating seal

7 Seal support

5 4 3

Track roller

Recoil spring and hydraulic adjuster cylinder

3 4

1

Guide

2 Shim

3 Shaft

4 Bearing

5 Floating seal

602187

6

Bushing

7

8

Wear strip

Thrust washer

9 Idler

1

Collar

2.Floating seal

3 Thrust washer

4 Bushing

5 Shaft

6 Roller"

602188

1 Fill vaJve

2 Stopper bolt

3 Cylinder

4

Cylinder shaft

5 Spring retain"er

6 Spring

7 Carrier roller bracket

602189 n ...

~,-\... lL","_ 15

(

'I

TESTING

AND

ADJUSTMENT


5'

2

ADJUSTING THE STEERING CLUTCHES AND BRAKES

6.5 to 7.5

(2-9/16 to

2-15/i6)

20 to 22

(7-7/8 to

8-11/1J

(B) Adjusting the clearance between brake band and outer drum

1.

Screw adjusting nut "6" all the way.

2, Flack off the nut 2-2/3 rotations.

Unit: em (in.)

8 9 10

6

602191

!NOTE)

The steering clutches and brakes are interrelated with each other. This means that they must be adjusted at one time. Make adjustments (A) thru

(D)

in that order.

(A) Adjusting 'the "released" position of steering clutch levers

1.

Loosen lock nut

"1."

2. Set lever "2" by means of stopper bolt

"3" so that it is 9.0 to 9.5 cm (3-9/16 to 3-3/4 in.) as measured from the front end of dashboard. (Equalize the right-hand and, left-hand lever positions.)

3. Loosen lock nut "4."

4. Set the knob

of

steering clutch lever by means of clevis "5" so that it is

6.5 to 7.5 cm (2-9/16 to 2-15/16 in.) as measured from the end of instrument panel.

18

(C) Adjusting the stroke of steering

, clutch .levers "

1.

Loosen lock nut "7."

2. Set the stroke by means of clevis "8" so that it is 20 to 22 cm (7-7/8 to

8-11/16 in.) from released position to fully pulled position.

!NOTE)

When making a connection to lever

"9," lightly push lever "9" forward until it encounters a resistance, with return spring "10" unhitched.

.>---r---

~I-=-=---

J h/

7

.--=----,

: I

------~

602192

(D)

Making a connection to steering valve


2. Bring roller "13" into contact with, the end of plunger (piston) "12" of steering valve by means of clevis "14."

!

NOTE)

Do not push in the plunger.

ADJUSTING THE BRAKE PEDAL

Unit: em (in.)

4

3


ADJUSTING THE CLUTCH PEDAL

4

3

5 - - - 1

Unit: em (in.)

20 (7-7/8)

1.5(9/16)

602193

[NOTE]

There is no need of adjusting the brake pedal stroke after the steering clutch has been adjusted properly. To be adjust on the pedal is its· free play.

1.

Loosen lock nut "L"·

2. Set the released position of the pedal by means of stopper bolt

"2" so that it is 20 cm (7-7/8 in.) as measured from the dashboard wall.


4. Set the free play of the pedal by means of clevis "4" so that it is 0.5 to LO cm (3/16 to 3/8 in.).

[NOTE]

Make sure that the RH and LH brakes are applied simultaneously.

602194

1. Loosen lock nut

"1."

2.

Set the released position of the pedal by meanS of stopper bolt

"2"

so that it is 20 cm (7-7/8 in.) as measured from the dashboard wall.

3.


4.

Set the free· play of the pedal by means of clevis "4" so that it is 1.5 cm (9/16 in.).

5. Loosen lock nut "5."·

6 •.

Set the stroke of the pedal by means of stopp·er bolt "6" so that it is 16 cm

(6-5/16 in.).

19


ADJUSTING THE CLUTCH BRAKE o

Q

2

4

3

5

6

502747 at ()

• To loosen:

1. Remove the cover, and gradually turn fill valve "1" counterclockwise to allow grease to escape from vent hole

tl2.1f

2. If grease does not appear at the vent hole, loosen the fill .valve until it is limited by the stopper.

3.

If grease does not appear at the vent hole and the vent hole appears to be open and the track appears to have tension, start the engine, and move the machine back and forth slightly.

4. If the track still appears to have tension even after such a backward and forward movement of the machine, insert a wood block into between the sprocket and track, and move the machine backward slightly. This will strain the track to force grease out of the vent hole.

[NOTE]

The clutch brake should be capable of stopping a rotating univeral joint in about

2.5 seconds when the clutch pedal is depressed all the way wi th the engine running at maximum speed.

1.

Adjust the length under test force of spring "1" to 4 cm (1-5/8 in.).

2. Loosen lock nuts "2" and "3."

3. Screw adjusting bolt "4" until brake band

"5" comes in full-face contact with drum

"6."

4.

Back off adjusting bolt "4" 2.5 to

3 rotations.

ADJUSTING THE TRACKS

Never look into the vent hole to see if the pressure in the track adjuster cylinder is released. Make sure of relief of the pressure by observing the backward movement of front idler.

• To adjust:

1. Apply grease, with a grease gun, into the fill valve until the slack or sag in the track is

20 to

30 mm

(3/4 to

1-3/16 in.).

2. Operate 'the machine backward and forward to equalize the adjustment.

.&J

CAUTION]

When applying grease into the fill valve, keep the dimension "A"

(between cylinder shaft flange and rigid bar) within

450 mm

(17-3/4 in.).

502740

20


TROUBLESHOOTING GUIDE

Flywheel clutch

Complaint

Clutch slips

Clutch drags

Clutch chatterS when disengaged

Incomplete djsengage·

ment, resulting in

hard shifting

Hard gear shifting on

transmission

Possible cause

(I) No pedal free play

(2)

Worn down clutch facings

(3) Clutch facings burnt, resulting in reduced coefficient of friction

(4) Dirty friction surfaces of clutch discs

(5) Weakened or broken clutch springs

(I) Pedal free play too large

(2) Not enough pedal stroke

(3) Release levers not set for uniform lever height

(4) Binding or sticky splines of du tch shaft

(5) Dirty friction surfaces of clutch discs

Release bearing seized, poorly

lubricated or damaged

Oil is too viscous

Remedy

•

Adjust.

•

Replace.

•

Replace.

•

•

•

•

•

•

Clean by washing, or replace.

Replace.

Adjust.

Adjust.

Adjust.

Disassemble and

repair) or replace.

• Clean by washing.

Disassemble and repair, lubricate

Of replace.

Change with oil of

proper viscosity.

Clutch brake maladjusted, or

band linings worn

Adjust, or replace

linings.

Remarks

Clutch oil line

Complaint

Oil pump is not lifting

oil, that is, not

discharging oil

Possible cause

(I) Suction strainer clogged

(2) Oil viscosity too high

(3)

Loose joint in connector

(4) Broken drive shaft of oil pump

(5) Rotors worn or seized

Remedy

•

Clean.

• Change with oil of

proper viscosity.

• Retighten.

• Replace.

•

Replace.

Remarks

21


Transmission

Complaint

Gears slip out of mesh

Hard shifting

Noisy

Possible cause

(I) Incomplete meshing action due to improperly assembled shift control mechanism

(2) Inner end of shift lever worn down or loose

(3) Gear teeth unevenly worn

(4) Too much backlash

(5) Shaft splines badly worn, resulting in loose fit

(I)

Dragging clutch

(2) Shift lever or forks loose or worn

(3) . Foreign matter lodged

between gears

..

(4)

Oil Viscosity too high

Remedy

•

Disassemble and repair or replace.

•

•

Replace.

•

Replace gears.

• Replace.

•

Adjust clutch.

•

Repair or replace.

•

Repair or replace.

Clean by washing.

•

Change with oil of proper viscosity.

•

Repair or replace.

(5)

End faces of gear teeth damaged

(6) Distorted or broken forks

(1) Not enough oil, or oil is dirty

(2)

Too much backlash

(3)

Worn, damaged or rattling

bearings

(4)

Excessively worn shaft splines

(5)

-Damaged or worn gear teeth,

or improper tooth contact

(6) Bevel gear out of adjustment

(7)

Gears out of alignment, or teeth distorted

•

Repair or replace.

•

Add or change.

•

Change gears:

•

Adjust or replace.

•

Repair or replace.

•

Repair or replace.

•

Adjust.

.

•

Adjust, or replace.

Remarks

(

I.

22


Bevel gear

Complaint

Excessive gea"r noise

Oil becomes too hot

Oil leakage

Abnormal wear

Possible cause

(I)

Gear oil wanting or dirty


(4) Cracked case

(I) Gear oil not enough, dirty or of wrong kind

Remedy

•

Add or change.

•

Adjust.

Remarks

•

Noise on turning to one side means some

rattling condition

due to worn splines, loose bearings or excessive backlash.

(3)

Bearings worn down,

damaged or loose

• Adjust or replace.

(4) Damaged or 'vorn gear teeth

•. Repair or repl;lce. or poor tooth contact

(5) Bevel gear improperly installed

•

Adjust.

(I)

Gear oil wanting or dirty,

or of wrong kind

• Add or change.

•

Adjust or replace. (2) Backlash too much or too little

(3) Bearings too tight, too loose, or damaged

• Adjust or replace.

(4) Bearings out of alignment

(I)

Too much gear oil, or oil viscosity too low

• Misalignment could be the cause.

• Raceways could be in cracked, spalled

or otherwise

damaged condition.

•

Adjust.

•

Remove excess oil

to hold oil level as prescribed, or change oil by one meeting

viscosity specification.

• Leakage of oil into steering clutch side

incapacitates this

device.

(2) Defective oil seal

(3) Portions of shaft in contact

with oil seals worn

• Replace.

• Repair or replace.

•

Loose bearings cause

shaft to wobble and thus promote oil leakage even if oil

seals are in sound condition.

•

Repair or repJace.

•

Add or change.

• Change oil if metal

particles are noted in

oil. Such particles or gritty matter pro-

motes wear.

(2) Bevel gear out of adjustment

•

Adjust.

23


Steering clutches and brakes

Complillnt Possible cause

Clutch slips (overheats) (I) Control linkage out of adjust-

ment

(2) Dnings dirty

Clutch drags

Remedy

•

Adjust.

Rem~rks

•

Check 'ever free play.

(3) Disc plates and friction plates not capable of smooth sliding

movement

>.

• Wash with gasoline, or replace the disc plates.

•

Investigate to locate a point through which oil is entering clutch case. Wash case

interior c1ean, as necessary.

•

Repair drums and

•

Be sure that each plates, eliminating disc plate moves offsets

<ir any smoothly in or on ifregularity inter-

drum.

fering with smooth axial sliding move-

m.ent..

• Replace plates.

(4) Spalled, flaked or damaged linings of disc plates

(5) Weakened or broken clutch springs

(6) Disc plates and friction plates warped

(7) Defective clutch cylinder

(I)

Clutch out of adjustment

(2) Excessive rattle in steering control linkage

(3) Worn or damaged release bearing

•

Replace.

•

Habitual "half-clutch"

operation tends to

overheat clutch and

thus weakens springs.

• Repair or replace. •

Warped plates are usually a result of

overheating, for .which

habitual "half·clutch" operation is usually to blame.

•

See the topic,

"Steering clutch cy1inder."

•

AdjUSt.

•

Adjust.

(4) Dirty disc linings.

(5) Disc plates and friction plates

sticking or warped

(6) Defective clutch cylinder

• Replace. • Grease bearing fully at the time of reassem bly.

•

Clean by washing, or replace ..

•


• Warped disc plates are

I caused by overheating

resulting from habitual

"half·clutch"

operation.

•

See the topic,

"Steering clutch cy1inder. "

24


Complaint

Not enough braking force

Dragging brake

Possible cause

(I)

Brake out of adjustment

(2)

Brake lining dirty

Remedy

Remarks

•

Adjust.

•

Clean by washing. •

Be aware of possibility of oil leaking in from final drive case and bevel gear

case. Drain out oil and water,

if any, now and then.

•

Rephice.

(3) Lining worn down, with rivet heads in rubbing condition

(4)

Brake band warped, broken or otherwise damaged

(5)

Dragging clutch

(J) Maladjustment

•

Repair or replace.

•

Adjust or repair.

•

Dragging clutch is often cause of apparent poor braking.

I

I

I

•

Adjust as prescribed.

•

Uneven or inade·

quate band-to·drum clearance is likely to

result in overheating.

Readjustment is necessary if pulling steering clutch lever just a little causes

machine to turn.

(2) Return spring weakened

(3)

Brake band distorted

•

Readjust or replace.

•


Steering valve

Complaint

Jerky movement

Poor returning action

of piston

Possible caUse

(1) Foreign particles lodged between valve (plunger) and bore

Remedy

•

Disassemble and clean.

Change hydraulic oil if dirty.

(2) Weakened or broken return spring

(3) Valve (plunger) and bore worn

(I) Foreign particles lodged

between piston and bore

(2)

Weakened or broken valve

spring

•

Replace.

•

Replace.

• Disassemble and clean.

•

Replace.

Remarks

25

TESTING AND ADJUSTMEN'T

Steering clutch cylinder

Complaint

Clutch drags or grabs

Clutch slips, resulting

in no power flow

Possible cause

(1)

Oil leaks inside cylinder

(2) Valve (plunger) and bore worn

(3) Relief valve out of adjustment

(4) Air leaks at pipe joints

Steering control valve defective

•

•

Remedy

Repair or replace.

Repair or replace.

•

Adjust.

•

Retighten.

Repair or replace.

Final drives

Complaint

Noisy

Overheating

Oil leakage

Remarks

Possible cause

(1) Not enough gear oil, or dirty gear oil


Remedy Remarks

• Add or change. • After working machine on muddy or flooded ground, check oil for con· tamination by examining oil sampled out of drain point.

•

Repair or replace.

• Loose bearings or worn shaft promotes

tooth wear, resulting in excessive backlash.

•

Repair or replace.

(3) Worn or damaged shaft or teeth

(I) Not enough gear oil, wrong klnd of oil or dirty oil

(2) Damaged bearings

•

Add or change.

•

Replace.

(1)

Too much gear oil, or oil viscosity too low

•

Remove excess oil or use gear oil of

proper viscosity.

•

"Damage" here means

spalled or chipped

bails, rollers or race-

ways or broken cages.

Inspect bearings very carefully,for bearing trouble can result in costly major repair.

•

Oil leakage into

steering clutch case

results in slipping clutch.

(2) Faulty oil seals

(3)

Bolts securing case or cover are loose, or packings are

broken

•

Replace.

•

Retighten. Replace broken packings.

26

I.


Complaint

Sprocket rattles

Sprocket teeth wear abnormally

Side faces of sprockets

wear

Possible cause

(I) Worn or damaged bearings

Remedy

•

Replace.

Remarks

• Damaged bearings

escape notice because

their effects usually show up when mao

chine is running.

If the sprocket is suspected to rattle, check its bearings immediately.

(2) Worn splines in fit of sprocket to its shaft

(I) Track chain stretched (due to permanent elongation)

(2)

Master pin worn

(3) Side faces of sprocket teeth

worn

• Replace.

• Replace pins and bushings.

• Replace.

• Repair by welding or

•

Abnormal sprocket replace.

tooth wear is often

due to misalignment of sprocket, track

rollers and front

idler or of the track frame. When check· ing these for align· ment, check track

frame, too, for mis-

alignment particu· larly at its front end.

(I) Track frame misalignment relative to sprocket

(2) Front idler mispositioned in

place, or its wear strips excessively worn

(3)

Track chain insufficiently

tensioned

(4)

Track pin bushings badly worn

•

Adjust.

• Repair by welding or

• With pin bushings replace. badly worn, track

moves in wavy fashion to rub side faces

of sprocket.

(5) Too much axial play of track

rollers

(6) Track frame distorted

• Realign frame.

•

Reposition and adjust

•

Front idler, track

idler, or"replace wear rollers and sprocket

strips. wheel must be in perfect alignment in

fore-aft direction or

side faces of sprocket and links or track roller flanges will rapidly wear off.

•


• Repair.

27


Undercarriage

Complaint

Front idlers, track rollers

and carrier rollers wear

abnormally

Possible cause

(I)

Improper installation or mis-

alignment

(2)

Track frame misaligned relative, to chassis

(3) Distorted track frame

(4) Worn link pins and bushings

(5) Front idler and track rollers have too much axial play

(6) Track links worn

(7) Loose track chain

'Rollers tend to overheat, or will not roll

(I) Inadequate lubrication

(2)

Rolling clearance between

bushing and shaft too small, or roller has little or no axial play

Remedy

•

Check position of each and set it correctly.

• Adjust.

Remarks

•

So that track chain

will move straight,

front idler and other rollers must be lined up straight. This is particularly important for front idler.

•

Track frame must be trued up with respect to sprocket, and two frames, right and left, must 'be perfectly parallel.

• Repair. • Refer to (4).

•

Repair' or replace.

•

Track chain will move in wavy fashion to rub roilers and sprocket

if pins and bushings are worn down.

•


•


(Sec,ure specified linkheight.)

•

Tension track.

• Track chain will oscil·

late sidewise to promote wear of flange parts of rollers

if idler and rollers

have too much

sidewise play.

•

This rnalcondition

allows roller flanges to rub link bosses.

•

An insufficiently ten-

sioned track promotes flange wear.

•

Disassemble and lubricate.

•

Loss of lu bricant is

often accompanied

by presence of muddy

water in rolling clearance. Such muddy water means

that floating seal has failed.

•


I

\

28


Complaint

Abnormal noise from undercarriage

Possible cause

(3) Interference between track roller and track frame, or foreign matter lodged between the two

(4) Unevenly worn rollers

(5) Track tensioned too tight

(6) Bolts securing roller shaft bushings broken·

(I)

Loose shoe bolts

(2) Bolts securing roller shaft collar loose

(3) Bolts securing roller shaft bushing broken or missing

(4) Track pitch elongation

(5) Interference of track chain

with roller flanges

Remedy Remarks

• Adjust axial play of •

Interference is likely

shaft, or remove

to occur when bushing foreign matter. end faces are worn, .

resulting in excessive

axial play of shaft.

•

Repair. •

"Uneven wear" means

here localized wear

due to abrasive con-

tact between a stuck roller and track.

•

Adjust. •

This condition is often due to recoil spring being fouled up with

dirt, sand, etc.

•. Disassemble and

repair.

• Retighten. •

This retightening should be carried out as early as possible; otherwise the whole shoe assembly would fail beyond repair.

•

Retighten.

•

Disassemble and

repair.

•

Replace link pins and bushings.

•

Repair.

•

This condition not only gives rise to noise

but also promotes

wear of rollers.

•

This condition is evi-

denced by shiny metal

surfaces on roller

flanges and side faces of sprocket teeth and, ifleft unheeded, will result in the kinds of

wear already mention-

ed.

29

TESTING AND--ADJUSTMENT

Complaint Possible cause

Track chain tends to get

(I)

Track tension not enough

off idler and rollers

(2)

Froni idler mispositioned

Remedy

• Adjust.

•

Relocate idler to

correct position.

•

Adjust or replace.

Remarks

(3)

Recoil spring insufficiently preloaded or broken

(4)

Roller flanges worn

(5) Abusive steering by operator

(6) Sprocket teeth worn

•

Repair or replace.

• Avoid backing and sharp turning on rough ground.

• .Repair by welding.

•

Refer to Complaint

"Pront idlers, track rollers and carrier rollers wear abnormally."

(

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DEC.a6


Pub. No.

99879-00120-

4

/

SERVICE MANUAL

MITSUBISHI

TRACTOR··

BD20··

. TRACTOR SHOVEL

BS3G

CONTENTS

DIRECT POWERSHIFTTRANSMISSION

• OPERATING PRINCIPLE

• TESTING AND ADJUSTMENTS

• MAINTENANCE STANDARDS

• DISASSEMBLY AND REASEMBLY

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FOREWORD


Correct servicing will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.

Safety is not only your concern but everybody's concern. Safe working habits cannot be bought or manufactured; they must be learned through the job you do. By learning what CAUTION or WARNING symbol emphasizes, know what is safe what is not safe. Consult your foreman, if necessary, for specific instructions on a job, and the safety equipment required.



[ NOTE) ..............

An operating procedure, condition, .etc., which is essential to highlight.

.&.r

CAUTION)

....... Operating procedures, practices, etc., which if not strictly observed, will result in damage to or destruction of machine .

. . . . . . Operating procedures, practices, etc., which if not correctly followed, will result in personal injury or loss of life.

TABLE OF CONTENTS

OPERATING PRINCIPLE

General description

Power train

2

2

Damper

DPS transmission

7

8

Description 8

Hydraulic control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. II

Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13


DPS transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24

Adjusting the inching pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31

Adjusting the transmission control lever . . . . . . . . . . . . . . . . . . . . . . . .. 31

Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32


DPS transmission .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38

Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

DISASSEMBLY AND REASSEMBLY

DPS transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44

Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Disassembly and reassemb.ly ., ... " ................. ' ...... 47

Transmission control valve

Transfer

61

................................................. 63

Bevel gear

............................................... 65

Damper 66

(

\.

( !

OPERATING

PRINCIPLE

OPERATI NG. PR iNCIPLE

POWER TRAIN

GENERAL DESCRIPTION

2 3

602306

2

1 Engine

2 Damper

3 Universal joint

4 Transmission

5 Transfer

6 Bevel gear

7 Steering clutch

8 Final drive gear

9 Track

10 Hydraulic pump

11 Transmission oil pump

Power train

602307

The power train of direct powershift model consists of, from engine "I" to track "9," damper "2," universal joint "3," transmission "4," transfer "5," bevel gear

"6," steering clutch "7" and final drive

gear

"8."

Power developed by the engine is transmitted through damper and universal joint to the transmission. The transmission has three forward speeds and three reverse. From the transmission output shaft, power flows to the final drives, right and left, through transfer, bevel gear and steering clutches, right and left.

The tracks are driven by the sprockets of final drives.

The engine and damper are coupled together integrally and are mounted on the frame by four mounts fitted with barrel-shaped vibration-insulating rubber pads.

The transmission and transfer are housed in a single case, which is rigidly bolted to the front face of steering clutch case.

OPERATING PRINCIPLE

3

POWER TRAIN

~

Engine

1

Universaljolnt 3

Transmission 4

Damper 2

Transmission oil pump 1]

Final drive 8 clutch 7

OPERATING PRINCIPLE

602308 j)\";~d' T"'O"'\4".f'~1\, ~J

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DAMPER

OPERATING PRINCIPLE

2

- - - 3

1 Coil spring

2 Friction plate

3 Flywheel

Damper

The damper consists essentially of six coil springs "1" and two friction plates "2."

Its hub is splined to the shaft and one of the friction plates is bolted to the flywheel.

The combination of coil springs and friction plates absorbs power impulse from the engine which would otherwise be transmitted directly to the gears in the transmission as when the engine is quickly accelerated or decelerated and shocks from the ground through power train.

'002309

7

OPERATING PRINCIPLE

Description

DPS TRANSMISSION

13

~'---17

5

(

1 Reverse clutch

2 Forward clutch

3 3rd-speed clutch

4 2nd-speed clutch

51st-speed clutch

6 Input shaft

7 Output shaft

8 Sun gear

9 Planet gear

10 Ring gear

11 Carrier

12 Piston housing

13 Piston

14 Ma ting plate

15 Friction plate

16 Return spring

17 Bevel pinion

18

Gear pump

19 Oil filter

602310

8

OPERATING PRINCIPLE

8

9 10

11 12

13

14

2 3 16

602311

1 Reverse clutch

2 Forward clutch

3 3rd-speed clutch

4 2nd-speed clutch

51st-speed clutch

6 Input shaft

7 Output shaft

8 Sun gear

9

Planet gear

10 Ring gear

11

Carrier

12 Piston housing

13 Piston

14 Mating

This transmission consists of five sets of planetary gear train, each having a hydraulically controlled clutch pack, control valve, oil pump, oil filter and their related parts. plate

15 Friction plate

16 Return spring

17 Bevel pinion

18 Gear pump

19 Oil filter

Each planetary gear set comprises sun gear "8," planet gears "9," carrier "11" and ring gear "10." The sun gear rotates; the carrier revolves; and the planet gears rotate on their own shafts or pins and revolve with the carrier, on which they are mounted.

The two planetary gear sets on the input side are for directional control - forward or reverse drive and the remaining three sets on the output side are for speed selection 1st-speed, 2nd-speed or

3rd-speed dri ve.

9

OPERATING PRINCIPLE

Let us see the paths of power flow in the transmission in forwrd 1st speed position and in reverse position.

Friction plates "15" are engaged with the external splines of ring gear "10" and mating plates "14" with the internal splines of housing "12." "To engage the clutch" is to admit the pressure oil from the control valve into the piston chamber of housing "12."

By the admitted oil, piston "13" pushes the stack ·of the friction and mating plates to compact them together. "To disengage the clutch" is to relief this pressure. When the pressure is removed from the piston, return springs "16" push the piston back to loosen the stack of the plates.

In forward 1st speed position, forward clutch "2" and 1st-speed clutch "5" are engaged. Because forward ring gear "10" is locked, power from input shaft "6" flows to carrier "11" through sun gear

"8." From this carrier "11," the power flows to the sun gear of 1st-speed clutch through carrier and then to output shaft

117. f1

In reverse position, reverse clutch "1" is engaged. In this case, the reverse carrier is locked, and the reverse sun gear and ring gear rotate in reverse direction. The flow of power from this ring gear is similar to that in forward 1st ·speed drive.

From the output shaft, power flows through single-stage-reduction transfer gear to the bevel pinion.

Forward 2nd speed position

Forward 3rd speed position

Reverse 1st

speed position.

ReverSe 2nd speed position

Forward lst speed position

Reverse 3rd speed position

5

17

602312

10

602313

602317

(

OPERATING PRINCIPLE

Hydraulic control circuit

10

6

-

16

7

15

2

602318

1 Suction strainer (with magnet)

2 Oil pump

139.3 liters (10.4 U.S. gaO/min at 2400 rpm!

3 Main relief valve

119 - 22 kgf/cm' (270 - 313 psi) [1.86 - 2.16 MPa)1

4 Accumulator valve

13 - 13 kgf/cm' (42.7 - 185 psi) [0.29 - 1.27 MPaJi

5 Main orifice

6 Speed selector valve

7 Differential valve

I

Differential pressure: 2 kgf/cm' (28.4 psi) [0.20 MPa)!

8 Directional selector valve

9 Inching valve

10 - 5 kgf/cm' (0 -71 psi) [0 - 0.49 MPa]!

10 Main relief pressure test port ("M")

11 Speed clutch pressure test port (liS

II)

12 Directional clutch pressure test port (liD

II)

13 Oil cooler

14 Oil filter

I

Bypass pressure: 1 kgf/cm' (14.2 psi) [0.10 MPa]1

15 Lubrication relief valve

II -

2 kgf/cm' (14.2 - 28.4 psi) [0.10 - 0.20 MPa]!

16 To steering valve

11

12

OPERATING PRINCIPLE

The hydraulic control circuit consists essentially of suction strainer "I," oil pump "2," main relief valve "3," oil cooler

"13," oil filter "14," lubrication relief valve "15," control valve and steering clutch circuit.

Suction strainer "I" is a 100-mesh stainless type element with a magnet and serves to protect oil pump "2."

Oil pump "2" is of external gear type and is driven by the gear to which drive is transmitted from the transmission input shaft.

Oil cooler "13" is of multi-plate type and is mounted on the bottom side of engine radiator.

Oil filter "14" is of cartridge type.

It opens its bypass circuit when its element is clogged and the pressure difference across it exceeds 1.0 kgf/cm 2 (14.2 psi)

[0.10 MPa] to maintain constant flow of oil to the lubrication circuit.

Lubrication relief valve "15" maintains the oil pressure in the lubrication circuit at 1 to 2 kgf!cm 2 (14.2 to 28.4 psi) [0.10 to 0.20 MPa] for protection.

The oil in the oil sump is lifted by oil pump "2" through suction strainer "1." Oil from the pump flows into two circuits, one leading to the steering valve for actuating the steering clutches and the other to· main relief valve "3" for actuating the clutch pistons of planetary gears.

After delivering the main pressure, the excess oil is cooled by oil cooler "13," flows through oil filter "14," lubricates planetary gears and transmission parts, and gravity-returns to the oil sump for recirculation.

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1 Oil strainer

2 Oil pump

3 Main relief valve

4 Steering valve

5 Steering clutch cylinders

6 Oil cooler hoses

-

6

602319

Transmission control valve o Description o

0 o o

OPERATING PRINCIPLE

602320

1 Main relief valve

2 Accumulator valve

3 Speed selector valve

4 Directional selector valve

This control valve comprises accumulator valve "2," inching valve "5," differential valve "6," directional selector valve "4" and speed selector valve "3."

(1) Accumulator valve

"I" gradually rises the oil pressure in the clutch piston chamber to insure smooth clutch engagement (smooth starting).

(2) Differential valve "6" keeps the pressure applied to the directional clutches (forward and reverse clutches) lower than the pressure applied to the speed clutches

(1st-speed, 2nd-speed and 3rd-speed clutches) by 2 kgf/cm 2 (28.4 psi)

[0.20 MPa). Consequently, the speed clutch is engaged earlier than the directional clutch and the directional clutch serves to transmit the power.

(3) Directional selector valve "4" directs the oil to either forward clutch

5 Inching valve

.6 Differential valve

7 Neutral switch piston chamber or reverse clutch piston chamber.

(4) Speed selector valve "3" directs the oil to any of the 1st-speed,

2nd-speed and 3rd-speed clutch ports.

(5) Inching valve "5," actuated by the inching pedal, reduces the pressure in the forward or reverse clutch piston chamber to control the clutch in transition from full engagement to full disengagement for moving the machine in an inching manner.

(6) Main relief valve

"I" maintains the pressure of oil discharged from the pump. Because of this valve, the pressure applied to the clutch piston chambers is always constant and fUll-flow oil is supplied to the lubrication circuit except when oil is supplied chambers. to clutch piston

13

OPERATING PRINCIPLE o Operation

The control valve operation will be described on the assumption that the transmission control lever is moved from neutral to forward 1st speed position.

[NEUTRAL position]

As the engine starts, main pressure is applied through main port "2" to speed selector valve "3" and accumulator valve pressure chamber "4."

Speed selector valve "3" is in neutral position, covering the port leading to the

1st-speed clutch piston chamber. As the pressure rises in the cham ber "4," accumulator valve "1" moves to the left to 'cover main port "2." Now, a circuit through main orifice "5" is formed to allow the oil from the pump to flow into the chamber "4" for pressure accumulation. This pressure accumulation continues until the accumulator valve comes to the left end of its stroke. f~{i]

Main pressure

2

(

602321

14

OPERATING PRINCIPLE

[FORWARD 1ST SPEED position]

1.

Pre filling of 1st-speed clutch piston chamber

When the transmission control lever is moved from neutral to forward 1st speed position, speed selector valve "3" moves to "1st speed" position and directional selector valve "6" to "forward" position, uncovering 1st-speed clutch port (C1) and forward clutch port (CF) respectively.

Under this condition, the pressure is being applied to the 1st speed clutch piston chamber but it is not applied to the forward clutch piston chamber yet.

The moment the oil in accumulator valve pressure cham ber "4" enters the 1st-speed clutch piston chamber for prefilling, accumulator valve "1" returns to the right end to. uncover main port "2." Now, a circuit bypassing main orifice "5" is formed to assist in prefilling the

1st-speed clutch piston chamber.

Neutral

1st speed

-

2nd speed

3rd speed

4

[~@~

Main pressure

II

Speed (1st) clutch

pressure

3

...

6

....

Reverse

Forward

602322

15

16

OPERATING PRINCIPLE

2. Pre filling of forward clutch piston chamber

Upon completion of prefilling the

1st-speed clutch piston chamber, the speed clutch pressure rises beyond 2 kgf/cm 2 (28.4 psi) [0.20 MPa]. This pressure moves differential valve "7" to the left end, allowing the speed clutch pressure oil to enter forward clutch pressure port (CP) through inching valve

"8.

11

Since accumulator valve "1" does not move yet, keeping main port "2" uncovered, the oil from the pump flows into the forward clutch piston chamber without being metered.

1st speed

JI!==:;!

~!~

Main pressure

• Speed (1st) clutch pressure

1i®1

Directional (forward) clutch

H@"

pressure

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-

602323

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OPERATING PRINCIPLE

3. Modulation action

Upon prefiJIing the forward clutch piston chamber, differential valve "7" is returned to its pressure regulating position for maintaining the difference between the

1st-speed clutch pressure and forward clutch pressure at constant level (2 kgf!cm 2 (28.4 psi) [0.20 MPa]) and, at the same time, accumulator valve "1" starts moving to the left to cover main port

112.11

Then, only the oil metered by main orifice "5" flows into the 1st-speed clutch circuit to move accumulator valve "I" slowly and to increase both forward and

1st-speed clutch pressures gradually. This is called "modulation action."

Since the speed clutch pressure is always higher than the directional clutch pressure, the 1st-speed clutch and forward clutch are engaged in· that sequence. This means that shock produced during shifting is arrested by the forward clutch. Both forward and 1st-speed cl utches are engaged during this modulation action to insure smooth shifting.

1st speed

1m

Main pressure

II

Speed (lst) clutch pressure

/l:Wm

Directional (forward) clute

~~.;.~<:.

pressure

...

Fonvard

602324

17

OPERATING PRINCIPLE

4. Completion of shifting

When accumulator valve "I" comes to the left end of its stroke, bypass orifice "9" opens again and the 1st-speed clutch pressure rises rapidly to the level of main pressure. Thus, shifting into forward 1st speed is completed.

Differential valve "7" still remains in the pressure regulating position. This keeps the forward clutch pressure lower than the 1st-speed clutch pressure by 2 kgf/cm2 (28.4 psi) [0.20 MPa].

In the operation for shifting into other speeds, too, differential valve "7" is returned to the right end of its stroke for draining the directional . clutch pressure, because the speed clutch pressure decreases in advance. Susequent actions are the same as those described for neutral to forward 1st speed shifting.

9

li]

Main pressure and speed (Ist)

..... :.; clutch pressure

I,ll

~~~~~~enal

(forward) clutch

I

7

602325

18

OPERATING PRINCIPLE

5. Inching action

The inching valve regulates the directional clutch pressure for driving the machine in an inching manner or extremely slowly. Inching valve plunger

"I" is connected to the inching pedal

(left pedal) through rod.

As long as the inching pedal is in released position, plunger "I" is kept pushed to the left end of its stroke by return spring "2." Under this condition, prImary pressure in passage "3" is admitted into secondary pressure passage

"4," thus maintaining 21 kgf!cm 2 (299 psi)

[2.06 MPa] pressure there.

5 3 4 6

7 o

o

8

2

1 Plunger

2 Re turn spring

3 Primary pressure passage

(from differential valve)

4 Secondary pressure passage

(to directional selector valve)

21 kgf/cm

(299 psi)

2

[2.06 MP.)

Stroke (mm)

5 Valve

6 Pressure regulating spring

7 Spring

8 Oil passage

602326

19

OPERATING PRINCIPLE

As the inching pedal is depressed, plunger

"1" is moved to the right. When it is moved 4 mm (0.16 in.), valve "5" meters the oil flowing into passage "4" from passage "3" and, at the same time, starts draining oil from passage "4" to the oil sump through passage "8" to reduce the directional clutch secondary pressure down to 5 kgf/cm 2 (71 psi) [0.49 MPa].

5 3 4 l!...!.I

o

l!...!.I

8

4 mm (0.16 in.)

5 kgf/cm2 (71 psi)

[0.49 MPa] o

L--'-c------:..:-=:=..!_

5 10 15

S(Ioke (mm)

602327

As the inching pedal is farther depressed, pi unger "1" is moved to the position indicated. Now, pressure regulating spring

"6" becomes expanded and pressure proportional to the load this spring so expanded is builtin the pressure cham ber, decreasing secondary pressure (PD2)' Thus secondary pressure (PD2) varies from 5 to o kgf/cm 2 (71 to 0 psi) [0.49 to 0 MPa] within the range of 4 to 16.5 mm (0.16 to 0.65 in.) stroke of plunger

"1."

( l"""

BIIID

. r - .

) -'(C

~

'-'--"

!V

J

~

6

1

Iri

I

I· I

1

VY

WU

~ ~

",N

BE

~

0

20

'0

'a

~c

10

r--

0 lP

4 mm (0.16 in.)

5 kgf/cm2 (71 psi)

10.49 MPa] t

16.5 mm (0.65 in.) o kgf/cm2 (0 psi)

J

[OIMPa]

5 10 15

Stroke (mm)

602328

20

OPERATING PRINCIPLE

When· the inching pedal is depressed all the way and plunger "1" is moved 16.5 mm (0.65 in.) of its stroke, pressure regulating spring "6" restores to free state, causing spring "7" to move valve

"5" to the right. This will completely stop oil flow to passage "4," and passage

"4" and passage "8" are communicated to each other without being metered.

Consequently, secondary pressure falls to zero and the machine is brought into a complete stop as in neutral.

In summary, the inching pedal may be used like the clutch pedal of a directdrive model. The machine can be started smoothly by depressing the inching pedal quickly all the way to the end of its stroke and then releasing it gradually to a position within the range of 4 to 16.5 mm (0.16 to 0.65 in.) of the stroke of plunger "1," depending on the load, to gradually increase the pressure acting on the directional clutch piston.

4 6

7 o

8

o

o

16.5 mm (0.65 in.) o kgf/ em'

[0 MPa}

(0 psi) o

'--J..;---;~"';';"-

5 10 15 p

Stroke (mm)

602329

21

TESTING

AND

ADJUSTMENT


DPS TRANSMISSION

Inspection

A good program of diagnosing and testing has three basic steps.

1.

Asking the operator

You can ge t the full story from the operator; he will tell you how the system or the machine acted when it began to fail, what was abnormal about it. Ask about how the machine was used, when it was finally serviced. Remem bel', most failure are usually traced to poor servicing or abuse of the machine.

2. Checking the machine

(1) Check the oil level in the transmission.

(2) Check the transmission case and oil lines for any· sign of leaks.

(3) Check the inching pedal and transmission control lever linkages for adjustment.

3. Operating the machine

Get on the machine and operate it for testing. During the test, shift the transmission into all gears, forward and reverse, and operate the inching pedal. If the machine fails to start smoothly, or if inching or shifting is hard, see

Troubleshooting guide, which follows.

Testing the clutches for slippage

(1) Start the engine, depress and lock the brake pedal.

(2) Run the engine at maximum speed, and move the transmission control lever into forward 2nd speed position.

(3) If the engine stalls as soon as the transmission control lever is shifted, all clutches are not slipping.

2nd-speed) is slipping.

If it does not stall for more than 3 seconds, or if it does not stall at all,

;any: of the clutches (forward

24


Trouble diagnosis by oil pressure readings

1.

If transmission shifts hard:

,

Possible cause

Remedy

Complaint

No shift to some speeds.

"M" port pressure: Normal

"D" and "S'! port pressures:

Abnormally low - not higher than 10 kgf/cm' (142 psi)

[0.98 MPa]

(I)

Clutch piston sealing ruptured

(2) Control valve gasket ruptured

(3) Absence of O·ring or broken a-ring in pipe between trans-

mission case and clutch case

(4) Oil hole blanking ball off

• Disassemble and replace.


•

Disassemble and install a-ring or replace broken one.

• Fit ball by driving.

No shift to all speeds.

No shift to some speeds.

"M," "DOl and "S" port pressures

all normal.

(I) Defective oil pump

"M," "D" and US" port pressures:

(2) Clogged oil passage between

All low - not higher than

strainer and pump, between pump

10 kgf/cm' (142 psi) and line fIlter or between filter

[0.98 MPa]

and control valve; or leakage

1(3)

Main relief valve sticking

No shift to all gears.

"M" port pressure:

Normal

"D" and "S') port pressures:

Both gone (0 kgf/cm')

• Replace.

•

Check and clean clogged part by flushing; or repair leaking point.

• Disassemble and clean.

Neutral safety valve in malcondition due to weakened spring, foreign

matter stuck on valve seat, or sticky

Disassemble, clean by washing and repair or replace. Weakened spring must be replaced.

! valve

I

Clutch plates burnt or friction-material

Disassemble and replace. surfaces lost due to peeling

If forward clutch plates burnt and

seized:

Machine starts on F 1, F2 and F3 but engine stalls on RI, R2 and

R3.

If 1st-speed clutch plates burnt and

seized:

Machine starts on FI and RI but engine stalls on F2. R2, F3 and R3.

25


2. If shock is felt when shifted:


Indicating hand of pressure gauge -

Accumulator valve sticking jumps momentarily from 0 to 21 kgf/cm' (299 psi) [2.06 MPa] on shifting" to any speed.

Indicating hand of pressure gauge

(I)

Clutch piston sticking jumps momentarily from 0 to 21 kgf/cm' (299 psi) [2.06 MPa] on shifting to some speeds.

(2) Accumulator valve sticking

Remedy

..

Wash valve body, check bore for .'

damage and, as necessary, replace

valve and bore, if valve does not move sliding smoothly.

•

Disassemble and repair or replace.

•

Refer to above.

(The same trouble occurs unless slug is inserted properly.)

3. If time lag in shifting is excessive:

NOTE: Normally machine starts within 0.9 second in standing start.

Complaint

Possible cause

Lag is large in shifting from N to

(I)

Accumuiator valve sticking

I and from N to 2, but is normal in shifting from 1 to 2 and 2 to I.

Indicating hand takes 2 seconds or more in deflecting from 0 to

21 kgf/cm' (299 psi) [2.06 MPa].

(2) Accumulator valve spring weakened

Indicating hand takes longer time than normal to deflect from 0 to 21 kgf/cm' (299 psi)

[2.06 MPa] upon shifting to any speed.

(I) Accumulator valve sticking

(2) Accumulator valve spring

weakened

(3)

Main orifice clogged

(4)

Insufficient pump output

Indicating hand takes longer time than normal to deflect from 0 to 21 kgf/cm' (299 psi)

[2.06 MPa] upon shifting to some speeds.

(I) Clutch piston sealing ruptured

(2) Absence of O-ring or broken

O-ring in pipe between trans~

mission case and clutch case'

Remedy

•

Wash valve body, check bore for

damage and,

3S necessary, repJace

valve and bore, if they do not· move sliding smoothly.

•

Replace . .

• Ref~r t.o above.

• Replace.

•

Disassemble and clean.

•

Disassemble and clean clogged parts of lines.

•

Disassemble and replace.

•

Disassemble and install O-ring

or replace broken one.

"

(

26


4. If inching pedal malfunctions:

Complaint

Clutch grabs even if inching pedal is depressed.

"M," US" and uDI> port pressures: Nonnal

Clutch grabs even if inciting pedal is depressed.

"Mil and

"S"

port pressures: Nonnal

"D" port pressure: Does not

drop to 0

kgf/cm

2

Releasing inching pedal after fully depressing causes machine

to jerk in standing start.

<1M" and "S" port pressures:

Normal

"D" port pressure: Rises but not smoothly as pedal mOves in releasing direction.

Releasing inching pedal quickly falls to make machine pick up speed quickly: machine slarls off slowly.

UM" port pressure: Normal

"D" port pressure: Changes in the normal manner.

"S"

port pressure: Nonna}

(does not drop).

Possible cause

Clutch plates in forward or reverse clutch seized

(l) Control linkage maladjusted

(2)

Clutch valve defective

,

Clutch valve sticking

I

NOTE: If S·mm (0.31-in.) dia. rod is positioned the other way around, clulch valve will not function properly.

Pilot valve sticking

NOTE: Be sure slug is correctly positioned. With slug mispositioned, pilot valve

behaves as it were sticky.

Remedy


•

Check and adjust.

•

Disassemble; wash and repair

replace.

or

Disassemble and clean by washing.

Replace 3-piece spool as necessary.

Be sure g·mm (031.in.) dia. rod is

correctly positioned.

Wash valve body. Check accumulator valve orifice for damage.

Replace valve and body as neces-

sary.

27


5.

If transmission overheats:

Complaint

Possible cause

"M,I) "D" and uS"'port pressures

(I) Oil level too high are normal or slightly lower.

(2)

Oil level too low

"M," "D" and USH port pressures are normal

(1)

Clutch plates seized

(2) Mechanical trouble inside

transmission

6.

If output power is not enough:

Complaint

Possible cause

"M," "D" and

US" port pressures

Oil level too low

are low.

'1M," "D" and "S" port pressures

(1)

Engine lacks power

are normal.

(2) Mechanical trouble inside

transmission

7.

If oil pressures are high:

Complaint

Possible cause

"M," "D" and "S" port pressures

(I) Main relief valve sticking rise above 21 kgf/cm' (299 psi)

[2.06 MPa].

(2) Main relief valve spring defective or shim adjustment improper

Remedy

•

Lower oilleve!.

•

Raise oilleve!.

•


•

Overhaul and replace defective parts.

Remedy

Add oil.

•

Tune up engine.

•

Overhaul and replace defective parts.

Remedy

•

Disassemble and wash.

•

Replace or readjust by shim-

mingo

28

Testing the control valve

Connect an oil pressure gauge to each of

"JIll," "S" and "D" ports in testing the hydraulic pressures with the control valve mounted on the transmission. When running the transmission and control valve on the bench in order to break them in, be sure to form an oil cooler bypassing circuit by connecting two rubber hoses, one leading to the cooler inlet and the other from the cooler outlet.

TESTING AND ADJUSTMeNT

1 Main pressure: "M" port

2 Speed clutch (1st-speed, 2nd-speed and 3rd-speed) pressure: "S" port

3 Directional clutch (forward and reverse) pressure: "D" port

602330

29


Pressure designation

Main pressure

Port and gauge connection

M port; PF

1/8"

connection with

O·ring

1st·speed,2nd·speed and 3rd·speed clutch

pr.essure

:Forward and reverse clutch pressure

Sport; PF

1/8"

connection with

O·ring

D port; PF

1/8"

connection with

O·ring

Speed clutch

pressure

Sport; PF

1/8"

connection with

O·ring

Pressure requirement

With engine running at high idling speed and contro11ever kept in neutral, this pressure is required to take the following value:

21 kgf/cm

2

(299 psi)[2.06 MPa]

If not, adjust setting of main relief valve by increasing or decreasing thickness of its shim.

With'engine running at high idling speed, this pressure is required to remain at a level.equal to

main pressure.

With engine running at high idling speed, this pressure is required to take the follOwing value: o kgf/cm

2 for both clutches with control lever

in neutral.

,

Not lower than main pressure by 2 kgflcm

2

(28.4 psi) [0.20 MPa] , with control lever in

1st, 2nd or 3rd speed pOSition.

Measure time required for pressure to change

and residual pressure when control lever is shifted from neutral to any position, or from

one position to another.

Shifting

N

'--.

1

1 ~ 2

2

--->

+--

3

Time

0.7- 1.3 sec.

0.4 - 1.0 sec.

0.4 - 1.0 sec.

Bench test criteria for transmission oil pump

Direction of rotation

Hydraulic oil

Pump drive speed

Discharge flow

Clockwise (as viewed from drive gear side)

Engine oil, SAE lOW, 50° ± 5°C (122° ± 9°F)

2600 rpm

40 liters

(10.6

U.s. gal)/minute

30

ADJUSTING THE INCHING PEDAL

5

3


ADJUSTING THE TRANSMISSION

CONTROL LEVER a

6 .7

4

602331


2. Reposition stopper bolt "2" so that the inching pedal is 20 cm (7-7/8 in.) as measured from the dashboard wall.

3.


4.

Adjust the length of rod by turning clevis

"5"

so that lever

"4"

starts moving when the inching pedal is depressed.


6. Reposition stopper bolt "7" so that the pedal stroke is 14.5 cm (5-11/16 in.). a

5

3

602332

[NOTE)

Clearance lever

"1"

(0.02 to position.

"a" between guide

"2"

and should be 0.5 to 2.0 mm

0.08 in.) in any lever


2. Turn rods "4" and "5" to adjust clearance "a."

31



Transmission


Machine does not move in one or

A. Low oil pressure more speeds or all clutches slip.

(1)

Not enough oil

(2)

Loose, broken or maladjusted control linkage

(3) Oil pump or its drive defective

(4) Air being sucked into pump

Machine jolts on shifting.

Slow response of transmission

to shifting.

•

•

RefIll.

Remedy

Repair or readjust.

(5) Internal oil leakage in control valve

unit due to wear or failure of sealing members such as piston

seals and O-rings

(6) Main relief valve internally dirty with foreign matter stuck in sliding clearance, or out of adjust-

ment

(7) Oil too low in viscosity

•

Overhaul or replace.

•

Check packed joint in pump

suction and repair or replace.

•

Disassemble and repair or

replace defective parts.

•

Overhaul. Correct its pressure setting.

•

Use Class CD oil (engine oil) of

API classification, whose viscos·

ity rating is SAE lOW.

B. Mechanical failure

(1)

Transmission shaft damaged

(2)

Seized or bound clutch piston, friction plates or mating plates, resulting in reduced clutch capacity

(3) Friction plates or mating plates

worn or damaged

(4) Bevel gears or other gears defective

C. Neutral safety valve malfunctions

(I)

Accumulator valve not working

properly

(2)

Pilot valve malfunctioning

(3) Oil viscosity too high

(1)

Clogged orifice in control valve

unit

(2)

Not enough oil

(3) Control linkage maladjusted

(4) Air being sucked into oil pump due

to loose packed jOint in suction fine

(5) Faulty seal ring on clutch piston

(6) Damaged O·ring in path of oil to clutch piston


•

Disassemble, repair or replace.

•


•



•


replace.

•


replace

•

Use SAE lOW oil.

•

Disassemble and clean.

•

Refill.

•

Readjust.

•

Retighten or replace packing.

•

•



32

(


Complaint

Not enough output.

Transmission does not shift into neutral. or remains

Abnormal oil temperature rise.

Loss of safety function of hydraulic interlock (safety valve).

Possible cause

(1) Engine not delivering enough power

(2) Not enough oil

(3) Air being sucked into oil pump

(4) Sticking or bound spool in main relief valve

(5) Weakened spring in main relief

valve.

(6) Worn-down oil pump

(7) Strainer or nIter clogged

(8) Badly worn clutch piston ring or

O-ring

(9) Water in oil

(10) Control linkage maladjusted

(11) Slipping clutches due to low main

pressure

(12) Damaged clu tch piston

(13) Dragging wheel brakes

Remedy

•

Re-tune engine.

•

Refill.

•

Check jOint and replace pack-

ing as necessary.

•


replace.

•

Disassemble and replace the spring.

•

Replace.

• Clean or replace.

•


•

Change oil.

•

Readjust.

•

Readjust.

(I) Control linkage maladjusted

(2) Burnt clutches

•


•

Readjust.

• Readjust.

•

Disassemble and replace burnt

parts.

•

Disassemble. repair or replace.

(3) Clutch piston, friction plates or mating plates binding.

(4) Clutch valve seized, resulting in no

pressure drop

(5) Oil level too high or too low

•

Disassemble, repair or replace.

(I)

Air being drawn into oil circuit

(2) Water in oil

(3) Burnt or worn bearings

(4) Instrument out of order

(5) Dragging clutches

(6) Clutch valve linkage maladjusted

(7) Dragging wheel brakes

(8) Continuous overloading of machine

(I)

Safety valve not functioning

(2) Shift control linkage maladjusted

•

Adjust to the prescribed level.

•

Retighten joints and connec-

tions, replace gaskets, or check

oil level and add oil, as necessary.

•

Change oil.

• Disassemble and repair or

replace.

•

Replace.

•

Replace friction and rna ting plates.

•

Readjust.

•

Readjust.

•

Avoid abusive use of machine.

•

Disassemble and repair or replace.

• Readjust.

33


Complaint

Main pressure is too high.

(Tltis is not a symptom; it is a finding obtained by checking with pressure gauge.)

Transmission responds too slow

to shifting.

(This is the symptom of main pressure being too low.)

Possible cause Remedy

(I)

Main relief valve maladjusted

•

Overhaul and adjust.

(2)

Internal oil passage in main relief

•

Overhaul and clean. valve clogged

(3) Bound or sticking main relief valve

(4) Wrong kind of hydraulic oil

•

Overhaul and clean.

• Use oil meeting the specifica-

tions.

(I)

Clogged oil strainer or fIlter

(2)

Worn-down oil pump

(3) Main relief valve maladjusted

(4)

Bound or sticking main relief valve

(5) Air being drawn into oil circuit

(6) Not enough oil

(7) Oil leakage from loose joint or

connection.

•

•

•

•

Clean Or replace.

Replace.

Readjust.


• Retighten joints and connec-

tions, replace gaskets, or add

oil to oil pan.

•

Add oil.

•

Inspect and repair, replacing

O-rings and seals as necessary.

Clutch oil pressure is abnormally

(1) low when inching pedal is in

released condition.

Main pressure too low

(This is not a symptom; it shows

up as slow response of trans-

mission or as slipping clutch.)

(2)

Clutch valve spool defective

(3) Clutch piston seal ring defective

(4)

Inclting pedal control linkage maladjusted

I

•

Refer to the procedure imrne-

I diately above.

(Transmission responds too

slow to shifting.)

I

•

Repair or replace.

•

Replace.

• Readjust.

Machine jolts even when inching pedal is pressed gently.

•

Readjust.

Machlne picks up speed too slowly even when inching pedal is released sharply.

(1) Inching pedal control linkage maladjusted

(2)

Clutch valve out of order

(I)

Clutch pedal control linkage maladjusted

(2)

Clutch valve out of order

•

Repair Or replace.

•

Readjust.

•

Repair or replace.

34


Transfer

Remarks


Remedy

Machine does not move

Machanieal trouble inside transfer Repair or replace. in any speed

Machine does not move One or more gears damaged in one or more speeds,

forward or backward.

Noisy operation

,

(1) Not enough oil

!

(2) Backlash too large

I

I

,

Oil leakage

0

0

Replace.

Add oil.

Readjust or replace

0

Check bearings, shaft parts. and gears for wear -

cause of excessive

backlash.

I

(3)

Bearings worn or damaged

I

I

(4) Shaft splines worn

0

0

Replace.

Replace. i

(5)

Gear tooth contact ineer-

0

Readjust or replace.

I

rect, or teeth worn or

I damaged

I

I

I i (I)

Oil level too high

I

(2) O·rings damaged i

0

Lower oilleve!. i

0

Replace.

I i

(3) Oil seals damaged

I

(4) Transfer case installation

0

Retighten or replace loose or packing defective

0

Replace. packing.

Overheating i

(1) Oil level too low

!

!

,

(2) Backlash too large or too small

0

0

Add oil.

Repair or replace.

0

Check bearings for spalled or cracked

races.

1(3)

Bearings misaligned

0


!

(1) Oil insufficient or dirty

Abnormal wear

0

Add or change oil.

0

Check oil for pre· sence of metal chips.

(2) Abuse

0

Avoid abuse of machine.

35

MAINTENANCE

STANDARDS

38


DPS TRANSMISSION

Unit: mm (in)

8

Service

limit

26.10

(1.0276)

Remarks

Ref.

No.

Item

Assembly standard

(Standard clearance)

~~---------r~~.~~---~~~

Total thickness (new parts)

Reverse

clutch

Friction plates (4 pcs)

Mating plates (4 pcs)

Pressure plate (I pc)

27.70

(1.0905

±

±

0.80

0.0315)

---

3

Forward and

2nd· and

Ist·speed clutches

Total thickness (neiv parts)-

Friction plates (3 pes)




Pressure plate

(IJl.C2 __

I

21.57 ± 0.62

15.44 ± 0.44

(0.6079

±

±

0.0244)

0.0173) (0.5748)

I

14.60

I

I

2 3rd·speed clutches

Pressure plate (1 pc)

(0.8.492

1 - - + - - - - - - - - 1 ' - - - - - - - -... - - - - - - + - - - - - - - - - + - - - - + - - - - - - - - - 1

Total thickness (new parts)

20.40

(0.8031)

4

Friction plates o fRfN

( t )

I

(0.1161 ± 0.0039)

41 (1.61)

-1

2.4

5

(0.0965)

I

I Thickness of eac hf't' plate

--j

I thm 3

1--~+-~~-~~+-F-r-ee~le-ng-t-h--~~-

5 kgf(Ibf) [NJ/mm (in.)

Free length

±

1.1)/(1 42) (12.1)/(142)

[54.0J·

13.5 (0.531)

I--+---------I~~---~-+--~-------+~~----~------j

Diameter:

6

Return springs

of reverse

clutch piston

Return springs of forward,

Test force/length under test force

3rd·, 2nd· and


1st-speed

test force

clutches kgf (Ibf) [N] /mm (in.)

I--+--------I~~~-

7 Thrust plates Thickness

6.6 ± 0.5

(14.6

33 (1.30)

36

[64.7 ±4.9J·

6.01

±

0.5 29

(13.25 ± 1.1)/(1 14)

[59.0 ± 4.9J

2.00 ± 0.05

.

(0.0787 ± 0.0020)

5.5

5

36

29 flW(1·14

1.80

(0.0709)

13.5 (0.531)

Total 30 pes

Free length

Spring of lubrication relief valve

53 (2.09)


test force.

kgf (lbf) [NJ /mm (in.)

1.49±0.12 215

(3.29 ± 0.26)/(0846)

[14.6 ± 1.2J .

Diameter:

13 (0.51)

MAINTENANCE STANDARDS

5

6

602311

602333

39


Ref.

No.

5

I

2

3

4

6

7

8

Main relief valve spring (inner)

Main relief valve

spring (outer)

Differential

valve spring

Accumulator valve spring

(inner)

Accumulator

valve spring

(outer)

Inching valve

return spring

Speed selector plunger detent spring

Inching valve spring

Item

Free length


test force

kgf (Ibf) [N] /mm (in.)

Free length


test force


Free length

Test force/length under test force kgf (Ibf) [N] /mm (in.)

Free length


test force


Free length


test force

kgf(Ibf) [N]/mm (in.)

Free length


Free length


Free length


test force


(

TRANSMISSION CONTROL VALVE

Unit: mm (in. )

Assembly standard

(Standard clearance)

82.5 (3.248)

7.6 ± 0.5 550

(16.8 ± 1.1)/(2

[74.5 + 4.9] .

1(5)

68.0 (2.677)

10.0 370

(22.1)/ (1457)

[98.1] .

59.5 (2.343)

5.6±0.6 355

(12.3 ± 1.3)/(1 398)

[54.9+5.9] .

151.0 (5.945)

50.4 ± 5.0 1200

(111.1 ± 11)/(47'24)

[494.3 + 49] .

132.0 (5.197)

61.1 ± 6.1 780

(134.7 ± 13.5)/(3 071)

[599.2 + 59.8] .

78.0 (3.071)

I

8.1 ± 0.8 590

(17.7 ± 1.8Y(2 323)

[79.4+7.8 .

17.0 (0.669)

5.2±0.2

150

(11.5 ± 0.4)/(0 59!)

[51+2.0] .

·31.5 (1.240)

I

3.3 150

(7.3)/(0 59!)

[32.4] .

Servke

limit

Remarks

Diameter:

13.3 (0.524)

Diameter:

18.5 (0.728)

Diameter:

13.5 (0.531)

I

Diameter:

22 (0.87)

Diameter:

31 (1.22)

Diameter:

25 (0.98)

Diameter:

7.5 (0.30)

Diameter:

15 (0.59)

(

40

I

MAINTENANCE STANDARDS

8

602320

41

DISASSEMBLY

AND

REASSEMBLY


DPS TRANSMISSION

REMOVAL AND INSTALLATION

Removal

Preparatory steps

(1)

Remove the under guard.

(2) Drain the oil from the transmission.

[11 liters (2.9 U.S. gal), approx.]

(3) Drain the oil from the transfer arid bevel ger cases. [7 liters (1.8 U.S. gal), approx.]

1.

Remove the following parts:

1 Floor plates (platform) (3 pes)

2 Electrical wire between battery switch and battery

3 Clamp for electrical wire between ba ttery and starter

44

4 Opera tor's seat and sea t plate

5 Rear cover

Weight of operator's seat and seat plate

31 kg (68Ib), approx.

6 Steering clutch levers

7 Steering control rods

8 Brake control rods


6

602336

9 Steering clutch oil pipes (2 pcs)

10 Oil cooler pipe

11 Oil cooler hose

12 Springs (2 pcs)

13 Inching control rod

14 Electrical wire for neutral switch

10

~\

13

602338

45

DISASSEMBLY AND REASSEMBl

2. Disconnect the following parts:

15 Inching valve link

16 Speed selector valve and directional selector valve links

3. Remove the following parts:

17 Universal joint

18 Transmission

Weight of transmission

and transfer

182 kg (400 Ib). approx.

[NOTE)

Before lifting off the transmission, shift it forward to pull the pInIOn back out of mesh with the bevel gear.

Installa tion

To install the transmission, follow the reverse of removing procedure, and proceed as follows:

(1)

Make sure that the electrical wires, pipes and hoses are connected properly.

(2) Adjust the inching pedal. (Refer to the topics, Adjusting the inching pedal, TESTING AND ADJUSTMENT.)

(3) Fill the transmission and transfer cases with recommended oil.

46

602339

(


Disassembly

Preparatory steps

(1) Remove the transfer assembly.

(2) Remove the oil filter.

(3) Remove the transmission control valve and main relief valve.

(4) Remove the oil pump and oil pipe.

(5) Remove the suction strainer.

(6) Remove the air breather, oil filler and oil level gauge.

Remove the groups in the order listed below for disassembly.

A TransmissIon case and flange group

B Reverse clutch group

C Forward clutch group and 3rd-speed cl utch group

D 2nd-speed clutch group

E 1st-speed clutch group and cover group

When disassembling the transmission, place it on a workbench having a hole for admitting the output shaft and cover mounting bolts, with the front (engine) side up.

C-lt----{

D-lI----{

E


47


A Transmission case and flange group

1.


1 Lock washer

(to be straightened for removal)

2

Washer

3

Bolt (1 pc)

4 Oil filter screw

5 Oil pipe (4 pes)

6 Transmission case

6

5 t--4.

602343

[NOTEl

To remove transmission case "6," attach the hangers to its front face, and lift it off with that face up.

Thread size of hangers

MIO x

1.25 mm

2. Remove the following parts from case

"5 ":

7 Flange

8 Oil seal

9 Retaining ring

10 Ball bearing

11 Snap ring'

12 Oil pump driven gear

13 Ball bearing

14 Retaining ring

15 Ball bearing

16 Retaining ring

7

8 i ! t - - l 0

602344

602345

48



26

19

602346

1 Pump drive gear

2 Lubrication relief valve

3

4

Bolt (8 pes)

Snap ring

5 Snap ring

6

Bolt

7 End housing

8 Mating plates (4 pcs)

9 Friction plates (4 pes)

10 Return spring (5 pes)

11 Pressure plate

12 Piston

13 Piston seal

14 Piston seal

15 Input shaft

16 Ball bearing

17 Ring gear

18 Reverse planet carrier

(to be ·removed as an assembly including

"19" thru "24")

19 Seal ring

20 Spring pin (3 pes)

21 Pin (3 pes)

22 Planet gear (3 pes)

23 Thrust plates (6 pes)

24 Needle roller bearing (3 pcs)

25 Ball bearing

26 Reverse clutch piston housing


49


C Forward clutch group and 3rd-speed clutch group

31 33

15

602347

1· Needle roller bearing

2 Mating plates (3 pes)


4 Return spring

(5 pes)

5

Pressure plate

6 Snap ring


21 Needle roller bearing (3 pes)

22 Forward

&

3rd-speed planet carrier

23 Seal rings (3 pes)

24 Piston

25 Piston seal

7 Ring gear

8 Ring gear

9 Snap ring

26 Piston seal

27 Piston

28 Piston seal

10 Bolt (9 pes) 29 Piston seal

11 Forward

&

3rd-speed clutch piston housing 30 Pin (5 pes)

(to be removed as an assembly including 31 Ball bearing

"12" thru "30")


(to be removed as an assembly including

"13" thru "23")

13 Pin (3 pes)


15 Thrust plate (6 pes)



18 Pin

(3 pes)

32 Ball bearing

33 Snap ring

34 Pressure plate




38 Ring gear



50



15

11

1 2nd-speed clutch piston housing

(to be removed as an assembly including "2" thru "4")

2 Piston

3 Piston seal

4 Piston seal

5 Pressure plate

6 Return spring (5 pcs)

7 Friction plates (2 pcs)

8 Mating plates (2 pcs)

9 Snap ring

10 Snap ring

11 2nd-speed plane t carrier


12 Spring pin (3 pcs)

13 Pin (3 pcs)

14 Planet gear (3 pcs)

15 Thrust plate (6 pcs)

16 Needle roller bearing (6 pcs)

17 Ball bearing

18 Ring gear


602348

51



52

•

602349 lIst-speed clutch piston housing


2 Piston

3 Piston seal

4 Piston seal

5 Pressure plafe




9 Oil seal retainer

10 Oil seals (2 pes)

11 Retaining ring

12 Snap ring

13 Output shaft

14 Ball bearing

15 Retaining ring

16 1st-speed planet carrier


17 Ring gear


19 Pin (3 pes)




23 Seal ring

24 Ball bearing

25 Cover


(

Inspection

1.

Friction, mating and pressure plates

Measure the assembled (total) thickness of the plates. Replace the plates if the measurement exceeds the service limit.

Item

Assembly standard

Unit: mm

(in.)

Service

limit

Assembled (total)

thickness of reverse

clutch plates:




27.70±0.80 26.10

(1.0905±0.0315) (1.0276)

Assembled (total) thickness of forward and 3rd-speed clutch ,I 21.57±0.62 plates: (0.8492±O.0244)

Friction plates (3 pcs) ,

Mating plates (3 pcs) il


20.40

(0.8031) thickness of 2nd- and

1st-speed clutch plates:

Friction plates (2 pes)

Mating plates (2 pes)


Thickness of friction

plate

15.44±O.44 14.60

(0.6079±O.OI73) (0.5748)

2.95±0.10 2.45

(0.1 1 61±0.0039) (0.0965)

2. Thrust plates

Measure the thickness plate. Replace the measurement exceeds the of each thrust plate if the service limit.

Item

Thickness of thrust plate

Unit: mm (in)

Assembly

standard

Service

limit

2.00±0.05

1.80

(0.0787±0.0020) (0.0709)


602350

602351

53


Reassembly

To reassemble the transmission, install the groups in the reverse order

(II

E" thru

"A"),


19 1B

21

20

54

12 11 15 14

24

23 25

9

10

Reassembling order

4 3

I

23

~I

12 14

I

24

'13

.L

21

.---.

22

-->

20 r

18

.---.

19 r

10--+9 L L 2

16 r r r L r r r r r L .

15 11 17 8 7 6 5

1'25

1

602352



I.

14

13

7

18

17

Reassem bling order

16 r r r

18 r

L

11 r r r r r r r r

17 10

15r14 13 1 2 ·

9 8 7

~

4 r

5 2 1 r r

Transmission case

602353

55


C Forward clutch group and 3rd-speed clutch group

5 4 3 2 8 7 6 2 3

11

24===~~.J1

25

26

28

29

27

34

35

9 14 6

12

8

20

23 22 33

602354

Reassem bling order

2625

LL24

21 ->19 16->14 rrr rrrrrr' rLrrrrr rrrr

I!:gsmission rrrrrLrrrLrr22389 137363534 30 87611105234

2332333120 181715 1312 rr27

2829

\.

56



602333

Reassem bling order

15

23 r

r

r

I

21 26 r

'rrrrrrrrrrrrrrrrr

18 16 24

r r

12

11 17 9 8 10 2

19 -+ 7

25 4 5 3 6 1

Transmission case

20-+22 14 13

57


A Transmission case and flange· group

4

602333

(

602368

Reassembling order rrrrrrr

9 10 8 14 15 16 13

r

I r r r r r r r

Transmission case

6 7 2 1 3 5 4

11 ->12

Tips for reassembly

1.

Apply a coat of engine oil to the 0ring of oil filter screw.

2. Bend each lock washer properly

- against the flat of bolt.

58

602356

(


3. Planet carrier spring pin installation

Drive in the spring pin with its gap positioned in the direction of carrier rotation. Drive in the planet pin with its mark "A" outside.

4. Clutch piston installation

Apply a coat of hydraulic oil (SAE lOW) to the sliding surface of each piston seal before installing the seal to the clutch piston.

I

o x

(~JI

~.

/~

(

""t -

T"

~602358

5. Piston housing installation

Install the piston housings (5 pcs) with their recessed portions alined as shown.

This illustration shows the piston housings viewed from the engine side.

602359

6. Oil seal installation to retainer

Install the oil seal to the retainer as shown.

602360

59


7. Testing after reassem bly

Apply dirt-free pressure air to the oil holes in the transmission case' to make sure that the clutch pistons move smoothly in the housings

A Oil hole for reverse clutch

B Oil hole for forward clutch

C Oil hole for 1st-speed clutch

D oii hole for 2nd-speed clutch

E Oil hole for 3rd-speed clutch

Air pressure

2 -3 kgf/cm'

(28.4 - 42.7 psi)

[196 - 294 kPa)

602361

60


TRANSMISSION CONTROL VALVE

Removal and installation

1.

Dismount the transmission assembly including the control valve from the machine, and remove the valve from the transmission. (Refer to the topics,

Removal, DPS TRANSMISSION.)

2. To install the control valve, follow the reverse of removing procedure.

D isassem bly

1 Regulator valve body

2 Roller pin

3 Plug

4 Relief valve

5 Slug

6 Inner spring

7 Ou ter spring

8 Roller pin

9 Plug

10 Cover

11 Accumulator piston

12 Seat


602362

13 Outer spring

14 Inner spring

15 Pin (3 pcs)

16 Plug (2 pcs)

17 Spring (2 pcs)

18 Detent ball (2 pcs)

19 Cover

25 Inching valve

26 Slug

27 Spring

28 Cover

29 Spring

30 Inching valve plunger

31 Roller pin

20 Speed selector plunger

21 Spring

22 Differential valve

32 Plug

33 Oil seal (2 pcs)

34 Oil seal

23 Directional selector plunger 35 Valve housing

24 Spring

61


Reassembly

(Clean all control valve parts except for seals by alkali washing before installing them for reassembly.)

8 9 7 6

4 5

32

12

1

10

0

o o

0

0

,

,

'-'

33

23

28

29

602320

Reassembling order

15

1'35-+19 r r r r r ,. ,.

1'1

9 8 7 6 4 5 2 3 r ' r r r i

1011121314

,---'

~

J

!

II

33 20

......

~16

15 17 18 r r r r r ,------'

33 23 32 31 22 21 r r r r r r

30 29 . 27 25 26 24

34-+28

62

TRANSFER


Refer to the topics, DPS TRANSMISSION.

Disassembly

3

12


1 2 4 8

14

11

•

1 Lock washer

2 Washer

3 Cover

4 Bearing cage

5 Shims (1 set)

6 Shim

(1 set)

7 Snap ring

8 Roller bearing

9 Driven gear

10 Bevel pinion

11 Roller bearing

12 Dri ve gear

13 Ball bearing

14 Ball bearing

15 Case


602364

63

64


Reassembly

8

7

5,6

4

2

1

3

13--t---'IC

15

~1---14

12

9

10

11

Reassem bling order

r,qrrrTfTTT"

10-+11 rr

4

8 7

602369

(

(

DISASSEMBLY AND REASSEMBLY.

Tips for reassem bly

Pinion adjustment

The distance from the end face of bevel pinion and the outer face of transfer case is specified for each transfer because of the selective assembly. The specification is formed by a certain value (represented by the letter "m" and marked on the end face of pinion) per cent and 46.2 mm (1.819 in.). The per-cent value is either positive

(+) or negative (-). To bring this distance into +0.1 mm (+0.004 in.) of the specification, the thickness of shims (58827-10900 and 58827-11000) must be adjusted.

The shims are available in these thicknesses:

Unit· mm (in )

Part number

Shim thicknesses

58827·10900

0.1 (0.004),0.4 (0.016),1.0 (0.039)

58827·11000

0.1 (0.004),0.4 (0.016), 1.0 (0.039)

Value of urn"

marked here

Shim thickness

----i~.JI.<-'

Specifi"d distance

(46.2 mm ± "m"/100) ± 0.1 mm

[(1.819 in. ± "m"/100) ± 0.004 in.]

602365

BEVEL GEAR

Installa tion

[NOTE

1

Install the bevel gear on the left side in case of DPS transmission; install it on the right side in case of

DD transmission.

65

OISASSEMBL Y AND REASSEMBLY

DAMPER·

Removal

The damper resembles a conventional disc clutch and is to be removed together with the engine. For removal of the damper, refer to the topics, FLYWHEEL

CLUTCH, DISASSEMBLY and

REASSEMBLY volume, except for the following items:

(1) Clutch control rod

(2) Rubber hose for steering clutch oil

(3) Rubber hose for oil .cooler (flywheel clutch group)

InstaIla tion

To install the damper, follow the reverse of removing procedure.

Disassembly

.~

(

(

66

1 Drain plug

2 Flange

3 Air breather

4 Connector

7 8

5 Damper cover

6 Shaft

7 Ball bearing

8 Snap ring

5

9 Oil seal

10 Damper

602367

Reassembly

Reassem bling order

"J--PTf

Engine rr r

5

3

-->

4

8 7 9

9

2


602309

67

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DEC.a6


Pub. No.

99879-001205

/

SERVICE MANUAL

MITSUBISHI

··TRACTOR·

····.····D··············· .. ··--···

TRACTOR SHOVEL

CONTENTS

HYDRAULIC SYSTEM

• OPERATING PRINCIPLE

• TESTING AND ADJUSTMENTS

j j

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FOREWORD


Correct servlcmg will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.

Safety is not only your concern but everybody's concern. Safe working habits cannot be bought or manufactured; they must be learned through the job you do. By learning what CAUTION or WARNING symbol emphasizes, know what is safe what is not safe. Consult your forem'an, if necessary, for specific instructions on a job, and the safety equipment required.



I

NOTE

I ..............

An operating procedure, condition, .etc., which is essential to highlight.

&.1

CAUTION

I

....... Operating procedures, practices, etc., which if not strictly observed, will result in damage to or destruction of machine.

Operating procedures, practices, etc., which if not correctly followed, will result in personal injury or loss of life.

(

)

(

TABLE OF CONTENTS

OPERATING PRINCIPLE

General description

2

Control valve

3-section control valve (BD2G-PAT) . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

4

2-section control valve (BD2G-PT)

9

2-section control valve (BS3G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Main relief valve

Safety valve

Makeup valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . " 19

19

........................................... 20


Testing cylinder rods for drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . " 24

Testing lift cylinders for blade holding ability (BD2G-PAT, PT) ...... 25

Testing cylinders for actuating speed . . . . . . . . . . . . . . . . . . . . . . . . .. 25

BS3G Tractor Shovel ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27

Testing cylinder rods for drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27

Testing cylinders for holding ability . . . . . . . . . . . . . . . . . . . . . . . . " 29

Testing cylinders for actuating speed . . . . . . . . . . . . . . . . . . . . . . . . . 29

Adjusting main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31

Adjusting safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31

Troubleshooting guide '" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32

(

OPERATING

PRINCIPLE

OPERimNGPRINCIPLE

GENERAL DESCRIPTION

Angling cylinder Lift cylinder

Angling valve plunger

Tilt cylinder

B3

A3'

B2·

A2

B1

A1

Angling cylinder

Lift cylinder

Lift valve plunger

Main relief valve

180 kif/cm' (2560 psi) {l7.7 MPaJ

Hydraulic pump

Check valve

Tilt valve plunger

Makeup valve

Check valve

BD2a-PAT hydraulic circuit diagram

L l l - - - Hydraulic Hlter

602195

Tilt cylinder Lift cylinder

Tilt valve plunger v

Check valve

Makeup valve v

Safety valve

200kgf/cm'

, (2844 psi) [19.6 MPaJ

+---+

-J.---

- - - 2 : " ,

Check valve

Lift valve plunger

Lift cylinder Main relief valve

180kgf/cm' (2560 psi) [17.7 MPaJ

M

Hydraulic filter

Hydraulic pump

602196

BD2a-PT hydraulic circuit diagram

2

OPERATING PRINCIPLE

Dump valve plunger

Safety valve

200 kgf/cm' (2844 psi) [19.6 MPa]

Makeup valve

Dump cylinder

Lift cylinder

,-;:::::::\:::tJ l

A2

B1'

A1

Safety valve

] 4'1IIIDi--I-.f-_160 kgf/cm'

(2275 psi) [15.7 MPa]

Check valve

Makeup valve

Check valve

. Lift valve plunger

Main relief valve

180 kgf/cm' (2560 psi) [17.7 MPa]

M

Hydraulic pump

A..-U-_--Hydraulic ftiter

602197

BS3a hydraulic circuit diagram

3

OPERATING PRINCIPLE

CONTROL VALVE

3-SECTION CONTROL VALVE (BD2G-PAT)

3

-1--4

(

4

1 Inlet & lift valve plunger section

2 Tilt valve plunger section

3 Angling valve plunger section

4 End plate

5 Main relief valve

180 kgf!cm 2 (2560 psi) [17.7 MPa)

6 Makeup valve

602198

T Tank port

P Pump port

A 1 Lift cylinder (rod side)

B1 Lift cylinder (head side)

A2 Tilt cylinder (head side)

B2 Tilt cylinder (rod side)

A3 Angling cylinder

(RH rod side and LH head side)

B3 Angling cylinder

(RH head side and LH rod side)

(

Control valve sections

OPERATING PRINCIPLE

602199

Lift valve plunger section

A2,A3 o o

1 Plunger

Tilt/angling valve plunger section

3 Makeup valve

2 Main relief valve

602200

5

6

OPERATING PRINCIPLE

I!

tAl

-

l~

602201

(

602202

Lift valve plunger in pushed-in [FLOAT] position

OPERATING PRINCIPLE

602203

7

OPERATING PRINCIPLE

Tilt valve plung~r in pushed-in [RIGHT TILT] position

Angling valve plunger in pushed-in [LEFT ANGLING] position

8 o o

Tilt valve plunger in pulled-out [LEFT TILT] position

Angling valve plunger in pulled-out [RIGHT ANGLING] position

602204

(

82 { ) 83 o o

602205

OPERATING PRINCIPLE

2-SECTION CONTROL VALVE (BD2G-PT)

----1--3

2

1 Inlet

& lift valve plunger section

2 Tilt valve plunger section

3 End plate

4 Main relief valve

1180 kgf/cm'

(2560 psi)

[17.7

MPaJ/

5 Safety valve

/200 kgf/cm' (2844 psi) [19.6 MPaJ/

6 Makeup valve

5

T Tank port

P Pump port

A 1 Lift cylinder (rod side)

B1 Lift cylinder (head side)

A2 Tilt cylinder (head side)

B2 Tilt cylinder (rod side)

602206

9

OPERATING PRINCIPLE



A2 82

602207

10 o o

Tilt valve plunger section

1 Plunger

2 Main relief valve

3 Safety valve

4 Makeup valve

602208

It

Q

.Bl

OPERATING PRINCIPLE

-

Lift valve plunger in pushed-in [LOWER] position

602209

602210

11

12

OPERATING PRINCIPLE

k

Lift

valve plunger in pushed-in [FLOAT] position

t""----......

.

",

602211

(

.I~

j;.

':-'-...,..

~."...-~-:.

~. in pushed-in [RIGHT TILT] position

OPERATING PRINCIPLE o o

~

in

pulled-out [LEFT TILT] position

~

B2

602212 o o

602213

13

OI'ERATING PRINCIPLE

2-SECTlON CONTROL VALVE (BS3G)

(

.14

1 Inlet & lift valve plunger section

2 Dump valve plunger section

3 End plate

4 Main relief valve

\180 kgf!cm (2560 psi) [17.7 MPa]j

5 Safety valve

1160 kgf!cm (2275 psi) [15.7 MPa]1

6 Safety valve

1200 kgf/cm (2844 psi) [19.6 MPa]1

7 Makeup valve

6

T Tank port

P Pump port

A1 Lift cylinder (head side)

B1 Lift cylinder (rod side)

A2 Dump cylinder (rod side)

B2 Dump cylinder (head side)

602214


OPERATING PRINCIPLE

2

A1 81


602199

Dump valve plunger section

1 Plunger

2 Main relief valve

3 Safety valve

4 Makeup valve

4

. 602215

15

OPERATING PRINCIPLE

~ in pulled-out [RAISE] position

, !

Lift valve plunger in pushed-in [LOWER] position

602201

602202

16

(

--....-.....

OPERATING PRINCIPLE

602203

17

OPERATING PRINCIPLE

..

...

~

- ,

in pulled-out [ROLLBACK] position

18

"

in pushed-in [DUMP] position

602216

602217

(

OPERATING PRINCIPLE

MAIN RELIEF VALVE

This va.lve protects. hydraulic components by limiting ·the line pressure to a preset value. It is a sort of safety valve, and limits the. line pressure _ by relieving through t\vo~stage action •

.

Relieving action

P

1 Valve

2 Spring

3. Valve body

4 Pilot valve

5 Spring

6 Adjusting screw

600010

A Chamber

B Orifice

D pilot valve

P Pump port

T Tank port port

Start of relieving action

T B A D

600057

Because of the pressure difference· (drop of the pressure in cham ber "A" occurring because pilot valve port "D" is larger than orifice "B"), valve "1" slides to the right, thereby opening ·tank port "T," through which a large amount of oil flows into the tank to lower the line pressure;

SAFETY VALVE

This valve is used in the circuit leading to the cylinder. When an external force acts on the· cylinder and the pressure in the circuit to that cylinder rises abnormally, it opens to relieve such a high pressure for protection of hydraulic components.

Normal (closed) state

1

A 2 3 4 5

6

600056

As the line pressure rises to and above the preset value, it pushes pilot valve "4" off its seat by overcoming the force of pilot valve spring. This bleeds the oil out through outlet port to the tank port, creating a large pressure difference

across valve "1."

1 Valve body

2 Valve

3 Piston

4 Spring

5 Adjusting screw

6 Nut

600399

A Chamber

B Orifice

C Cylinder port

T Tank port

19

OPERATING PRIN81PLE

The pressure in the circuit leading to the cylinder acts on piston "3" through orifice

"B."

In the normal state, this pressure is lower than the force of spring "4," and valve "2" is kept closed by the force of this spring.

Making-up action

T

Safety valve action

4

T

600400

When the pressure rises above the preset value, it pushes valve "2" overcoming the force ·of spring "4." Under this condition, the oil from cylinder port "C" flows into tank port "T."

MAKEUP VALVE

This valve is used in the circuit leading to the cylinder to prevent the cylinder from moving erratically. a. Makeup valve for dump cylinder

Normal (closed state)

600402

Valve "I" is kept clo.sedby the force of spring "2" and hydraulic· pressure acting on it. When an external force acts on the cylinder to move it faster as in LOWER position, the pressure in the circuit leading to cylinder port

"c" drops lower than the pressure in the circuit leading to tank port "T." In such a case, the tank port pressure opens valve "1" to allow oil to flow back into cylinder port

"C" for making up for the· want of oil in the circuit leading to the cylinder. b. Makeup valve for lift cylinder

2

3

1 Valve

2 Steel ball

3 Spring pin

602218

C Cylinder port

T Tank port

20

1 Valve

2 Spring

2

600401

C Cylinder port

T Tank port

Making-up action

(

602219

Function of safety valve and makeup valve

When control valve plunger is in neutral position

B

OPERATING PRINCIPLE

602272

A Port A

B Port B

T Tank port

W hen cylinder is loaded

Assume that the pressure

In por t

"B" rises. Safety valve "1" in that port will be forced to open, thereby bleeding out the excess pressure. Now, such a pressure rise means that the cylinder piston is moved by an external force and that,

1 Safety valve

2 Makeup valve because the piston will move slightly, the pressure in port "A" drops to create a vacuum condition. Under this condition, the makeup valve on that side acts to admit some make-up oil from tank port

"T" into port !lA."

21

TESTING

AND

ADJUSTMENT

BD2G TRACTOR

TESTING CYLINDEIt:RODS FOR DRIFT

B. Blade tilt cylinder (BD2G-PTA, PT)

Test 1

A. Blade lift cylinders (BD2G-PAT, PT)

Test 1

NEUTRAL

o--oe-o

602220

Extend the lift cylinders to push on the ground with the blade to raise the front end of the machine. Move. the control lever to NEUTRAL, stop the engine, and observe the retraction of each lift cylinder rod.

Test 2 .

LOWER

0+0-0

Raise the front end of the machine with the blade tilted left, move the control lever to NEUTRAL, stop the engine, and observe the retraction of tilt cylinder rod.

Test 2

602221

With the front end of the machine raised as in Test 1, stop the engine, move the control lever to LOWER, and observe the retraction of each lift cylinder rod.

Raise the front end of the machine with the blade tilted left, stop the engine, move the con trol lever to RIG HT TILT, and observe the retraction of tilt cylinder rod. .

24

C. Blade angling cylinders (BD2G-PAT)

Test 1

NEUTRAL

o-e-o


TESTING LIFT CYLINDERS FOR BLADE

HOLDING ABILITY (BD2G-PAT, PT)

NEUTRAL o-o-e-o

Raise the front end of the machine with the blade angled right .or left, move the control lever to NEUTRAL, stop the engine, and observe the retraction of angling cyinder rod.

Test 2

602222

Raise the blade until the C frame is parallel to the ground, move the control lever back to NEUTRAL, stop the engine, and measure the extension of lift cylinder rod.

Rod extension:

20 nun

(0.8 in:), max. in 5 minutes at oil temperature

30 to

40°C (86'lb 104°F) .

TESTING CYLINDERS FOR ACTUATING

SPEED

Run the engine at idling (about 800 rpm) speed.

A. Blade lift cylinders (BD2G-P AT, PT)

Test 1

RAISE

()-O-()+e

Raise the front end of the machine with the blade angled right or left, stop the engine, move the control lever to the opposite angling side, and observe the retraction of angling cylinder rod.

602223

Lift

circuit actuating speed test - 1

Time reqUired for raising blade to maximum height from ground

Specification

4.0 sec.

25


Test 2

FLOAT eo-o-o

602224 lift circuit actuating speed test - 2 Specification

Time required for allowiog blade to lower to ground from maximum height with control lever io FLOAT

0.8 sec.

Test ·3

LOWER

.0--.0--0

602225 lift circuit actuating speed test - 3 Specification

Time required for loweriog blade to ground from maximum height with controllever io LOWER

2.4 sec.

B. Blade tilt cylinder (BD2G-PA T)

Tilt circuit actuating speed test

Time required for altering raised blade from right (or left) tilt to left

(or right) tilt

Specification

RH>LH 2.0 sec.

LH>RH 1.6 sec.

(

C. Blade angling cylinders (BD2G-PAT)

Angling circuit actuating speed test Specification

Time required for alteriog raised blade from right (or left) angling to left (or right) angliog

5.4 sec.

D. Blade lift cylinders (BD2G-PT)

Test 1

Specification lift circuit actuatiog speed test - I

Time required for raisiog blade to maximum height from ground

4.0 sec.

Test 2

Lift circuit actualiog speed lest - 2

Time required for allowing blade

10

lower to ground from maximum

height wilh control lever in FLOAT

Specification

0.8 sec.

Test 3

Lift circuit aclualiog speed lest - 3

Time required for lowering blade to ground from maximum height with conlrollever in LOWER

Specification

2.4 sec.

E. Blade tilt cylinders (BD2G-PT)

Specification Tilt circuit acluatiog speed test

Time required for alteriog raised blade from right (or left) tilt to left

(or right) tilt.

RH>LH 1.8 sec.

LH>RH 2.2 sec.

(

26

BS3G TRACTOR SHOVEL

TESTING CYLINDER RODS FOR DRIFT Test 3

A. Bucket lift cylinders

Test l'i':~


(

Raise the front end of the machine by pushing on the ground with the bucket, move the control lever back to

NEUTRAL, stop the engine, and observe the extension of lift cylinder rod.

Testi(

602228

Fill up the bucket with material, raise the bucket to maximum height, stop the engine, move the control lever back to

NEUTRAL, and observe the retraction of lift cylinder rod.

Test 4

With the front end of the machine raised as in Test 1, stop the engine, move the control lever to LOWER, and observe the extension of lift cylinder rod.

602229

Fill up the bucket with material, raise the bucket to maximum height, stop the engine, move the control lever to RAISE, and observe the retraction of lift cylinder rod.

Test results

Possible cause

In Test I alone. lift

Makeup valve in rod·side cylinders yield to load

circuit is leaky.

and extend.

In Tests I and 3, lift cylinders yield to load

and extend or retract.

I. Leakage past piston inside cylinder.

2. Leakage through sliding

clearance around plunger inside control valve.

In Tests 2 and 4, lift

Leaky check valve (leakage cylinders yield to load through between valve and

and extend or retract. seat or between seat and

valve body).

27


B. Bucket dump cylinders

Test 1

Test 3·

<!G~~Zt:~R~e~traction

Retraction

Raise the front end of the machine by pushing on the ground with the bucket being fully dumped, move the control lever to NEUTRAL, stop the engine, and observe the retraction of dump cylinder rod.

Test 2

602232

Fill up the bucket with material, raise the bucket until the arms become nearly parallel to the ground, move the control lever to NEUTRAL, stop the engine, and observe the retraction of dump cylinder rod. . .

Test 4

Retraction

Retraction

With the front end of the machine raised as in Test 1, stop the engine, move the control lever to DUMP, and observe the retraction of dump cylinder rod.

602233

Fill up the bucket with material, raise the bucket until the arms become nearly parallel to the ground, stop the engine, move the control lever to DUMP, and observe the retraction of dump cylinder rod.

28

(


Test results

In Test I alone, dump cylinders yield to load

and retract.

Possible cause

I. Safety valve in head-side circuit is leaky or damaged.

2. Makeup valve in rod·side circuit is leaky.

In Test 3 alone, dump cylinders yield to load and retract.

1. Safety valve in rod·side circuit is leaky or damaged.

2. Makeup valve in head· side circuit is leaky.

In Tests I and 3, dump 1. Leakage past piston cylinders yield to load

and retract.

inside cylinder.

2. Leakage through sliding

clearance around

plunger inside control valve.

In Tests 2 and 4, dump Leaky check valve (leakage cylinders yield to load through between valve

and retract and seat or between seat

and valve body).

TESTING CYLINDERS FOR HOLDING

ABILITY


Retraction


602235

Raise the bucket fully, dump it until its cutting edge is parallel to the ground, move the control lever to NEUTRAL, stop the engine, and measure the extension of dump cylinder rod.

Rod extension: .

7 mm (0.28 in.), max. in 5 minutes at oil temperature

30 to 40'C (86 to 104'F)

(NOTEl

The test criteria cited above are for a new machine at shipping from the factory. A machine working in field may be permissible up to nearly twice these values.

TESTING CYLINDERS FOR ACTUATING

SPEED


Run the engine at idling (about 800 rpm) speed.

Test 1

602234

Raise the bucket fully, move the control lever to NEUTRAL, stop the engine, and measure the retraction of ]ift cylinder rod.

Rod retraction:

5 mm (0.20 in.), max. in 5 minutes at oil temperature

30 to 40'C (86 to 104'F)

602236

29


Lift circuit actuating speed test - I

Time required for raising empty bucket to maximum height from ground

Specification

IS.7 sec.

Test 2


Run the engine at minimum speed (low idling speed).

®

(

Lift circuit actuating speed test - 2

Time required for allowing empty bucket to lower to ground from maximum height with control lever in FLOAT

602237

Specification

3.9 sec.

Test 3

602277

Dump circuit actuating speed test

-<D

Specification

Time required for dumping empty bucket fully from full rollback position (with lift cylinders fully extended)

3.1 sec.

Dump circuit actuating speed test.-0) Specification

Time required for rolling back empty bucket fully from full dump position

3.3 sec.

602238

Lift circuit actuating speed test - 3

Time required for lowering empty bucket to ground from maximum height with control lever in LOWER

Specification

S.3 sec.

30

ADJUSTING MAIN RELIEF VALVE

Relief pressure

180 kgf/cm'

(2560 psi)

[17.7 MPa]


ADJUSTING SAFETY VALVE

Safety valve location

BI;>2G·PT AI port in lift

cyJinder rod-side circuit

BS3G

B2 port in dump cylinder head-side circuit

BS3G A2 port in dump cylinder rod-side circuit

Setting

200 kgf/cm'

(2844 psi)

[19.6 MPa]

160 kgf/cm'

(2275 psi)

[15.7 MPa]

200kgf/cm'

(2844 psi)

[19.6 MPa]

2

0 0 0 0

600010

1. Install a test pressure gauge on the inlet port.

Pressure gauge range

o to 250 kgf/cm'

(0 to 3555 psi)

[0 to 25 MPa]

2. Remove cap nut "I" from main relief valve, and loosen jam nut "2."

3. Start the engine, and run it at maximum speed.

4. Move the control lever to RAISE: this will raise the line pressure. See if the test gauge reads the specified relief pressure; if not, make an adjustment by means of adjusting

screw 113.

11

Pressure change resulting

from 1/4 rotation of

adjusting screw

II to 13 kgf/cm'

(156 to 185 psi)

[1.1 to 1.3 MPa]

600399

1.

Install a test pressure gauge on each port.

Pressure gauge range

o to 250 kgf/cm'

(0 to 3555 psi)

[0 to 25 MPa]

2. Loosen lock nut

"1."

3. Apply hydraulic pressure due to an external force to each port, and see if the test gauge reads the specified pressure; if not, make an adjustment by means of adjusting screw "2."

Pressure change resulting

from 1/4 rotation of

adjusting screw

10 to

11 kgf/cm'

(142 to 156 psi)

[1.0 to l.l MPa]

[NOTE]

Do not attempt to adjust main relief valve and safety valve in field whenever possible. Replace them with properly adjusted ones.

31



HYDRAULIC SYSTEM

Complaint

I. Pump noisy, cylinder action jerky and abnormal oil foaming

2. Oil temperature too high

3. Pump,not delivering enough oil

4. Cylinder motion slow

5. Cylinder motion erratic

Possible cause

(I)

Air in hydraulic system

(2) Air leaks at pump inlet

(3) Pump parts worn

(4) Oil viscosity too heavy

(1)

Oil viscosity too heavy

(2) Tendency to overloading

(3) Pump parts worn

(I)

Oil level low in tank

(2) Oil viscosity too heavy

(3) Pump speed low

(4) Pump performance low ,

(I)

Pump not delivering enough oil because of:

(a) Worn pump parts,

(b) Improperly assembled pump

(2) Cylinder piston seals defective

(3) O·ring seals in circuits defective

(1) Piston seal rings worn

(2) Control valve plungers worn

(3) Makeup valve or safety valve nol seating properly

(4) Main relief valve maladjusted or

inoperative

(5) O·rings in circuits defective

Remedy

• Prime.

•

Prime.

• Replace.

• Change·oil.

•

Change oil.

•

Reduce load.

• Replace.

."

"

•

Add.

•

Change oil.

•

Disassemble and inspect.

•


•

Replace.

•

Reassemble.

•

Replace.

•

Replace.

•

Replace.

•

Replace.

•


•


•

Replace.

(

32


BLADE (BD2G)

Complaint

I.

Blade (PAT)

2. Blade (PT)

3. Cutting edges and end bits

4. Frame

5. Trunnions (PT)

6. Braces (PT)

Possible cause

(I)

Cracks, distortion, dents or broken

welds

(2) Pin holes

WOrn

(3) Blade surface worn

(4) Cutting edge mounting seats distorted

(5) Guide worn

(6) Ball studs worn

(I)

Cracks, distortion, dents or broken welds

(2)

Pin holes worn

(3) Blade surface worn

(4) Cutting edge mounting seats distorted

(I)

Cracks, distortion or dents

(2) Abnormal wear

(I)

Twist, cracks, distortion, dents or

broken welds

(2) Pin holes and trunnion bearings (pr)

worn

(I)

Abnormal wear

(2) Mounting bolts loose or damaged

(I)

Distortion or wear

(2) Adjusting screw threads damaged or

worn

Remedy

•

Repair or replace.

•

Repair or replace bushings.

•

Repair (reinforce by welding steel plate of about 3.2 mm (0.13 in.) thickness.

•

Repair.

• Replace.

•


•

Repair or replace.

•

Repair or replace.

•

Repair (reinforce by welding steel plate of about 3.2 mm (0.13 in.) thickness.

• Repair.



•


•

•

•

Replace.


Retighten or replace.


•

Repair or replace.

SHOVEL (BS3G)

Complaint

I.

Bucket

2. Uft arms and control

arms

Possible cause

(I)

Cracks, distortion, dents or broken

welds

(2)

Pin holes worn

(3) Cutting edge abnormally worn

(4) Teeth broken or badly worn

(I)

Cracks or distortion

(2)

Pin holes worn

Remedy

•


•

Repair.

• Repair.

•


•


• Repair.

33

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DEC. 86


Pub. No.

99879-00120-

6

/

SERVICE MANUAL

MITSUBISHI

TRACTOR

B 2 8

TRACTOR SHOV'EL

BS3G·

CONTENTS

POWER TRAIN .


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FOREWORD


Correct servicing will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.

Safety is not only your concern but everybody's concern. Safe working habits cannot be bought

Or manufactured; they must be learned through the job you do. By learning what CAUTION or WARNING symbol emphasizes, know what is safe - what is not safe. Consult your foreman, if necessary, for specific instructions on a job, and the safety equipment required.



I

NOTE

I ..............

An operating procedure, condition, etc., which is essential to highlight.

Lt.!

CAUTION

I

....... Operating procedures, practices, etc., which if not strictly observed, will result in damage to or destl1.lction of machine .


-

" '

.

\

TABLE OF CONTENTS

Engine dismounting and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

Flywheel clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Direct-drive (D D) transmissi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

Steering clutches and brakes

Steering valve

26

... , ........................... " .............. 38

Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44

Front idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45

Recoil springs and hydraulic adjuster cylinders . . . . . . . . . . . . . . . . . . . . .. 47

Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 51

Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 54

Track carrier rollers ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Special tools 60

I

·,·1

ENGINE DISMOUNTING AND MOUNTING

Dismounting

Preparatory steps

(1) Drain the oil from the engine and flywheel clutch case. [Engine oil: 7· liters (1.8 U.S. gal), approx., clutch oil: 5.5 liters (1.5 U.S. gal), approx.]

It may be possible to drain the oil with the engine and clutch lifted.

(2) Drain the coolant. [13 liters (3.4 U.S. gal), approx.]

(3) Raise the bucket fully, and support the lift cylinders there by the brackets to prevent the bucket from lowering accidentally. Lower the bucket to the ground after removing the radiator guard and side covers

(BS3

b)·

(4) Disconnect the hoses and pipes from the blade tilt cylinder (BD2G-PT).

1 Fron t guard

2 Rubber hoses (2 pcs)

3 Shield rubber

4 Clamp

5 Pipes (2 pcs)

[NOTE]

Disconnect pipes "5" after removing the side covers.

1

ENGINE DISMOUNTING ANO MOUNTING


1 Engine hood

2 Side covers (both sides)

3 Upper hose and lower hose

4 Oil cooler pipes (2 pcs)

5 Radiator and radiator guard

6 Floor plate (platform)

7 Under guard

[NOTEl

W hen unscrewing the bolts securing radiator guard "5" on BD2G-PAT, raise or lower the C-frame for access to the bolts.

602371

2. Remove the following electrical wires and parts on and around the engine:

8 Oil pressure switch wire

9 Thermo switch wire

10 Alternator wire

11 Hydraulic rubber hoses (2 pcs)

[NOTEl

Before disconnecting the wires, mark them for the components to which they are to be reconnected at the time of installation.

12 Air cleaner indicator wire

13 Glow plug wire

14 Stop solenoid wire.

15 Starter wire

16 Engine control cable

17 Fuel hose

18 Ground wire

11

602372

18

.

~2t:~::i:£::.

14

15

602373

2


19 Muffler

20 Air cleaner

21 Clutch control rod


.1.


22 Steering clutch oil rubber hoses (2 pes)

23 Oil cooler rubber hoses (2 pes)

24 Electrical wire (by loosening clamps)

3



602376

25 Disconnect the universal joint.

26 Attach lifting slings to the engine hitching bolts.

27 Remove the castle nuts, washers and bolts.

28 Lift off the engine and flywheel clutch.

[NOTE]

To leave the engine proper alone, remove the following parts:

Weight of engine and flywheel clutch assembly a) Flywheel clutch b) Hydraulic pump

340 kg (750 lb). approx.

\

4


Mounting

To mount the engine and flywheel clutch, follow the reverse of dismounting procedure.

Tips for mounting

1. Insert bolt "5" into its mount bracket, and brackets relative to the hole in locate frame. each the

2. After the engine has been lowered on to the brackets, check top clearance

"B" and bottom clearance "A."

(1) Locate shim "1" and washer "2" on bottom side .and shim "3" and washer

"4" on top side.

(2) Check to make sure that clearance

"A" between the bottom end of mount bracket and washer "2" is 1.8 to 2.8 mm (0.07 to 0.11 in.).

If this clearance is zero (0) at one or more brackets, replace all brackets.

(3) With mount bolt "5" in place, see if clearance "B" is 1.2 to 2.2 mm (0.05 to 0.09 in.); if not reduce or increase the thickness of shim "3" to set the clearance wi thin this range at each bracket.

(4) Tighten castle nut "6" to the specified t6rqlle.

1 Shim

3 6

2 Washer

602377

5 Bolt

602246

5

6


(5) After tightening all the brackets, check to make sure that the engine cl utch are level.

Use the following replacement parts as necessary.

Washers: 58611-11200,

4-mm (O.16-in.) thickness

58611-02400,

6-mm (O.24-in.) thickness

Shims: 58611-02500

(

64361,..74611 ,

I-mm (O.04-in.) thickness

64361-74612,

0.5-mm (O.02-in.) thickness

64361-17516, o

.5-mm (O.02-in.) thickness

)

3. After mounting the engine and clutch on the frame:

(1) Make sure that the electrical wires, pipes and hoses are connected properly.

(2) Adjust the clutch pedal. (Refer to

TESTING AND ADJUSTMENT volume.)

(3) Adjust the engine control.

(4) Fill the engine and clutch with recommended oil and coolant.

(

(

FLYWHEEL CLUTCH

The flywheel clutch can be disassembled after it is dismounted from the machine together with the engine, or on the machine. For dismounting of the clutch from the machine, refer to the topic,

ENGINE DISMOUNTING AND MOUNTING.

Disassembly of the clutch on the machine

Preparatory steps

(1)

Remove the under guard.

(2) Drain the oil from the clutch. [5.5 liters (1.5 U.S; gal), approx.]

1.


1 Floor plate (platform) (center, 1 pc)

2 Steering clutch levers (2 pcs)

3 Steering control rods (2 pcs)

4 Brake control rods (2 pcs)

5 Clutch control rod

(1 pc)

602445

7

FLYWHEEL CLUTCH

6 Rubber hoses for steering clutches (2 pcs)

7 Rubber hoses for oil cooler (2 pcs)

8 Electrical wire (by loosening clamps)

2. After removing the universal joint, remove the following parts from the clutch case:

(1) Oil pump

(2) Relief valve

(3) Oil strainer

(4) Clutch brake

3. Remove the oil filler from the threaded hole (M10 x 1.25) at the top of clutch case "9." Attach hook "A" in that threaded hole, and lift off the case.

4. Unscrew the bolts securing the clutch case, and move the case backward until it is possible to pull the main drive shaft out of the clutch cover .

. [NOTEj

Shift the lifting sling from hook "A" to attached to one of the bolt holes. hitching point shackle "B" case mounting

[NOTEj

Remove the universal joint together with the flange attached to the front end of input shaft.

[NOTEj

When lifting off the clutch case, cover the dashboard for protection against damage.

(

602446

8

5. Tilt clutch case "9" with its rear

(transmission) side lower than its front side, as shown, and take the case down.

6. For removal of the parts from the clutch case and removal of the pressure pIa te assem bly from the engine flywheel, refer to the topic,

Disassembly.

Reassembly

To reassemble the clutch, follow the reverse of disassembling procedure.

Disassembly of the clutch dismounted with the engine

Relief valve removal and installation

1.


1 Pipe

2 Bracket

3 Relief valve

4 Block

2. When installing the valve to the block, apply a coat of oil to the O-ring of the oil pump-side connector.

FLYWHEEL CLUTCH

602447

9

FLYWHEEL CLUTCH

Disassembly (The following procedure assumes that the clutch is dismounted with the engine but it may be followed in disassembling the clutch on the machine.)

5

.,

602380


1 Drain plug

2 Oil level gauge

3 Oil (iller

4 Clutch case (to be removed as an assem bly including "5" thru "45")

5 Suction pipe

6 Oil pump

7 Filter cover

8 Filter

9 Filter case

10 Adjusting bolt

11 Pin

12 Clevis

13 Brake band

14 Support

15 Castle nut

16 Spring

17 Spring seat

18 Lever

19 Support

20 Pin

21 Bolt 43 Snap ring

22 Pin 44 Bearing

23 Pin

24 Lever

45 Spacer

46 Washer (to be removed as an assembly

25 Oil seal

26 Needle roller bearing

27 Shaft including "47" thru "56")

47 Lock plate

28 Oil seal

48 Nut

29 Needle roller bearing

49 Return spring

30 Release lever (fork)

50 Pressure spring

31 Bearing

51 Pin

32 Bearing

52 Release lever

33 Release hub

53 Pin

34 Bushing

54 Lever support

35 Cover

55 Clutch cover

36 Oil seal

56 Pressure plate

37 Cover

57 Clutch disc

38 Snap ring

58 Mating plate

39 Bearing

59 Clutch disc

40 Main drive shaft

41 Snap ring

42 Gear

10

(

FL YWHEELCLUTCH

Tips for disassem bly

1.

Clutch case removal

Remove oil filler "3" from the threaded hole (MIO x 1.25) at the top of clutch case ·"4." Attach the hook in that threaded hole, and lift off the case.

2. Pressure plate assembly removal

Before removing pressure plate assembly, mark pressure plate "56" and clutch cover

"55." lnstall clutch disc arbor "A" (special too!) in the splined hole of clutch disc,· and run guide bolt "B" into each clutch spring hole. Tighten the guide bolts to compress the clutch springs lightly, and remove the pressure plate assembly.

60238t lnspection

1. Clutch discs

Measure the face runout, facing wear and fit of hub splines. Replace the disc if any of these measurements exceeds the service limit.

Item

Thickness of facing

Face mnout

Fit of hub splines

Assembly standard

Unit: mm (in.)

Service limit

5.7 - 6.3

-0.4 (-0.016) for

one side

(0.224 - 0.248) -0.8 (-0.031) for both sides

0.7 (0.028), max. 0.7 (0.028), min.

0.05 - 0.15

(0.0020 - 0.0059)

0.30 (0.0118)

Measuring face runout Measuring facing wear

601158

11

FLYWHEEL CLUTCH

2. Pressure springs

Measure the free length, test force and squareness. Replace the spring if any of these measurements exceeds the service limi t.

Unit: mm (in.)

Item

Assembly standard

Free length 70.6 (2.780)

Test force/length

43.5 ± 2.2

under test force

(95.9 ± 4.9) kgf (lbl) [NJ / .

[426.6 ± 21.6J/ mm (in.) 48.2 (1.898)

Squareness 2°,max.

Service limit

68.5 (2.697)

39.2

(86.4)

[384.41/

48.2 (1.898)

3°) min.

3. Pressure plate

Measure the flatness and friction surface. Replace pla te if any of these exceeds the service limit. wear of the the pressure measurements

Item

Thickness of

friction surface

Assembly standard

20.2 (0.795)

Unit: mm (in.)

Service limit

19.7 (0.776),

max.

Flatness

0.05 - 0.15

(0.0020 - 0.0059)

0.30 (0.0118)

4. Mating plates

Measure the flatness and wear of the friction surface. Replace the rna ting plate if any of these measurements exceeds the service limit.

Item

Thickness of

friction surface

Flatness

Unit· mm (in)

Assembly standard

Service limit

13.0 (0.512)

12.5 (0.492),

max.

0.05 - 0.10

(0.0020 - 0.0039)

0.20 (0.0079)

12

602382

602383

400067

(

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5. Pump drive gear

Measure the pump drive gear backlash.

Replace the gear if the measurement exceeds the service limit.

Item

Backlash

Unit: nun (in.)

Assembly standard Service limit

0.35 -0.42

0.70 (0.0276),

(0.0138 - 0.0165)

min.

6. Brake band

Measure the thickness of the facing.

Replace the band if the measurement exceeds the service limit.

Item

Thickness of facing

Unit: mm (in.)

Assembly standard

Service limit

5.0 (0.197)

3.0 (0.118),

max.

. FLYWHEEL CLUTCH

602384

602385

13

FLYWHEEL CLUTCH

Reassembly

47T

I

·gh .

1.7 kgf.m (12.3lbf.ft) [16.7 N·m]

5

(

602386

Reassembling order

. r ' r r r r r 56

1'1'1524950554847

L

515453 r ' r r r ' , r l l l r - r - r ' r 1 ' 1 ' r ' r - r r ' l Flywheel

595857 46 765321918121011141320211716151 r

4

444544 r - r ' r ' r r r 40

3539383734

1'1'33

32 31

14

Tips for reassembly

1. Clutch disc installation

Use clutch disc arbor "A" (special tool) to install pressure plate assembly including parts "46" thru "56," mating plate "58" and clutch discs "57" and "59." When installing them, note that the clutch discs are "dished."

Tighten the mounting bolts to the specified torque in a criss-cross pattern.

2. Release lever height adjustment

(1) Place flywheel "C" (or a jig equivalent to the flywheel) on a surface plate, and set up dial gauge

"E" as shown. Place 74-mm (2.91-in.) block gauge "0" on the friction surface of the flywheel, and set the dial gauge to indicate 0 mm for the

74-mm (2.91-in.) height.

I

NOTE]

Support the dial gauge solidly to retain the original setting.

(2) Install the clutch disc, mating plate, clutch disc and clutch cover assembly in that order on flywheel "C" (or the jig). Then, remove guide bolts

"B."

(3) Point the dial gauge spindle to the tip of release lever, read its indication, and tighten or loosen the lever nut until the gauge indicates 0 mm. After repea ting this process on the other three release levers, give mallet blows to the tip of each release lever at least 50 times, giving it

14-mm (0.6-in.) stroke at each blow.

This is for setting the release levers in their adjusted conditions.

Check the lever height once again and, if necessary, adjust it, making sure that the difference in height between any two levers is below 0.7 mm (0.028 in.).

59

FLYWHEEL CLUTCH

57

A

602387

600355

600356

15

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FLYWHEEL CLUTCH

(4) Install lock plate "47" to lever nut

"48," holding the nut so it does not rotate, and secure the release lever to clutch cover "55" with bolt.

3. Split pin installation

Insert the split pin into release lever "30" in parallel with the shaft and spread its ends properly to avoid interference with the pump drive gear.

~

)

r--,

L

0©J

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r - '

602388

4. Oil seal installation

Apply a coat periphery of installa tion. of ThreeBond 1104 to the oil seal "36" before

(

16

DIRECT-DRIVE

(DO)

TRANSMISSION

Removal

Preparatory steps

(1) Remove the under guard.

(2) Drain the oil from the transmission case and bevel gear case. [9.5 liters

(2.5 U.S. gaD, approx.]


1 Floor plate (platform) (center, 1 pc)

2 Electrical wir.e between battery switch and battery

3 Clamp for electrical wire between battery and starter

~

~

1 '-.....(' l

4 Operator's seat and seat plate

5 Rear cover

Weight of operator's

seat and seat plate

31 kg(68Ib),

approx.

2

,3

17

,.1

DIRECT·DRIVE (DD) TRANSMISSION

6 Steering clutch levers

7 Steering control rods

8 Brake control rods

,

!

2. Disconnect the following parts:

9 Steering clutch oil hoses (2 pes)


10 Universal joint

11 Transmission

Weight of universal joint

Weight of transmission

2 kg (41b), approx.

73 kg (l611b), approx.

[NOTEj

Before lifting off the transmission, shift it forward to pull the pIllion back out of mesh with the bevel gear.

18

602337

602389

602390

Installation

To install the transmission, follow the reverse of removing procedure, and proceed as follows:

(1)

Make sure that the electrical wires, pipes and hoses are connected properly.

(2) Fill the transmission case and bevel gear case with recommended oil.

Disassembly

Remove the groups in the order listed below for disassembly:

A Gearshift lever (transmission control lever) group

B Main drive shaft (input shaft) group

C Shift fork group

D Coun tershaft group

E Bevel gear shaft group

DIRECT·DRIVE (DD) TRANSMISSION

19

DIRECT·DRIVE (DO) TRANSMISSION

A Gearshift lever (transmission control lever) group and

B Main drive shaft (input shaft) group i

I

20

~

0 0 0 / '

A9 o~

810

89 88

~

7

816

~

/"--

;>

~

~~

J'l

85

2J

815 86

83

813

602391

602392


AI, A2 Hose clamps·

(to be loosened; "AI" thru

"A7" to be removed as an assembly)

A3 Cover

A4 Cover

A5 Retainer

A6 Spring

A 7 Control lever

AS Lever case

A9 Transmission cover

B1 Flange

(to be removed as an assembly including "B2")

B2 Plug

B3 Cover

(to be removed as an assembly including "B4")

B4 Oil seal

B5 Lock nut

B6 Lock washer

B7 Spacer

(to be removed as an assembly including "BS" thru "B14")

BS Input gear

B9 2nd-speed reverse

B10 Spacer

B11 1st-speed reverse

B12 Spacer

B13 Ball bearing

B14 Input shaft

B15 Snap ring

B16 Ball bearing gear gear

(

(

DIRECT-DRIVE (DO) TRANSMISSION

C Shift fork group. 0 Countershaft group and E Bevel gear shaft group

602394

(Remove

the

Cl Expansion plug

C2 Spring

C3 Steel (detent) ball

C4 Spring pin

C5 3rd-speed shift rail

C6 3rd-speed shift fork

(to be removed as an assembly including parts in the order numbered for disassembly.)

C19 1st-speed shift fork

(to be removed as an 014 Ball bearing assem bly incl uding

"C20" thru "C22")

C 20 Spring retainer

C21 Spring

C22 Plunger

013 Snap ring

El Cover

E2 Washer

E 3 Bearing cage


"C7" thru "C9")

C 7 Spring retainer

C8 Spring

C9 Plunger

CI0 Steel (detent) balls

(2 pcs)

C 11 Spring pin

C 12 2nd-speed shift rail

C 13 2nd-speed shift fork

C14 Interlock pin

C15 Steel (detent) ball

(2 pcs)

C 16 Spring pin

C17 Collar

C 18 1st-speed shift rail

01 Cover

02 Washer

03 Washer

04 Spacer


"05" thru "012")

05 Counter gear

06 Spacer

07 2nd-speed drive gear

08 Spacer

09 1st-speed drive gear

010 Spacer

011 Roller bearing

012 Countershaft

"E4" thru "E5")

E4 Shim

E5 Ball bearing

E6 1st-speed sliding gear

(to be removed as an assem bly including

"E7" thru "EI2")

E7 2nd-speed sliding gear

E8 3rd-speed sliding gear

E9 Snap ring

EI0 Spacer

Ell Roller bearing

E12 Bevel pinion shaft

21

DIRECT-DRIVE (DO) TRANSMISSION

Tips for disassembly

L Detent group (interlock mechanism) removal

To remove the detent group, place the gearshift lever in NEUTRAL.

I

NOTE]

Carefully handle steel (detent) balls

"C3," ·"ClO" and "CIS" to prevent them from getting lost.

2. Shaft removal

Drive the transmission shafts off the case in the following directions:

(1)

Drive off input ·shaft (main drive shaft) "B14" to the steering clutch case side.

(2) Drive off countershaft "D12" to the steering clutch case side.

(3) Drive off bevel pinion shaft "E12" to the universal joint side.

3. Bevel pinion shaft bearing cage removal

Using jacking bolts, remove bearing cage

"E3" together with bearing "ES" and shim

"E4."

4. Bevel pinion shaft bearing removal

Remove the inner race and rollers of bearing "ElL" Remove the outer race if necessary.

22

602243

602395

602396


• i

Inspection

1.

Shift forks

Measure the clearance of each shift fork in its groove in the sliding gear. Replace the fork if the measurement exceeds the service limit.

Unit· mm (in)

Item·

Assembly standard

Service limit

Clearance of shift fork in

groove

OJ -03

(0.004- 0.012)

0.5 (0.020)

2. Detent springs

Measure the free length and test force of each spring. Replace the spring if any of these measurements exceeds the service limit.

Unit: mm (in.)

Item

Free length

Test

forcel

length under

test force

kgf (lbf)

[NJI

mm (in.)

Assembly standard

Service limi t

62 (2.44)

9.80 ± 0.49

(21.61 ± L08)

[96.11 ±4.8IJI

55 (2.1 7)

60.5 (2382)

7.5

(16.5)

[73.5JI

55(2.17)

3. Gear backlash

Measure the backlash of gears. Replace the gears if the measurement exceeds the service limit.

Unit: mm (in.)

Item

Assembly standard

Service limit

Gear backlash

0.12-0.28

(0.0047 - 0.0110)

0.6 (0.024)

601460

601461

600164

602384

23


Reassembly

602167

Reassembling order r r--+

E3E5

r

r--+ r--+ r--+ r--+ r-' r--+

r

r--+ r--+ r--+ r--+ r--+ r - ' ' ' r-> r--' ,.,...

I

E8 E7 E6 E2 E4 El

I

01009 08 07 06 0504 014 013 03 01

II',EI2

EllEl0E9

1'1' 0 12

01102 r: r--+ r--+ , .

I

87 88 89 81 0 81 1 81 2 81 3 83 84 81 82 case

I I r l ' 8 1 4

816815

I

85

86

(

24

Tips for reassembly

1. Detent group (interlock mechanism) installa tion

(1) Install 1st-speed shift rail "CI8" and steel balls "CI5" in that order.


602397

(2) Insert interlock pin "C14" into the hole of 2nd-speed shift rail "C12", and put steel balls "CI0" and

3rd-speed shift rail "C5" in that order.

[NOTE]

Install the detent parts with each shift rail held in NEUTRAL.

2. Bevel pinion shaft installation

(1) Measure dimension "L" from the end face of pinion to that of transmission case, making sure that it is as specified below:

L = 46.2

+

0.1 mm

(1.819-.:':. 0.004 in.)

(2) The standard value of this dimension is indicated on the end face of pmlOn. Referring to that value, increase or decrease the thickness of shim "E4" to be fitted to pinion shaft

"EI2" on the opposite side of the pinion if .the dimension is greater or smaller than the specification.

E12

602398

602399

25

STEERING CLUTCHES AND BRAKES

Removal

Preparatory steps

(i)

Drain the oil from the bevel gear case and transmission case. [9.5 liters (2.5

U.S. gal), approx.]

(2) Remove the, tracks (on both sides).

It is not necessary to remove the tracks unless they engage the sprockets.

(Refer to the topic, Removal,

TRACKS.)

1.

Disconnect the following electrical wires:

(1)

Wire between battery switch !I1ld battery

(2) Clamp for wire between battery and starter


(i)

Floor plate

(2) Operator's seat and seat plate

(3) Rear cover


1 Steering control rods (2 pcs)

2 Brake control rods (2 pcs)

3 Springs (4 pcs)

(

602400

26

4 Steering clutch oil pipes (4 pcs)

5

Levers

(2 pcs)

6

7

8

Bracket

Steering valve

Cover --


602401

9

Cover

10

Shaft

11 Spring

12 Steering brake mounting bolts (4 pcs)

13 Bracket

602402

27

.. , .i


4. Lift the rear end of' the machine by positioning a jack under the steering clutch case so that the sprockets can be rotated, and block the final drive cases, using wood blocks, as shown.

602403

5. Hold the clutch pedal in depressed position, and place the gearshift lever in forward 1st position.

6. Unscrew bolts "14" and "15" securing the steering clutch

& brake assembly.

To do this, turn the splined portion of transmission input shaft "S" to rotate that assembly to remove the bolts one by one.


14 Mounting bolts

15 Mounting bolts

A Steering clutch

& brake assembly

() ()

602404

(

28

(

16 Washer

17

Hose

B

Steering clutch & brake assembly

Installation

To install the steering clutch

& brake assembly, follow the reverse of removal procedure, and proceed as follows:

(1)

Make sure that the oil pipes are connected properly.

(2) Fill the bevel gear case and transmission case with recommended oil.

Tips for steering clutch & brake assembly and cylinder assembly removal

These assemblies can be taken out of the steering clutch case with the operator's seat tilted forward by removing bracket

"13" and its related parts without removing the operator's seat and seat plate.

B


,,-1

!

602406

29


Diassembly

A Steering clutch & brake assembly


Al Pin


"A2" thru "A9")

A2 Lever

(to be removed as an assem bly incl uding

"A3" thru "A5")

A 3 Spring pin

A4 Pin

A5 Roller

A6 Anchor

A7 Clevis

A8 Adjusting nut

A9 Brake band assembly

AIO Outer drum

A11 Bolt

Al2 Plate

Al3 Plate

Al4 Spring

Al5 Spacer

Al6 Pressure plate

Al7 Disc plate

Al8 Friction plate

Al9 Inner drum

602407

30


(

B SteerIng I, der assembly

,

-.J

<®

B1

B5

L______

B1 Flange

B2

Shift~r

B3 BearIng

C~B~e_v_e_l_g_e_a_r

0

602408

B4 Piston ,

B5 Backup rmg

B6 Cylinder

1

- - - 1

C

1

Locking plate

C2 Nut

C

3

S t screw

(to e

)

b

C2

C7

Q?

1U C4

C5

C6

C4 Bearing cag~ed as an

(to be remo d' g "C5" bly inclu m "C7") and ou

C5 Oil seal

C

~ i~:::~ bearing

g

C9 Drive sha

602409

31


Inspection

1.

Friction plates

Measure the thickness and fit of its teeth in outer drum splines. Replace the plate if any of these measurements exceeds the service limit.

Unit: mm (in.)

Item

Thickness

Fit in Quter

drum splines

Assembly standard

Service limit

8.7 (0.342) 6.0 (0.236)

0.16 - 0.52

(0.0063 - 0.0205)

0.80 (0.0315)

2. Disc plates

Measure the thickness, fit of its teeth in inner drum splines and total thickness of friction plate and disc plates. Replace the disc plate if any of these measurements exceeds the service limit.

Unit: mm (in.)

Item

Thickness

Assembly standard

Service limit

2.8 (0.110) 2.3 (0.091)

Fit in inner

0.14 - 0.30 drum splines (0.0055 - 0.01 18)

Total thickness offriction plates and disc plates

69 (2.72)

0.60 (0.0236)

66 (2.60)

60t474

(

601473

32

(

Reassembly

Tightening {Orallle:,

3.5

±

0.3

(25.3

±

2.2

[34.3

±

2.9


(25.3 ± 2.2IbHt) [34.3 ± 2.9 N·m]

Tightening torque

16 - 19 kgf·m

(116 - 137Ibf.ft)

[157 - 186 N·m]

Al o

A5

A3,A4

A6~~~=m=

A9

A7

!

II

=

602412

602244

33

. '1


Reassembling order

C Bevel gear assembly

I

I '

I I I I I Steering clutch case

I

I I I C9 C7 (Outer race) C4 C5 Cl C2 C3

C6 C8 C2 C7 (Inner race)

(

A Steering clutch & brake assembly

I

I ' I ' I' I' I ' r

Flange (Bl)

A13 A15 A14 A19 A17 A16

IA10

I I

I I I jA9

I

I A2 A8 A6 A 1

A7 A5

A4

A3

B Steering clutch cylinder assembly

I

B4

B5+ B6

r

I

I ' I '

Drive shaft

I

B3 B2 Bl

(

Tips for reassembly

1. Drive shaft installation

(1)

Before instaliing drive shaft "C9," fit the inner race of left-hand roller bearing "C7" and collar "C6" to the shaft.

(2) After installing shaft "C9" and bevel gear "CS" in the steering clutch case, fit the inner race of right-hand roller bearing "C7" to the shaft.

34

2. Tapered roller bearing preload adjustment

(1) Tighten two adjusting nuts "C2," right and left, to settle them in place.

Lock one of the nuts with its lock plate "C1," and tighten or loosen the other nut to adjust the preload.

(Tightening the nut increases the preload.)

(2) Hook a spring balance to the tooth of bevel gear in mesh with the pinion with a wire, pull the balance in the tangential direction, and read the balance indication.

Item

Preload

Spring balance indication

Assembly standard

0.72 - 0.88 kgf·m

(5.21 - 6.37 Ibf.ft)

[7.06 - 8.63 N·m]

6.55 - 8.00 kgf

(14.44 - 17.641bf)

[64.23 - 78.45 N]

3. Bevel gear and pinion backlash adjustment

(1)

Put a fuse stock into between the bevel gear and. pinion at the place indicated as "E," roll it and measure the amount of flattening.

(2) Measure the backlash at a total of four places by turning the bevel gear

90

0 at a time, and take the smallest measurement for comparison with the assembly standard.

(3) To adjust loosen the left. the backlash, tighten or adjusting nuts, right and

Unit: mm

(in.)

Item

Assembly standard

Backlash

0.15 - 0.20

(0.0059 - 0.0079)

I

NOTE]

If one nut in loosened, for instance, the other nut must be tightened by the same amount to keep the preload unchanged.


602413

602413

35


4; Tooth contact adjustment

(1) To move the bevel pinion "G" toward or .away from the bevel gear "CS" for tooth contact adjustment, decrease or increase shims "F" between the bearing cage and transmission case.

(2) To determine the tooth contact pa ttern, brush red lead sparingly on the bevel gear teeth, and rotate the pinion backward and forward until a contact pattern . is noted on both concave and convex faces of the gear teeth.

[NOTE]

To make the tooth contact pattern more visible, lightly press the gear when rotating the pinion.

Correct tooth contact

Contact (indicated by the dark areas on the tooth faces) is heaviest toward the toe-end and extends about 30% of the tooth length on both convex and concave faces.

602415

~

Correct tooth contact

602416

Incorrect tooth contact

• Pinion too far away from bevel gear

(1)

Contact extends toward the toe-end of concave faces and toward the heel-end of convex faces.

(2) To correct this contact, decrease the thickness of shims "F," and turn adjusting nuts "C2" to move pinion

"G" away from gear "CS." Again brush red lead on the gear teeth, and check the contact pattern.

~~

Pinion too far away from bevel gear

602417

36


(

• Pinion too close to bevel gear

(1) Contact extends toward the heel-end of concave faces and toward the toe-end of convex faces.

(2) To correct this contact, increase the thickness of shims "P," and turn adjusting nuts "C2" to move gear

"CB"

toward pinion "G." Recheck the contact pattern by brushing red lead.

lNOTE)

The foregoing tooth contact adjustments are meaningless unless the bevel gear and pinion backlash has been adjusted properly.

~

Pinion

(00 close

(0 bevel gear

602418

37

STEERING VALVE


For removal and installation of steering valve, refer to the the topic,

Removal, STEERING CLUTCHES

BRAKES.

AND

Disassembly

(

38

3

2

1

(Remove the parts in the order numbered

1 Cover

2 Oil seal

3 Pison

4

Valve spring

5 Plunger valve

6 Return spring

7 Cover

8

9

Oil seal

Piston

10 Valve spring for disassembly.)

11 Plunger valve

12 Return spring

13 Valve housing

602419

(

Reassembly

10 9

8

T

11 12

13

STEERING VALVE o

3.4

6

5

602278

Reassembling order

39

i

FINAL DRIVES

Removal (disassembly)

Preparatory steps

(1)

Separate the tracks. (Refer to the topic, Removal, TRACKS.)

(2) Drain the oil from the final drive gear cases.

(3) When it is necessary to remove pinion

"18," remove the steering. clutch

& brake assembly. (Refer to -the topic,

Removal.)

(

602420


1 Cover

2

Castle nut

3 Washer

4 Sprocket

5

Seal case

6

7

Floating seal

Shim

8

Screw

9

11

Gear case


"10" thru "14")

10 Tapered roller bearing

(to be removed as an assem bly including

"1111 through "14")

Gear

12 Spacer

13 Tapered roller

14 Shaft

15 Snap ring

16 Tapered roller

17 Snap ring

18 Pinion

19 Ball bearing

20 Oil seal bearing bearing

40

(

Tips for removal

1.

Gear case removal

Using a jig, remove gear case "9" together with shaft subassembly comprising parts "10" thru "14."

Unit· kg (Ib)

Standard and swamp models

Weight of gear case and shaft Super·swamp model subassembly

Ultra-super·swamp model

-

60 (132), approx.

70 (154), approx.

90 (198),

. approx.

The final drive shaft. and its gear are supported by the gear case on one side and by the frame on the other.

Thus, pulling the· gear case alone from the frame is not only dangerous but also harmful to the shaft subassembly. Be sure to remove the case to which the shaft subassembly is installed.

2. Tapered roller bearing removal

(1)

Remove the inner race and rollers of tapered roller bearing "10" as the components of the shaft subassembly.

Remove the outer race of this bearing from the steering clutch case when required. .

(2) Similarly remove tapered roller bearing

"13." Remove its outer race from the gear case "9."

(3) The outer race of tapered roller bearing "16" comes off together with gear case "9" when removed.

Remove it from the gear case by loosening the screw when required.

FINAL DRIVES

41

FINAL DRIVES

Inspection

1.

Pinion and gear backlash

Measure the backlash, and pinion and gear if the

.exceeds the service limit. replace the measurement

Unit: mm

(in )

Item Assembly standard Service limit

Backlash

0.17 - 0.37

(0.0067 - 0.0146)

1.00 (0.0394)

Installation (reassembly)

2. Sprockets

Measure the tooth width, and replace the sprocket if the measurement exceeds the service limit.

Unit: mm (in)

. Item

Assembly standard Service limit

Sprocket tooth width

40 (1.57) 36 (1.42)

16 8 . 17

4

3

2

1

18

19

14

6

10

5

13

9 12 11 ightening torque:

7.6 - 9.2 kgf·m (55.0 - 66.5Ibf.ft) [74.5 - 90.2 N·m]

602421

Reassem bling order

2rii

r r r r 1 8

19 17 16 15 10

(Outer race)

, r ............ rrr+r->Steering clutch case

13 9 8 7 5 6 4 3 2 1 r r r

14

1 2

1 1 1 0

(Inner race)

42

(

FINAL DRIVES

Tips for reassembly

Tapered roller bearing preload adjustment

(1)

To adjust the preload of tapered roller bearing, decrease or increase the thickness of shims "7" between the gear case and oil seal cover.

(2)

Decreasing the thickness of the shims increases the preload of the bearing.

Unit: kgf.m (lbf·ft) [Nom]

Item

Tapered roller bearing

(pinion) preload

Assembly standard

0.29 -0.37

(2.10 - 2.68)

[2.84 - 3.63]

Starting 'torque "T" of pInIOn

=

"F" kgf Obf) [N] x

"L" m (in.)

(distance from center of pinion)

[Example]

If "L" is 25 cm (9.84 in.), balance reading should be 1.16 kgf (2.56 Ibf)

[11.4 N] to 1.48 kgf (3.26 Ibf) [14.5

N] as calculated below:

0.29 kgf'm (2.10 Ibfoft) [2.8 N'm]

= 0.25 m (9.84 in.) x Xl

Xl = 1.16 kgf (2.56 Ibf) [11.4 N]

0.37 kgf·m (2.68 Ipfoft) [3.6 N 'm]

=

0.25 m

(9.84 in.) x X2

X2

=

1.48 kgf (3.26 Ibf) [14.5 N]

Xl - X2

~~I~I--~====sEpr~in~g~b~ru~a~nc~e~fft~'

Pinion

L

602422

(

43

UNDERCARRIAGE

Removal

Preparatory steps

(1) Separate the tracks. (Refer to the topic, Removal, TRACKS.)

(2) On the PT model, disconnect the hydraulic hoses from the tilt cylinder, and remove the blade and blade arms.

1.


1 Bolts securing rigid bar

2 Bolts securing rear support

2. Lift or jack up the machine a little, and securely block the rigid bars and steering clutch cases, using wood blocks, as shown.

3. Remove the under carriage.

Installa tion

To install the undercarriage, follow the reverse of removing procedure.

44 l.

FRONT IDLERS


Preparatory steps

(1)

Separate the tracks.

(2) Drain the oil from the idler.

1. Unscrews the bolts (4 pes). Hitch a wire to the idler, and pull the idler assembly off the track frame.

2. After installing the idler, center it in the track frame.

Disassem bly

6

7

5

4

3


1 Guide

2 Shim

3 Bearing

4 Floating seal

5 Thrust washer

6 Shaft


"7

11 and 118 11

)

7 Bushing

8 Idler

Weight of front idler

38 kg (84 lb), approx.

45

FRONT IDLERS

Reassembly

Tightening torque:

6.5 ± 0.7 kgf·m

(47.0 ± 5.1 Ibf·ft)

[63.7 ± 6.9 N·m]

4

Tightening torque:

7.6 ± 0.8 kgf·m

_ - - - t '

(55.0

±

5.81bf·ft)

[74.5 ± 7.8 N·m]

7

Reassembling order

Tips for reassembly

Lubrication

(1) Fill the idler with recommended oil through the plug hole in the shaft.

(2) Use an adaptor and volume pump for this filling.

Capacity

(approx.)

60 ee (3.7 eu in.) (SAE 90 gear oil)

Part name

Adaptor

Volume pump

Part number

58809-15100

58309·03100

46

(

602187

(

(

RECOIL SPRINGS AND HYDRAULIC ADJUSTER CYLINDERS


Preparatory step

. Release the pressure in the hydraulic adjuster cylinder completely.

1.

Remove hydraulic adjuster cylinder assem bly

"1."

Weight of hydraulic adjuster· cylinder assembly

IS kg

(33Ib). approx.

2. Remove carrier roller bracket assembly

(recoil spring assembly) "2."

Weig.ht of carrier roller braci<et assembly (with carrier roller)

I

42 kg

(93Ib). approx.

3. Remove the track carrier assembly. (Refer to the

Removal, TRACK CARRIER

ROLLERS.) roller topic,

4. After installing the track, adjust its tension.

602439

47

. !

,


Disassembly

10

8

11

12

13

, i

9

15

5

602426


1 Cover

2 Stopper l Fill valve

4 Washer

5 Cylinder


"6" and 117")

6 Dust seal

7 Rod packing

8 Plate

9 Shaft

10 Ring

11 Spring retainer

12 Spring


14 Bracket

(for ultra-super-swamp model)


(for ultra-super-swamp model)

48



To remove recoil spring "12," hold plate

"8" with the arbor of a press having a capacity of 3 tons (6615 lb) as shown, unscrew four bolts, and gradually back off the press arbor to let the spring expand. Take out the plate, spring retainer "11" and spring.

602427

o o o

~4-_-12

602428

49

,.1

· 1


Reassembly

4

Tightening torque:

3.5

±

0.5 kgf·m

(25.3

±

3.61bf·ft)

[34.3 ± 4.9 N·m]

13

Tightening torque:

. 26 ± 2 kgf·m

±

141bf·ft)

±

20 N·m]

7 5

Reassembling order

10-8

9 rr i

13

, . , . 5

4 3 t

'1'1

Tips for reassembly

Recoil spring installation

Compress spring "12" as in case of disassembly, and install plate "8" to the spring.

602249

(

50

(

TRACK ROLLERS

Removal

Preparatory steps

(1) Loosen the tracks.

(2) Drain the oil from the track rollers.

1.

Place two wood blocks "A" of 300-mm

(12-in.) square section behind the sprockets in a chocking manner, and move the machine to ride onto these blocks until the track rollers "1" and

"3" float up and away from the track.

2. Apply the brake lock, and chock the tracks at front end with blocks "B."


1 Track roller (center, 3 pcs)

2 Track roller guard (front and rear)

3 Track roller (front and rear)

Weight of track roller

15 kg (33 Ib), approx.

Installation

1.

To install the track rollers, follow the reverse of removing procedure.

2. Drive the machine forward out of its chocked condition.

Tightening torque for track roller bolts

6.0 ± 0.6 kgf·m

(43.4 ± 4.3lbf·ft)

[58.8 ± 5.9 N·m)

602429

..

602430

51

- "1

,

TRACK ROLLERS

Disassembly

4

3

(Remove the parts in the order numbered -for disassem bly.)

1 Collar

2 Floating seal

3 Thrust washer

4 Shaft

5 Bushing

6 Flanged roller

@

!

V

602431

(

52

..

I

-~1

Reassembly

!

Tightening torque:

7.6 ± 0.8 kgf·m

(5.5

±

5.8Ibf·ft)

[74.5 ± 7.8

N·m]

Reassembling order

TRACK ROLLERS

602188

Tips for reassembly

1. Floating seal installation

(1) When fitting the floating seals, use a properly sized round bar or the special tool to prevent damage to the seals and O-rings.

~[CAUTION)

Never use a screwdriver ·or a sharpedged tool to fit the floating seals.

(2) Using a lint-free cloth or a brush and washing fluid, clean the surfaces of metal rings of floating seals, making sure that these rings are free of any

grime.

2. Lubrication

(1) After reassembling the roller, fill it with recommended oil through plug hole in the shaft.


Capacity approx.

75 cc (4.6 cu in.) (SAE90 gear oil)

Adaptor

Part name

Volume pump

Part number

58809·15100

58309·03100

53

TRACKS

Removal

1.

Move the machine until the master pin comes to the rear upper part. of sprocket.

2. Loosen the tracks. (Refer to the topic,

Track, adjustment.)

3. Drive out master pin

"1."

4. Remove bushing "2," seal washers "3" and spacers "4" (standard and swamp models). Remove the bushing and seal

(super-swamp and ultra-super-swamp models).

5. Insert a bar into the link and, while holding the bar, move the machine slowly forward to layout the track.

6. Lift the side of the machine, and remove the track.

7. After lifting the side of the machine, place wood blocks under the rigid bar and steering clutch case.

Track weigh t

Standard model

Swamp model (S)

BD2G (P)

BS3G (F)

Super·swamp model (SS)

Ultra·super-swamp model (SSS)

Installa tion

1. To install the track, follow the reverse of removing procedure.

2. Insert a bar in to the link, and aid the track to climb over the sprocket, carrier roller and· front idler, as the machine is moved slowly forward.

3. Install the seal washers properly.

Drive in the master pin wi th its center hole outside. (For detail of seal washer installation, refer to the topic,

Reassembly.)

4. To drive in the master pin, insert the guide bar, bushing, seal washers, etc. into the link, and drive in the pin in a manner of driving out the guide bar.

602432

Unit: kg (Ib)

280 (620), approx.

310 (680), approx.

420 (930), approx.

470 (1040), approx.

600 (1320), approx.

602433

54

TRACKS

Disassembly

5

5

3 : - - - - - - - '

5-----~~1

10---;7"


Ia Standard shoe

Ib Swamp shoe (curved apex shoe)

2 Pin

3 Bushing

4a Seal washer

4b Seal

5 Link

602434

55

TRACKS

Reassembly

(

1a

Reassembling order

Tips for reassembly

Install the seal washers and seals as shown.

Seal washer

(standard and swamp models)

Seal

(super-swamp and

ultra-super-swamp

models)

56

602184

Tightening torque:

17 - 20 kgf-m

(123 - 145Ibf-ft)

(167 - 196 N-m]

602185

(

602435 \

,

TRACK CARRIER ROLLERS

Removal

Preparatory steps

(1)

Loosen the tracks.

(2) Drain the oil from the track carrier rollers.

Push up the track above the carrier roller to produce some clearance between track "1" and carrier roller "2," and remove the following parts:

3 Bolts (2 pcs)

2 Track carrier roller

Weight of track carrier roller

11 kg (24Ib), approx.

Installa tion

1.

To install the track follow the reverse procedure. carrier roller, of removing

2. Insert the shaft into the bracket so that the arrow mark on one end points upward and the spring pin hole on the other comes to the top side.

3. Adjust the tension of tracks.

3

602436

602437

57

58


Disassembly

.

,

8

4

5


1 Cover

2 Washer

3 Floating seal


"4" and "5")

4 Bushing

5 Roller

6 Snap ring

7 Seal support

8 Shaft

602438

(

(

f

Reassembly

Reassem bling order

6~8

rrrrrr r

Carrier roller bracket

7 3 4 5 2 1

Tips for reassembly

Lubrication

(1) After reassembling the roller, fill it with recommended oil through plug hole in the cover.


Capacity

approx.

35 ee (2.1 eu in.) (SAE 90 gear oil)

Adaptor

Part name

Volume pump

Part number

58609·00300

58309·03100


:ri1:ht<miIlg torque:

.2kgf·m

±

8.7Ibf.ft)

19.6

±

11.8

N·m]

Tightening torque:

4.2 ± 0.4 kgf·m

(30.4 ± 2.9 Ibf.ft)

[41.2

±

3.9

N·m]

602186

59

60

Part number

58809·10200

Wrench

Part name

SPECIAL TOOLS

Shape

Use

Bevel gear adjustment

(

58609-00300

Adaptor

58809·15100

Adaptor

602441

Carrier roller lubrication

Front idler and track roller

lubrication

58309-03100

Volume pump

58809·15600

Clutch disc arbor

Carrier roller) front idler

. and track roller lubrication

\

602444

Flywheel clutch installation

(clutch disc assembly aligning)

(

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DEC. 136


Pub. No.

99879-00120-

7

/

SERVICE MANUAL

MITSUBISHI

TRACTOR······

B

·2G·····

TRACTOR SHOVEL

BS3Gi

CONTENTS

HYDRAULIC SYSTEM


j j

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FOREWORD

This service manual has instructions and procedures for the subject on the front cover. The infonnation, specifications, and illustrations used in this manual are based on infonnation that was current at the time this issue was written.

Correct sefVIcmg will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.

Safety is not only your concern but everybody's concern. Safe working habits cannot be bought or manufactured; they must be learned through the job you do. By learning what CAUTION or WARNING symbol emphasizes, know what is safe - what is not safe. Consult your forem'an, if necessary, for specific instructions on a job, and the safety equipment required.



[ NOTE

I ..............

An. op.erating

~roced~re,. condition, etc., whIch IS essentIal to hIghlIght.

.&J

CAUTION

I

....... Operating procedures, practices, etc.,

, which if not strictly observed, will result in damage to or destruction of machine .


..

,

.

<~

.

.

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TABLE OF CONTENTS

Hydraulic pump

Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4

Power angling/tiit blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14

Power tilt blade . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16

Bucket and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18

Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32

(

(

HYDRAULIC PUMP

Removal

Preparatory step

Remove the side cover (RH) from the engine room •

.&.1"4i;@@D

Raise the bucket all the way, and securely support it by external means. (BS30)


1

2

Rubber hose (suction side)

Pipe

3 Rubber hose (discharge side)

4

Pipe and connector

5 Hydraulic pump

Installation

To install the pump, follow the reverse of removing procedure.

Tightening torque for hydraulic pump mounting bolts

4.2 kgf·m

(30.41bf·ft)

[41.2 N·m]

602280

HYDRAULIC PUMP

Disassembly

7

14

12

~,

5

6

602281

1 Cover

2 Packing ring

3 Bushing seal (2 pcs)

4

Bushing (2 pcs)

5

Driven gear

6

Drive gear

7 Body seal (2 pes)

8

Body

9

Packing ring

10

Bushing seal (2 pcs)

11 Bushing (2 pcs)

12 Oil seal

13 Dust seal

14

Mounting flange



1.

Lay down the pump body. Pull out the drive gear by hand, and remove the bushings.

2. Layout the disassembled parts neatly in the order in which they came out, identifying each for its position.

Particularly, the shaft and its bushings must be identified positionally by marking or otherwise so that they will be restored to their original position in reassembly.

(NOTE)

If the bushings will not come out, tap on the pump body with a plastic hammer to shake the bushings loose.

Be sure to place the pump body on a wood top bench and tap lightly.

2

(

Reassembly

Tightening torque:

4.7 - 5.0 kgf.m

(34.0 - 36.2

Ibf·ft)

[46.1 - 49.0 N·m]

1

4

5

8 11 7

12

2 3

HYDRAULIC PUMP

6

Reassembling order

3 2

I I I ,

5 6 4 11

L9

10 ria

1

, , 1 4

12 13

Tips for reassembly

A ttach packing rings and bushing seals to the bushings, apply a coat of high-grade grease to the bushings, and insert them in to the pump body.

601398

I

NOTE)

1) When inserting a pair of bushings

"4" and "11," hold them squarely to the bore to avoid scuffing.

2) If the outside surface of the bushing is found wi th scra tch marks, remove high spots on the surface by lightly polishing with an oil stone.

3) When reinstalling the gears, mesh drive gear "6" with the driven gear in the same tooth position as before.

4) Before installing the cover, wrap the splined portion of the drive gear shaft with one or two layers of cellophane tape to prevent damage to the oil seal.

3

CONTROL VALVE

Removal

Preparatory steps

(1)

Lower the implement to the ground, and stop the engine.

(2) Move the control" lever to all operating . positions to relieve the pressure in the hydraulic circuits.


1 Cover

2 Control linkage assembly

3 Oil pipes

4 Control valve

(NOTEl

Loosen the return oil and push the hose hydraulic tank. hose cIa m ps, toward the

BD2G

Weight of control valves

Control valve for power angling/tilt blade

Control valve for power tilt blade

13.5 kg (30 lb), approx.


Control valve for BS3G


1

602282

Installation

To install the control valve, follow the reverse of removing procedure.

Tips for installation

W hen installing the control valve, check to make sure that the clevis of each control linkage and the plunger of control valve are properly installed. The clevis and plunger should be at a right angle to the adjacent ones when installed, as shown.

4

BD2G

Control valve for power angling/tilt blade

Tilt plunger section

(center)

Control valve for power tilt blade

Control valve for BS3G

Tilt plunger section

(left as viewed from front side)

Dum plunger sec·

O from front side)

CONTROL VALVE

3-section control valve (BD2G with power angling/tilt blade)

Disassembly and reassembly

.G Tightening torque:

. 5.0 ± 0.5 kgf·m

(36.2 ± 3.6 Ibf·ft)

. [49.0 ± 4.9 N·m] Tightening torque: F

10 ± I kgf.m

(72.3 ± 7.2 Ibf·ft)

[98.1 ± 9.8 N·m]

A Tightening torque:

2.7 ± 0.3 kgf·m

(19.5 ± 2.2 Ibf·ft)

[26.5 ± 2.9 N·m]

E

B

C D

A Tie rod

B Inlet and lift valve plunger section

C Tilt valve plunger section

D Angling valve plunger section

E End plate

F Main relief valve

G Makeup valve

[NOTE]

1) Be sure to tighten the tie rods to the specified torque, or the plungers will not move smoothly and the implement will drift excessively.

2) After reassembly, make sure that the plungers move smoothly.

602198

5

6

CONTROL VALVE

Disassembly r r

C8~

C9-@

D8----'~

D9

~

Cl0

A Dl0

\)

fe

B17---@)

',

E

I

DI~~ c:'

0 .

<1;7/.1>

1(

t

0

I

<'f"'f

\)~

CllB18

C13 C12

C14, D14

D7--l

D6-(§lC7~

D5~C6~

B23

D3----e

C4~

D2~C3~

Dl

P

C:~

I c'Ifj

4 4

B14

B13

~'~

(§If'--...

Bl tl

B6

B7

B4

°

°

<:l>--B12

~Bll 0

~.~~~*BI9

~B5

0

B8

0

13

B3

©>

B2

Bl Cap (to be removed as

B14 Oil seal an assembly including Bl5 Plate

"B2" thru "B4")

B2 Snap ring

B3 Plate

B16 Spacer

B17 Oil seal

B18 Plunger

B4 Detent sleeve

B5 Steel (detent) balls

B19 Plug

B20 Plug

B6 Spring pin

B7 Steel (detent) ball

B21 Spring

B22 Check valve

B8 Spring

B9 Plunger plug

B23 Housing

BI0 Spring guide

Bll Spring

B12 Spring guide

B13 Seal cover plate

602284

CI, Dl Cap

C2, D2 Plunger plug

C3, D3 Spring guide

C4, D4 Spring

C5, D5 Spring guide

C6, D6 Seal cover plate

C7, D7 Oil seal

C8, D8· Seal cover plate

C9, D9 Oil seal

CI0, DI0 Plunger

Cll, Dll Plug

C12, Dl2 Spring

C13, D13 Check valve

C14, D14 Housing


(

(

" \

Reassembly

CONTROL VALVE

7

Tightening torque:

2.0 ± 0.2 kgf·m

(l4.5 ± 1.4 Ibf·ft)

[19.6 ± 2.0 N·m]

822 823

D 1

602199

Tightening torque:

2.0 ± 0.2kgf·m

(l4.5 ± 1.4 "Jbf.ft)

[19.6

± 2.0 N·m]

D9

602200

Reassembling order


B4

--+

Bl r r r r r r r r

L

B12 Bll Bl0 B9 B8 B7 B5 B6 r r r r

B23 j j j r r r r

B18 B16 B11 B15

~

B20 B21 B22

B3 B2 B13 B14

C Tilt valve plunger section r r r

C14j j j r r r r r r r

Cl 0 C9 C8 Cll C12 C13

C5 C4 C3 C2 Cl C6 C7

D Angling valve plunger section

(Identical with C Tilt valve plunger section)

7

CONTROL VALVE

2-section control valve (BD2G with power

tilt

blade)


Tightening

~o-rq-u-e-: ----.;-F~t?r~~~~I;f~~

10 ± 1 kgf·m

(72.3 ± 7.2 Ibf.ft)

[98.1 ± 9.8 N·m)

G Tightening torque:.

5.0 ± 0.5 kgf·m

(36.2 ± 3.6 Ibf·ft)

[49.0

±

4.9 N·m)

A Tightening torque:

2.7 ± 0.3 kgf·m

(19.5 ± 2.2 Ibf.ft)

[26.5

±

2.9 N·m) o o

B

F

Tightening torque:

5.0 ± 0.5 kgf·m

(36.2 ± 3.6 Ibf·ft)

[49.0

±

4.9 N·m)

A Tie rod


C Tilt valve plunger section o

End plate

E Main relief valve

F Safety valve

G Makeup valve c

8



602206

(

Disassembly

'g

.J. ,'"

?

:::~ ~ f tI

• " 'J'-. ( )

1;9

<3 o e o /

,,-,'

{>

'0'

i~

Cl~

C13 B18

C14

r-

J '

J

C16 "-

, M ' ,//

Clef'

C7-----l@!;l!OO.O

0 0 °

C6---I@

C12~

/r~

B19

B20

' /

C5

C4

@

Iii g;

~

Cl---~

B22

~

CONTROL VALVE

\.

Bl Cap (to be removed as an assembly including

"B2" thru "B4")

B2 Snap ring

B3 Plate

B4 Detent sleeve


B6 Spring pin


B8 Spring

B9 Plunger plug

BI0 Spring guide

B11 Spring

B12 Spring guide


B14 Oil seal

B15 Plate

B16 Spacer

B17 Oil seal

B18 Plunger

B19 Plug

B20 Spring

B21 Check valve

B22 Housing

Cl Cap

C2 Plunger plug

C 3 Spring guide

C4 Spring .

C5 Spring guide

C6 Seal cover plate

C7 Oil seal

C8 Seal cover plate

C9 Oil seal

CI0 Plunger

Cll Plug

C12 Plug

C13 Plug

C14 Spring

C 15 Check valve

C16 Housing


602285

9

CONTROL VALVE

Reassembly

B3

B4

~§'ldJL~~=-t~--B19

Tightening torque:

3.5

±

0.4 kgf·m

(25.3 ± 2.9Ibf·ft)

~~I-'l~rh'nr'i'l'i~RTIh!-.!r'-,~-'1":=~[34.3

± 3.9 N·m]

B6

602207

B10

C12

Tightening torque:"

10 ± I kgf·m

(72.3

±

7.21bf·ft)

[98.1 ± 9.8 N·m]

Tightening torque: C2

2.0 ± 0.2 kgf·m

(14.5

±

1.4lbf.ft)

[19.6 ± 2.0 N·m]

Tightening torque:

1.1 ± 0.1 kgf·m

(8.0

±

0.7Ibf·ft) C6 C7

[10.8 ± 1.0 N·m]

Reassem bling order

C16

C11

C13

Tightening torque:

3.5

±

0.4 kgf·m

(25.3 ± 2.9 Ibf·ft)

[34.3 ± 3.9 N·m]

C8

C10 C9

602208


84 ..... 81

, r' , , , , , ,

L

812 811 810 89 88 87 85 86

E-H-F

r r , r

822

1 1 1

, , , ,818816817 815

~

B19820821

83 82 813 814

( roo, "

1-> "

Cll

C Tilt valve plunger section

!

r , r

C16 '-1 '-1 '-1

r ,

,Cl0 C9 C8 C!2 C13 C14 C15


(

10

CONTROL VALVE

2-section control valve (BS30)


Tightening torque: E

10 ± I kgf·m

(72.3 ± 7.21bf·ft)

[98.1 ± 9.8 N·m]

H

F Tightening torque:

. ~.O ± 0.5 kgf·m

(36.2 ±3.61bf·ft)

[49.0 ± 4.9 N·m]

Tightening torque:

2.7 ± 0.3 kgf.m

(19.5 ± 2.21bf.ft)

[26.5 ± 2.9 N.m]

-,----D

B

C

~:tG*------G

Tightening torque:

5.0 ± 0.5 kgf·m

(36.2 ± 3.61bf·ft)

[49.0 ± 4.9 N·m]

602214

A Tie rod


C Dump valve plunger section

D End plate

E Main relief valve

F Safety valve a

Safety valve

H Makeup valve

I

NOTE)



11

12

CONTROL VALVE

Disassembly

B15~ ~E

H

B16~~

1;[

'I

0

G

.e'?

I

/i~ o

C16

C15@()()

~

C7

C6

r{

I

.Yll

C13

•

'V~ ~

v

I

!!§J.

~

0

6

G-e

\)~

Cll B18

B23 ,

,J

'g

@

I

'J'

(

, / /

"'~

/G""l"

~O

/

I

B21

'B22

g; g

~ B14~~

C l - @

~.

B13~~~ f~ r~~~o

B6_~B5

B7---<> B8

B4-tl

B3--o

B2~

B1 Cap (to be removed as an assembly including

"B2" thru "B4")

B2 Snap ring

B3 Plate

B4 Detent sleeve


B6 Spring pin


B8 Spring

B9 Plunger plug

810 Spring guide

Bll Spring

B12 Spring guide


B14 Oil seal

B15 Plate

B16 Spacer

B17 Oil seal

B18 Plunger

B19 Plug

B20 Plug

B21 Spring

B22 Check valve

B23 Housing

C1 Cap

C 2 Plunger plug

C3 Spring guide

C4 Spring

C5 Spring guide

C 6 Seal cover pIa te

C7 Oil seal

C8 Seal cover plate

C9 Oil seal

C10 Plunger

Cll Plug

C12 Spring

CI3 Check valve

CI4 Plug

C15 Spring

C16 Makeup valve

C17 Housing


602286

(

(

CONTROL VALVE

Reassembly

817

Tightening torque:

3.5 ± 0.4 kgf·m

(25.3 ± 2.91bf·ft)

(34.3 ± 3.9 N·m]

602199

Tightening torque:

3.5 ± 0.4 kgf·m

(25.3 ± 2.9 Ibf· ft)

[34.3 ± 3.9 N·m]

Tightening torque: ± 0.3 kgf·m

822

Cl

1-.:(_19_.5_±

_2._2_1b_f_'ft~):-[2_6_.5_±_2_.9_N_._m~] ~ rt==~"';"----v-?

C2 ---~

Tightening torque:

2.0 ± 0.2 kgf·m

(14.5 ± 1.4Ibf.ft)

[19.6 ± 2.0 N·m]

Tightening torque:.

1.1

± 0.1 kgf·m

(8.0

±

0.7 Ibf.ft)

[10.8 ± 1.0 N.m]

602215

Igmenll"g torque: 5.0 ± 0.5 kgf·m

±

3.61bf·ft) [49.0 ± 4.9 N.m]

Reassem bling order


I' I' I' I' I' I'

B19

~rE

B4~81

I' I' I' I'

823, , , r r

L r r r'

I'

B18 B16 B17 B15

~

B20 B21 B22

812 811 Bl0 89 88 87 B5 86 B3 82 B13 B14

C Dump valve plunger section

I' I' I' I' r~

I' r~ r

G1rF


r

r'

C17 r

'1 , '-I r

I'

Cl 0 C9 C8

r

Cll C12 C13

C16 C15 C14

13

POWER ANGLING/TILT BLADE

Removal

Preparatory steps

(1)

Place wood blocks llilder the blade frame.

(2) Lower the blade to the ground, stop the engine, and move the control levers to all operating positions to relieve the pressure in the hydraulic circuits.

1.


1

Rubber hoses (for lift cylinders, 4 pcs)

2 Rubber hoses

(for angling cylinders, 4 pes)

3 Rubber hoses (for tilt cylinder, 2 pes)

4 Lock plate

5 Pin

2. Move the machine backward, leaving the blade on the ground.

3. The blade may be lifted off with a hoist and slings.

Weight of power angling/tilt blade 550 kg (1213 lb), approx.

I

Installation

To install the blade, follow the reverse of removing procedure.

14

602288

(

(

POWER ANGLING/TIL T BLADE


28

29

~

30

@J:D

.

•

,

.~

•

.

---:.!....o

-om

29

1 Pin

2 Lift cylinder

3 Cover

4 Plate

5 Plate

6 Hose

7 Block

8 Pin

9 Pin

10 Angling cylinder

11 Cover

12 Cover

13 Cover

14 Hoses

15 Hoses

16 Block

17 Pin

18 Pin

19 Tilt cylinder

20 Plates

21 Bracket

22 Plate

23 Plate

24 Bar

25 Pin

26 Bracket

27 Cap

28 Blade

29 End bit

30 Cutting edge

31 C-frame

Power angling/tilt blade - Disassembled view


/

2

602289

Reassembly

To reassemble the blade, follow the reverse of disassembling procedure.

15

POWER TILT BLADE

Removal

Preparatory steps

(1) Lower the blade to the ground, stop the engine, and move the control lever to all operating positions to relieve the pressure in the hydraulic circuits.

(2) Place wood blocks under the blade arms.

1.


1 Lock plate

2 Pin

3 Lift cylinder and lever

4 Rubber hoses (for tilt cylinder, 2 pcs)

2. Remove cap "5," separate the blade arm from the trunnion, and reinstall the cap on each side.

3. Lift off the blade and arms.

Weight of power tilt blade

400 kg (882 lb), approx.

4. The blade may be removed by moving the machine backward, leaving the blade on the ground.

Installation

To install the blade, follow the reverse of removing procedure.

16

(

602290

(

602291

POWER TILT BLADE


16

18

['..

14

.

'---=:rV~ rf

12

17

602292

1 Pin

2 Lift cylinder

3 Pin

4 Rod

5 Lever

6

Cover

7 Pin

8 Tilt cylinder

23

Ultra-super-swamp model (SSS)

21

. .

20

.....

"'%'"

22

.

".

.

.

.

" •

•

f'-'

oJ

I

. ' "

'

, e '.

"%~"

22

21

;>--:ff

602305

9

10

11

12

13

14

15

16

Pin

Tilt braces

Pin

Braces

Cap

Pin

Arm

Blade

17

18

19

20

21

22

23

End bit

Cutting edge

Trunnion·

Blade

End bit

Bit

Cutting edge

Power tilt blade -- Disassembled view


17

BUCKET AND LINKAGE

Removal

Preparatory steps

(1) Lower the bucket to the ground, stop the engine, and move the control lever to all operating positions to relieve the pressure in the hydraulic circuits.

(2)

Fasten the lift cylinders to the lift arms with wires.

1.

Remove the following parts at four bucket mounts:

1

Bolt

2

Pin

3 Seal

4

Bucket

Weight of bucket

240 kg

(529 Ib), approx.

2. Attach slings to the lift arms.

3.


5

Rubber hoses (for dump cylinders, 4 pcs)

6

Rubber hoses (for lift cylinders,

4 pcs)

7

Lock plates

(4 pcs)

8 Pin

(4 pcs)

9

Pin

(2 pcs)

10 Seals

11 Bushing

12 Bucket linkage

Weight of bucket linkage

400 kg (882

Ib), approx.

1Z


13 Lock plate (4 pcs)

14 Pin (4 pcs)

15 Tower

'18

602295

(


8

BUCKET AND LINKAGE

.

9

~~c

c

.

c c

10

12

8 7

1 Pin

2 Lift cylinder

3 Pin

4 Dump cylinder

5 Pin

6 Arms

7 Pin

8 Arms

9 Pipe

10 Frame

11 Tooth

12 Bucket

Bucket and linkage - Disassembled view


602296

19

HYDRAULIC CYLINDERS

Removal

Preparatory steps

(1)

Lower the blade or bucket to the ground.

(2) Lift the cylinders with slings.

1.

Remove the following parts

1 Covers for angling cylinders of power angling/tilt blade

2 Cover for tilt cylinder of power tilt blade


3 Piston rod-side pins of cylinders

4 Piston rod-side cap of cylinder

(tilt cylinder of power tilt blade)

5 Rubber hoses

6 Head-side pins of cylinders

[NOTEl

Before disconnecting the rubber hoses, be sure to stop the engine, and move the control levers to all operating positions to relieve the pressure in the hydraulic circuits.

Power angling/tilt blade

5

Power tilt blade

602298

(

20

HYDRAULIC CYLINDERS

·3. Remove the following parts:

7 Pipes and connectors for each cylinder

8 Cylinders

BD2G

BS3G

Weight of cylinders (approx.) Unit: kg (Ib)

Power angling! tilt blade

Power tilt blade

Bucket

Lift cylinder

Angling cylinder

Tilt cylinder

Lift cylinder

Tilt cylinder

Lift cylinder

Dump cylinder

13.5

(30)

12.5

(28)

13.8 .

(30)

13.5

(30)

15.0

(33)

29.0

(64)

17.0

(37)

Installation

1.

To install the cylinders, follow the reverse of removing procedure.

2. Insert the head-side pin, and connect the rubber hoses to the cylinder.

While extending the piston rod, insert the rod-side pin.

Disassembly

[NOTE]

Two types of hydraulic cylinders

- ring nut type and gland screw type

- are used. These types differ from each other in disassembling and reassembling procedures.

BD2G

BS3G

I

Power anglingl tilt blade

Power

blade

Bucket

tilt

Lift cylinders

Angling cylinders Ring

Tilt cylinder nut type

Lift cylinders

Tilt cylinder

Lift cylinders

Dump cylinders

Gland

screw

type

Bucket

21

HYDRAULIC CYLINDERS

Ring

nut

type

(Example: Lift cylinder for power angling/tilt blade and power tilt blade for BD2G)

22

1 Ring nut

2 Ring

3 Nut (to be removed as an assembly including "4" thru "11")

4 Piston (to be removed as an assembly including "5")

5 Piston .seal

6 Guide bushing (to be removed as an assembly including "7" thru "11")

7 Dust seal

8 Rod packing

9 Buffer ring

10 Bushing

11 Piston rod

12 Bushing

13 Cylinder tube

(Remove the parts in the order numbered for disassem bly.)

602300

(

Gland screw type

(Example: Tilt cylinder for power tilt blade for BD2G)

·0

6

11

HYDRAULIC CYLINDERS

L--/C)

3

5

4

.

1 Ring

2 Gland screw

3 Nut (to be removed as an assembly including "4" thru "12")

4 Piston (to be removed as an assembly including "5")

5 Piston seal

6 Guide bushing (to be removed as an assembly including "7" thru "10")

7 Backup ring

8 Dust seal

9 Rod packing

10 Buffer ring

11 Piston rod

12 Cap

13 Cylinder tube


602301

23

HYDRAULIC CYLINDERS


1. On the ring nut type cylinder, use a chisel and a hammer, and loosen the portion of cylinder upset on the nut at juncture.

2. Using a hook wrench "A" (special tool), remove the gland screw or ring nut.

Cylinder

Hook wrench

part number

BD2G

BS3G

Lift cylinder

Power

angling/

Angling cylinder tilt blade

Tilt cylinder

Power

tilt blade

Bucket

05312-10500

Lift cylinder

Tilt cylinder

Lift cylinder

05312-10600

05312-10500

05312- 10600

05312- 10800

Dump cylinder

05312-10600

3. On the ring nut type cylinder, slightly push in guide bushing "6," and remove ring "2" with a screwdriver.

[NOTE]

Do not use a sharp-edged tool to remove ring

"2,"

When removing the ring, be careful not to scratch the bore surface of the cylinder.

2

6

602302

602303

602304

(

24

Reassembly

Reassembling order

Ring nut type cylinder

2

5

4

3

HYDRAULIC CYLINDERS.

11 10

6 7

8

~

7

->

6 +- 9

r-->"

r---

13

" " L l ' i l l

2 1

(Tighten)

10 1 5

->

4 3

Gland screw type cylinder

2

4

5

3

13

12

00

6022571

12

11

8 9 10 7 6

8 9

' , . /

7->6+-10

I I

' , 1 3 r

L r r

12 2 5-+4 3

11

(Tlohten) 1 b

13

602258

25

HYDRAULIC CYLINDERS

Tips for reassembly

1.

Piston seal installation

(1)

Have a -tool shown in the sketch and chart below to fit the piston seal.

[NOTE]

Dimension "0" must be 0.5 to 1.0

(0.02 to 0.04 in.) smaller than inside diameter of the piston. mm the

BD2G

Cylinder

Power

angling/ tilt blade

Power

tilt blade

BS3G Bucket

Lift cylinder

Angling cylinder

0

0

Tilt cylinder

.

Lift cylinder

Tilt cylinder

Lift cylinder

Dump cylinder

0

0

0

Unit: mm (in.)

Piston

1.0.

24 27 30

(0.94) (1.06) (1.18)

0

0

(2) Squeeze the seal in the palm of the hand three or four times to soften it.

Unit: mm (in.)

"1

Co>

~

~

0

'"

-

-- -

v

Cl

D i"Cl

250 (9.84)

, /

---J

H

CI: Chamfer I (0.04)

600149

600150

(

26

(3) Hold the protective vise jaws. piston in a vise, with

(copper) caps fitted to the

(4) Apply a thin coat of hydraulic oil to the seal. Fit the seal into the groove as much as it will go in, and insert the tool in to the piston.

(5) Hold down the seal by left hand, and turn the arm of the tool by right hand while pushing it down. After about 3/4 of the seal has been forced onto the piston, hold down the seal by right hand.

(6) Turn the arm by left hand to force the remaining 1/4 onto the piston.

HYDRAULIC CYLINDERS

600151

600153

27

HYDRAULIC CYLINDERS

(7) Install the backup ring to the piston.

600154

(

(

(

28

2. Piston nut tightening

Tighten the piston nut to the specified torque.

Unit: kgf·m (lbf.ft) [N·m)

BD2G

Cylinder

Lift cylinder

Tightening

torque

50.0 ± 2.5

(361.7 ± 18.1)

[490.3 ± 24.5)

Power

Angling cylinder angling! tilt blade

Tilt cylinder

Power

tilt blade

Lift cylinder

Tilt cylinder

70.0 ±3.5

(506.3 ± 25.3)

[686.5 ± 34.3)

50.0 ± 2.5

' (361.7 ± 18.1)

[490.3 ± 24.5]

BS3G Bucket

I

Lift cylinder

Dump cylinder

95 ± 5

(687.1 ± 36.2)

[931.6 ± 49.0)

I 50.0 ± 2.5

(361.7 ± 18.1)

[490.3 ± 24.5]

3. Ring installation

If the guide bushing is pushed in the cylinder more than is necessary, the

O-ring would be damaged by the sharp edge of the port when the bushing is pulled out. Do not push in the bushing more than "L" dimension.

Cylinder

Lift cylinder

Power

angling!

Angling cylinder

BD2G tilt blade

Tilt cylinder

Power

tilt blade

Lift cylinder

Unit· mm (in )

Dimension

"L"

16 (0.63)

14 (0.55)

16 (0.63)

HYDRAULIC CYLINDERS

602305

29

HYDRAULIC CYLINDERS

4. On the ring nut type cylinder, install the ring nut to the cylinder with its small chamfer on the head side of the cylinder and, using a hook wrench "A"

(special too]) and a torque wrench "B," tighten it to the specified torque.

5. On the gland screw type cylinder, tighten gland screw to the specified torque with a hook wrench "A" and a torque wrench "B."

L

Torque wrench reading T' =

----;;-£-...0+'-1;:;;-'

T

BD2G

Power

Cylinder

Lift

Unit: kgf·m (lbf.ft) [N·m]

Tightening

torque

"T"

cylinder

Angling cylinder

IS.O ± I.S

(108.S ± 10.8)

[147.1 ± 14.7] anglingl tilt blade

Tilt cylinder p

23S.4

±

2.4

±

23.S]

Power

tilt blade

BS3G Bucket

Lift cylinder

Tilt cylinder

Lift cylinder

Dump cylinder

IS.O± I.S

(108.5 ± 10.8)

[147.1 ± 14.7]

4S.0 ±4.S

(32S.5 ± 32.S)

[441.3 ±44.1]

7S.0 ± 8

(S42.5 ± S7.9)

[73S.5 ± 78.S]

4S.0 ± 4.5

(325.5 ± 32.S)

[441.3 ± 44.1]

6. On the ring nut type the cylinder to the chiseling. cylinder, upset ring nut by

Replace the ring nut after it has been used two or three times.

A

B

T'

600165

30

HYDRAULIC CYLINDERS

7. After tightening the gland screw to the specified torque on the gland screw type cyJinder, drill a hole in the screw, and install a locking ring to prevent the screw from loosening.

The diameter and depth of this hole are as shown below:

Unit· mm (in)

Cylinder

Locking ring hole

Diameter Depth

"d"

"L"

BD2G

BS3G

.

Power

Tilt tilt blade cylinder

3.5 (0.14) 10.5 (0.41)

Bucket

Lift cylinder

4.5 (0.18) 12.5 (0.49)

Dump cylinder

3.5 (0.14) 10.5 (0.41)

/

31

Part number

05312·10500

Part name

Hook wrench

05312·10600

05312·10800

SPECIAL TOOLS

IJ

Shape

~

600328

Use

Ring nut or gland screw removal and installation

BD2G - Power angling/tilt blade

Lift cylinders

Angling cylinders

BD2G - Power tilt blade

Lift cylinders

BD2G - Power angling/tilt blade

Tilt cylinder

BD2G - Power tilt blade

. Tilt cylinder

BS3G - Bucket

Dump cylinders

BS3G - Bucket

Lift cylinders

(

32

j j

I

I

I

I

I

I

I

I

I

I

I

DEC. '86


Pub. No.

99879-00120-

8

/

(

UPDATING OF SERVICE MANUAL

A revised edition will be issued for each volume when the system covered in it is improved or changed.

Wheli you receive a revised edition, supersede the existing volume by the revised edition and enter the 9th-digit and 10th-digit figures of Pub. No. of the revised edition in the blank of "Revised Edition Check Column" of the updating list in the next page.

When you receive any supplement, enter its title in "Title of Separate Volume" column of the updating list.

The updating list, if properly filled, will help check to see if the updated volumes are filed in this binder by referring to the Publication List.

For some models, the binder will be divided into the two, SYSTEMS OPERA TJON and

DISASSEMBLY AND REASSEMBLY.

*

* *

*

* *

*

*

*

*

*

*

*

*

*

*

* * *

*

*'* *

*

*

*

* *

*

* * * * * *

*

*

**

Update your service with updated infol1uatibn!

Update your service information without delay!

*

*

* *

*

*

*

*

*

*

*

,

,

MITSUBISHI BD2GTRACTOR AND BS3CfTRACTOR

SHOVEL'

Applicable Model: OOOOl-UP

,

'

Separate Cover, Filing

Location Order

I

"

, Title

, of

Separate Volume

,

'Mitsubishi Diesel ,Engine S4E2 for

BD2G and BS3G

Pub. No.,

99879-00120·il'

"

Pub.

No. 99879:00120

RlvlsedEdition

Cnec!< Column

,

2

Mitsubishi Diesel Engine S4E2 for

BD2G and BS3G

' Fuel System/Electrical System

99879-00120-2/

•

,

3

4

5

6

Power Train (Direct DrlveModel)

Operating Principle/Testing and

Adjustment

Direct Powershlft Transmission

Operating Principle/Testing and

Adjustment/Maintenance Standards!

Disassembly and Reassembly

Hydraulic System

Operati~g

Principle/Testing and

Adjustment

99879-00120-4/

99879-00120-5/

99879-00120-6/

7

8

Power Train/Hydraulic System

Maintenance Standards

Power Train

Disassembly and Reassembly

,

Hydraulic System

Disassembly and Reassembly

99879-00120-3/

99879·00120-7/

99879-00120-8/

,', '

, '

,

'

,

,

:

-

, I

,

'. ?;H

"

; i

,

,

-;~

l

;1

. ej

..

~

'.~

-

~

! '

r

"

9

Wiring Dlagl'1lm for BD2G and BS3G

99879-00120:9/

"

,

10

,

II

12

Dec.

1986

Binder Pub. No.

98AAB-00360

*PubJication to be issued in future.

(

Mitsubishi Heavy Industries S4E2 Service manual

SERVICE MANUAL

·.MITSUBISHI

. DIESEL ENGINE

for BD2G/BS3G

CONTENTS

•

•

GENERAL

"

·3

MAINTENANCE STANDARDS

"

."

.goo

."

'8

-

.§

1

)1

)1

~

SPECIAL TOOLS

OVERHAUL INSTRUCTIONS

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

.----&1

1

ENGINE ACCESSORY REMOVAL AND INSTALLATION

¢"

ENGINE PROPER

l

___ &.[

,--------.&.1

.-----Lt,.[

jJ;1

jt--@"ll)

~-------II~N~OT~El--------~

--

t

r

I

r-----.&J

r--------LI~NO~T~El--------~

]---~

"B"

=~

1

I

I

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Q(

1-

["

---...

~~

p

INTAKE & EXHAUST SYSTEMS

LUBRICATION SYSTEM

COOLING SYSTEM

WORKSHOP THEORY

99879-00120-

SERVICE MANUAL

MITSUBISHI

DIESEL ENGINE

for BD2G/BS3G

CONTENTS

TABLE OF CONTENTS

FUEL SYSTEM

WARNING

.-----Lt,.l

•

I

I

I

I

..

.-----.&,.!

"

"