Tm215f-Tm217f-Iseki Manuel d'ATELIER PDF [PDF]

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ISEKI TM TRACTOR SERVICE MANUAL CONTENTS CHAPTER 1. GENERAL INFORMATION ....................................................................................................................... 5 §1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS ......................................................................... 5 1. MODEL NAME PLATE ................................................................................................................................. 5 2. CHASSIS PRODUCTION NUMBER ........................................................................................................... 5 3. ENGINE MODEL AND SERIAL NUMBER ................................................................................................... 5 §2. SPECIFICATIONS ............................................................................................................................................... 6 Engine .................................................................................................................................................................. 6 Transmission ........................................................................................................................................................ 6 Power take-off (PTO) ........................................................................................................................................... 6 Hydraulics ............................................................................................................................................................ 6 Electrical system .................................................................................................................................................. 7 Capacities ............................................................................................................................................................ 7 Track setting ........................................................................................................................................................ 7 Maximum axle loading ......................................................................................................................................... 7 Tyre size............................................................................................................................................................... 7 General dimensions ............................................................................................................................................. 8 § 4. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION ........................................................ 9 1. BEFORE OPERATION ................................................................................................................................ 9 2. PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING STANDARDIZED PARTS ............................... 9 CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS ........................................................ 13 §1. OPERATION CHART FOR DISASSEMBLING AND RE-ASSEMBLING BY MAJOR BLOCKS ........................ 13 §2. DISASSEMBLY OF FUNCTIONAL BLOCKS .................................................................................................... 14 1 EXTERIOR PARTS .................................................................................................................................... 14 2 SEPARATION OF THE ENGINE FROM THE CLUTCH HOUSING .......................................................... 15 3 REMOVAL OF THE ENGINE ..................................................................................................................... 16 4 SEPARATION OF THE CLUTCH HOUSING FROM THE FRONT TRANSMISSION CASE .................... 16 5 REMOVAL OF THE CYLINDER CASE ..................................................................................................... 16 6 REMOVAL OF THE CHANGE METAL (SUPPORT) .................................................................................. 17 7 SEPARATION OF THE FRONT TRANSMISSION CASE FROM THE REAR TRANSMISSION CASE .... 17 8 REMOVAL OF THE MID-PTO ................................................................................................................... 17 9 SEPARATION OF THE REAR AXLE HOUSING FROM THE REAR TRANSMISSION CASE ................. 17 10 REMOVAL OF THE FRONT AXLE ............................................................................................................ 18 11 REMOVAL OF THE RADIATOR ................................................................................................................ 18 CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES .................................................................................... 19 1. 2. 3. 3.1. 3.2. 3.3. 4. 4.1. 4.2. 5.

SPECIFICATIONS ............................................................................................................................................. 19 ENGINE ............................................................................................................................................................. 19 TIGHTENING TORQUE OF MAJOR FASTENERS .......................................................................................... 20 RADIATOR ......................................................................................................................................................... 21 CONSTRUCTION .............................................................................................................................................. 21 REMOVAL AND RE-INSTALLATION ................................................................................................................. 21 INSPECTION ..................................................................................................................................................... 21 COOLING FAN AND BELT ................................................................................................................................ 22 SPECIFICATIONS ............................................................................................................................................. 22 ADJUSTMENT OF BELT ................................................................................................................................... 22 AIR-CLEANER ................................................................................................................................................... 23 1

TM TRACTOR SERVICE MANUAL 5.1. 5.2. 5.3. 6. 6.1. 6.2. 6.3. 7.

REMOVAL AND RE-INSTALLATION ................................................................................................................. 23 INSPECTION ..................................................................................................................................................... 23 CLEANING THE ELEMENT .............................................................................................................................. 23 FUEL SYSTEM .................................................................................................................................................. 24 FUEL SYSTEM DIAGRAM ................................................................................................................................ 24 INSPECTION ..................................................................................................................................................... 24 FUEL FILTER ..................................................................................................................................................... 24 TROUBLESHOOTING ....................................................................................................................................... 25

CHAPTER 4. CLUTCH SYSTEM .................................................................................................................................. 27 1. 2. 3. 4. 5.

CONSTRUCTION .............................................................................................................................................. 27 DISASSEMBLY .................................................................................................................................................. 27 INSPECTION ..................................................................................................................................................... 28 PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 29 TROUBLESHOOTING ....................................................................................................................................... 31

CHAPTER 5. TRANSMISSION ...................................................................................................................................... 33 1. GEAR-TYPE TRANSMISSION ............................................................................................................................. 33 1.1. POWER TRAIN .................................................................................................................................................. 33 1.2. CONSTRUCTION .............................................................................................................................................. 35 1.3. DISASSEMBLY .................................................................................................................................................. 35 1.4. INSPECTION ..................................................................................................................................................... 36 1.5. PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 36 2. HST TRANSMISSION ....................................................................................................................................... 37 2.1. POWER TRAIN .................................................................................................................................................. 37 2.2. CONSTRUCTION .............................................................................................................................................. 39 2.3. DISASSEMBLY .................................................................................................................................................. 39 2.4. INSPECTION ..................................................................................................................................................... 40 2.5. PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 40 3. MID-PTO ............................................................................................................................................................ 41 3.1. CONSTRUCTION .............................................................................................................................................. 41 3.3. INSPECTION ..................................................................................................................................................... 41 3.4. PRECAUTION FOR RE-ASSEMBLY ................................................................................................................ 41 CHAPTER 6. REAR AXLE AND BRAKES ................................................................................................................... 43 1. 2. 3. 3.1. 3.2. 3.3. 4. 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 5.

GENERAL DESCRIPTION ................................................................................................................................ 43 CONSTRUCTION .............................................................................................................................................. 44 REAR AXLE HOUSING AND DIFFERENTIAL GEARS ..................................................................................... 45 DISASSEMBLY .................................................................................................................................................. 45 INSPECTION ..................................................................................................................................................... 45 PRECAUTIONS FOR RE-ASSEMBLY AND ADJUSTMENT ............................................................................. 45 BRAKES ............................................................................................................................................................ 47 SPECIFICATIONS ............................................................................................................................................. 47 CONSTRUCTION .............................................................................................................................................. 47 DISASSEMBLY .................................................................................................................................................. 48 INSPECTION ..................................................................................................................................................... 49 PRECAUTIONS FOR REASSEMBLY ............................................................................................................... 49 BRAKE ADJUSTMENT ...................................................................................................................................... 49 TROUBLESHOOTING ....................................................................................................................................... 50

CHAPTER 7. MANUAL STEERING SYSTEM .............................................................................................................. 51 §1. CONSTRUCTION .............................................................................................................................................. 51 §2. DISASSEMBLY, INSPECTION, AND REASSEMBLY ........................................................................................ 52 1. DISASSEMBLY .......................................................................................................................................... 52 2

2. 3. 4.

INSPECTION ............................................................................................................................................. 53 REASSEMBLY AND ADJUSTMENT ......................................................................................................... 54 TROUBLESHOOTING ............................................................................................................................... 56

CHAPTER 8. FRONT AXLE .......................................................................................................................................... 57 §1 CONSTRUCTION .............................................................................................................................................. 57 1. SECTIONAL VIEWS .................................................................................................................................. 57 2. MAJOR COMPONENTS ........................................................................................................................... 58 §2. DISASSEMBLY .................................................................................................................................................. 59 1. FRONT AXLE AND DIFFERENTIAL GEARS ............................................................................................ 59 2. FINAL CASE AND RELATED PARTS ....................................................................................................... 60 DISASSEMBLY OF THE FINAL CASE ASSEMBLY .......................................................................................... 60 §3. INSPECTION ..................................................................................................................................................... 60 §4. PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 61 §3. TROUBLESHOOTING ....................................................................................................................................... 62 CHAPTER 9. HYDRAULIC SYSTEM ............................................................................................................................ 63 §1. GENERAL DESCRIPTION ................................................................................................................................ 63 1. HYDRAULIC SYSTEM DIAGRAMS .......................................................................................................... 63 1.1. STANDARD TYPE ..................................................................................................................................... 63 1.2. HU & U TYPES .......................................................................................................................................... 64 1.3. HYDRAULIC SYSTEM MAIN PIPING ....................................................................................................... 66 1.4. HYDRAULIC SYSTEM PIPING ................................................................................................................. 67 §2. SPECIFICATIONS ............................................................................................................................................. 69 §3. CONSTRUCTION, DISASSEMBLY AND INSPECTION OF MAJOR COMPONENTS ..................................... 70 1. SUCTION FILTER ..................................................................................................................................... 70 2. HYDRAULIC PUMP (GEAR PUMP) .......................................................................................................... 70 3. FLOW CONTROL VALVE AND METAL (U) ............................................................................................... 71 3.1. CONSTRUCTION AND COMPONENTS ................................................................................................... 71 3.2. INSPECTION OF FLOW CONTROL VALVE ............................................................................................. 72 4. AIR-BLEEDING OF THE HYDARULIC CIRCUIT ...................................................................................... 72 5. CYLINDER CASE ...................................................................................................................................... 73 5.1. CONSTRUCTION AND COMPONENTS ................................................................................................... 73 5.2. DISASSEMBLY .......................................................................................................................................... 74 6. MAIN CONTROL VALVE ........................................................................................................................... 75 6.1. CONSTRUCTION ...................................................................................................................................... 75 6.2. FUNCTION ................................................................................................................................................ 76 6.3. DISASSEMBLY, INSPECTION AND REASSEMBLE OF THE MAIN CONTROL VALVE .......................... 77 §4. REASSEMBLY OF MAJOR COMPONENTS .................................................................................................... 79 §5. TROUBLESHOOTING ....................................................................................................................................... 81 CHAPTER 10. HYDROSTATIC TRANSMISSION ......................................................................................................... 85 1. 2. 3. 3.1. 3.2. 3.4. 4. 4.1. 4.2. 4.3. 4.4. 4.5. 4.6.

CONSTRUCTION AND NAMES OF MAJOR COMPONENTS ......................................................................... 85 OPERATING DIAGRAM OF HST ...................................................................................................................... 86 FUNCTION ........................................................................................................................................................ 87 VARIABLE TYPE PUMP .................................................................................................................................... 87 FIXED TYPE MOTOR ........................................................................................................................................ 88 VALVES ............................................................................................................................................................. 88 DISASSEMBLY AND REASSEMBLY ................................................................................................................ 91 REQUIRED TOOLS ........................................................................................................................................... 91 PRESS-IN JIGS ................................................................................................................................................. 92 PRECAUTIONS FOR DISASSEMBLY .............................................................................................................. 93 DISASSEMBLY .................................................................................................................................................. 93 CRITERIA FOR REPLACING WORN PARTS ................................................................................................... 97 PRECAUTION BEFORE REASSEMBLY .......................................................................................................... 98 3

TM TRACTOR SERVICE MANUAL 4.7. 4.7. 5. 5.1. 5.2. 6.

REASSEMBLY ................................................................................................................................................... 98 LIST OF MAJOR COMPONENTS OF HST ..................................................................................................... 107 HST CONTROL PEDALS ................................................................................................................................ 108 DIMENSIONS OF PEDALS ............................................................................................................................. 108 NEUTRAL ADJUSTMENT ............................................................................................................................... 109 CONFIRMATION ITEMS AFTER ADJUSTMENT ............................................................................................ 109 TROUBLESHOOTING ..................................................................................................................................... 110

CHAPTER 11. POWER-ASSISTED STEERING SYSTEM ......................................................................................... 111 §1. CONSTRUCTION ............................................................................................................................................ 111 §2. MAJOR COMPONENT .................................................................................................................................... 112 §3. INTEGRAL ORBIT ROLL ................................................................................................................................. 113 1. COMPONENTS ....................................................................................................................................... 113 2. DISASSEMBLY ........................................................................................................................................ 114 2.1. DISASSEMBLY OF ROTOR SIDE .......................................................................................................... 114 2.2 DISASSEMBLY OF CONTROL SIDE ...................................................................................................... 115 2.3. INSPECTION ........................................................................................................................................... 116 3. RE-ASSEMBLY ....................................................................................................................................... 116 3.1. RE-ASSEMBLY OF CONTROL SIDE ...................................................................................................... 116 3.2. RE-ASSEMBLY OF GEROTOR SIDE ..................................................................................................... 118 §4. TROUBLESHOOTING ..................................................................................................................................... 120 CHAPTER 12. ELECTRICAL SYSTEM ...................................................................................................................... 123 1. 2. 3. 3.1. 3.2.

FUSES, FUSIBLE LINKS AND SLOW-BLOW FUSE ...................................................................................... 123 SAFETY SYSTEM WIRING DIAGRAM ........................................................................................................... 124 TROUBLESHOOTING ..................................................................................................................................... 125 BATTERY ......................................................................................................................................................... 125 METERS, GAUGES, AND SWITCHES ........................................................................................................... 125

CHAPTER 13. SERVICING DATA ............................................................................................................................... 129 1. SPECIFICATIONS & CAPACITIES .................................................................................................................. 129 Engine Oil ........................................................................................................................................................ 129 Engine Coolant ................................................................................................................................................ 129 Fuel Tank ......................................................................................................................................................... 129 Transmission & Differential Housing (Including Hydraulic System) ................................................................. 129 Front Axle ......................................................................................................................................................... 129 Grease Fittings ................................................................................................................................................ 129 2. LUBRICATION/FILL POINTS ........................................................................................................................... 130 3. PERIODIC MAINTENANCE SCHEDULE ........................................................................................................ 131 4. SERVICE STANDARDS .................................................................................................................................. 132 APPENDIX ................................................................................................................................................................. 137 1. 1.1. 1.2. 1.3. 1.4. 2.

PRECAUTIONS FOR REASSEMBLY ............................................................................................................. 137 MECHANICAL TRANSMISSION ..................................................................................................................... 137 HYDROSTATIC TRANSMISSION ................................................................................................................... 139 FRONT AXLE AND DRIVE MECHANISM ....................................................................................................... 141 REAR AXLE AND BRAKES ............................................................................................................................. 143 WIRING DIAGRAM .......................................................................................................................................... 145

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CHAPTER 1: GENERAL DESCRIPTION

CHAPTER 1. GENERAL INFORMATION §1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS Each tractor is identified by means of the tractor model and serial numbers. As a further identification, the engine and chassis are also provided with identification numbers. 1

KM/H

3

x1000

RPM

1

2

3

000 1 H

2

TO ENSURE PROMPT, EFFICIENT SERVICE WHEN ORDERING PARTS OR REQUESTING REPAIRS FROM AUTHORIZED ISEKI DEALER, RECORD THESE NUMBERS IN SPACES PROVIDED.

0

(1) Model name plate (2) Punched model name and serial number on the right side of the front frame Fig. 1-1

(3) Cast engine model name and punched engine serial number on the right side wall the cylinder block

1. MODEL NAME PLATE

2. CHASSIS PRODUCTION NUMBER T00E F 00001 Chass production serial number

1 MODEL TYPE

2

TMOOOO

4WD

EOO

Manufacturer's model name

3

NO.

OOOOOOO O

4

T92E: TM215 ; T93E: TM217

3. ENGINE MODEL AND SERIAL NUMBER ISEKI & CO., LTD. TOKYO/JAPAN (1)

TM215 or TM217 F .................. Standard transmission with 4WD FH ............... HST transmission with 4WD M ................. Mid-PTO U ................. Power-assisted steering sytem

(2)

Type E41 .............. Agricultural tyres E42 .............. Turf tyres

(3)

Production No.

(4)

Production date The year of 1977 is alloted to “G,” and the following years are expressed alphabetically except for “I.”

1

2 (1) Engine model (2) Serial Number

Fig. 1-2

Fig. 1-3 5

TM TRACTOR SERVICE MANUAL

§2. SPECIFICATIONS Models ....................................................................................................................................... TM215 ................................................. TM217 Sub-models ................................................................................................................ F ....... FMU ... FHU ... FHMU F ......... FU ..... FMU ... FHU ... FHMU

Engine Make ................................................................................................................................................................................ ISEKI Diesel Model ........................................................................................................................................... E393 ................................................... E3100 Type ................................................................................................................................................................. Indirect injection, overhead valve Displacement .............................................................................................................................. 928 cc ................................................. 1006 cc Number of cylinders ................................................................................................................................................................. 3 Bore ................................................................................................................................................... 74 mm .................................................. 74 mm Stroke ................................................................................................................................................. 72 mm .................................................. 78 mm Engine horsepower (gross)@ engine rpm ...................................................................................... 15.5/2500 ............................................... 17/2500 PTO horsepower (estimate) ................................................................................................... 13.5 .................... 13 ............................. 15 ............................. 14 Firing order ......................................................................................................................................................................... 1 – 3 – 2 Compression ratio ................................................................................................................................................................. 22.5:1 Low idle speed ..................................................................................................................................................................... 950 rpm High idle speed ................................................................................................................................................................... 2750 rpm Valve clearance (cold) – intake and exhaust ...................................................................................................................... 0.25 mm Air cleaner ................................................................................................................................................................. Single – dry element Engine cooling ....................................................................................................................................................... Liquid, forced circulation Cold starting .................................................................................................................................................................. Glow plugs (3)

Transmission Primary ................................................................................................................................ F3/R1 ............... Infinite ...................... F3/R1 ...................... Infinite Range ........................................................................................................................................................................................ 2 Gear selections .................................................................................................................... F6/R2 ................ F2/R2 ....................... F6/R2 ....................... F2/R2 Clutch ................................................................................................................................................................ Dry single disc (Dia: 184 mm) Brakes ............................................................................................................................................................. Mechanically acutuated dry shoes Speed range (km/h) Forward 1 ........ 1.2 ................. 0 to 8.4 ......................... 1.2 ........................ 0 to 8.8 2 ........ 2.1 ................ 0 to 19.5 ........................ 2.3 ....................... 0 to 20.6 3 ........ 3.5 ........................................................ 3.7 4 ........ 5.9 ........................................................ 6.2 5 ....... 10.6 ...................................................... 11.3 6 ....... 17.4 ...................................................... 18.5 Reverse 1 ........ 1.9 ................. 0 to 5.9 ......................... 2.0 ........................ 0 to 6.2 2 ........ 9.5 ................ 0 to 13.7 ....................... 10.1 ...................... 0 to 14.5

Power take-off (PTO) Control ........................................................................................................................................................................... Lever and pedal Rear PTO shaft ........................................................................................................................................... 35 mm (1.375 in) diameter – six spline Output ......................................................................................................................................................................... Clockwise rotation Speeds @ engine rpm ...................................................................................................... 540 @ 2308 ....... 540 @ 2398 .............. 540 @ 2308 .............. 540 @ 2398 ................................................................................................................................. 1000 @ 2385 ..... 1000 @ 2399 ............ 1000 @ 2385 ............ 1000 @ 2399 Mid PTO (accessory) shaft ......................................................................................................................... 25 mm (1 in) diameter – fifteen spline Output .................................................................................................................................................................. Clockwise rotation Speeds @ engine rpm .............................................................................................. 2000 @ 2446 ..... 2000 @ 2400 ............ 2000 @ 2446 ............ 2000 @ 2400

Hydraulics Main hydraulic system Pump ............................................................................................................................................................... Gear pump (Open centre) Output – maximum .................................................................................................................................................. 18.0 litres/min Pressure – relief valve setting .................................................................................................................................... 140 kgf/cm3 Rear linkage type ......................................................................................................................................................... Three-point hitch Control .............................................................................................................................................. Operated by single ‘position’ control lever Lift capacity ................................................................................................................................................. 480 kg measured at link ends

6

CHAPTER 1: GENERAL DESCRIPTION Models ...................................................................................................................................... TM215 .................................................. TM217 Sub-models ................................................................................................................ F ....... FMU ... FHU ... FHMU F ......... FU ..... FMU ... FHU ... FHMU Steering system type ......................................................................................................................................... Manual/ Power-asisted (Option) Pump .................................................................................................................................................................... Gear/ Flow divider Output – maximum .................................................................................................................................................. 5.5 litres/mikn Pressure – relief valve setting .................................................................................................................................... 105 kfg/cm3

Electrical system System voltage .................................................................................................................................................... 12 volt - negative (-) ground Battery .............................................................................................................................................................................. 36 hA (5 hr) Charging .................................................................................................................................................... 40 amp alternator with internal regulator

Capacities Engine crankcase with filter ............................................................................................................................................... 2.7 litres Transmission and differential housing (including hydraulics) (litres) ........................... 13.5 ..... 14.0 ..... 15.0 ..... 15.0 13.5 ..... 14.0 ..... 14.0 ..... 15.0 ..... 15.0 Fuel tank ............................................................................................................................................................................ 13.5 litres Cooling system ................................................................................................................................................................... 5.1 litres Front axle - four-wheel drive .............................................................................................................................................. 2.7 litres

Track setting Front four-wheel drive Agricultural tyres (dished in only) ...................................................................................................................................... 750 mm Turf tyres (dished in only) ................................................................................................................................................... 870 mm Rear four-wheel drive Agricultural tyres (adjustable wheels) ........................................................................................ 770 to 950 mm .................................... 800 to 910 mm Turf tyres (dished in only) ................................................................................................................................................... 900 mm

PTO shafts Rear PTO Speeds ..................................................................................................................................................... 540 rpm and 1000 rpm (Clockwise rotation) Shaft daimeter and spline teeth .................................................................................................................................... 35 mm, 6-spline Mid-PTO Speeds ................................................................................................................................................................ 2000 rpm (Clockwise rotation) Shaft diameter and spline teeth ................................................................................................................................... 25 mm, 15-spline

Maximum axle loading Front four-wheel drive - both models .................................................................................................................................. 650 kg Rear axle - both models ....................................................................................................................................................... 750 kg Total limit: ........ 1200 kg

Tyre size Front Agricultural tyre ..................................................................................................................... 5 – 12 4PR ......................................... 5.00 – 12 4PR Turf tyre ............................................................................................................................................................... 20.5 × 8.00-10 4PR Rear Agricultural tyre ..................................................................................................................... 8 – 16 4PR ............................................. 8-18 4PR Turf tyre ............................................................................................................................................................... 29 × 12.00-15 4PR

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TM TRACTOR SERVICE MANUAL

A1

A2

General dimensions

E

B

D C

Fig. 4 Models .............................................................................................................................................. TM215 ................................................. TM217 Sub-models ....................................................................................................................... F ....... FMU ... FHU ... FHMU F ......... FU ..... TMU ... FHU ... FHMU Agricultural tyres/turf tyres A1 Height over steering wheel ............................................................................................... 1280 mm/1270 mm .............................. 1300 mm/1270 mm A2 Height over ROPS .................................................................................................... Ask your local ISEKI dealer. .............. Ask your local ISEKI dealer. B Minimum width ................................................................................................................... 1000/1190 mm .................................. 1000 mm/1190 mm C Overall length ........................................................................................................................... 2545 mm .............................................. 2545 mm D Wheelbase ................................................................................................................................ 1425 mm .............................................. 1425 mm E Minimum ground clearance ....................................................................................................... 255 mm ................................................ 280 mm Turning radius (4WD engaged) without brakes ........................ 2600 mm ........... 2600 mm .................. 2700 mm .................. 2700 mm with a brake ............................ 1900 mm ................ — ........................ 1900 mm ....................... — Turning radius (4WD disengaged) without brakes ........................ 2400 mm ........... 2400 mm .................. 2400 mm .................. 2400 mm with a brake ............................ 2100 mm ................ — ........................ 2100 mm ....................... — Weight (without ROPS and seat) ................................................................................... 555kg .... 570kg ... 585kg ... 595kg 570kg ... 575 kg ... 585kg .. 600kg .. 610kg

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CHAPTER 1: GENERAL DESCRIPTION

§ 4. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION 1. BEFORE OPERATION

installer which is specially designed to push only the outer race and vice versa.

1) Always be safety-conscious in selecting clothes to wear and suitable tools to use.

2) The installer must be designed to install the bearing on the shaft in a parallel position.

2) Before disassembly, be sure that you familiarize yourself with the assembled condition for subsequent reference in re-assembly.

3) When installing a bearing which appears the same on both sides, install it so that the face which has the identification number faces in a direction for easy visual identification. All the bearings which are to be installed in the transmission case should be placed so that their identification number faces outward.

3) Keep parts and tools in proper order during operations. 4) Before servicing electrically charged parts, be sure to disconnect the negative battery terminal.

4) If a shaft or a hole where a bearing is to be installed has a stopper, the bearing should be pushed in completely until it is seated against the stopper.

5) To prevent oil or water leaks, use liquid gasket as required. 6) When reassembling disassembled parts, discard used gaskets, O-rings, or oil seals and install new ones.

5) Installed bearings should turn smoothly. (2) Oil seals

7) When lifting up only the front or rear part of the tractor, be sure to wedge the grounded wheels.

1) Oil seal installer should be designed so as not to deform the oil seals.

8) When the tractor is jacked up, be sure to support the entire tractor with something like a stand. Holding it up with a jack only is a dangerously unstable procedure.

2) During installation of an oil seal, be careful not to damage the lips, and assure that it is pushed in parallel to the shaft or hole. 3) When oil seals are installed, there should be no turnover of the lips nor dislocation of the springs.

9) When replacing parts, use authorized, genuine ISEKI parts only. ISEKI assumes no responsibility for accidents, operating problems or damage caused by the use of imitation parts. Also, the use of unauthorized parts will result in relatively poor machine performance.

4) When a multi-lip seal is installed, the grooves between lips should be filled with grease, not adhesive. 5) Use a lithium-based grease.

2. PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING STANDARDIZED PARTS

6) There should be no oil or water leaks through the installed soil seals. (3) O-rings

(1) Roller or ball bearings

1) O-rings should be coated with grease before installing.

1) When a bearing is fitted in by the outer race, use an 9

TM TRACTOR SERVICE MANUAL 2) Installed O-rings should not be twisted or slack. 3) Installed O-rings should maintain proper air tightness. F

(4) Snap rings

F

1) Snap ring installers should be designed so as not to permanently deform the snap rings. F

2) Installed snap rings should be seated securely in the groove.

Fig. 1-6

3) The roll pins installed in the transmission or other parts where much force is applied should be retained with wire.

3) Be careful not to overload the snap ring to the extent that it is permanently deformed. 4) How to install the snap ring:

(6) Cotter pins When installing a snap ring, install it as shown in the figure with its round edge side turned toward the part to be retained. This round edge is formed when the snap ring is pressed out.

When installed, cotter pins should be bent securely at the ends as shown in the figure.

Snap ring

Snap ring

Fig. 1-7

(7) Bolts and nuts Round edge side

1) Special bolts are installed at several locations, so be sure not to interchange them with other bolts.

Fig. 1-5

(5) Spring (roll) pins

2) Bolts and nuts should be tightened to their specified torques with a torque wrench.

1) Spring pins should be driven in properly and tightly.

3) When locking the bolts or nuts with wire or a lock washer, be sure to wind the wire paying sufficient attention to its winding direction and bend the lock washer for secure locking.

2) Spring pins should be installed so that their seams face the direction from which the load is applied.

4) When locking bolts and nuts with an adhesive, apply the adhesive on the thread and tighten securely.

10

CHAPTER 1: GENERAL DESCRIPTION 5) Apply an adhesive to parts through which there is a possibility of oil leaks, such as stud bolts and tapped-through parts. 6) Each lock nut must be tightened securely. 7) When tightening bolts and nuts, refer to the tightening torque table. (8) Grease fittings 1) After installation, each grease fitting should be filled with grease. 2) When installing grease fittings of types B and C, be sure to turn the fitting tips in a direction that will provide easy access for a grease gun. (9) Other precautions 1) Be sure not to damage any finished surfaces or parts. 2) Always refrain from forcing the installation. 3) Each lever knob should be coated with an adhesive before installation. 4) Each contact surface should be coated with an adhesive and bolts tightened evenly. Adhesive coated surfaces should be installed within 30 minutes after application of the adhesive. The contact surfaces should be flawless and free from foreign matter, especially grease before application of the adhesive. 5) Precautions for applying adhesives – The surface or the thread where an adhesive is to be applied should be completely free of chips. – The surface or the thread where an adhesive is to be applied should be completely free of oil and grease.

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TM TRACTOR SERVICE MANUAL

12

CHAPTER 2: DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS §1. OPERATION CHART FOR DISASSEMBLING AND RE-ASSEMBLING BY MAJOR BLOCKS Battery Radiator Centre pivot

Axle Bracket

Front Axle

Power-assisted steering cylinder 4WD differential gears 4WD final case

Flywheel Clutch

Engine

Clutch Housing HST model

Gear transmission model

Input shaft 4WD drive-shaft HST unit Plate HST metal (support) Mid-PTO system Range shift gears PTO shift gears Drive pinion

Front Transmission

Rear Transmission

Rear Axle

Cylinder case

Control linkage Valve system Position and arm 13

Input shaft 4WD drive-shaft Input metal (support) (4WD change gears) Change metal (support) (main/range change system) Mid-PTO system Input gears Main shift gears Range shift gears 4WD shift gears PTO shift gears Drive pinion

PTO metal (PTO shaft) Ring gear (Differential system)

Wheel shaft Final reduction gears Brake system Diff-lock (RH)

TM TRACTOR SERVICE MANUAL

§2. DISASSEMBLY OF FUNCTIONAL BLOCKS

1

EXTERIOR PARTS

1.1. SIDE COVERS, HOOD AND FRONT i. Remove the side cover. ii. Open the front grille. iii. Disconnect the cable couplers. Important: The negative battery cable should be disconnected ahead of time to prevent short circuit. iv. Remove the front grille. v. Remove the hood. 1.2. SEAT, FENDERS AND RELATED PARTS Gear transmission model i. ii. iii. iv. v. vi. vii. viii.

Remove the seat. Remove the dif-lock pedal. Remove the main change lever knob. Remove the levers (range change lever and position control lever). Remove the change cover. Remove the fender stays. Remove the fenders. Remove the seat bracket. HST model

i. ii. iii. iv. v. vi. vii. viii.

Remove the seat. Remove the HST pedals. Remove the range change lever knob. Remove the levers (Mid-PTO change lever and position control lever). Remove the change cover. Remove the fender stays. Remove the fenders. Remove the seat bracket.

1.3. FLOOR AND RELATED PARTS Gear transmission model i. Remove the brake spring (RH). 14

CHAPTER 2: DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS ii. Remove the throttle wire (RH). iii. Disconnect the couplers of the stop light switch. iv. Remove the floor. HST model i. Remove the brake spring (RH). ii. Disconnect the couplers of the stop light switch. iii. Remove the floor. 1.4. STEERING POST, METER PANEL AND RELATED PARTS i. Remove the steering wheel. ii. Remove the steering column cover around the throttle lever. iii. Remove the rear cover of the steering column and also disconnect the couplers of the wiring inside the cover. iv. Disconnect the couplers of the cables. v. Manual steering: Remove the steering arm from the steering post. vi. Power-assisted steering: Disconnect the pipes from the orbit-roll. vii. Remove the steering post assembly. viii. Remove the meter cable. ix. Remove the meter panel along with the dash cover.

2

SEPARATION OF THE ENGINE FROM THE CLUTCH HOUSING

i. Drain transmission oil. ii. Remove the hood and other parts referring to 1.1 and 1.3. of 1. iii. Remove the bolts of 4WD shaft cover and remove the 4WD shaft cover from the pivot metal (support). iv. Disconnect the couplers of the wiring at the right bottom of the steering wheel column. v. Remove the throttle wire. vi. Disconnect the fuel pipe from the fuel filter. Note: Plug the pipe to prevent fuel from spilling. vii. Remove the fuel filter along with the stay. viii. Disconnect the delivery and suction pipes from the gear pump. ix. Disconnect the fuel tank along with the fuel tank bracket. x. Remove all the bolts but one which tighten the engine and clutch housing. Important: One bolt should remain there for safety to prevent the engine and clutch housing from being separated completely. xi. Use wooden chocks between the front axle and the front axle bracket so that both sides to hold the engine securely. xii. Support the transmission case with a garage jack and hoist the engine with a chain block. Then remove the last bolt. 15

TM TRACTOR SERVICE MANUAL xiii. Separate the engine from the clutch housing carefully.

3

REMOVAL OF THE ENGINE

i. ii. iii. iv. v. vi.

Separating the engine from the clutch housing referring to 2. Disconnect the earthing bolts at the right side of the front axle bracket. Drain the engine coolant. Detach the coolant drain hose. Detach the water pipes. Remove the bolts tightening the engine and front axle bracket. Note: For safety the engine should be lifted with a chain block for safety ahead of time. vii. Detach the front axle bracket.

4 i. ii. iii. iv. v. vi. vii. viii. ix.

5 i. ii. iii. iv. v. vi. vii.

SEPARATION OF THE CLUTCH HOUSING FROM THE FRONT TRANSMISSION CASE

Drain transmission oil. Remove the floor referring to 1 to 3. Remove the 4WD drive shaft. Remove the change cover. Remove the brake rod. Remove the delivery and suction pipes. Remove the parking brake rod from the parking brake lever. Remove the bolts which hold the clutch housing and front transmission case together. Separate the clutch housing from the front transmission case. Note: When connecting the clutch housing and front transmission case together, shift the main shift and range shift levers to a position other than the neutral position.

REMOVAL OF THE CYLINDER CASE

Remove the seat. Remove the seat bracket on the cylinder case. Remove the position control lever. Remove the bolt of the delivery pipe at the right side of the cylinder case. Remove the top link bracket. Remove the bolts which hold the cylinder case and rear transmission case together. Separate the cylinder case from the rear transmission case.

16

CHAPTER 2: DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

6 i. ii. iii. iv. v. vi.

7 i. ii. iii. iv. v. vi. vii. viii. ix.

8

REMOVAL OF THE CHANGE METAL (SUPPORT)

Remove the seat. Remove the dif-lock pedal. Remove the change cover. Remove the seat bracket on the change metal. Remove the bolts which hold the change metal and front transmission case together. Separate the change metal from the rear transmission case.

SEPARATION OF THE FRONT TRANSMISSION CASE FROM THE REAR TRANSMISSION CASE

Drain transmission oil. Remove the cylinder case and change metal referring to 5 and 6. Remove the brake rod. Remove the parking rod from the parking brake lever. Remove the bolt at the delivery pipe on the rear axle housing (RH). Remove the PTO metal (support). Put out the bearings and PTO gear onto the PTO drive shaft. Remove the bolts which hold the front and rear transmission cases together. Separate the front transmission case from the rear transmission case.

REMOVAL OF THE MID-PTO

i. Drain transmission oil. ii. Remove the rod from the mid-PTO lever. iii. Remove the mid-PTO assembly.

9 i. ii. iii. iv. v. vi.

SEPARATION OF THE REAR AXLE HOUSING FROM THE REAR TRANSMISSION CASE

Drain transmission oil. Drain transmission oil in the rear axle from the bottom of the rear axle housing. Remove the fenders referring to 1 to 2. Remove the brake rod. Remove the delivery pipe. Remove the parking brake shaft along with the bracket. 17

TM TRACTOR SERVICE MANUAL vii. Remove one of the rear tyres. Note: Support a part of the joint of the front and rear transmission cases on a garage jack. viii. When removing the right-hand rear axle housing , remove the dif-lock pedal. ix. Remove the bolts which hold the rear axle housing and rear transmission case together. x. Separate the rear axle housing from the rear transmission case.

10

REMOVAL OF THE FRONT AXLE

i. ii. iii. iv. v.

Remove the bolt of 4WD shaft cover and remove the 4WD shaft cover from the pivot metal (support). Remove the 4WD drive shaft along with the 4WD shaft cover. Manual steering: Disconnect the drag rod from the drag arm. Power-assisted steering: Disconnect the hose from the orbit-roll. Remove the front tyres. Note: The front part of the tractor should be lifted up with a chain block ahead of time. vi. Drain the front axle oil from the bottom of both final cases. vii. Remove the centre pivot and the setting bolts from the front axle bracket, and then the front axle can be removed downward. Note: As the front axle is a very heavy component, remove it carefully while supporting it with a garage jack.

11 i. ii. iii. iv. v. vi.

REMOVAL OF THE RADIATOR

Remove the hood, side cover and front grille referring to 1.1 of 1. Drain the coolant. Disconnect the upper and lower hoses. Disconnect the drain hose. Remove the radiator shroud. Remove the radiator along with the radiator stay.

18

CHAPTER 3: ENGINE SERVICE DATA AND ACCESSORIES

CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES For detail information about the engines, please refer to the relevant service manual which is available separately. 1. SPECIFICATIONS TRACTORS ....................................................................................................................... TM215 ........................................... TM217 ENGINE Model .................................................................................................................................................. E393 ................................................... E3100 Type ....................................................................................................................................................................... 4-cycle, indirect injection Cylinders/Total displacement ........................................................................................................... 3/928 cc ............................................... 3/1006 cc Bore & Stroke ............................................................................................................................ 74 mm × 72 mm .................................. 74 mm × 78 mm Compression ratio ................................................................................................................................................................. 22.5:1 PERFORMANCE Engine output [ps(kW)/engine rpm] ............................................................................................... 15.5/2500 ............................................. 17.0/2500 Low idle speed (rpm) ............................................................................................................................................................. 950 High idle speed (rpm) ............................................................................................................................................................ 2750 Fuel consumption (g/ps-h) ................................................................................................................... 220 ....................................................... 215 Maximum torque (Bm/rpm) ............................................................................................................. 50/1800 ................................................ 55/1800 FUEL SYSTEM Injection pump type ....................................................................................................................... Bosch, PFR .......................................... Bosch, PFR (NP-PFR3MD) (ND-PFR3M) Nozzle type .......................................................................................................................................................................... Throttle Governor ........................................................................................................................................................................ In the gear case Fuel shut-off ................................................................................................................................................................. Electric solenoid LUBRICATION SYSTEM Type ............................................................................................................................................................................. Forced circulation Oil pump type ..................................................................................................................................................................... Trochoid Oil filter type ...................................................................................................................................................................... Full flow Relief valve pressure (kgf/cm2) .......................................................................................................................................... 4.0 – 4.5 Oil capacity (litre) ................................................................................................................................................................... 3.1 COOLING SYSTEM Cooling fan .......................................................................................................................................................... Diameter: 330 mm, 7 blades Drive ....................................................................................................................................................................................... Belt Pulley ratio ............................................................................................................................................. Crankshaft pulley/fan pulley: 101/78 = 1.29 AIR SYSTEM Type ............................................................................................................................................................................. Natural aspiration Air cleaner ..................................................................................................................................................................... Single element ELECTRICAL SYSTEM Alternator ................................................................................................................................................................................ 40 A Starter motor ........................................................................................................................................................................ 1.4 kW Starting aid ....................................................................................................................................................................... Glow plugs

19

TM TRACTOR SERVICE MANUAL TIMING Valve timing Inlet

open .................................................................................................................................................... BTCD 10° close .................................................................................................................................................... ABDC 46° Exhaust open .................................................................................................................................................... BBDC 46° close .................................................................................................................................................... ATDC 10° Valve clearance (mm) ............................................................................................................................................................. 0.25 Fuel injection timing ......................................................................................................................................................... BTDC 19° Nozzle opening pressure (kgf/cm2) ....................................................................................................................................... 120 Thermostat

close (°C) ................................................................................................................................................. 76.5 open (°C) ................................................................................................................................................... 90

2. TIGHTENING TORQUE OF MAJOR FASTENERS (kgf·m) Cylinder head

Cylinder head bolts ................................................................. 5.5 – 6.5 Rocker shaft holder ................................................................ 1.9 ±0.5 Injection nozzles ..................................................................... 4.5 ±0.5 Glow plugs ............................................................................. 1.75 ±0.25

Cylinder block

Bearing caps ........................................................................... 5.0 ±0.5 Oil pan .................................................................................... 0.8

Crankshaft

Connecting rod bearing caps .................................................. 3.0 ±0.3 Flywheel ................................................................................. 9.5 ±1.0 Crankshaft pulley ................................................................... 18.5 ±1.9

Timing gear case

Gear case ................................................................................ 1.9 ±0.5

Others

Inlet/Exhaust manifold ........................................................... 1.9 ±0.5 Fan .......................................................................................... 0.8 ±0.2 Starter motor ........................................................................... 8.4 ±0.8 1.9 ±0.5 kgf·m

1.75 ±0.25 kgf·m

5.5 — 6.5 kgf·m 4.5 ±0.5 kgf·m

1.9 ±0.5 kgf·m

0.2 kgf·m 0.8 ±0.2

9.5 ±1 1 kgf·m 1.9 ±0.5 kgf·m 8.4 ±0.8 kgf·m 3.0±0.3 kgf·m 18.9 ±1.9 kgf·m 3.0 ±0.3 kgf·m

5.0±0.5 kgf·m

Fig. 3-1 20

0.8 kgf·m

CHAPTER 3: ENGINE SERVICE DATA AND ACCESSORIES 3. RADIATOR

3.3. INSPECTION

3.1. CONSTRUCTION

(1) Inspection for radiator water leaks Water leaks are liable to occur at the fitting portion between the upper tank and the core section or between the lower tank and the core section. a. Leak test with compressed air Air hose Pressure gauge

Air bubbles Plug

Radiator

Fig. 3-2

Plug Leaking portions

Compressor

Overflow pipe Water basin

Fig. 3-3

3.2. REMOVAL AND RE-INSTALLATION

Note: Never allow the test pressure to exceed 1 kgf/cm2 (14.2 psi).

Remove and re-install the radiator in accordance with the instructions in CHAPTER 2.

b. Leak test with a radiator cap tester

Note: - Coolant should be replaced if it becomes contaminated with rust or sludge. - Before adding new coolant, flush the inside of radiator and engine block with clean water.

Testing pressure

Precautions for filling antifreeze - As concerns the mixing ratio of antifreeze, follow its manufacturer’s instructions. - Antifreeze should be blended well with water before filling. - When the coolant level is lowered due to evaporation, maintain the level by adding water, not by using antifreeze solution. - When the coolant level is lowered due to leaks, maintain the level by adding an antifreeze solution of the same mixing ratio. - As antifreeze corrodes paint, take care not to spill it on painted parts.

Fig. 3-4

21

1.0 kgf/cm2 (14.2 psi)

TM TRACTOR SERVICE MANUAL (2) Inspection for radiator clogging

Re-tighten loose hose clamps securely if water is leaking through the hose clamps, or replace them if necessary.

a. Cleaning the inside of radiator

4. COOLING FAN AND BELT Lower tank

4.1. Specifications Cooling fan ........................................... 330 mm, 7 blades Drive ................................................................ Belt Pulley ratio .................................... Crankshaft pulley/fan pully: 101/78 = 1.29

Radiator cores Upper tank

4.2. Adjustment of belt To adjust belt tension, loosen the alternator pivot bolt and nut and tensioning bracket bolt. Pull outward on top of the alternator to correctly tension belt and tighten the bolt first and then tighten the pivot bolt.

Fig. 3-5

– Cleaning with a detergent b. Cleaning the radiator exterior

Note: Do not pry against the alternator housing or pulley. Only pry against the alternator mounting flange carefully to prevent damage.

– Cleaning the net (wire mesh) After the tractor has been operated in dusty conditions, check the net daily and clean it if necessary. – Cleaning the radiator cores Clean the radiator cores by applying water spray or compressed air so as to form a right angle with the radiator cores, applying moving water in a parallel direction.

X

Note: When cleaning the radiator cores with pressurized water, be sure to apply it at a right angle to the cores. Slanted application might deform their cooling fins. Fig. 3-6

(3) Visual inspection of the exterior parts Belt deflection at X point ........................... 8 – 10 mm

When the radiator exterior is corroded, cracked, or badly damaged and the radiator core fins are crushed or damaged, replace the radiator. Also replace damaged or fatigued water hoses. 22

CHAPTER 3: ENGINE SERVICE DATA AND ACCESSORIES 5. AIR-CLEANER

i. Prepare solution of warm water and nonfoaming detergent . ii. Soak the element for thirty minutes. iii. Agitate the element in solution until oil and soot are loosened. iv. Rinse the element until rinse water becomes clear. v. Allow the element to completely dry. Do not dry by using compressed air or heat.

5.1. Removal and re-installation Release clips and uncover. Remove the element. Examine the element and seals for damage and brittleness. If the element is damaged in any way it must be replaced. Re-install in reverse order of removal and clip securely.

– After cleaning (or washing) the element examine for pin holes, punctures, or tears. If the element paper, canister or seal show any signs of physical damage, the element must be replaced. Note: Replace an element which has already been washed five times.

Fig. 3-7

5.2. Inspection – Inspect the air cleaner visually for cracks, deformation or other damage. Repair damage if possible, or replace it. – Check the rubber packing at each joint, rubber pipes, and the evacuator valve. – Inspect the paper element.

Fig. 3-8

5.3. Cleaning the element Element may be cleaned (if in serviceable condition) using following procedures: – Using compressed air not to exceed 200 kPa, remove loose dirt, grass, chaff, etc. from the inside of element. Be careful not to damage element pleats with air flow. – If the element is coated with oil or soot: 23

TM TRACTOR SERVICE MANUAL 6. FUEL SYSTEM

– Inspect the filter element, sediment bowl and O-ring (3) – Examine the small O-ring in the filter head and replace as necessary.

6.1. Fuel system diagram

6.4. Air-bleeding Procedure a. Fill the fuel tank. b. Turn the fuel cock (1) to “OPEN.” c. Loosen the air-bleeding screw (2) and let air bubbles out. d. Loosen the air-bleeding screw (3) of the fuel injection pump and let air bubbles out of the pump.

ON

CAUTION: Fuel emitted from loosened injection lines is under high pressure. Keep hands and face away when the engine is cranked. Clean all spilled fuel following air-bleeding procedure(s).

Fig. 3-9

6.2. Inspection Use only clean diesel fuel of correct grade. Introduction of water or dirt into the fuel tank or other part of the fuel system can cause repeated plugging of the fuel filter and possible injection pump and injector damage.

3

6.3. Fuel filter To replace the fuel filter element or clean sediment, turn the fuel valve to the OFF position (top).

2

1 Fig. 3-11

3

5

4 2 1 Fig. 3-10 24

CHAPTER 3: ENGINE SERVICE DATA AND ACCESSORIES 7. TROUBLESHOOTING

Problems (1) Overheating

Causes

Countermeasures

1) Low coolant level 2) 3) 4) 5) 6) 7) 8) 9) 10)

Fatigued pressure valve springs Loose or broken fan belt Oily fan belt Faulty thermostat Faulty water pump or water leaks Clogged water passages Improper injection timing Clogged air passages Fuel gas enters water jacket due to broken cylinder gasket.

Replenish coolant and inspect for water leaks. Replace radiator cap. Adjust belt tension or replace. Replace. Replace. Repair or replace. Clean radiator and water passages. Adjust injection timing. Clean radiator exterior. Inspect cylinder head and replace cylinder gasket.

(2) Over-cooling

1) Faulty thermostat 2) Excessive low atmospheric temperature

Replace. Decrease radiator working area by radiator masking.

(3) Loss of coolant

1) Leaking radiator 2) Loosely clamped or broken water hose 3) Fatigued pressure valve spring 4) Leaking water pump 5) Water leakage through cylinder head gasket 6) Cracked cylinder head or body

Repair or replace. Re-tighten or replace.

(4) Noisy cooling fan

1) 2) 3) 4)

Faulty water pump bearing Loose or bent fan Unbalanced fan Faulty fan belt

25

Replace radiator cap. Repair or replace. Inspect cylinder head and replace gasket. Replace. Replace. Re-tighten or replace. Replace. Replace.

TM TRACTOR SERVICE MANUAL

26

CHAPTER 4: CLUTCH SYSTEM

CHAPTER 4. CLUTCH SYSTEM 1. CONSTRUCTION

a

Ø184

b

Ø127

c

Ø240

d*

3 ±1.0

e

7.8 ±0.3

b

a

c

*Difference in lever height from each other should be within 1.0 mm.

e

Fig. 4-1

d

2. DISASSEMBLY (1) Seperate the clutch housing from the engine, referring to 2 of Chapter 2. (2) Remove the clutch assembly from the flywheel. Note: • When loosening tightening bolts, loosen them gradually in diagonal order. • Be careful to keep the clutch disc facings from oil. Reference: • Two reamer bolts are used to determine the installed position of the clutch housing. 27

TM TRACTOR SERVICE MANUAL 3. INSPECTION

c. Hardened lining surfaces must be repaired by use of sandpaper, or be replaced with new ones.

(1) Inspection of clutch disc d. When loose rivets are found, replace the clutch disc assembly because those rivets will loosen again even if they are re-tightened.

Check the clutch disc for wear or cracks on the facing, loose rivets, broken torsion springs, or wear of the hub splines.

e. Install the disc on the input gear and inspect the rotational play. If the measurement deviates from the specified value, replace the disc.

a. Measure the depression of the rivets. If the depression is 0.2 mm or less and cracks or burnt damage are found on the surface, the disc must be replaced. Rivet depression

Usable limit 0.3 mm (0.012 in.)

Rotational play of the hub spline

Usable limit 0.2 mm (0.008 in.)

f. Measure the deviations of the clutch disc. If the measurements are beyond the usable limits, replace the clutch disc assembly. Revet depression

Usable limit 0.4 mm (0.016 in.) or less 1.0 mm (0.039 in.) or less 1.0 mm (0.039 in.) or less

Surface deviation Lateral run-out Vertical run-out

Clutch disc

Dial gauge

Fig. 4-2

Note: Be sure to replace any clutch disc which has 0.2 mm or less in rivet depression. Use of a disc with insufficient rivet depression will result in serious damage to the flywheel and the pressure plate.

Fig. 4-3

g. Standard thickness and usable limit of the clutch disc are as shown in the table below. A disc assembly whose thickness is or will be less than the usable limit in a short period of use should be replaced with a new one.

b. Any oil-stained clutch disc must be replaced. However, slight oil stain may simply be removed by use of a volatile solvent.

Standard value 7.8±0.3 mm (0.307±0.012 in.) 8.3±0.3 mm (0.327±0.012 in.)

Note: The causes of oil stains must be located and necessary corrective measures must be taken.

Usable limit* 6.6 mm (0.260 in.) 7.0 mm (0.276 in.)

*Rivet depression should be more than 0.2 mm (0.008 in.). 28

CHAPTER 4: CLUTCH SYSTEM b. Check the clutch cover and diaphragm springs for distortion, deformation, loss of tension, and damage. If any defective parts are found, replace the clutch cover assembly. (3) Inspection of release bearing The release bearing is a lubrication-free type, so it should never be washed in cleansing oil. Wipe it clean with a cloth and check its smoothness by turning it manually. Replace a defective bearing. Fig. 4-4

4. PRECAUTIONS FOR RE-ASSEMBLY

h. Check damper springs for damage and fatigue. A defective one should be replaced with a new one. Damper spring play

Reassemble in reverse order of disassembly, following the next precautions.

Usable limit 1.5 mm (0.06 in.)

(1) Keep oil from getting on the clutch disc, pressure plate, and flywheel.

(2) Inspection of clutch cover assembly

(2) Install the clutch disc with the longer spline boss turned towards the transmission.

a. Check the pressure plate’s friction surface for deformation, scratches, stepped wear, and oil stain. If it is defective, replace the clutch cover assembly.

(3) When installing the clutch assembly on the flywheel, align the clutch and the flywheel using the clutch centering tool. Then tighten the clutch on the flywheel to the specified torque.

Flatness of pressure plate surface: Standard value less than 0.05 mm (0.002 in.)

Usable limit 0.5 mm (0.06 in.)

Tightening torque

1.5–2.2 kgf·m (11–16 ft.lbs)

Note: First align the clutch with the flywheel using the two reamer bolts. Then install other bolts and tighten them evenly to the specified torque.

Fig. 4-5

29

Fig. 4-6

TM TRACTOR SERVICE MANUAL (4) Tighten yoke set bolt securely with adhesive applied. (5) Apply a thin coat of molybdenum disulphidebased grease to the spline parts of the input shaft and clutch disc in advance. (6) Pack the inside of the sleeve with grease and apply grease to the outer circumference of the sleeve guide in advance. After installation, make sure they slide smoothly. Use a heat-resistant grease. (7) Apply an even coat of adhesive (THREE BOND TB1215) to the contact surfaces of the engine rear plate and clutch housing before assembling them.

Fig. 4-8

(8) Adjust the free play of the clutch pedal “A” to be 20 to 30 mm at the pedal top by adjusting the clutch rod. Clutch pedal free play “A” (at pedal top)

20 – 30 mm (0.8 – 1.2 in.)

A

Fig. 4-7

30

CHAPTER 4: CLUTCH SYSTEM 5. TROUBLESHOOTING 1. PROBLEM: Clutch slippage The initial stage of clutch slippage is very hard to detect, but the following suspect symptoms are noticeable. (1) The tractor is not generating adequate power when performing heavy duty operations. (2) Output is not commensurate with increase in engine speed when the engine is accelerated suddenly during operation. (3) Increased fuel consumption These symptoms are apt to be mistaken for engine problems. Clutch slippage that is not repaired will result in serious damage such as excessive wear of the clutch facing, the clutch cover, and even flywheel or clutch seizures. TEST METHOD: If the parking brakes are applied and the transmission gears shifted to top speed and the engine stops, then the clutch is normal. But if the engine does not stop, it shows that the clutch is slipping.

Probable causes

Countermeasures

a. No play in the release bearing

Adjust.

b. Broken or fatigued diaphragm spring

Replace.

c. Excessive wear of clutch facing

Replace.

d. Oil stained or hardened clutch facing

Repair or replace.

e. Deviation of flywheel or pressure plate

Repair or replace.

2. PROBLEM: Poor disengaging When the clutch does not disengage properly, the transmission gears are noisy when shifted, or shifting or the gears is difficult.

31

TM TRACTOR SERVICE MANUAL

32

Fig. 5-1

12T

47T

15T

11T

ENGINE

21T 8T

CLUTCH

30T

33 18T

34T

20T

30T

MID-PTO

20T

33T

15T

15T

19T

25T

24T

23T

26T

20T

32T

33T

17T 16T

33T

14T

7T

34T

19T

19T

42T

PTO

11T

58T

CHAPTER 5: TRANSMISSION

CHAPTER 5. TRANSMISSION

1. GEAR-TYPE TRANSMISSION

1.1. POWER TRAIN

TM TRACTOR SERVICE MANUAL a. Speed shifting steps of rear wheel driving gears Gear combinations Preliminary reduction Forward

Reverse

15/33

15/33

Transmission range

Main shift

Final reduction

Reduction ratio

7/42✻11/58

0.00314 0.00568 0.00934

L

14/34

1st 2nd 3rd

17/32 24/25 30/19

H

33/16

1st 2nd 3rd

17/32 24/25 30/19

0.01574 0.02845 0.04679

L H

14/34 33/16

1st 1st

24/23✻20/32 24/23✻20/32

0.00386 0.01933

b. Speed shifting steps of front wheel driving gears Gear combinations Preliminary reduction Forward

Reverse

15/33

15/33

Transmission range

Main shift

Final reduction

Reduction ratio

20/30✻8/21✻ 11/15✻12/47

0.00473 0.00854 0.01405

L

14/34

1st 2nd 3rd

17/32 24/25 30/19

H

33/16

1st 2nd 3rd

17/32 24/25 30/19

0.02368 0.04280 0.07039

L H

14/34 33/16

1st 1st

24/23✻20/32 24/23✻20/32

0.00580 0.02907

c. Final reduction ratio of front wheel shaft and rear wheel shaft Front: Rear = 1 : 0.6647

34

CHAPTER 5: TRANSMISSION 1.2. CONSTRUCTION

Fig. 5-2

1.3. DISASSEMBLY (1) Separate the clutch housing from the front transmission case referring to 4 of Chapter 2.

(7) Remove the input gear. (8) Remove the reverse shaft and take out the reverse gear.

Note: In the following operations, the directions in which the thrust collars are installed should be memorized or written down.

(9) Remove the drive pinion and take out the assembly of the 4WD change gear, range shift counter gear and main shift counter gear along with related parts.

(2) Separate the transmission case from the rear transmission case referring to 7 of Chapter 2.

(10) Remove the PTO shaft and take out the PTO (3) Remove the input shaft along with the spline change gears, mid-PTO counter gear and related boss. parts. (4) Remove the input metal (support).

(11) Remove the shifter and shifter stay.

(5) Remove the 4WD output gear. (6) Remove the change shaft and take out the main and range shift gears. 35

TM TRACTOR SERVICE MANUAL

Fig. 5-3

1.4. INSPECTION (1) Check each gear and shaft for damage, tooth (2) Before installing the PTO drive shaft, set the PTO bearing, etc. change gear to the shifter. (2) Make sure that all radial roller bearings and (3) After assembly, make sure that each shift lever needle roller bearings turn smoothly and have no moves smoothly. flaws. Operating load at lever top

(3) Make sure that the oil seal lips and lip contact surfaces on shafts have no flaws. 4WD shift lever

6 kgf

PTO shift lever

4 kgf

1.5. PRECAUTIONS FOR RE-ASSEMBLY (1) When assembling, pay attention to the installing direction of the gears, collars, etc. Never forget to install bearings and collars.

36

12T

47T

11T

21T 8T

CLUTCH

Fig. 5-4

37

32T

18T

MID-PTO

17T

30T

19T

29T

18T

19T

29T

17T

19T

15T

34T

24T 30T

25T

35T

7T

11T

42T

58T

19T

19T

PTO

2.1. POWER TRAIN

15T

ENGINE

HST

CHAPTER 5: TRANSMISSION

2. HST TRANSMISSION

TM TRACTOR SERVICE MANUAL a. Speed shifting steps of rear wheel driving gears Gear combinations HST efficiency

Preliminary reduction

Transmission range

Forward

0.92

19/17

L H

19/29 29/19

Reverse

0.65

19/17

L H

19/29 29/19

Final reduction

Reduction ratio

7/42✻11/58

0.02129 0.04961 0.01504 0.03505

b. Speed shifting steps of front wheel driving gears Gear combinations HST efficiency

Preliminary reduction

Transmission range

Forward

0.92

19/17

L H

19/29 29/19

Reverse

0.65

19/17

L H

19/29 29/19

Final reduction

Reduction ratio

19/30✻18/17✻8/21 ✻11/15✻12/47

0.03222 0.07507

c. Final reduction ratio of front wheel shaft and rear wheel shaft Front: Rear = 1 : 0.6608

38

0.02277 0.05304

CHAPTER 5: TRANSMISSION 2.2. CONSTRUCTION

Fig. 5-5

2.3. DISASSEMBLY (7) Remove the input gear.

(1) Separate the clutch housing from the front transmission case referring 4 of Chapter 2.

(8) Remove the reverse shaft and take out the reverse gear.

Note: In the following operations, the directions in which the thrust collars are installed should be memorized or written down.

(9) Remove the drive pinion and take out the assembly of the 4WD change gear, range shift counter gear and main shift counter gear along with related parts.

(2) Separate the transmission case from the rear transmission case referring to 7 of Chapter 2.

(10) Remove the PTO shaft and take out the PTO change gears, mid-PTO counter gear and related (3) Remove the input shaft along with the spline parts. boss. (11) Remove the shifter and shifter stay.

(4) Remove the input metal (support). (5) Remove the 4WD output gear. (6) Remove the change shaft and take out the main and range shift gears. 39

TM TRACTOR SERVICE MANUAL 2.4. INSPECTION

direction of the gears, collars, etc. Never forget to install bearings and collars.

Fig. 5-6

(1) Check each gear and shaft for damage, tooth bearing, etc.

(2) Before installing the PTO drive shaft, set the PTO change gear to the shifter.

(2) Make sure that all radial roller bearings and needle roller bearings turn smoothly and have no flaws.

(3) After assembly, make sure that each shift lever moves smoothly. Operating load at lever top

(3) Make sure that the oil seal lips and lip contact surfaces on shafts have no flaws. 2.5. PRECAUTIONS FOR RE-ASSEMBLY (1) When assembling, pay attention to the installing 40

4WD shift lever

6 kgf

PTO shift lever

4 kgf

CHAPTER 5: TRANSMISSION 3. MID-PTO

3.3. INSPECTION (1) Check each gear and shaft for damage, tooth bearing, etc. (2) Check to see that each bearing turns smoothly without hitching.

Fig. 5-7

3.1. CONSTRUCTION (3) Make sure that the oil seal lips and lip contact surfaces on respective shafts have no flaws.

(1) Separate the mid-PTO assembly from the front transmission case referring to 8 of Chapter 2.

3.4. PRECAUTION FOR RE-ASSEMBLY (2) Remove the wire and roll pin. (1) When assembling, pay attention to the installing direction of the gears, collars, etc. Never forget to install bearings and collars.

(3) Remove the countershaft and take out the counter gear and related parts. (4) Remove the cap and snap ring.

(2) After assembly, make sure that each shift lever moves smoothly.

(5) Remove the shaft assembly rearward. Operating load at lever top

(6) Remove the mid-PTO lever assembly from the 4WD lever. PTO shift lever

41

Gear transmission

HST transmission

11 kgf

6 kgf

TM TRACTOR SERVICE MANUAL

42

CHAPTER 6: REAR AXLE AND BRAKES

CHAPTER 6. REAR AXLE AND BRAKES 1. GENERAL DESCRIPTION The rear axle system is of the central axle type, which contains the final reduction gears, differential gears, diflock, and brakes. The power from the engine is transmitted to the right and left wheel pinions through the differential gears, and to the rear wheels. A inner shoe-expansion, mechanically-operated brake system has been adopted, which can produce superior braking force with excellent durability. It is a dry-type of simple construction, so it is very easy to service. The dif-lock mechanism which is housed in the right-hand rear axle housing can lock the differential gears by depressing the dif-lock pedal while equalizing the rotational speeds of both wheels.

Fig. 6-1

43

14 13

44

Fig. 6-2

(1) & (2) Bevel pinion set (Difpinion gear & dif-ring gear) (3) Dif-pinion (12T) (4) Pinion thrust collar (5) Dif-side gear (14T) (6) Thrust collar (7) Pinion shaft holder (8) Differential case (9) Dif-pinion shaft (10) Dif-lock shift fork (11) Dif-lock clutch (12) Shifter stay (13) Dif-lock cam (14) O-ring (P10A)

Dif-lock lever (HST models)

Dif-lock pedal (Mechanical transmission models)

A

2. CONSTRUCTION

A

1

11

10

A

8

(15) Wheel pinion (11T, RH) (16) Wheel pinion (11T, LH) (17) Wheel gear (58T) (18) Shims (19) Dif-case metal (LH) (20) Oil seal (TC0458) (21) Snap ring (22) Oil seal (QLE488011.5) (23) Wheel shaft (24) PTO drive shaft (25) Washer (20 × 28 × 2) (26) Sleeve (27) PTO shaft (28) Seal ring (29) Oil seal (TC355558)

A

15

12 9

4

7 3

6 5 3

4

17

2

16

25

21

20

18

26

22

19

27

23

28

29

TM TRACTOR SERVICE MANUAL

CHAPTER 6: REAR AXLE AND BRAKES 3. REAR AXLE HOUSING AND DIFFERENTIAL GEARS

3.1. DISASSEMBLY

i. As drive pinion and ring gear make a pair, take care not to interchange either of them with one of other pairs. ii. Adjust the backlash to be 0.2 to 0.25 mm by shimming

REAR AXLE HOUSING a. Drain the transmission oil. b. Remove the PTO shield cover. c. Remove the cylinder case referring to Chapter 25. d. Remove the PTO metal and PTO shaft assembly. e. Remove the rear axle housing referring to Chapter 2-9.

Standard shimming thickness

0.4 mm

iii. After adjustment, tap the outer circumference with a copper hammer and make sure that the backlash does not change. Check backlash at four points 90 degrees apart from each other.

DIFFERENTIAL GEARS b. After reassembling, each gear and related part should move smoothly.

f. Remove the right and left dif-case metal. Note: When the dif-case metal is too tightly fit into the rear transmission case to be removed manually, use push bolts. The push bolts should be screwed in evenly and gradually. g. Remove the differential assembly. h. Remove the bearings from both sides of the differential assembly. i. The differential assembly can be disassembled by removing the dif-pinion shaft. Note: The lock pin should be removed ahead of time.

Fig. 6-3

3.2. INSPECTION a. Check each gear and shaft for damage, tooth bearing, etc. b. Check the bevel pinion for the differential and pinion thrust collar for wear. c. Check to see that each bearing turns smoothly without hitching. d. Make sure that the oil seal lips and lip contact surfaces on shafts have no flaws. 3.3. PRECAUTIONS FOR RE-ASSEMBLY AND ADJUSTMENT a. Backlash adjustment between the drive pinion and ring gear 45

TM TRACTOR SERVICE MANUAL TOOTH BEARINGS Correct bearing Inner circumference

When the drive pinion and the ring gear are meshed correctly with each other, and their backlash is within the specified range (0.1 - 0.2 mm), the bearing trace is positioned at the middle of the ring gear tooth and is approximately three fourths of the total tooth width.

Outer circumference

Face bearing

This shows that the drive pinion and the ring gear are meshed too shallowly and their backlash is too large. This will result in rapid wearing of the tooth top. This bearing must be repaired by shifting some the left dif-case metal shims to the left side.

Flank bearing

This shows too deep a meshing of the drive pinion and the ring gear and too small a backlash. This will cause stepped tooth wear. Repair this in the reverse way of repairing the face bearing.

46

CHAPTER 6: REAR AXLE AND BRAKES 4. BRAKES 4.1. SPECIFICATIONS Type Brake drum

Free play of brake pedals

Dry, inner-shoe expansion, mechanically operated Diameter

Ø114 mm (Ø4.49 inches)

Lining width

30 mm (1.18 inches) 30 – 40 mm (1.18 – 1.57 inches)

4.2. CONSTRUCTION

Fig. 6-4 47

TM TRACTOR SERVICE MANUAL 4.3. DISASSEMBLY

9

1 2 3 4

7

5

6 8

(1) (2) (3) (4) (5) (6)

Brake drum Snap ring (for shaft) Brake shoe Tension spring Snap ring (for shaft) O-ring

(7) Brake cover (8) Brake cam comp. (9) Wheel pinion

Fig. 6-5

Disassembly of the brake system is possible without separating the rear axle housing from the rear transmission case.

b. Remove the snap ring and take out the brake drum. Then extract the wheel pinion.

a. Remove the brake cover and detach the brake shoes from the brake cam.

48

CHAPTER 6: REAR AXLE AND BRAKES 4.4. INSPECTION

4.6. BRAKE ADJUSTMENT

a. The usable limit of the brake shoe thickness is 2.2 mm (0.087 in.) at the middle. Usable limit

Correct free-play A of each individual brake pedal is 20 to 30 mm (7/8" to 1-1/8"). Note: • Through use, free-play will increase and brake balance will be affected. Adjust and balance brakes before free-play becomes excessive. •• HST models do not have individual wheel brakes.

2.2 mm (0.087 in.)

A

Fig. 6-6 Fig. 6-8

b. Check the brake drum for damage such as abnormal wear, cracks, etc., and replace when defective.

PARKING BRAKES When above adjustment is completed, check operation of parking brakes. Depress the pedal fully and apply parking brakes. It should have brakes locked with lever approximately in center of travel. If not, adjust the lock nuts (A) correctly. Make sure lock nuts are secured when brake adjustment is completed.

4.5. PRECAUTIONS FOR REASSEMBLY Reassemble in reverse order of disassembly, keeping the following precautions. a. The brake shoes and inner surface of the brake drum should be free from oil or dust. b. Apply heat-resistant grease to the points indicated in Fig. 6-7.

Mechanical transmission models

A

Apply grease.

HST models

Fig. 6-7 49

TM TRACTOR SERVICE MANUAL 5. TROUBLESHOOTING

Problems Insufficient braking force

Overheated brakes

Unbalanced braking

Brake pedals do not return smoothly.

Abnormal noise

Causes

Countermeasures

• Poorly adjusted pedal play

Readjust.

• Oil leaks in brake chamber

Repair or replace.

• Worn or seized lining

Replace lining.

• Excessive pedal play

Readjust.

• Poorly centred shoes

Readjust.

• Improper brake operation

Operate brakes properly.

• Improperly adjusted pedal play

Readjust.

• Oil leaks in brake chamber

Repair.

• Linings on one brake are worn or seized.

Replace linings.

• Broken return springs

Replace.

• Poorly lubricated moving parts

Remove rust and lubricate properly.

• Worn or damaged bearings

Replace.

• Worn or damaged parts like wheel gears, wheel pinions, wheel shafts, etc.

Replace.

50

CHAPTER 7: MANUAL STEERING SYSTEM

CHAPTER 7. MANUAL STEERING SYSTEM §1. CONSTRUCTION The steering system is a mechanical ball-screw type. It is constructed as illustrated and functions as shown in the diagram.

Steering wheel

Steering wheel shaft Ball screw Pitman arm

Knuckle spindles

Steering wheel shaft

Drag arm Tie rod

Drag rod

Knuckle arm Steering wheel column

Fig. 7-1

Thrust ball bearing

Lock nut Adjust nut

Ball screw

Worm sector Pitman arm

Grease filling

Fig. 7-2

Drag rod 51

TM TRACTOR SERVICE MANUAL §2. DISASSEMBLY, INSPECTION, AND REASSEMBLY 1. DISASSEMBLY (1) Draw out the Pitman arm with a puller. Note: Make sure that aligning marks are applied to both sector shaft and Pitman arm. If they are not, apply them before disassembly. Aligning marks

Sector shaft

Fig. 7-5

(5) Shift the sector shaft to the neutral (straight travelling) position by turning the worm and pull off the sector shaft.

Pitman arm

Fig. 7-3

(2) Drain the gear box of oil through the filler by removing the plug. (3) Remove the lock nut for the adjusting screw and then remove the bolts which tighten the side cover.

Fig. 7-6

(6) Remove the bolts which tighten the rear cover and take out the rear cover and shims. Then draw out the ball-nut assembly.

Fig. 7-4

(4) Hold the side cover to prevent it from turning and remove the side cover by turning the adjusting screw clockwise. Fig. 7-7 52

CHAPTER 7: MANUAL STEERING SYSTEM Note: • Never put the ball-nut assembly upright. If this is done, the ball-nut slides down by its own weight and hits the disappearing end of the worm screw groove, which leads to damage of the ball-tube.

Therefore it must always be kept level. • Never disassemble the ball-nut assembly. (7) Removal of the bearings and seals from the gear box, cover, etc., should be done only if required.

2. INSPECTION Wash disassembled parts in fresh light oil or cleansing oil and then inspect them carefully following the next criteria. Part names Ball nut assembly

Sector shaft

Bearings

Inspection items

Criteria for part replacement

Ball-nut performance

If its starting torque exceeds 0.5 kgf·m (3.6 ft·lbs) even after washing it clean, or if it does not work smoothly, replace the assembly.

Ball groove of worm

If it is damaged by dents or exfoliation, replace the assembly.

Deformed ball tube or tube clamps

If the starting torque is more than 0.5 kgf·m (3.6 ft·lbs), replace the assembly.

Loose tube clamps or tightening screws

Tighten them to 15 – 25 kgf·cm (1.1 – 1.8 ft·lbs).

Thrust play of ball-nut

If the play exceeds 0.1 mm (0.004 in.), replace the assembly.

Cracks, deformation, wear, etc.

Replace a defective shaft.

Distorted serrations

Replace the shaft.

Clearance between T-groove and shims

If the clearance exceeds 0.15 mm (0.006 in.) replace the shaft. (5 kinds of shims are available.)

Dented or exfoliated racing surfaces Dents caused by the balls or rollers

Replace any bearings which have suffered such damage.

Cracks or exfoliation Deformed cages Other parts

Cracks, deformation, and other damage. 53

Replace any parts which have suffered such damage.

TM TRACTOR SERVICE MANUAL Note: Be sure to replace the following parts as an assembly.

starting torque of the system should be adjusted to a specified level by shimming. Starting torque

• Ball-nut assembly The worm, ball-nut, and balls are adjusted exclusively as an assembly. Therefore none of the components can be replaced as an independent part.

•

• Gear box assembly and side cover assembly The assemblies which have roll bushes should be replaced as an assembly.

•

3. REASSEMBLY AND ADJUSTMENT •

All disassembled parts should be washed clean and all seals should be coated with grease in advance.

•

(1) When the bearings for the worm have been removed, install their outer races into the gear box and rear cover respectively.

2 – 5 kgf·cm (0.14 – 0.36 ft·lbs)

Note: Five kinds of shims in thickness are available [mm (in.)]: 0.05, 0.07, 0.08, 0.10, 0.20 (0.0020, 0.0028, 0.0031, 0.0039, 0.0079)(5 kinds) Increasing or decreasing rate of starting torque by shimming: Starting torque increases or decreases about 0.01 kgf·m (0.072 ft·lbs) by an increment of 0.01 mm (0.0004 in.) of shimming. Start adjusting the starting torque with a thicker shim. Then try thinner shims until the proper torque is obtained. The bearings are pre-loaded, so turn the steering shaft several time before measuring the starting torque.

(5) After the shimming adjustment, tighten the rear cover to the specified torque.

Fig. 7-8

(2) When the oil seal has been removed, install it into the gear box.

Fig. 7-9 Tightening torque

(3) Install the ball-nut assembly with the bearings into the gear box. The bearings and ball-nut should be coated with sufficient grease in advance.

1.7 – 2.8 kgf·m (12.3 – 20.3 ft·lbs)

(6) Set the adjusting screw and a shim into the Tgroove in the sector shaft end. And adjust the clearance to be less than 0.05 mm (0.002 in.) by trying the following shims.

(4) Install the shims and then the rear cover. Here 54

CHAPTER 7: MANUAL STEERING SYSTEM

Tightening torque

1.7 – 2.8 kgf·m (12.3 – 20.3 ft·lbs)

(9) Install the Pitman arm on the sector shaft by matching the aligning marks and tighten them to the specified torque. Then adjust the backlash with the adjusting screw at top of the Pitman arm.

Fig. 7-10 Five kinds of shims are available [mm (in.)]: 1

2

+0.035 (0.0014) +0.015 (0.0006)

+0.065 (0.0037) +0.045 (0.0018)

1.5 (0.059) 3 +0.095 (0.0037) +0.075 (0.0030)

1.5 (0.059) 5

1.5 (0.059) 4 +0.125 (0.0049) +0.105 (0.0041)

1.5 (0.059)

+0.155 (0.0061) +0.135 (0.0053)

Fig. 7-12

1.5 (0.059)

(7) Set the ball nut midway on the worm and insert the sector shaft into the gear box.

Tightening torque

14 – 18 kgf·m (101 – 130 ft·lbs)

Backlash at top of Pitman arm

0.5/190 or less

Note: Be sure to engage the rack and gear correctly. One (10) Secure the adjusting screw with the lock nut. tooth shift is the most common mistake. (8) Apply adhesive to the side cover packing in advance. Tighten the side cover to the specified torque. (Refer to Fig. 7-11.)

Fig. 7-13 Lock nut tightening torque Fig. 7-11 55

3.0 – 4.0 kgf·m (0.18 – 0.69 ft·lbs)

TM TRACTOR SERVICE MANUAL 11) After reassembly, check the following items.

b. Steering starting torque when assembled completely:

a. Steering shaft’s starting torque in the neutral (straight travelling) position and with the sector shaft installed:

Starting torque

12.5 kgf·cm (0.90 ft·lbs) or less

c. Working angles of sector shaft Starting torque

2.5 – 9.5 kgf·cm (0.18 – 0.69 ft·lbs)

Working angles

38° each in both directions

4. TROUBLESHOOTING Symptoms Steering wheel is heavy to turn. (when heavy throughout whole operation)

Presumable causes • Poor ball-nut assembly

Wash ball-nut assembly or replace.

• Poor bearings

Reassemble them. (Poor shimming or improper assembling is presumable.)

• Other abnormal friction parts

Replace.

System is noisy.

Insufficient lubrication

Steering wheel cannot be turned.

Broken or deformed parts • • • •

Free play of steering wheel is excessive.

Hitched steering wheel operation (when it becomes heavy at a specified point or points)

Countermeasures

Lubricate each friction part.

Broken ball-nut assembly Broken sector shaft Broken bearings Other broken parts

Replace broken ones.

• Poorly adjusted adjusting screw

Adjust it properly.

• Worn ball-nut assembly

Replace it.

• Deformed covers

Replace a defective one.

• Poorly assembled

Reassemble.

Insufficient steering angles (sector shaft)

Poorly assembled (misalignment between sector gear and ball-nut)

Reassemble.

Oil leaks

Deformed or damaged parts

Replace a damaged cover. Replace damaged seals like packings, O-rings, Oil seals, etc. Or wash, apply liquid packing to contacting surfaces, and reassemble.

Others

Damaged parts

Replace. 56

CHAPTER 8: FRONT AXLE

CHAPTER 8. FRONT AXLE §1CONSTRUCTION 1. SECTIONAL VIEWS

FRONT AXLE (Front view)

FRONT WHEEL DRIVE (Side view) Fig. 8-1 57

29

30

31

31

Fig. 8-2

29

30

58 7

6

27

5

(1) O-ring (P71) (2) Rear pivot metal (support) (3) Bush (62x67x30) (4) O-ring (G70) (5) Axle housing (6) Oil seal (7) Bush (35x39x26) (8) Front pivot metal (support) (9) Final case (A) (10) Final case (B) (11) Wheel cover (12) Seal (QLNY35571116) (13) Front wheel shaft (14) Knuckle arm (15) Tie-rod (16) Drag rod (Manual steering) (17) Plate (18) Bearing unit (19) Joint B assembly

8

28

2. MAJOR COMPONENTS

4

33

9

2

24

(20) Oil seal (21) Bush (20x38x26) (22) Oil seal (21) (23) Snap ring (52C) (24) Collar (48x52x17) (25) Snap ring (52C) (26) Collar (25x32x3) (27) Bevel pinion set (28) Front differential case (29) Bevel gear (15) (30) Bevel pinion (11) (31) Washer (32) O-ring (G90) (33) Oil seal (34) Bevel gear (47T)

32

3

25 26

1

23

22

34

10

21

20

11

HST type

19

12

15

18

13

17 16

14

TM TRACTOR SERVICE MANUAL

CHAPTER 8: FRONT AXLE §2. DISASSEMBLY 1. FRONT AXLE AND DIFFERENTIAL GEARS 22 23 24 26

25

27

31 29

28 30

30 29 31

Fig. 8-3 (1) Remove the steering cylinder (power-assisted steering models), drag rod (manual steering models) and tie-rod. (2) Remove the final case assembly from the front axle end. (3) Separate the front axle from the front axle bracket. (4) Remove the drive pinion. (5) Remove the differential assembly, left to right.

59

TM TRACTOR SERVICE MANUAL 2. FINAL CASE AND RELATED PARTS DISASSEMBLY OF THE FINAL CASE ASSEMBLY (1) Remove the knuckle arm. (2) Divide the final case assembly into the final case (A) and final case (B).

14

32

9

10 34

11

33

Fig. 8-4

§3. INSPECTION (1) Check the gears for damage and tooth bearing.

surfaces of the shafts for damage. Pay special attention to the oil seals of the rotating parts of the final case and wheel shaft. Shaft seals are used for these parts. When oil leaks through these oil seals, replace them. They should also be checked for thrust play and right angle play to the axis.

(2) Check the bevel gears and thrust collars of the differential for wear. (3) Make sure that each bearing turns smoothly. (4) Check the oil seal lips and the seal contacting 60

CHAPTER 8: FRONT AXLE (5) Check the bushes for the front and rear pivot metals (supports) for wear. When they are worn out exceeding the usable limit, replace them.

(3) After installing the front axle on the axle bracket, adjust the fore-and-aft play of the front axle to the specified valve. (4) Front axle end-float: Fore and aft play of the front axle (1) in its supports should be 0.1 to 0.3 mm (0.004-0.012"). End-float is measured with axle raised off the ground. Loosen the lock nut (2) and turn the adjusting bolt (3) as needed to achieve correct measurement. Tighten the lock nut.

Standard value Usable limit Front bush bore

Ø35

+0.05 +0.034

mm

0.2 mm

Rear bush bore

Ø62

+0.186 +0.116

mm

0.2 mm

* Bush bore should be measured when the bushes are installed.

§4. PRECAUTIONS FOR RE-ASSEMBLY (1) When replacing the shaft seals of the rotation parts of the final case and wheel shaft, never hit the surface of the flange of the sleeve. Damaged flange surfaces will cause oil leaks. 1 Jig

2

Sleeve

Improper

3

Fig. 8-7

Proper

Note: Excessive end-float will cause noise. This noise will be more pronounced when using 4WD.

Fig. 8-5

(2) When sub-assembling the differential, insert the spring pin so as for the seal to turn in the direction of external force applied. After inserting the spring pin, retain it with wire. Seam of roll pin should face in direction in which load is applied.

Fig. 8-6

61

TM TRACTOR SERVICE MANUAL

§3. TROUBLESHOOTING Problems and probable causes

Countermeasures

• Steering wheel hard to turn: 1) 2) 3) 4)

Inflate to specified pressure: 1.8 kgf/cm2 (25.6 psi) Replace. Grease or replace. Grease or replace.

Too low tyre inflation Broken thrust bearing Stuck or broken ball joint of tie-rod end Seizure or poor lubrication of axle end bush

• Vibrating or pulling steering wheel: 1) 2) 3) 4) 5)

Unbalanced wheels Wheel deflection Unequal diameter of both tyres Loose, worn, or damaged wheel axle bearing Loose, worn, or damaged wheel steering wheel shaft 6) Worn final case bush 7) Loose final case—front axle tightening bolts 8) Loose front wheel (tyre) tightening nuts

Adjust balance. Repair or replace. Adjust inflation or replace. Repair or replace. Retighten or replace. Replace. Retighten. Retighten.

• Steering wheel tends to turn to the right or left while traveling on straight paved road: 1) Deflected wear of tyre 2) Different tyre diameters 3) Damaged final case bearing

Replace. Adjust inflation or replace. Replace.

• Excessive or eccentric wear of tyre: 1) 2) 3) 4)

Improper tyre inflation Worn front wheel shaft bearing Poorly adjusted toe-in Front wheel drive (4WD) is always engaged.

Adjust. Replace. Readjust correctly: 2 – 6 mm (0.08 – 0.24 in.) Engage 4WD only when required.

• Noise: 1) 2) 3) 4) 5)

Loose fasteners Worn or damaged final case bearing Worn bush Wear or poor movement of tie-rod end Excessive backlash of differential and bevel gear

Tighten correctly to specified torque. Replace. Replace. Lubricate or replace. Adjust.

• Different steering angles in both directions: 1) Lengths of RH and LH tie-rods are different.

Adjust.

62

CHAPTER 9: HYDRAULIC SYSTEM

CHAPTER 9. HYDRAULIC SYSTEM §1. GENERAL DESCRIPTION arm Lift

1. HYDRAULIC SYSTEM DIAGRAMS 1.1. STANDARD TYPE

W

Cylinder

Position control lever

Link mechanism

Safety valve Main control valve

(Remote hydraulic control port)

Relief valve

Sub-control valve

Gear pump

Suction filter

Reservoir

Fig. 9-1 MAIN CYLINDER W

SAFETY VALVE Craking pressure: 155 kg/cm2 Relief pressure: 190 kg/cm2

LOWERING RATE CONTROL VALVE C CONTROL VALVE

T3 T1 T2

P

P1

MAIN RELIEF VALVE Relief pressure: 140 kg/cm2

MAIN PUMP 7.91 cc/rev. x 2500 rmp x 0.912/1000 = 18 litres/min. STRAINER (100 mesh)

Fig. 9-2 RESERVOIR

63

TM TRACTOR SERVICE MANUAL 1.2. HU & U TYPES

Lift

arm

W

Position control lever Cylinder Link mechanism

Oil cooler Safety valve

HU type (A)

Oil filter

(B)

(Remote hydraulic control port)

Mini-orbit roll

Sub-control valve U type

HST

Flow-control valve

Gear pump

Suction filter

Reservoir

In type HU, fluid flows from the mini-orbit roll to the oil cooler and HST via line A. In type U, fluid returns from the mini-orbit roll to the delivery pipe via line B.

Fig. 9-3 64

Main control valve Relief valve

Fig. 9-4

65

MINI-ORBIT ROLL

STRAINER (100 mesh)

MAIN PUMP 7.91 cc/rev. x 2500 rmp x 0.912/1000 = 18 litres/min.

L/C FILTER

FLOWDIVIDER 5.51 litres/min.

Relief pressure: 105 kg/cm2

U type

B. pressure Max. 10 kg/cm2

HU type

POWER STEERING CYLINDER

Cracking pressure: 2.0 kg/cm2

B

HST UNIT

OIL COOLER

RESERVOIR

T

OIL FILTER (10µ)

Pgλ

Pgβ

T2

T3

SAFETY VALVE Cracking pressure: 155 kg/cm2 Relief pressure: 190 kg/cm2

P

C

P1

MAIN RELIEF VALVE Relief pressure: 140 kg/cm2

T1

CONTROL VALVE

LOWERING RATE CONTROL VALVE

W

MAIN CYLINDER

CHAPTER 9: HYDRAULIC SYSTEM

TM TRACTOR SERVICE MANUAL 1.3. HYDRAULIC SYSTEM MAIN PIPING

(1) Suction filter (2) Suction pipe (3) Hydraulic pump (4) Metal (U)

(The drawing shows type U & HU.)

(5) Front delivery pipe (6) Rear delivery pipe (7) Cylinder case

7

1

4

5

2 6 Fig. 9-5 66

3

67

Fig. 9-6

Hose should be clamaped along with battery cable.

4

5

3

1

2

Two hoses should be clamped on underside of floor stay.

Hose and battery cable should be clamped on axle bracket.

Hose and battery cable should be clamped together.

7

6

IN

OUT

A

(1) Hydraulic pump (2) Metal (U) (3) Hose (650) (4) Oil cooler (5) Clamp (6) Hose (1350) (7) Oil filter (8) HST unit

A

8

CHAPTER 9: HYDRAULIC SYSTEM

1.4. HYDRAULIC SYSTEM PIPING (The drawing shows type H.)

68

Fig. 9-7

5

Two hoses and battery cable should be clamped together.

2

(1) Hydraulic pump (on right side of engine) (2) Metal (U) (on right side of engine) (3) Mini-orbit roll (4) Clamp (5) Clamp (6) Oil cooler (7) Oil filter (8) HST unit

Hose should be clamaped along with battery cable.

Hose should pass under axle bracket.

6

1

4

R

L

Two hoses should be clamped on underside of floor stay.

7

Two hoses should be clamped on floor stay.

P

T

IN

OUT

A

3

8

A

TM TRACTOR SERVICE MANUAL (The drawing shows type HU.)

CHAPTER 9: HYDRAULIC SYSTEM §2. SPECIFICATIONS

Suction filter

Rated flow rate Filtering density Filtering area

11 litres/min. 100-mesh 80 cm2 (12 cu.in.) or more

Gear pump

Working oil temperatures Theoretical delivery Maximum pressure

-30 to 90°C 7.91 cc 200 kgf/cm2 (2844 psi)

Flow-control valve

Working oil temperatures Maximum pressure Leaking when fully closed

-20 to 100°C 280 kgf/cm2 (3982 psi) 1 cc (0.16 cu.in.)/min. or less [under a cylinder load of 100 kgf/cm2 (1422 psi) and at an oil temperature of 50±5°C]

Relief valve

Cracking pressure

120 kgf/cm2 (1707 psi) or more [Leak: less than 300 cc (4.8 cu.in.)/min.] 140/+3/-0 kgf/cm2 (1911/+43/-0 psi) (under a flow rate of 15 litres/min.) 0.1 cc (0.16 cu.in.)/min. or less [under a pressure of 100 kgf/cm2 (1422 psi)]

Relief pressure Leak

Main control valve

Maximum flow rate (p–c) Maximum pressure C-port leak

18 litres 210 kgf/cm2 (2987 psi) 5 cc (0.8 cu.in.)/min. or less [under a pressure of 100 kgf/cm2 (1422 psi)]

Piston and cylinder

Piston diameter Cylinder bore Piston stroke

Ø65 mm (Ø2.56 in.) Ø65 mm (Ø2.56 in.) 75 mm (1.95 in.)

Lift capacity (at lower link end)

480 kgf (1411 psi)

Safety valve

155/+5/-0 kgf/cm2 (2250/+71/-0 psi) (under a flow late of 0.3 litre/min.) 190 kgf/cm2 (2702 psi) or more (under a flow rate of 20 litres/min.) 0.1 cc (0.016 cu.in.)/min. or less [under a pressure of 100 kgf/cm2 (1422 psi)]

Cracking pressure Relief pressure Leak

69

TM TRACTOR SERVICE MANUAL §3. CONSTRUCTION, DISASSEMBLY AND INSPECTION OF MAJOR COMPONENTS 1. SUCTION FILTER The filter is installed in the bottom of the transmission case. It has a reusable paper element, which should be washed clean periodically.

1 2

3

(1) Suction filter (2) Spacer (3) O-ring (P21) (4) O-ring (P28) (5) O-ring (P28) (6) Set bolt

4

5 6

Fig. 9-8

2. HYDRAULIC PUMP (GEAR PUMP) 6

8

7

9

10 3

Fig. 9-19

2

11

4

5

(1) Body (2) Rear cover (3) Drive gear (4) Driven gear (5) Side plate (6) Bush (7) Gasket (type 8) (8) Gasket (9) Oil seal (TC14287) (10) Snap ring (11) Steel ball

1

Note: As the hydraulic pump is a precision device, the original performance of the pump cannot always be restored after it has been disassembled. Consequently, it is recommended a defective pump be replaced with a new pump assembly. 70

CHAPTER 9: HYDRAULIC SYSTEM 3. FLOW CONTROL VALVE AND METAL (U) Hydraulic fluid is divided into the power-assisted steering system (mini-orbit roll assembly) and HST unit through the flow control valve housed in the metal (U) (valve casing). 3.1. CONSTRUCTION AND COMPONENTS FLOW CONTROL VALVE

6

7

4

1

10 3

5

2

METAL (U)

9

11 8

CF

EF

9

8

11

10

Fig. 9-10 1

(1) Body (2) Spool (3) Spring guide (4) Spring (5) Spool stopper (6) Plug

5

2

(7) O-ring (8) O-ring (9) O-ring (10) O-ring (11) Filter

3 7

4

6

Fig. 9-11

To mini-orbit roll (types U & HU)

To control valve

From mini-orbit roll (type U)

To oil cooler (type H) From transmission case

Fig. 9-12 71

TM TRACTOR SERVICE MANUAL 3.2. INSPECTION OF FLOW CONTROL VALVE When hydraulic fluid is not divided as intended, diasssemble the flow control valve, wash disassembled parts and reassemble them. After reassembly, remove the filter and confirm that the spool slides smoothly from filter-mounted side. 4. AIR-BLEEDING OF THE HYDARULIC CIRCUIT

Fig. 9-14

After transmission oil has been replaced, bleed air from the hydraulic oil circuit by loosening plug (1). Note: Never remove the plug, as oil will be ejected through the plug hole when the engine is started. Power-assisted steering models

1

Manual steering models

Fig. 9-13

HST model has a hydrostatic cartridge oil filter, which is located under the left step. Replace the cartridge afte the first 50 hours and then every 200 hours.

72

CHAPTER 9: HYDRAULIC SYSTEM 5. CYLINDER CASE 5.1. CONSTRUCTION AND COMPONENTS 2

(1) Cylinder case (2) Cylinder head (3) Relief valve (4) O-ring (G60) (5) O-ring (P55) (6) Backup ring (7) Piston (8) O-ring (9) Lift crank (10) Lift shaft (11) Bush (40 x 43 x 30) (12) Bush (40 x 39 x 30) (13) Support pin (14) Position arm (15) Link shift arm (16) Support link (17) Spool link (18) Crank link (19) Control valve (20) Adjusting pin

4 1

5

6

9

8 7

19

20 14

1 12

2 13 8 3

4

5

6

7 15 16 18

17 9 10 11

Fig. 9-15

19

73

TM TRACTOR SERVICE MANUAL 5.2. DISASSEMBLY 1

8 2

20

A 15 18

17 9 16

13

A

19

Fig. 9-16

(1) Remove the cylinder case assembly referring to Note: Chapter 2-5. Make sure that aligning marks are applied on both (2) Remove the position lever assembly and position lift arms and lift shaft. The lift shaft can be withcontrol arm. drawn only leftwards. (3) Remove the tension spring, spring hook, and the (8) Take out the lift shaft leftwards. pin connecting the spool link. Note: (4) Remove the spring pin of the adjusting screw. Make sure that aligning marks are applied on the (5) Remove the main control valve assembly along lift shaft and lift crank. with the adjusting pin. (9) Take out the link mechanism along with the lift (6) Remove the safety valve assembly and then the crank. cylinder head. (10) Separate the rod and lift crank along with the lift (7) Extract the lift arm (RH). crank. (11) Draw out the piston from the cylinder head side. 74

CHAPTER 9: HYDRAULIC SYSTEM 6. MAIN CONTROL VALVE 6.1. CONSTRUCTION 1 2

13

14

3 5

12

8

11

10

(1) Body (2) Main spool (3) Socket set screw (4) Compensator spool (5) Check valve guide (6) Steel ball (7) Compensator spring (8) Check valve spring (9) Plug (10) Plug (11) Sunk plug (12) O-ring (13) O-ring (14) Relief valve assembly

4 7 9 12 10 2 13

1 11

4 7 3 6 5 14

8

Fig. 9-17

6

9

12

75

TM TRACTOR SERVICE MANUAL 6.2. FUNCTION

NEUTRAL POSITION

LOWERING POSITION

LIFTING POSITION

Fig. 9-18 76

CHAPTER 9: HYDRAULIC SYSTEM • The steel ball and its seating surface on the body should be free of flaws. • Adjust the relief pressure with the adjusting screw by loosening the lock nut in advance.

6.3. DISASSEMBLY, INSPECTION AND REASSEMBLE OF THE MAIN CONTROL VALVE As the main control valve is a precision component, it is not recommended to be disassembled unnecessarily.

Cracking pressure

120 kgf/cm2 (1707 psi) [under a leaking rate of 300 cc/min. or less]

MAIN CONTROL VALVE BODY When disassembling, abide by the following precautions: a. Be sure to use clean cleansing fluid. b. Clean the inside of the valve body by washing and blowing it with compressed air. c. When the valve or spool is found with minor flaws, correct them with an oil stone or replace them with new ones. d. A deformed or broken spring should be replaced with a new one. e. All used O-rings should be replaced with new ones. f. Reassemble the parts while applying fresh oil to them.

Valve Adaptor

Fig. 9-20

After adjustment, be sure to tighten the lock nut to the specified torque. Then stake it without fail

INSPECTION OF THE RELIEF VALVE Tightening torque

7

5

(36) 15 T

2

6

1

8

(1) Valve body (2) Seat (3) Steel ball (4) Spring seat (5) Spring

4

M20, P1.5

3

(6) Lock nut (7) Adjusting bolt (8) Spring holder

Fig. 9-19 77

3.5 – 4.0 kfg·m (25.3 – 28.9 ft·lbs)

TM TRACTOR SERVICE MANUAL INSPECTION OF THE SAFETY VALVE 1

10

After adjustment, be sure to retain the adjusting screw with the lock nut and then stake the nut without fail.

9 (30.3)

2

11

Tighten the lock nut to the specified torque. Tightening torque

8

7

6

(1) Valve body (2) Seat (3) O-ring (4) Steel ball (5) Spring seat

5

4

Note: If copper packing (9) is damaged or deformed, replace it with a new one.

3

(6) O-ring (7) Lock nut (8) Adjusting bolt (9) Packing (10) Spring

Fig. 9-21

Install the valve on a nozzle tester as shown in Fig. 9-21 and adjust the cracking pressure to the specified value by turning the adjusting screw with a screwdriver. Cracking pressure

3.5 – 4.0 kfg·m (25.3 – 28.9 ft·lbs)

155 +- 50 kgf/cm2 (2505 +- 71 0 psi) [under a leaking rate of 300 cc/min. or less]

Valve Adaptor

Fig. 9-22 78

CHAPTER 9: HYDRAULIC SYSTEM §4. REASSEMBLY OF MAJOR COMPONENTS Reassemble in reverse order of disassembly by following the following instructions.

(7) When installing the safety valve assembly, mount the O-ring (P12) using a thin coat of grease. Do this carefully to assure it is not damaged. Then tighten the valve to the specified torque.

(1) Carefully and thoroughly clean all parts. Never allow foreign matter to enter the system.

Valve tightening torque

(2) When installing the lift crank and lift arm on the lift shaft, align their marks. The difference in height above the ground between both lift arms must be maintained within 6 mm when they are lowered by 8 degrees from level.

O-ring (P12)

8.5 – 10.0 kgf·m (61.5 – 72.3 ft·lbs) Safety valve

(3) When installing the adjusting pin, apply grease to the groove for O-ring and over the friction surface. Adjusting pin O-ring

Packing

Safety valve Sub-control cover

Control valve

Fig. 9-23

(4) Before installing the control valve, secure the Oring with grease so that it will not drop. When installing the adjust pin through the cylinder case, make sure the projection of the valve, with which the descending speed of the valve is adjusted, is securely seated in the groove in the end of the adjusting pin. Temporarily tighten the valve to conform that the adjusting pin turns smoothly before securely tightening the valve.

Fig. 9-24

(8) When installing the sub-control cover and the cylinder head, make certain that the oil holes are not clogged.

(5) Before and after installing the valve assembly, confirm that the spool works normally.

(9) Adjust the starting torque of the control lever to between 1.5 and 1.8 kg with the aid of the two nuts (M8).

(6) After having installed the parts inside the cylinder case: shaft, crank, links, etc., make sure the spool link, the related parts, and the spool work smoothly.

79

TM TRACTOR SERVICE MANUAL

Adjusting nuts

Fig.9-25

(10) When installing the suction pipe assembly, securely clamp the rubber hose connecting pipes A and B so as not to let air in. Centring deflection between pipes A and B should be maintained within 4 mm. Take care not to apply excessive stress to the connecting rubber hose during installation.

80

CHAPTER 9: HYDRAULIC SYSTEM §5. TROUBLESHOOTING Problems Lift does not rise.

Causes

Countermeasures

Insufficient engine speed

Raise engine speed slightly.

Insufficient transmission oil

Maintain oil level by replenishing with the same kind of oil.

Air taken in through suction piping

Tighten securely or replace broken parts.

Clogged suction filter

Clean.

Broken or poorly fuctioning hydraulic pump

Inspect pump and repair or replace if necessary. Pay particular attention to shaft seal because a broken seal sometimes intakes air.

Poor link mechanism

Inspect, adjust, repair, or replace if necessary.

Excessive load on lift

Decrease load.

Broken cylinder

Replace.

Too low viscosity of transmission oil

As it will cause oil leaks or internal wear, replace with gear oil of SAE 80.

Maladjusted relief valve

Readjust.

Excessive internal leaks

Inspect cylinder and valves. Replace damaged seals, and repair. (Check each part systematically.)

Broken control valve (Even when spool is shifted to up position, lift does not rise.) • Stuck compensator plunger

Repair flaws by lapping with oil stone.

• Clogged orifices or slanted orifices in pilot passage

Clean them with compressed air or a sharp point.

• Broken or fatigued relief valve spring

Replace spring.

• Bitten or stuck check valve plunger

Repair flaws by lapping with oil stone.

Broken flow-control valve • Stuck poppet

After disassembling and cleaning, repair flaws by lapping with oil stone.

81

TM TRACTOR SERVICE MANUAL

Problems Too low rising speed of lift

Lift lowers even when adjusting knob is closed fully with adjusting handle. (When engine is stopped.)

Causes

Countermeasures

Afore mentioned causes can also be possible.

Repair according to above instructions.

Too small a spool stroke in control valve

Inspect, readjust, or replace link mechanism if necessary.

Broken compensator spring in control valve

Replace spring.

Flow-control valve • Stuck poppet

After disassembling and cleaning, repair flaws by lapping with oil stone.

• Poor poppet seat

Replace valve.

• Poor O-ring

Replace.

Safety valve

Lift does not lower.

• Oil leaks due to poor sealing

Inspect and re-tighten each joint.

• Poor seating

Replace valve.

Flow-control valve knob is turned to the lock position.

Turn knob to down position.

Seized lift shaft

Apply grease and repair or replace bushings or bushings and shaft if necessary.

Stuck poppet of slow-return check valve

Lap after disassembly, cleaning, and repair flaws with oil stone.

Broken control valve • Stuck main spool

Lift lowering speed too slow

When hydraulic control lever is raised, relief valve beeps.

After disassembling and cleaning, repair flaws by lapping with oil stone or replace unit as an assembly.

Above mentioned causes can also be possible.

Repair or adjust according to instructions mentioned above.

Insufficiently lowered control lever

Lower lever sufficiently.

Excessively closed flow-control valve

Open valve sufficiently.

Maladjusted lever stopper check valve

Readjust lever stopper guide position.

Poor link mechanism

Inspect, readjust, repair, or replace link mechanism if necessary. 82

CHAPTER 9: HYDRAULIC SYSTEM

Problems Fluid overheating

Pump noise

Excessive wear, deflection or damage of pump

Causes

Countermeasures

Excessively high working pressure

Inspect and adjust.

Too high or low viscosity of working fluid

Replace with fluid of adequate viscosity.

Insufficient fluid

Maintain specified level by replenishing.

Too high internal friction of pump

Replace.

Partially clogged suction filter or suction piping.

Clean.

Air inhaled through suction piping connections

Inspect and re-tighten.

Air inhaled through intake pipe connection for pump

Inspect and re-tighten.

Loosened pump cover tightening bolts

Inspect and re-tighten.

Too rich oil viscosity

Replace with oil of specified viscosity.

Trapped foreign matter

Disassemble and clean.

Broken or worn pump parts

Inspect and replace defective parts.

Dirty fluid

Eliminate foreign matter and inspect filters.

Circuit pressure exceeds pump capacity

Adjust relief valve or replace if necessary.

Oilless operation due to insufficient oil quantity

Inspect transmission oil level and maintain specified oil level by replenishing. In either case, clean, and repair pump parts and replace damaged ones if necessary.

Oil leaks outside pump.

Broken or fatigued oil seal or O-ring

Replace.

Oil leaks from piping or joints

Poorly connected piping

Inspect, clean, and eliminate dust. Repair flaws with oil stone if necessary. Re-tighten.

Faulty O-rings

Replace.

Broken piping

Replace with a new one after washing clean related parts.

Faulty oil seal

Replace oil seal or bushing if necessary.

Oil leaks around lift arm.

83

TM TRACTOR SERVICE MANUAL

84

CHAPTER 10: HYDROSTATIC TRANSMISSION

CHAPTER 10. HYDROSTATIC TRANSMISSION 1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (27)

Case Port block Cylinder block Slant board Piston Valve plate Valve plate Pump shaft Motor shaft Trunnion shaft Bore plug Thrust bearing Ball bearing Needle bearing Bush Bush Sliding piece Cover Spring Spring Spring Valve 48

(28) Valve (30) Poppet (33) Plug (34) Plug (36) Snap ring (37) Snap ring (38) Snap ring (41) Spring holder (42) Oil seal (47) O-ring (48) O-ring (49) Gasket (50) Pin (51) Guide (52) Ping (53) Pin (54) Cradle bearing (55) Socket head bolt (61) Oil seal (62) Pin (64) Cover

34

34

48

(65) (66) (67) (69) (72) (74) (75) (76) (79) (80) (81) (82)

Ball bearing Ball bearing Oil seal Snap ring Washer Plug Spring Piston Shim A Shim B O-ring O-ring

55 51

53

50

54

50

50

18 38 67

55

65 27

20

50 69 3

20

10 5

41

66 72

13

17

71 64 4 14

6

80 74

15

61

38

8

80

42

74

38

76

76

81

81

37

36 19 82

9

11

79

79

75

75

33

36

42 15

47

33

21

47 21

48

34

34

48

37

7 2

30

28

Fig. 10-1 85

22

20

3

5

41

17

13

1

14

Fig. 10-2

Input shaft

86 Strainer

NEUTRAL POSITION

Cooler

Low pressure relief valve

Oil reservoir

Charge pump

Neutral

Filter

Output shaft

PTO shaft

Check valves

Neutral valves

High pressure relief valve

TM TRACTOR SERVICE MANUAL 2. OPERATING DIAGRAM OF HST

CHAPTER 10: HYDROSTATIC TRANSMISSION 3. FUNCTION 3.1. VARIABLE TYPE PUMP Nine pistons are housed in the cylinder block, which is connected to the engine and revolves as the engine does, while the slant board does not. When the slant board and shaft are perpendicular to each other, cylinder displacement volumes A and B do not vary, so no delivery or suction takes place. Spline

Piston A

Slant board

INPUT

Shaft B

Cylinder block

Fig. 10-3

If the slant board is angled by α degrees, displacement volumes A and B become different from each other: A > B. If the shaft turns in the direction of “Q,” delivery of fluid takes place as the displacement volume varies from B to A. Consequently if delivery and suction pipes are connected to the two arched ports respectively, a pump mechanism is formed. In this case, “Ps” is the suction port and “Pd” is the delivery port. α A

INPUT Q

B

Fig. 10-4 87

Pd

Ps

TM TRACTOR SERVICE MANUAL 3.2. FIXED TYPE MOTOR Nine pistons are housed in the cylinder block. A valve plate with two arched ports, Ps and Pd, is in contact with one end of the cylinder block. The ports are connected to the delivery pipe or the suction pipe respectively. When pressurized fluid is led into the cylinder block port Ps, the fluid pushes the piston, which causes the cylinder block to turn. This further causes the shaft to turn in the direction of “a” through the splinemeshed part between the cylinder block and shaft. Thus a motor mechanism is formed. Sland board

Piston

Cyinder block Valve plate

Shaft OUTPUT a

Pd

Fig. 10-5

3.4. VALVES

Ps

;; ;; ;; ;;;; ;; ;; ;; ;; ;;;;

LOW PRESSURE RELIEF VALVE AND SUCTION CHECK VALVE The low pressure relief valve works to maintain the specified charge pressure from the gear pump. Charge pressure replenishes the lowered flow rate of the charge fluid due to leaks by letting fluid into the case through the check valve. Excessive fluid is drained to the case through the low pressure relief valve. When the tractor is parked on a slope with the engine shut off, some reverse torque which is applied to the output shaft through the rear axle causes the high pressure side to leak. In this state, if no fluid were replenished to the closed circuit, air would become trapped inside the circuit, spoiling the braking effect of the circuit and allowing the tractor to start rolling down the slope. The suction check valve however prevents materialization of this no braking effect by replenishing the closed circuit.

Relief valve

Suction valve

The suction valve lets higher pressurized fluid automatically from the case into the low pressure circuit to maintain the specified pressure in the low pressure circuit.

Fig. 10-6

88

CHAPTER 10: HYDROSTATIC TRANSMISSION HIGH PRESSURE RELIEF VALVE A direct type both-direction relief valve is installed across the main passages A and B. When the pressure in the passage A is higher, surface “a” of the poppet receives pressure which pushes the poppet overcoming the force of the spring and opens the valve: to the left as shown in the figure. When the valve opens, the fluid in the passage A flows to the passage B. When the pressure in the passage B is higher, surface “b” of the poppet receives pressure which pushes the poppet overcoming the force of the spring and opens the valve: to the left as shown in the figure. When the valve opens, the fluid in the passage B flows to the passage A.

6

7

9

1

8

10

2

11

4

;; ;;; ;; ;; ;;; ;; ;; ;;;;;

3

5

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

a

A

b

B

• 1 mm increase in shimming thickness of shims (4) and (5) increases 40 to 50 kgf in spring force. Fig. 10-7

89

Body Poppet Nut Shim A Shim B O-ring O-ring O-ring Backup ring Backup ring Spring

TM TRACTOR SERVICE MANUAL NEUTRAL VALVE The neutral valve ensures the neutral position of the HST when the engine is started. While the angle of the slant board is small and delivery rate is low, the fluid flows through orifice “f” into the case (passage B: drain circuit) and the motor does not turn: thus the neutral position is maintained.

;;;;;;;; ;;;;;; ;; ;;;;;;;;

As the angle of the slant board becomes larger, flow rate through orifice “f” increases and pressure drop across the orifice also increases. When the pressure difference thus generated pushes the valve to the left and disconnects the passage A from the passage B, all flow in the passage A is directed to the motor. The motor starts turning.

A

B

f

Fig. 10-8

Note: Sometimes air is trapped in the orifice “f” after reassembling the HST unit. Consequently try repeating forward and reverse travel several times to make sure there is no hitching when the tractor starts travelling. CHECK VALVE The check valves are installed symmetrically in both sides across the charge passage “C.”

The check valve prevents the fluid from the high pressure passage “A” from flowing into the charge passage “C” and replenish the charge fluid in the passage “B.” The check valve in the high pressure side “A” closes and that in the low pressure side “B” is pushed open by the charge pressure and the check valve end in the high pressure side. • When the pressures in both the high and low pressure sides become high and both valves are closed, the trunnion is hard to operate. To overcome this state, the end of the valve in the high pressure side pushes that of the valve in the low pressure side to open the latter valve forcibly.

90

;; ; ; ;; ;;;;;; ;;;

CHAPTER 10: HYDROSTATIC TRANSMISSION

A

C

B

Fig. 10-9

4. DISASSEMBLY AND REASSEMBLY

This section describes the disassembly and reassembly procedures and precautions of the two-axle type HST unit model HVFD-21C21-M. 4.1. REQUIRED TOOLS Ref. .................................. Name ....................................................................................... Size and specified values 1 .............. Plastic hammer ...................................................................... Hammering light alloy parts: 0.3 kgf 2 .............. Screw driver (conventional) .................................................. Nominal 150 mm 3 .............. Snap ring pliers (for hole type) ............................................. H-2, H-3 4 .............. Snap ring pliers (for shaft type) ............................................ S-1, S-3 5 .............. Hexagonal spanner ................................................................ Face-to-face width::

6 .............. Torque wrench ...................................................................... Specified torque:

5 mm 6 mm 8 mm 10 mm 7.2 5.2 5.0 3.75 3.0 1.75

kgf·m kgf·m kgf·m kgf·m kgf·m kgf·m

7 .............. Hexagonal bits for torque wrench ......................................... Face-to-face width:

5 mm 6 mm 8 mm 10 mm

8 .............. Socket for torque wrench ...................................................... Face-to-face width:

26 mm

91

TM TRACTOR SERVICE MANUAL 4.2. PRESS-IN JIGS 30

0.01 0.02 Z øD1

3.2a

3.2a

Z 0.01

R 0.2

R 0.2

Oil seal press-in jig øD1 should be - 1 mm of the nominal diameter of the oil seal to be pressed in. 30 3.2a

0.01 0.02 Z

ø74

3.2a

Z 0.01

R 0.2

R 0.2

Bush (17) press-in jig 70

0.01 0.02 Z

3.2a

3.2a ø21

ø30

Z 0.01

R 0.2

R 0.2

R 0.2

R 0.2

Bearing press-in jig

30

0.01 0.02 Z

3.2a ø32

3.2a

Z 0.01

R 0.2

R 0.2

Bearing press-in jig

Fig. 10-10 92

CHAPTER 10: HYDROSTATIC TRANSMISSION c. Remove the oil seal (61) from the cover (19).

4.3. PRECAUTIONS FOR DISASSEMBLY

The oil seal should be removed using the jig and a hand press.

a. Clean the exterior of the casing completely first taking care to cover all ports to avoid the entry of dust. b. Drain the case of oil. c. Select a clean, dust-free place to work in to prevent dust affecting precision parts. d. Handle disassembled parts carefully to avoid damage like dents, scratches, etc. by dropping or striking them.

Hand press

19 ø26 mm

Jig

61

4.4. DISASSEMBLY (1) Removal of the cover

Fig. 10-13

a. Remove the four screws (M8) (71).

(2) Removal of the port block a. Remove the eight socket head bolts (55).

Fig. 10-11

b. Remove the cover (19) from the case (1) Fig. 10-14

b. Remove the port block (2). When the operation above has been done, take the following precautions. – Take care not to allow the valve plate to fall. – As the low pressure relief valve (28) and spring (22) become free, take care not to miss them. – Remember to remove the two knock pin when the port block is removed. Fig. 10-12 93

TM TRACTOR SERVICE MANUAL (3) Removal of the valve plate

(5) Removal of the cylinder block of the motor

Remove the valve plates (6) and (7).

Remove the following parts from the case (1): cylinder block (3), piston (5), and thrust bearing (13).

A valve plate is lifted up easily with a conventional screw driver inserted into one of the grooves. 28

22

6

7 Fig. 10-17

50

(6) Removal of the motor shaft a. Remove the snap ring (37) from the case (1) and then remove the bore plug (11).

Fig. 10-15

(4) Removal of the cylinder block of the pump and slant board

b. After removing the bore plug (11), remove the snap ring (11) installed behind the plug.

Remove the following parts from the case (1): cylinder block (3), piston (5), spring (20), spring holder (41), thrust bearing (13), slant board (4), cradle bearing (54), bush (16), and thrust bearing (18). 3

54

4

20

Fig. 10-18

41 5

13

18

c. Remove the shaft (9) from the case (1) by driving the shaft end A with a plastic hammer.

16

Fig. 10-16

94

CHAPTER 10: HYDROSTATIC TRANSMISSION

Shaft end A

Fig. 10-19 Fig. 10-21

(7) Removal of the pump shaft d. Pry off the oil seal (67) from outsides the case. a. Remove the snap ring (37) from the case (1). e. Remove the snap ring (38) from the case. b. Remove the shaft (8) from the case (1) by driving the shaft end A (port block side) with a plastic hammer.

Shaft end A

Fig. 10-22

(9) List of friction parts relevant to the pistons and cylinder block. Fig. 10-20 (4) Slant board (pump) (3) Cylinder block (5) Piston (6) Valve plate (pump) (7) Valve plate (motor) (13) Thrust bearing (20) Spring (41) Spring holder

(8) Removal of the trunnion shaft a. Remove the three screws (M8) (71). b. Remove the snap ring (69) and then remove the trunnion cover (64). The two knock pin (50) should also removed. c. Drive the outside end of the trunnion pin with a plastic hammer and remove it towards the inside of the case.

The friction parts for the pump and for the motor should be kept separately. 95

TM TRACTOR SERVICE MANUAL

13

4

6

3

20 41

7

5 Fig. 10-23

(10) Disassembly of the port block a. Disassembly of the relief valve Remove the relief valve (27). b. Disassembly of the check valve Remove the plug (PF3/8) (33), and then spring (21) and poppet (30). c. Removal of the neutral valve Remove the plug (PF 1/2) (74) and then remove the shims (79) and (80). After that, remove the spring (75) and piston assembly (76).

27

75 76 75 80 80

30

21

33

Fig. 10-24 96

CHAPTER 10: HYDROSTATIC TRANSMISSION 4.5. CRITERIA FOR REPLACING WORN PARTS Friction parts which have worn and exceed the specified limit should be replaced with a new one. No. 1

Name Piston

Inspection items

CRITERIA for correction or replacement

a. Friction surfaces of pistons and cylinder block

i. When flaws, dents, or damage are found on such surfaces, it is impossible to correct these corresponding parts, so replace them with new ones. ii. The maximum clearance of the piston in the cylinder bore is set at 0.025 mm when shipped. If the clearance exceeds 0.035 mm, replace the piston set with a new one.

b. Piston sphere

2

Cylinder block

When flaws, dents, or damage are found, replace the piston with a new one.

Friction surface against valve plate

i. When the stepped difference between the friction surface and non-friction surface is in a range of 0.005 to 0.010 mm, correct the difference by lapping. ii. When flaws, dents, or damage are found, correct them by lapping. iii. If 0.01 mm of lapping cannot correct the damage, replace the cylinder block with a new one.

3

Valve plate

Friction surface against cylinder block

same as above

4

Thrust bearing

Friction surface against piston

When pitting or flaking is found, replace the bearing with a new one.

97

TM TRACTOR SERVICE MANUAL 4.6. PRECAUTION BEFORE REASSEMBLY a. b. c. d. e. f.

Wash disassembled parts in fresh cleansing oil and blow them with clean compressed air. Handle the cleansed parts carefully to avoid damage such as dents, scratches, etc. All removed sealing parts should be discarded and replaced with new ones. All fasteners should be tightened to specified values. Apply lithium-based grease to oil seals and O-rings: especially to the lips of oil seals. As for the jigs for installing oil seals, bearings and bore plugs, refer to Fig. 10-10.

4.7. REASSEMBLY (1) Reassembly of the trunnion shaft

tape to protect the oil seal lips.

a. Install the snap ring (38) into the case (1). Install the oil seal (67). Pushed-in extent:

1.2 mm below case surface

Install the oil seal using the press-in jig and a hand press. 67

38

1.2 mm

Fig. 10-27

c. Insert the two straight pins (50) along with the respective washers (72) into the case (1).

1 Fig. 10-25

b. Insert the trunnion pin (10) from inside the case.

Fig. 10-28

d. Install the screws (71) and tighten them to the specified torque.

Fig. 10-26

Before inserting the trunnion pin the snap ring groove on the pin should be wrapped with paper

Tightening torque

98

1.75±0.17 kfg·m (face-to-face width: 5 mm)

17.5± 0.2 m m

CHAPTER 10: HYDROSTATIC TRANSMISSION

17

Fig. 10-29

1

e. Install the snap ring (69). Fig. 10-31

Fig. 10-32 shows the state after finishing the step above.

Fig. 10-30

Fig. 10-32

f. Press in the bush (17) into the case (1).

(2) Reassembly of the slant board

Distance between the bush end and the bottom of the bore.

a. Press in the bush (17) into the slant board (4). Distance between the bush end and the bottom of the bore.

Install the oil seal using the press-in jig and a hand press.

Install the oil seal using the press-in jig and a hand press.

99

TM TRACTOR SERVICE MANUAL b. Install the snap ring (36) on the shaft (8).

17.5±0.2 mm

4

17

Fig. 10-33

b. Install the guide assembly (51) on the slant board.

Fig. 10-36

c. Install the shaft assembly (8) into the case (1). d. Install the snap ring (37) into the case (1).

Fig. 10-34

(3) Reassembly of the pump shaft a. Press in the bearing (14) onto the shaft (8). When pressing in the bearing, use the jig to apply force only to the inner race of the bearing. Never apply stress to the balls and the outer race. Install the oil seal using the press-in jig and a hand press.

Fig. 10-37

(4) Reassembly of the motor shaft a. Press in the bearing (14) onto the shaft (9). When pressing in the bearing, use the jig to apply force only to the inner race of the bearing. Never apply stress to the balls and the outer race.

Fig. 10-35

100

CHAPTER 10: HYDROSTATIC TRANSMISSION Install the oil seal using the press-in jig and a hand press.

d. Install the snap ring (37) into the case.

Fig. 10-38

b. Install the snap ring (36) onto the shaft (9).

Fig. 10-41

(5) Reassembly of the cylinder block in the pump side a. Install the pin (53), cradle bearing (54), and bush (16) into the case. Fig. 10-39

c. Install the shaft assembly (9) into the case and install the snap ring (37). Then press in the bore plug (11). Press-in extent

5.2 ±0.2 mm from case end

Install the oil seal using the press-in jig and a hand press. 11 5.2 mm

Fig. 10-42

b. Install the sliding piece (18) on the trunnion pin (10) and then install the sliding piece so that it engages the slant board (4).

37 9

Fig. 10-40 101

TM TRACTOR SERVICE MANUAL (6) Reassembly of the cylinder block in the motor side a. Install the thrust bearing (13) into the case. Install the thrust bearing so that the races of different thickness (5.5 mm and 3 mm) are positioned as illustrated below.

5.5 m

m

13

3 mm

Fig. 10-43

c. Install the thrust bearing (13) into the slant board. Install the thrust bearing so that the races of different thickness (5.5 mm and 3 mm) are positioned as illustrated below.

Fig. 10-46

13

5.5 mm

3 mm

b. Install the assembled cylinder block onto the shaft (9).

Fig. 10-44

d. Install the assembled cylinder block onto the shaft (8).

Fig. 10-47

(7) Reassembly of the port block a. Press in the needle bearing (2) into the port block so that the bearing end projects 2.5 mm above the port block surface and the punched marking of Fig. 10-45 102

CHAPTER 10: HYDROSTATIC TRANSMISSION the manufacturer is in position A. Press-in extent

2.5 mm above port block surface

Install the oil seal using the press-in jig and a hand press. 15

A

Fig. 10-50

2.5 mm

2

• High pressure relief valve assembly (27). Tightening torque

3.75±0.3 kfg·m (face-to-face width: 26 mm)

Fig. 10-48

b. Press in the two oil seals (42). Press-in extent

3 mm below port block surface

27 20 c. Install the snap ring (38). Fig. 10-51

38

3 mm

• Neutral valve assembly {composed of the parts (76), (75), (79), (81), and (74)}

2

42

Tightening torque

15

Fig. 10-49

d. Install the valves as follows: • Low pressure relief valve (28) Apply grease to the valve ahead of time to prevent it from coming out. 103

Fig. 10-52

7.2±0.7 kfg·m (face-to-face width: 10 mm)

TM TRACTOR SERVICE MANUAL • Check valve assembly {composed of the parts (30), (21), (47), and (33)}

8. Preparation for final assembly of the case a. Install the straight pins (50) into the case (1).

Tightening torque

5.2±0.5 kfg·m (face-to-face width: 8 mm)

b. Apply thin coat of lithium-based grease to the surface contacting the gasket and apply the gasket (49) to the case (1).

Fig. 10-53

d. Install the valve plates (6) and (7).

Fig. 10-55

As the pump and the motor use different valve plates, install them properly as illustrated below.

Apply grease to the spring ahead of time to prevent it from falling out.

Valve plate (6) (pump side)

Surface of cylinder block side (brass coloured)

c. Set up the spring (22) in the case.

Valve plate (7) (motor side)

Fig. 10-56

– Take care not to allow the valve plates to fall.

Fig. 10-54

– Make certain that the piston assemblies are properly housed in the cylinder blocks.

Surface of cylinder block side (brass coloured)

104

CHAPTER 10: HYDROSTATIC TRANSMISSION – Make sure that the spring for the low pressure relief valve is properly positioned in the case. – Before installing the port block onto the pump and motor shafts, the splined parts of the shafts should be wrapped with paper tape to protect the lips of the oil seals in the port block.

Press-in extent

Flush with cover surface

Install the oil seal using the press-in jig and a hand press. 60

Fig. 10-59

19

b. Install the O-ring (82) and two straight pins (5) into the case.

Fig. 10-57

(10) Installation of the port block a. Tighten the eight socket-head bolts (55) to the specified torque. Fig. 10-60 Tightening torque

5 ±0.5 kgf·m (face-to-face width: 8 mm)

c. Install the assembled cover (19) on the case and secure it with the screws (71). The screws should be tightened to the specified torque. Tightening torque

Fig. 10-58

(11) Reassembly of the cover a. Press in the oil seal (61) into the cover (19) Fig. 10-61 105

1.75±0.17 kgf·m

TM TRACTOR SERVICE MANUAL (11) Comfirmation items after reassembly a. After reassembly, confirm that the shafts (8) and (9) turn smoothly using an adjustable wrench or the like.

Fig. 10-62

Fig. 10-63

b. Also confirm that the trunnion turns smoothly.

106

CHAPTER 10: HYDROSTATIC TRANSMISSION 4.8. LIST OF MAJOR COMPONENTS OF HST A 53

54

8

4 51

B

17 13

16

5

18

41 20

9

3 50 34 74

80

79

75 -1

33

-2

49 50

13 36 14

41

-3

-8

30

27

-1 -6

42

-9

1

59

3

-10

61 37

5

-7

21

82

38

20 47

50

65

2 76

71 19

C

10

15

48

81

17

6

58

7 15

C

-2 -11

38 -3

55

48

-4 -2

A -5

-1

14

-8

76

34

37

-3

75

Fig. 10-64

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (13) (14) (15) (16) (17) (18) (19)

80 21

47

Case Port block Cylinder block Slant board Piston Valve plate Valve plate Pump shaft Motor shaft Trunnion shaft Bore plug Thrust bearing Ball bearing Needle bearing Bush Bush Sliding piece Cover

50

74

22

Spring Spring Spring Valve Valve Poppet Plug Plug Snap ring Snap ring Snap ring Spring holder Oil seal O-ring O-ring Gasket Pin Guide

(52) Ping (53) Pin (54) Cradle bearing (55) Socket head bolt (58) Name plate (59) Drive screw (61) Oil seal (62) Pin (64) Cover (65) Ball bearing (66) Ball bearing (67) Oil seal (69) Snap ring (72) Washer (74) Plug (75) Spring (76) Piston 107

71

67 72 66

28

33

(20) (21) (22) (27) (28) (30) (33) (34) (36) (37) (38) (41) (42) (47) (48) (49) (50) (51)

64

50 81

36

B

79 30

11

69

(79) (80) (81) (82)

Shim A Shim B O-ring O-ring

37

TM TRACTOR SERVICE MANUAL 5. HST CONTROL PEDALS 5.1. DIMENSIONS OF PEDALS

Pla

y:

Brake pedal

mm

Bolt (A)

Neutral arm

St an da rd

(236 mm)

HST pedal

le ng th :

m m

0

:2

st

ju

Ad

16 2

Reverse speed limitter

Adjust: 19 mm

Standard length: 10

m

3 mm

m

(76 mm)

Trunnion pivot

(72 mm)

Bolt (B)

30

Rod (65)

Rod (M8 x 110)

Fig. 10-65 (Neutral position)

108

CHAPTER 10: HYDROSTATIC TRANSMISSION 5.2. NEUTRAL ADJUSTMENT ADJUSTMENT The neutral adjustment should be done after all parts have been reassembled and the engine is ready for starting. • Install the rod (M8×110) and rod (65) in accordance with the standard dimensions. Rod (M8x110) Rod (65)

• Under the conditions mentioned above, with the range shift in H, depress the HST forward pedal to start the tractor and then release the pedal to check to see that the wheels properly stop turning. • When neutral setting is not achieved, find the neutral position by turning the neutral arm.

162 mm 103 mm

• Neutral is adjusted by the set position of the neutral arm. Consequently the neutral arm should be temporarily set at the centre of both slots in the trunnion pivot with the bolt (A) and bolt (B).

• After neutral adjustment, make sure that the heights of both HST peals are the same. If they are not, correct by adjusting both rods.

CONFIRMATION ITEMS AFTER ADJUSTMENT Pedal operation

While engine is stopped: • Depressforward and reverse pedals

• Pedals should depress smoothly. • Pedals should return smoothly when they are released.

• Confirm reverse speed

• Reverse speed should be set at 75% of forward speed. (Limitter height: 20 mm)

While engine is running at 2000 rpm or higher speed: • Depress forward and reverse pedals Neutral

While engine is running at full throttle: • With HST at neutral, check neutrality at each range speed.

Stopping

• Acceleration should be smooth.

While engine is running at full throttle: • With range shift in H and at full throttle, release the pedal when tractor travels more than 5 m after having reached maximum speed.

109

Tractor should not start travelling. • Stopping distance without brakes Less than 8 m without any excessive shock

TM TRACTOR SERVICE MANUAL 6. TROUBLESHOOTING Problems 1. The output shaft does not turn with the control lever tilted in either direction.

Causes

Countermeasures

• Defective HST pump or motor

If the trunnion shaft is positively activated, replace the HST unit with a new one.

• A defective check valve

Replace with a new one.

• Defective unloading valve

Measure the pressures in the high and low pressure circuits and then disassemble and wash the valve and reassemble it. Adjust it if necessary.

2. The output shaft does not stop with the control lever shifted in the neutral position.

• Worn trunnion lever and linking parts

Replace worn parts with new ones.

3. Insufficient output shaft speed

• High pressure oil is leaking from the pump or motor due to wearing.

Replace the HST unit with a new one.

• Defective check valve seat

Replace with a new part.

• Unloading valve is stuck in working position.

Disassemble and wash the valve and reassemble it. Adjust it if necessary.

• Due to broken oil seals or O-rings

Replace defective parts with new ones. Oil seals should be installed taking care not to damage their lips.

• Clogged air breather in the oil reservoir cap causes temperature rise and resulted thermal expansion of the oil in the reservoir, which causes internal pressure rise and leads to oil seal damage.

Clean the air breather. If it is badly clogged, replace the cap with a new one. Replace a damaged oil seal with a new one.

4. Oil leaking through shafts and sealing parts

110

CHAPTER 11: POWER-ASSISTED STEERING SYSTEM

CHAPTER 11. POWER-ASSISTED STEERING SYSTEM §1. CONSTRUCTION The steering unit (mini-orbit roll) controls hydraulic power and activates the front wheels directly through the power steering cylinder. It features minimized vibration at the steering wheel because vibration of the front wheels is not directly transmitted to the steering wheel. Hydraulic fluid divided into the system through the flow-divider valve is controlled by the orbit roll to activate the cylinder. In accordance with the operation of the steering wheel, the rotary valve and metering device built in the orbit roll controls the direction and flow rate of the hydraulic fluid and activates the power-assisted steering system works.

Power-steering cylinder

L

R

Steering wheel

Mini-orbit roll

Flow-divider P

T

To main circuit Main pump

Fig. 11-1 111

TM TRACTOR SERVICE MANUAL §2. MAJOR COMPONENT

Metal (U) and flow-divider assembly

Delivery pipe (type U)

Tank hose

To suction pipe (type U) [To suction filter of HST (type HU)]

R

T L

L From metal (U)

R

P

R

L

Cylinder

Delivery pipe assembly

Fig. 11-2 112

Mini-orbit roll assembly

CHAPTER 11: POWER-ASSISTED STEERING SYSTEM §3. INTEGRAL ORBIT ROLL 1. COMPONENTS

1

Bolts

6

19

• Adjusting plug

(1)

2 3

Retainer bolt assembly • Retainer bolt

1 (1)

20 21

• O-ring • Spring

(1) (1)

4

• Spring pin

(1)

22

• Poppet

(1)

5

Ball

1

23

• Collar

(1)

6

End cap

1

24

Bearing races

2

7

Gerotor

1

25

Thrust needle bearing

1

10 11

Spacer plate Drive

1 1

26 27

Seal Oil seal

1 1

12

Control valve assembly

1

28

Dust seal

1

13

• Housing

(1)

29

Retaining ring

1

14

• Sleeve

(1)

30

Seal bushing

1

15

• Spool

(1)

31

O-rings

3

16 17

• Pin • Centring springs

(1) (4)

33 34

Seal O-ring

1 1

18

• Flat springs

(2)

Fig. 11-3 113

TM TRACTOR SERVICE MANUAL 2. DISASSEMBLY • When repairing the steering unit, a clean workplace is essential. • Before disconnecting piping, clean around the ports of the unit. • Remove dust accumulating around the joint of the unit with a wire brush. Note: The unit should be held in a vice during operation, although almost of all the illustrations below for easy viewing do not show a vice. 2.1. DISASSEMBLY OF ROTOR SIDE

d. Remove O-ring (31) from end cap (6).

a. Hold the unit with the rotor side turned upward in the vice, inserting copper plates or the like between the unit and vice, and lightly tighten the unit. Overtightening may damage the unit.

e. Remove seal (33) and O-ring (34) from gerotor (7). f. Remove gerotor (7) taking care not to let the star rotor fall out. g. Remove O-ring (31) from the gerotor. O-ring

Gerotor

Fig. 11-4

Fig. 11-6

b. Remove the six bolts (1) and the retainer bolt assembly (2) using a 5/16" socket wrench.

h. Remove drive (11). i. Remove spacer plate (10) and then remove Oring (31) from housing (13).

c. Remove the end cap.

Housing

Bolt End cap

Spacer plate

O-ring O-ring

Fig. 11-5

Fig. 11-7 114

Driver

CHAPTER 11: POWER-ASSISTED STEERING SYSTEM j. Turn the housing upside down and remove ball (5) taking care not to allow it to fall into a groove, a side hole, etc.

d. Remove dust seal (28) with a screwdriver taking care not to damage the seal bushing. e. Remove two bearing races (24) and thrust needle bearing (25).

2.2 DISASSEMBLY OF CONTROL SIDE a. Remove housing (13) from the vice and place it on cloth. Pry the end of retaining ring (29) out of the groove using a small screwdriver and remove the ring from the housing.

Bearing race Thrust needle bearing

Bearing race

Fig. 11-11

f. Pull off spool (15) and sleeve (14) from housing (13). Note: Pull off the spool and sleeve assembly in the opposite direction of the flange while turning it right and left. Fig. 11-8

b. Turn spool (15) and sleeve (14) so that pin (16) becomes level. Then push the spool and sleeve to remove seal bushing (30).

Fig. 11-12

g. Pull off pin (16).

Seal bushing

Fig. 11-9

Pin

c. Remove oil seal (27) from seal bushing (30). Fig. 11-13

Oil seal Dust seal

h. Push out spool (15) a little and push off centring springs (17) and flat springs (18).

Seal bushing

Fig. 11-10 115

TM TRACTOR SERVICE MANUAL Refrain from drying them with cloth or paper, as lint and paper waste can contaminate the hydraulic system, which will lead to system trouble. Never file parts or polish them with coarse sandpaper. Note: Apply fresh grease to O-rings ahead of time.

Fig. 11-14

i. Pull off spool (15) out of sleeve (14).

We recommend used O-rings and seals be replaced with new ones whenever possible.

Note: Pull off the spool in the direction shown by the arrow head while turning it right and left.

3. RE-ASSEMBLY 3.1. RE-ASSEMBLY OF CONTROL SIDE a. Insert the spool (15) into sleeve (14) while turning the spool slowly. Control sleeve Spring groove

Spring groove

Fig. 11-15

j. Remove O-ring (26) from housing (13). Fig. 11-17 O-ring

Control spool

Note: Make sure that the spool turns smoothly by holding the spool’s splined part. b. Align the spring grooves of the spool and sleeve and insert centring springs (17) and flat springs (18) using a jig #600057. Set the spring ends flush with the sleeve circumference.

Relief valve

Fig. 11-16

Note: Never adjust the relief valve. When it is defective, replace control valve assembly (12). 2.3. INSPECTION Check the contact surfaces of all components. Replace defective ones. Wash all metal parts in clean solvent and dry them with pressurized air. 116

Fig. 11-18

CHAPTER 11: POWER-ASSISTED STEERING SYSTEM Note: Set the four centring springs (17) and the two flat springs (18) together with the cut-away parts turned downward.

Thrust needle bearing

Bearing races

O-ring

c. Insert pin (15) into the holes of the sleeve and spool and set both pin ends flush with the circumference of the sleeve.

Pin

Fig. 11-21

g. Set dust seal (28) into seal bushing (30). Fig. 11-19

d. Insert the assembly of spool (15) and sleeve (14) from the back of housing (13).

Dust seal

Retaining ring Oil seal

Seal bushing

Fig. 11-22 Fig. 11-20

Note: Insert the spool/sleeve assembly carefully without jamming it, while turning it right and left. Make sure that the assembly turns smoothly.

Note: Install the dust seal with the flat surface turned toward the bushing. h. Push oil seal (27) into seal bushing (30) securely by pushing it with your fingers.

e. Place housing (13) on a clean level surface and insert O-ring (26).

i. Insert seal bushing (3) into spool (15) while turning the bushing.

f. Insert the two bearing races (24) and thrust needle bearing (25).

Note: Drive the bushing into the spool securely using a plastic hammer.

Note: The thrust needle bearing should be sandwiched with the bearing races.

117

j. Insert retaining ring (29) into the groove of housing (13).

TM TRACTOR SERVICE MANUAL Screw driver blade

c. Place spacer plate (10) as shown and align the oil holes.

Dust seal Retaining ring

Note: The bolt hole and oil holes are different.

Seal bushing X-ring seal

d. Insert drive (11). O-ring

Port surface Drive Pin should be parallel to port surface.

Fig. 11-23

Note: Push open the retaining ring with a screwdriver so that it is seated completely and fully expanded in the groove. 3.2. RE-ASSEMBLY OF GEROTOR SIDE a. Insert ball (5) into the bolt hole and make sure that the ball is seated in the proper position.

Pin

Fig. 11-26

Note: Provide a guide line on the drive end face parallel with the pin axis with a felt pen for correct installation. e. Insert O-ring (31) on gerotor (7).

Fig. 11-24

Note: Make sure that the spool/sleeve assembly is deformed a little when the ball is installed. b. Insert O-ring (31) into housing (13).

Fig. 11-27

f. Install O-ring (34) and seal (33) on gerotor (7). g. A: line from a bottom land of the rotor to the opposite bottom land B: guide line for the pin axis C: Pin axis D: Port surface A, B, and C should be parallel to each other.

Fig. 11-25 118

CHAPTER 11: POWER-ASSISTED STEERING SYSTEM Bottom lands of star rotor

k. Apply oil to the threads of retainer bolt assembly (2) and bolts (1) ahead of time. Then insert them into end cap (6)

A

B Apply a line on drive end surface.

4

6

C D

1

2 3

7 5

Pin

Port face

Fig. 11-28 Fig. 11-30

h. Turn O-ring (31) on gerotor (7) toward spacer plate (10) and install the gerotor on the drive by aligning the bottom land to bottom land line of the gerotor with the guide line on the drive. Note: When the bolt holes of the gerotor and placer plate do not align to each other, turn the gerotor housing alone. i. Insert O-ring (31) on end cap (6). j. Place end cap (6) on gerotor (7) and align bolt holes. Screw End cap O-ring

Fig. 11-29 119

Note: Make sure that there is no pinching of the O-ring then tighten the bolts in the sequence mentioned above to the specified torque. Temporary tightening torque

1.1 kgf·m

Final tightening torque

2.1 kgf·m

Note: Fit a handle to the spool and make sure that the spool turns smoothly.

TM TRACTOR SERVICE MANUAL §4. TROUBLESHOOTING Problems Steering wheel is heavy to turn.

Presumable causes 1. Orbit roll a. Off-set column centre

b. Seized spool/sleeve assembly due to trapped foreign matter c. Back pressure too high d. Seven end cap bolts too tight 2. a. b. c. d.

Pump It is not operating. Worn or damaged pump It is rotating in reverse. Insufficient pump delivery

Countermeasure

Repair. (If bolts which tighten column on orbit roll are loosended and make steering wheel lighter to turn, the cause of trouble is an off-set centre of column.) Replace assembly. Correct. Correct.

Operate it. Replace. Correct. Correct pressure and flow rate.

3. Relief valve a. Defective b. Too low set pressure

Replace. Correct regulation pressure.

4. Flow-divider a. Seized piston

Disassemble, clean, reassemble.

5. Cylinder a. Insufficient pressure receiving area Replace with proper cylinder. 6. a. b. c.

Priority valve (load sensing) Seized spool Clogged damping orifice Insufficient control pressure of spring d. Low regulation pressure of relief valve Steering wheel does not return to neutral position when it is released or it has a tendency to turn by itself.

1. a. b. c.

Orbit roll Seized spool/sleeve assembly Back pressure too high Off-set centre from that of column

Cylinder does not react smoothly to turning of steering wheel or not at all.

1. Orbit roll a. Trapped air within gerotor 2. Pump a. Insufficient delivery against steering system requirement

120

Disassemble, clean, reassemble. Disassemble, clean, reassemble. Replace with proper spring. Correct regulation pressure.

Replace. Correct. Correct.

Bleed.

Increase delivery rate.

CHAPTER 11: POWER-ASSISTED STEERING SYSTEM

Problems

Steering wheel operates in reverse.

Oil leakage 1. Through shafts (circumference of splined part)

Presumable causes 3. Cylinder a. Trapped air b. Broken piston seal

Bleed. Replace.

4. Overload/anti-cavity valves a. Leaking

Replace valves.

1. Orbit roll a. Incorrect valve timing

Correct.

2. Piping a. Mistake in port connection

Correct.

Worn oil seal (X-ring) a. Contaminated working fluid b. Back pressure too high

2. Contact surfaces between housing, spacer plate, gerotor, and end cap

Countermeasures

Provide proper countermeasure to prevent oil contamination Correct.

Broken O-rings a. Pinched rings

121

Replace.

TM TRACTOR SERVICE MANUAL

122

CHAPTER 12: ELECTRICAL SYSTEM

CHAPTER 12. ELECTRICAL SYSTEM 1. FUSES, FUSIBLE LINKS AND SLOW-BLOW FUSE • A: the main fuse box is located inside the right-hand fan cover. • B and D: A green fusible link is located respectively. • C: 40-amp. slow-blow in line fuse is located. (a) (b) (c) (d) (e) (f) (g)

Headlamps Front turn signal lamps Front small lamps Stop lamps Tail lamps Rear turn signal lamps License plate lamp

12V 12V 12V 12V 12V 12V 12V

45/40W 21W 5W 21W 10W 12W 5W

1

5A 5A

A

3

10A

4

20A

6

5A

5

10A

7

20A

10

5A

11

5A

cb f e d

a

g E 7-pin socket (OPT)

a B

D

d e f

C cb 1 2

1 2 3 4

3 4

Ref. Amperage Circuit No. Function 1 5A 1 PTO 2 5A — — 3 10A 3 Stop lamps 4 20A 4 Direction indicator 5 5A 6 Engine stop relay 6 10A 5 Cab (AC) 7 20A 7 Warning flash lights 8 5A 10 Tail lamps (LH) 9 5A 11 Tail lamps (RH) * Work light (rear) is an accessory.

Left Right Left Right

Fig. 12-1 123

TM TRACTOR SERVICE MANUAL

MID-PTO SWITCH

2. SAFETY SYSTEM WIRING DIAGRAM 0.85 LY 0.85 RG 0.85 LY

REAR PTO SWITCH

301 :0.5 BW 700 :0.5 W

700 :0.5 W 202 :0.5 R

SAFETY SWITCH

202 :0.5 R

RW B BY BY

31 :2 32 :2

BY LR

30

R

SLOW-BLOW FUSE (50A)

14 :3

B

S

Fig. 12-2

30 B

25 :3

R

STARTER MOTOR

BY 13 :2

BATTERY

50

BY LR R

BR

2 2 2

MAIN SWITCH

FUSE (5A)

302 :0.5 99G :0.5 13 :2 31 :2

RELAY

302 :0.5 RW

20 B

124

CHAPTER 12: ELECTRICAL SYSTEM 3. TROUBLESHOOTING 3.1. BATTERY Inspection items

Problems

Countermeasures

a. Exterior parts Container, cover, and sealing parts

Fluid leaks due to cracks

Repair or replace battery.

Vent plugs

Corrosion or breakage

Repair or replace battery.

As excessive resistance between terminal post and clamp brings about a voltage drop and results in faulty starter operation. Measure voltage drop with a voltmeter while turning starter with fuel shut off.

When voltmeter reading is more than 0.2 to 0.3, it is excessive. Clean post and clamp, and tighten them securely. Pole plates (only when housed in a transparent casing)

Whitened (sulphated) Positive plates should be dark brown and negative ones should be grey. Positive plate grids are broken.

Replace battery.

Deposit (only when housed in a transparent casing)

Accumulated up to lower ends of pole plates, shorting them

Perform charging test and judge battery condition.

b. Voltage

Total voltage is less than 12V. battery condition.

Perform charging test and judge

c. Electrolyte

Pole plates appear above electrolyte. battery condition by applying charging test.

Maintain electrolyte level and judge

d. Specific gravity of electrolyte

Specific gravity of some cells is less than 1.200 and variation among cells is over 0.05.

Perform charging test and judge battery condition.

3.2. METERS, GAUGES, AND SWITCHES a. Tacho/hourmeter and meter cable Pointer does not work.

Faulty meter assembly Broken meter cable

125

Replace meter assembly. Replace cable assembly.

TM TRACTOR SERVICE MANUAL

Inspection items Pointer moves but is very unstable.

Problems

Countermeasures

Faulty meter Poorly lubricated meter cable Meter cable is being broken.

Replace. Lubricate. Replace.

b. Fuel gauge and sensor unit (switch) Pointer does not move.

Faulty pointer movement

Open circuit Faulty sensor assembly Faulty gauge assembly Faulty battery Faulty earth

Repair. Replace sensor assembly. Replace gauge assembly. Recharge or take necessary countermeasures. Repair.

Poorly contacted terminals Faulty sensor assembly

Repair. Replace sensor assembly.

Faulty gauge assembly

Replace gauge assembly.

c. Turn signal and hazard warning switch Both lamps do not flash.

Open circuit Burnt-out bulbs Faulty tun signal switch Faulty battery Faulty flasher unit

Repair Replace. Replace switch assembly. Recharge or take necessary countermeasures. Replace unit.

d. Head lamp switch Lamps do not light up as indicated when switch is turned to each position (Small, Low, High)

Burnt-out bulbs Open circuit Faulty battery Faulty battery grounding Faulty starter switch Faulty light switch Blown-out fuse

Replace. Repair. Recharge or take necessary countermeasures. Repair. Replace switch assembly. Replace switch assembly. Replace.

Head lamps are dim with switch turned to Low or High.

Faulty battery capacity Poorly contacted terminals Faulty bulbs Faulty light switch

Recharge. Repair. Replace. Replace switch assembly.

Faulty battery

Recharge or take necessary countermeasures. Repair. Replace. Replace switch assembly. Replace.

e. Starter switch Glow plugs and heater signal do not heat up red.

Faulty circuit wiring Burnt-out heater signal Faulty starter switch Faulty glow plugs

126

CHAPTER 12: ELECTRICAL SYSTEM

Inspection items Starter does not work when starter switch is turned to Start.

Problems

Countermeasures

Faulty battery Faulty circuit wiring Poorly contacted terminals Faulty starter assembly Faulty horn relay Faulty safety switch

Recharge or take necessary countermeasures. Repair. Repair. Refer to Engine manual. Replace. Replace.

Faulty horn switch Faulty engine oil viscosity Faulty horn Poorly contacted terminals Faulty horn relay

Replace switch assembly. Replace with proper viscosity oil. Replace horn assembly. Repair. Replace relay.

Low engine oil level Faulty engine oil viscosity Clogged oil filter element Faulty oil pressure switch Broken oil pump

Replenish oil level. Replace with proper viscosity oil. Replace element. Replace switch assembly. Replace pump assembly.

Faulty wiring Faulty alternator Faulty battery

Repair. Repair or replace alternator assembly. Recharge or take necessary countermeasures. Retighten or replace belt.

f. Horn and horn switch Horn does not sound.

g. Oil pressure pilot light Light is lit during operation

h. Charge pilot light Light is lit during operation.

Loose fan belt

127

TM TRACTOR SERVICE MANUAL

128

CHAPTER 13: SERVICING DATA

CHAPTER 13. SERVICING DATA 1. SPECIFICATIONS & CAPACITIES Engine Oil Use engine oil of the appropriate SAE viscosity. Oil must meet or exceed; MIL-L-2104C requirements, API Service “CD”. TM215 TM217 Capacity (litres) ............................................................................................ 2.7 .................................................... 2.7 Recommended Viscosity: 78 °F (25 °C) and Above ......................................................... SAE 30 W, 10 W - 30 ...................... SAE 30 W, 10 W - 30 32° - 78 °F (0° - 25 °C) ............................................................ SAE 20 W, 10 W - 30 ...................... SAE 20 W, 10 W - 30 Below 32 °F (0 °C) .................................................................. SAE 10 W, 10 W - 30 ...................... SAE 10 W, 10 W - 30 Recommended Change Intervals: Initial Oil and Filter Change ............................................................... 50 hours ............................................ 50 hours Oil and Filter Change, Thereafter ................................................ Every 150 hours .............................. Every 150 hours Engine Coolant Freezing Protection (Original factory Fill) .................................................. -34 °C (-30 °F) ................................ -34 °C (-30 °F) Recommended Coolant ................................................................ 50/50 mixture ethylene .................... 50/50 mixture ethylene glycol and water glycol and water System Capacity (litres) ............................................................................... 5.1 .................................................... 5.1 Fuel Tank Capacity (litres) ........................................................................................... 13.5 .................................................. 13.5 Fuel recommended, Above 4 °C (39 °F) ............................................................................ No. 2 or No. 2-D .............................. No. 2 or No. 2-D Fuel Recommended, Below 4 °C (39 °F) ............................................................................ No. 1 or No. 1-D .............................. No. 1 or No. 1-D Transmission & Differential Housing (Including Hydraulic System) Capacity (litres) F ............................................................................................................. 13.5 .................................................. 13.5 FU (with power-assisted steering) ........................................................... — .................................................... 14.0 FMU (with Mid-mount PTO and power-assisted steering) ................... 14.0 .................................................. 14.0 FHU (with HST and power-assisted steering) ....................................... 15.0 .................................................. 15.0 FHMU (with HST Mid-mount PTO and power-assisted steering) ........ 15.0 .................................................. 15.0 Recommended Lubricant .................................................................. Shell DONAX TD ............................ Shell DONAX TD or equivalent or equivalent Recommended Change Interval .......................................................... First 50 hours ................................... First 50 hours every 200 hours thereafter every 200 hours thereafter Front Axle Capacity (Common Reservoir) (litres) ......................................................... 2.7 .................................................... 2.7 Recommended Change Lubricant ....................................................... SAE 80 GL-4 ................................... SAE 80 GL-4 Recommended Change Interval ........................................................ Every 300 hours .............................. Every 300 hours Grease Fittings Greasing Interval (All Fittings) .......................................................... Every 50 hours ................................ Every 50 hours Recommended Grease ............................................................... Lithium-base grease No. 2 ............. Lithium-base grease No. 2 NOTE: Change intervals stated above are for normal usage. Due to adverse operating conditions that may be experienced (extremely dusty or muddy), change intervals may need to be more frequent. 129

TM TRACTOR SERVICE MANUAL 2. LUBRICATION/FILL POINTS General layout of lubrication, fill and drain locations on the tractor:

Ref.

Description:

Type:

1

Fuel Tank

Diesel Fuel

2

Radiator

Engine Coolant

3

Engine

Engine Oil

4

Transmission Case

Hydraulic Oil

5

Front Axle

Hydraulic Oil

6

Axle Pivots

Grease

7

Clutch Shaft

Grease

8

Brake pivots

Grease

9

Drag Rod & Tie-rod

Grease

10

Steering Gearbox

Hydraulic Oil

11

Knuckle Arm

Grease

HST models

9

11

5

8

9

4

6 1

8 10

Transmission oil level

7 2

9

3

9 Engine oil level

9

Greasing point Oil filler Oil drain Level point

11

Radiator filler Radiator drain

Fig. 13-1 130

CHAPTER 13: SERVICING DATA 3. PERIODIC MAINTENANCE SCHEDULE Recommended Interval, Each: Day

Item To

Action

Check

Required

50 hr 100 hr 200 hr 300 hr Year

●

All controls, switches

Inspect and repair

●

All fasteners, hardware

Check and tighten

●

Hoses, fan belt, wiring

Inspect and repair

Grease fittings

Lubricate

Engine oil level

Replace

Engine oil & filter

Check and replenish

Transmission oil level

Replace and clean

● ● (*)

●

● (*)

●

Transmission oil & screen

Replace cartridge

(*)

●

Hydrostatic oil filter

Replace cartridge

Front axle oil level

Replace

Front axle oil

Clean of debris

Air screens & radiator

Check and replenish

Radiator coolant

Drain, flush & replace

●

Fan belt tension

Check and adjust

●

Air cleaner dust ejector

Clean

Air cleaner elements

Inspect, clean or replace

●

Fuel tank level

Fill

●

Fuel filter sediment bowl

Inspect and clean

Fuel filter element

Replace and bleed

●

Battery & cables

Check, clean & tighten

●

Battery electrolyte level

Check and replenish

●

Lights, flashers & horn

Check and repair

●

Clutch pedal free-play

Check and adjust

●

Brake adjustment & balance

Check and adjust

●

Tyre pressure & condition

Check and adjust

●

Wheel bolt torque

Check and adjust

●

Steering free-play

Check and repair

Front axle end-float

Check and adjust

Clutch housing leaks

Remove plug & check

● ● ● ●

●

●

● ●

Items marked (*) indicate initial service interval only. Subsequent (later) intervals marked “●”. Intervals above are for normal usage. Severe operating conditions (wet, dusty, etc.), or when previous servicing has indicated need for more frequent action, intervals may need to be shortened. 131

TM TRACTOR SERVICE MANUAL 4. SERVICE STANDARDS (mm)

Part names and inspection items

Tractor type

Standard value for reassembly

Usable limits

Service instruction and remarks

MT/HST

7.8±0.3

6.3

Replace.

1.0

0.2 or more

Replace.

Rotational play of hub spline

0.3

Replace.

Deviation

Surface evenness

0.4

Replace.

Lateral run-out

1.0

Vertical run-out

1.0

1. CLUTCH AND RELATED PARTS Clutch disc Thickness Rivet depression

Damper spring play

1.5

Clutch cover Flatness of place surface

less than 0.05

0.5

Diaphragm spring tension

415 kgf

340 kgf

Tightening torque of clutch cover

1.5 – 1.2 kgf·m

Clutch pedal play

20 – 30

Measure at pedal top. Adjust with clutch wire.

2. BRAKE AND RELATED PARTS Brake shoe thickness

2.2

Brake drum

Measure in the middle.

abnormal wear or cracks

Brake pedal play

30±5

Parking brake lever play

Measure at pedal top.

one to two notches

Adjust.

3. TRANSMISSION AND RELATED PARTS Backlash between drive pinion and ring gear

0.1 – 0.2

Adjust with 0.1 or 0.2 mm shim.

Backlash between dif-side gear and dif-pinion 4. STEERING SYSTEM AND 4WD SYSTEM Free play of steering wheel (on circumference) Front wheel steering angles

Manual

25 – 30

50

Power-assisted

30 or less

50

55±1° (inner)

Toe-in Fore-and-aft play of front axle

Adjust with adjusting bolt.

2–6

Adjust.

0 – 0.2

Adjust.

132

CHAPTER 13: SERVICING DATA

(mm)

Part names and inspection items

Tractor type

Standard value for reassembly

Usable limits

Service instruction and remarks

Front axle bush play

0.2

Replace.

Final case bush play

0.2

Replace.

5. HYDRAULIC SYSTEM Safety valve assembly (Tightening torque)

8.5 – 10.0 kfg·m (61.5 – 72.3 ft·lbs))

Control valve bolts (Tightening torque)

1.3 – 1.8 kgf·m (9.4 – 13.0 ft·lbs)

Relief set pressure Lift capacity (at lower link end)

Cracking pressure: 120 kgf/cm2 480 kgf

Lift arm top clearance Position control lever stopper

3–5 Set stopper just before relief valve works in up position.

6. ENGINE ACCESSORIES Antifreeze density of engine coolant Fan belt tension

Operation force of throttle lever

Should be determined in accordance with local conditions 8 – 10

Depress belt at a point between fan pulley and alternator pulley.

6 – 8 kgf

Adjust.

7. POWER-ASSISTED STEERING SYSTEM (INTEGRAL ORBIT ROLL) Cylinder

Dimension between rod ends: 355±2

Adjust

8. GEAR PUMP Gear contacting trace around intake port

Less than 1/2 of gear housing bore diameter

Contact trace width

0.05 or less

Clearance between metal bore and gear shaft

0.07 – 0.08

Clearance between metal shaft diameter and metal bore

0.015 – 0.025

Clearance between metals

0.010 – 0.020

133

0.1

Replace pump body.

TM TRACTOR SERVICE MANUAL

(mm)

Part names and inspection items

Tractor type

Standard value for reassembly

Gear offset projection against metal diameter

0.005 – 0.015

Pump cover tightening torque

3.0 – 3.5 kgf·m

Gear pump starting torque

Usable limits

Service instruction and remarks

0.3 kfg·m

9. MANUAL STEERING SYSTEM Starting torque of ball/nut worm

0.5 kgf·m

Replace.

Ball/nut thrust clearance

0.1

Replace.

Clearance between T-groove in sector shaft and shim

0.15

Replace.

Steering shaft starting torque

1.5 – 8 kgf·m

Rear cover tightening torque

16 – 20 kgf·m

Side cover tightening torque

1.7 – 2.8 kgf·m

Pitman arm tightening torque

14 – 18 kgf·m

Pitman arm end play Adjusting screw lock nut tightening torque Sector shaft working angles

0.5 or less

Adjust.

2.0 – 3.0 kgf·m

Adjust.

43° each

10. ELECTRICAL ACCESSORIES Electrolyte capacity (Specific gravity)

1.240 – 1.260

Terminal voltage

12V

134

10.8V

Charge.

CHAPTER 13: SERVICING DATA 4. SPECIFIED TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS

Size

4T bolts and nuts

7T bolts and nuts

7/9 bolts and nuts kgf·cm (N·m)

M5

2.9 – 3.9 (30 – 40)

4.9 – 5.9 (50 – 60)

5.9 – 6.9 (60 – 70)

M6

5.9 – 7.8 (60 – 80)

8.8 – 10.8 (90 – 110)

9.8 – 12.8 (100 – 130)

M8

12.8 – 17.7 (130 – 180)

19.6 – 26.5 (200 – 270)

24.5 – 34.3 (250 – 350)

M10

19.6 – 29.4 (200 – 300)

44 – 54 (450 – 550)

54 – 69 (550 – 700)

M12

49 – 59 (500 – 600)

74 – 88 (750 – 900)

88 – 108 (900 – 1100)

M14

69 – 78 (700 – 800)

98 – 118 (1000 – 1200)

128 – 147 (1300 – 1500)

M16

98 – 118 (1000 – 1200)

118 – 137 (1200 – 1400)

157 – 177 (1600 – 1800)

M18

118 – 137 (1200 – 1400)

157 – 177 (1600 – 1800)

196 – 235 (2000 – 2400)

M20

147 – 167 (1500 – 1700)

186 – 206 (1900 – 2100)

235 – 255 (2400 – 2600)

135

TM TRACTOR SERVICE MANUAL

136

TM TRACTOR SERVICE MANUAL

APPENDIX

APPENDIX Install gears in correct direction, i.e. chamfered sides facing rearward.

1. PRECAUTIONS FOR REASSEMBLY

Press in roll pin (6 x 16).

After assembly, clearance between gear (17T–24T) and gear (15T–34T) should be about 0.4 mm. They should not follow each other.

Install thrust collar with oil groove facing toward NRB.

1.1. MECHANICAL TRANSMISSION

Apply adhesive to surface contacting change metal. Apply adhesive to contacting surfaces.

Apply adhesive to surface contacting cylinder case.

As drive pinion and ring gear make a pair, they should have the same punched marking.

Apply grease to oil seals. Install oil seals in correct direction.

Apply grease to O-ring. It should not be damaged when installed.

Apply grease.

Backlash: Bac klash: 0.1 – 0.2 mm, which is adjusted by y shimming dif-metal.

Apply adheseive to surface contacting oil seal.

Apply adhesive to contacting surfaces. Install gear in correct direction, i.e. clutch claws facing forward. Insatall gear in correct direction.

Install thrust collar with oil groove facing NRB.

137

TM TRACTOR SERVICE MANUAL

APPENDIX

1.3. FRONT AXLE AND DRIVE MECHANISM

Apply wear-proofing grease.

Apply adhesive.

Apply grease to dust seal.

Apply wear-proofing grease. Apply grease.

Apply grease to bush.

Apply grease. Fore-and-aft play of front axle: 0 to 0.2 mm After play has been set, axle should rock smoothly.

Be sure to install snap ring. Drive in roll pin in correct direction and retain it with wire securely.

Be sure to install snap ring.

Apply wear-proofing grease. After assembly dif-pinions should turn smoothly.

Be sure to install snap ring.

Be sure to install snap ring.

Apply adhesive to contacting surfaces.

Be sure to install snap ring.

Apply grease to shaft seal, which should securely be driven in with a driving-in tool.

Apply grease. Be sure to install snap rings.

Apply wear-proofing grease.

Apply adhesive to blind plug.

141

Drive in roll pin in correct direction and retain it with wire securely.

TM TRACTOR SERVICE MANUAL

APPENDIX

2. WIRING DIAGRAM

Hazard warning signal switch

Instrument panel lamp 3.5W

POWER SUPPLY ACCESSORY EARTH

FUEL TEMP Main beam switch

Front samll lamp (Make COBO) 21W 5W

99C: 0.5 B 35: 0.5 YR

23: 0.5 LW

72A: 0.5 GB

205: 0.5 GR

73A: 0.5 GY

207: 0.5 RY

2A: 0.5 RL

99A: 0.5 B

1.25 L 1.25 LB 1.25 LW

72A: 0.5 GB

205: 0.5 GR

73A: 0.5 GY

207: 0.5 RY

2A: 0.5 RL

99A: 0.5 B

108B: 0.5 RW 34: 0.5 Y 134: 0.5 YB

0.5 YB 1: 0.5 YB 1:

23: 0.5 LW

0.5 YL 5:

35: 0.5 YR

0.5 YL 5:

10A: 0.5 YB

35: 0.5 YR

GB RL GY R GR 0.5 0.5 0.5 0.5 0.5 72B: 0.5 GB 207: 0.5 RY 73B: 0.5 GY 108A:0.5 RW 70A: 0.5 R

GW LgW LgR Lg GL G G G 206: 0.5 36A: 0.5 36B: 0.5 36C: 0.5

99D: 0.5 B

205: 0.5 GR

0.5 GW

99A: 0.5 B

990C:0.5 B

0.5 B 0.5 RB

204B:0.5 LY

0.5 GB

73B:0.5 GY

Front turn signal lamp (RH)

Fuel switch

10A: 0.5 RB

4:

36: 0.5 G

102: 0.5 LR 2: 0.5 RL 103: 0.5 YR 3: 0.5 RY

102: 0.5 2: 0.5 103: 0.5 3: 0.5 99D: 0.5

5A 5A 5A 5A

LR RL RY RY RB

Fuses 112: 0.5 LR 211: 0.5 RL 214: 0.5 YR 213: 0.5 RY

206: 0.5 GL

Flasher unit

1.25 L 1.25 LB 1.25 LW

99D: 0.5 B 214: 0.5 YR 212: 0.5 LR

0.5 0.5 0.5 0.5

Parking lamp switch

Head lamp (RH) 45/40 W (Make COBO)

Stop lamp switch

Mid PTO switch

73: 0.5 GY 204: 0.5 LY 210A: 0.5 RW 99B: 0.5 B

99:

0.85 B

70:

1.25 R

21W

Stop lamp (RH)

10W

Tail lamp (LH) (Make COBO)

21W

Rear turn signal lamp (RH)

For opt (AC) located under right fender 100W

1:

99B: 0.5 B

7:

0.5 YB

0.85 P

Engine stop solenoide

Diode (3A)

102: 0.5 LR 2: 0.5 RL 103: 0.5 YR 13: 0.5 RY 4: 0.5 GW 5: 0.5 YL 1: 0.5 YB 7: 0.85 P

102: 0.5 LR 2: 0.5 RL 103: 0.5 RY 13: 0.5 RY 4: 0.5 GW 5: 0.5 YL 1: 0.5 YB 7: 0.85 P 16A: 0.85 BW

23: 0.5 LW

23: 0.5 LW

10: 0.5 B

10: 0.5 B

99: 1.25 B 13: 2 BY

Battery 46B24R

99: 2 B 13: 2 BY

0.85 BW

11: 0.5 W

23: 0.5 LW

70: 1.25 R 210: 0.5 RW

70:1.25 R 210:0.85 RW

204: 0.5 LY 203: 0.5 LB 73: 0.5 GY 72: 0.5 GB 99: 0.85 B

204: 0.5 LY 203: 0.5 LB 73: 0.5 GY 72: 0.5 GB 99: 0.85 B

16: 0.85 BW 15: 0.85 LR

16: 0.85 BW 15: 0.85 LR

301:0.5 L&R 302:0.5 RW

301:0.5 LgR 302:0.5 LgR

204C: 0.5 RY

0.5 RY

99E: 0.5 B

0.5 B

Diode (3A)

0.85 B 99: 2 B

16B: 0.85 BW 302A: 0.5 LgR

Slow blow fuse (50A)(Red)

Opt for trailer 7-pole socket (Make COBO)

Ref. Circuit No. Amperage Functions 1 1 5A PTO 2 5A 3 3 10A Stop lamps 4 Direction indicator & CAB(AC) 4 20A 5 6 5A Engine stop relay 6 5 10A Spare (AC) 7 7 20A Warning flash lamps 8 10 5A Tail lamps (LH) 9 11 5A Tail lamps (RH)

14:3 R 32:0.85 LR 31:3 BY 66:3 BW 66A:3 BR 33A:3 RW

209:0.5 RB

108:1.25 WR 36:0.5 G 73:0.5 GY 72:0.5 GB 34:0.5 Y 4:0.5 GW 0.85 YB 0.85 LR 2 RW 3 RW

215: 3 R

700: 0.5 W

For opt (AC) switch

0.5 0.5 0.5 0.5 0.5 0.5

L

GY GB RW B RB RY

R

54 31 58L 58R

3R 0.85 LR 3 BY 3 BW 3 BR 3 RW

0.85 R 0.85 G 0.85 WB 0.85 GB 0.85 RG 0.5 GW 0.85 RW 0.85 RY

R

134: 32: 33: 33:

5A 5A 10A 20A 5A 10A 20A 5A 5A

73A: 0.5 GY 72A: 0.5 GB 210B: 0.5 RW 99F: 0.85 B 203A: 0.5 LB 204A: 0.5 LY

ND relay

215: 3 R

134: 32: 33: 33:

0.85 YB 0.85 LR 2 RW 3 RW

10: 0.85 RB 15: 0.85 LR 301: 0.5 LGB

0.5 LY 0.5 LB 1.25 WR 1.25 R 0.85 RL 204: 203: 108: 70: 8:

Enginestop relay

0.5 LY 0.5 LB 1.25 RW 0.85 RG 1.25 RG 0.85 R 0.85 RB 0.85 LR 0.85 RW

13: 2 BY

0.85 B 0.85 BW 0.85 P 0.85 RL

Starter motor

204: 203: 108: 70: 8: 37: 10: 15: 301:

212: 0.5 RL 213: 0.5 RY 99C: 0.5 B

Slow blow fuse (50A) (Green)

Slow blow fuse (50A) (Red)

S 30 B

E

12: 3 W 24: 3 W

Alternator 12V 40A

12V 1.4 kW

99B: 16: 7: 8:

B B

202: 0.5 R

216: 3 R

202: 0.5 R

216: 3 R

302: 0.5 LGB

216: 3 R

L

99F: 0.85 B

R

6: 3 BW 14: 3 R 31:2 BY 13:2 BY 99E:0.5 R 302:3 LgR

6: 3 BW 14: 3 R

25: 3 R

70B: 1.25 R

Glow plugs

Head lamp (LH) 45/40 W (Make COBO)

Legistration plate lamp (Make Hella)

5W

700:0.5 W

0.5 YB

301:0.5 LGB

1:

210: 0.5 RW

5:0.5 YL

10B: 0.5 RB

Hor n

L

T

Safety switch

50

H

17

30

2

B1

19

BR

1

B2

PTO switch

AC Front samll lamp (Make COBO)

Light switch Turn signal switch Horn switch

OFF 1 2

0.5 GB

72B:0.5 GB

0.5 RB

203B:0.5 LB

0.5 B

990D:0.5 LB

21W 5W

3

R OFF L

Front turn signal lamp (LH)

0 1

OFF ON

2 Main switch

Main switch

145

99A: 0.5 B 210: 0.85 RW 203: 0.5 LB 72: 0.5 GB

21W

Stop lamp (LH)

10W

Tail lamp (LH) (Make COBO)

21W

Rear turn signal lamp (LH)