ISEKI TH4260,4290,4330 Service Manual PDF [PDF]

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TH4330 TH4290 TH4260

TH TRACTOR SERVICE MANUAL

Contents CHAPTER 1. GENERAL INFORMATION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 4 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䊶䊶䊶䊶䊶䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 4 2. SPECIFICATIONS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 5 3. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 15 4. DRAWINGS OF TRANSMISSION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 18 CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 22 1. OPERATION CHART FOR DISASSEMBLING AND RE-ASSEMBLING BY MAJOR BLOCKS 䍃䍃䍃䍃22 2. EXTERIOR PARTS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 23 3. RADIATOR 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 30 4. SEPARATION OF ENGINE FROM FRONT TRANSMISSION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 31 5. REMOVAL OF ENGINE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 33 6. SEPARATION OF FRONT TRANSMISSION CASE FROM MIDDLE TRANSMISSION CASE䍃 34 7. SEPARATION OF MIDDLE TRANSMISSION CASE FROM REAR TRANSMISSION CASE 䍃䍃 35 8. SEPARATION OF REAR AXLE HOUSING FROM REAR TRANSMISSION CASE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 36 9. REMOVAL OF CYLINDER CASE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 37 10. REMOVAL OF FRONT AXLE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 37 11. REMOVAL OF POWER STEERING UNIT 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 38 CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 1. RADIATOR 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 2. COOLING FAN AND BELT 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 3. AIR CLEANER 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 4. FUEL SYSTEM 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 5. TROUBLE SHOOTING 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃

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CHAPTER4. CLUTCH 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 1. SPECIFICATIONS AND CONSTRUCTION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 2. DISASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 3. INSPECTION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 4. RE-ASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 5. TROUBLE SHOOTING 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃

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CHAPTER5. TRANSMISSION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 54 1. GENERAL DESCRIPTION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 54 2. REMOVAL AND INSTALLATION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 57 CHAPTER 6. HYDROSTATIC TRANSMISSION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 2. DISASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 3. REASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃

2

66 66 68 74

CHAPTER 7. FRONT AXLE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 86 1. CONSTRUCTION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 86 2. DISASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 87 3. INSPECTION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 88 4. PRECAUTIONS FOR REASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 89 5. TROUBLE㩷 SHOOTING 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 91 CHAPTER 8. STEERING SYSTEM 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 92 1. CONSTRUCTION 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 92 2. STEERING HYDRAULIC CIRCUIT 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 93 3. INTEGRAL ORBIT ROLL 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 94 4. DISASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 95 5. RE-ASSEMBLY 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 97 6. CYLINDER SYSTEM 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃100 7. TROUBLE SHOOTING 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃101 CHAPTER 9. HYDRAULIC SYSTEM 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 104 1. HYDRAULIC SYSTEM DIAGRAM 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃104 2. HYDRAULIC CIRCUIT DIAGRAM 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 106 3. PTO CONTROL VALVE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 108 4. SPECIFICATIONS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 110 5. CYLINDER 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 111 6. MAIN CONTROL VALVE䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 117 7. FLOW CONTROL VALVE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 124 8. SAFETY VALVE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 125 9. RELIEF VALVE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 126 10. GEAR PUMP 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 127 11. TROUBLE㩷 SHOOTING 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 130 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 CHAPTER 10. ELECTRICAL ACCESSORIES 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 1. CABLE LAYOUT 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 2. WIRE HARNESS LAYOUT 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 3. TROUBLE㩷 SHOOTING 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃

134 134 136 139

CHAPTER 11. LUBLICATION & MAINTENANCE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 142 1. SPECIFICATIONS & CAPACITIES 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 142 2. LUBRICATION & FILL POINTS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 143 3. PERIODIC INSPECTION TABLE 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 144 4. SERVICE STANDARDS 䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃䍃 145

3

TH TRACTOR SERVICE MANUAL

CHAPTER 1. GENERAL INFORMATION 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS Each tractor is identified by means of the

To ensure prompt, effcient service when

tractor model and serial numbers. As a fur-

ordering parts or requesting repairs from

ther identification, the engine and chassis㩷 㩷

authorized ISEKI dealer, record these num-

are also provided with identification num-㩷 㩷 㩷

bers in spaces provided.

bers.

(1) Model name plate

(3) C a s t e n g i n e m o d e l n a m e a n d

(2) Punched model name and serial num-

punched engine serial number on the

ber on the right side of the front frame

right side wall the cylinder block

Fig. 1-1

1.1. MODEL NAME PLATE

1.2. CHASSIS PRODUCTION NUMBER

TH4330....TH32S

TH4290....TH28S

TH4260....TH25S

1.3. ENGINE MODEL AND SERIAL NUMBER

Fig. 1-2 (1) MODEL (2) TYPE R.....ROPS H.....HST transmission M.....Mid-PTO U.....Power-assisted steering system E3CE…..TH4260 E3CF…..TH4290 E3CD…..TH4330

(3) Production No. (4) Production year The year of 1996 is allotted to "A" and the following years are expressed alphabetically

(1) Engine model

except for "I".

Fig. 1-3

4

(2) Serial Number

CHAPTER 1: GENERAL INFORMATION

2. SPECIFICATIONS (1) Specifications Specifications are subject to change without notice. MECHANICAL TRANSMISSION MODEL: SUB MODEL: ENGINE: Make Model Type Aspiration Displacement Number of Cylinders Bore Stroke Engine Horsepower (Gross) (Net) Firing Order Compression Ratio Low Idle Speed High Idle Speed Valve Clearance (Cold) ; Intake Exhaust Air Cleaner Engine Cooling Cold Starting Aid TRANSMISSION: Type Gear Speeds Clutch Brakes

TH4260F MDRE / MDE

Output Mid PTO Speed @ engine rpm

DRE

Gear Type, 3 speeds forward, 1 reverse with 3 speed range 9 gears forward, 3 reverse Dual clutch (㱢215 mm) Mechanically actuated sealed wet disk

Transmission driven Sliding gear and disk clutch 35 mm diameter, six spline Clockwise rotation 581 @2500 rpm 25.4 mm diameter fifteen spline Clockwise rotation 2000 @ 2500 rpm

25.4 mm diameter fifteen spline Clockwise rotation 2000 @ 2500 rpm

HYDRAULICS: Steering System; Type Pump Maximum Output Pressure Main Hydraulic System; Pump Maximum Output Pressure Rear Linkage; Type Size Control Lift Capacity

ELECTRICAL SYSTEM: System Voltage Battery cca @ 0 F (-18) Charging

TH4290F MDRE / MDE

Iseki Diesel E3CE-VB12 E3CF-VB24 Indirect injection, overhead valve Natural 1430 cc 1463 cc 3 85 mm 86 mm 84 mm 25.3 HP (18.9 kW) @ 2500 rpm 28.4 HP (21.2 kW) @ 2500 rpm 24.0 PS (17.7 kW) @ 2500 rpm 28.0 PS (20.6 kW) @ 2500 rpm 1-3-2 21.5 to 1 21.7 to 1 900-1000 rpm 930-970 rpm 2650-2750 rpm 2650-2750 rpm 0.35 mm 0.35 mm Dual stage, dry element Liquid, forced circulation Glow plugs (3)

POWER TAKE-OFF (PTO): Type Control Rear PTO; Shaft Output Engine Speed @ engine rpm Mid PTO; Shaft

DRE

Hydrostatic (power) Engine-mounted gear pump 9.8 l/min at 2500 rpm 11772 kPa Engine-mounted gear pump 28.0 l/min at 2500rpm Relief valve setting 14715 kPa Three-point hitch Category 1 Position (OPT draft control) 1100 kg measured at ball ends 800 kg measured at 24" behind

12 volt, negative (-) ground 433 cca 40 amp alternator with internal regulator/rectifier

5

-

TH TRACTOR SERVICE MANUAL

MECHANICAL TRANSMISSION MODEL: CAPACITIES: Engine Crankcase with Filter Transmission Fuel Tank Cooling system Front Drive Axle

TH4260F

TH4290F

3.6 liters 29.0 liters 23 liters

30 liters 7.1 liters 4.5 liters

TREAD WIDTH SETTINGS: Front 4WD Ag. Tires (6 - 14) Turf Tires (24 x 8.50 - 12) Oversize Turf Tire (26 x 12.00 - 12) Narrow Agri. Tire (6 - 14) Oversize Agri. Tire (7 - 14)

960 mm 1067 mm 1115 mm 960 mm 990 mm

Rear 4WD Ag. Tires (12.4 - 16) Turf Tires (315 / 80D - 16) Oversize Turf Tire (13.6 - 16) Narrow Agri. Tire (9.5 - 22) Oversize Agri. Tire (9.5 - 24)

1096 mm 946 mm, 966 mm 931 mm, 980 mm 880 mm 940 mm

MAXIMUM AXLE LOADING: Front Axle Rear Axle

875 kg 1000 kg

6

7

985 kg

Tire size 6 - 14 12.4 - 16

Front Rear

-

-

-

-

200 mm (under mid PTO case)

2350 mm 1340 mm (front wheel)

1370 mm

Turf Tire Front: 24 x 8.50 - 12 Rear: 315/80D - 16

925 kg

935 kg

Dimension diameter x width 653 mm x 155 mm 955 mm x 284 mm

975 kg

970 kg

980 kg

Agri. Tire

225 mm (under mid PTO case)

Wheelbase Min. Ground Clearance Turning diameter w/o brake Weight (with ROPS) Weight (with mid PTO) Weight (with ROPS & mid PTO)

D

-

Overall Length

C

2375 mm 1410 mm (rear wheel)

1395 mm

Overall Width

Height of Steering Wheel Overall Height ROPS

Agri. Tire Front: 6 - 14 Rear: 12.4 - 16

B

A2

A1

Reference

Tire size 24 x 8.50 - 12 315/80D - 16

1000 kg

950 kg

995 kg

Dimension diameter x width 614 mm x 216 mm 910 mm x 273 mm

980 kg

930 kg

975 kg

245 mm (under mid PTO case)

2395 mm 1225 mm (winker)

1415 mm

Narrow Agri. Tire Front: 6 - 14 Rear: 9.5 - 22

Turf Tire

250 mm (under mid PTO case)

2400 mm 1480 mm (front wheel)

1405 mm

TH4260 Wide Turf Tire Front: 26 x 12.00 - 12 Rear: 13.6 - 16

GENERAL DIMENSIONS (Mechanical Transmission)

2920 mm

5600 mm 955 kg

995 kg

945 kg

Wide Turf Tire Dimension diameter x width 660 mm x 310 mm 1009 mm x 355 mm Tire size 26 x 12.00 - 12 13.6 - 16

990 kg

940 kg

985 kg

2425 mm 1410 mm (rear wheel)

1395 mm

Agri. Tire Front: 6 - 14 Rear: 12.4 - 16

225 mm (under mid PTO case)

1665 mm 270 mm (under mid PTO case)

2420 mm 1260 mm (front wheel)

1440 mm

Oversize Agri. Tire Front: 7 - 14 Rear: 9.5 - 24

1010 kg

960 kg

955 kg

250 mm (under mid PTO case)

2435 mm 1480 mm (front wheel)

1405 mm

TH4290 Oversize Turf Tire Front: 26 x 12.00 - 12 Rear: 13.6 - 16

Narrow Agri. Tire Dimension diameter x width 653 mm x 155 mm 994 mm x 230 mm Tire size 6 - 14 9.5 - 22

985 kg

935 kg

940 kg

200 mm (under mid PTO case)

2400 mm 1340 mm (front wheel)

1370 mm

Turf Tire Front: 24 x 8.50 - 12 Rear: 315/80D - 16

1000 kg

950 kg

960 kg

270 mm (under mid PTO case)

2470 mm 1260 mm (front wheel)

1440 mm

Oversize Agri. Tire Front: 7 - 14 Rear: 9.5 - 24

Oversize Agri. Tire Dimension diameter x width 690 mm x 173 mm 1050 mm x 243 mm Tire size 7 - 14 9.5 - 24

990 kg

940 kg

950 kg

245 mm (under mid PTO case)

2445 mm 1225 mm (winker)

1415 mm

Narrow Agri. Tire Front: 6 - 14 Rear: 9.5 - 22

CHAPTER 1: GENERAL INFORMATION

R

Max. Speed (forward)

1 2 3 1 2 3 1 2 3

Mechanical Transmission SHIFT POSITIONS 㪩㪸㫅㪾㪼 㪞㪼㪸㫉 㪫㫀㫉㪼

8 4.71

10.38

10.90

1.88

1.97

4.94

22.19

1.82 2.69 3.72 4.57 6.73 9.32 10.07 14.83 20.55

1.91 2.82 3.91 4.80 7.06 9.79 10.57 15.57 21.56

23.28

Turf

Agri.

11.21

5.08

2.03

23.94

11.35

5.15

2.06

24.27

11.98

5.44

2.17

25.61 Reverse

TH4260 (Engine 2500 rpm) 㪢㪧㪟 Wide Turf Narrow Agri. Oversize Agri. Forward 1.97 1.99 2.10 2.90 2.94 3.10 4.02 4.07 4.29 4.93 5.00 5.27 7.26 7.36 7.77 10.06 10.20 10.76 10.87 11.01 11.62 16.01 16.22 17.12 22.17 22.47 23.71 High Idle 2700 rpm

10.90

4.94

1.97

23.28

1.91 2.82 3.91 4.80 7.06 9.79 10.57 15.57 21.56

Agri.

10.38

4.71

1.88

22.19

1.82 2.69 3.72 4.57 6.73 9.32 10.07 14.83 20.55

Turf

11.21

5.08

2.03

23.94

1.97 2.90 4.02 4.93 7.26 10.06 10.87 16.01 22.17 High Idle 2700 rpm

11.35

5.15

2.06

24.27

1.99 2.94 4.07 5.00 7.36 10.20 11.01 16.22 22.47

11.98

5.44

2.17

25.61

2.10 3.10 4.29 5.27 7.77 10.76 11.62 17.12 23.71

TH4290 (Engine 2500 rpm) 㪢㪧㪟 Wide Turf Narrow Agri. Oversize Agri.

TH TRACTOR SERVICE MANUAL

CHAPTER 1: GENERAL INFORMATION

Tire specification( Mechanical transmission ) Tire type

Front Wheel

Rear Wheel

Tire size

Pressure

Tire size

Pressure

Ag. Tires

6 - 14

177 kPa

12.4 - 16

98 kPa

Turf Tires

24 x 8.50 - 12

157 kPa

315/80D - 16

98 kPa

Wide Turf Tire

26 x 12.00 - 12

118 kPa

13.6 - 16

98 kPa

Narrow Agri. Tire

6 - 14

177 kPa

9.5 - 22

137 kPa

Oversize Agri. Tire

7 - 14

177 kPa

9.5 - 24

216 kPa

Front Tire type (Mechanical Transmission) Ag. Tires Turf Tires Wide Turf Tire Narrow Agri. Tire Oversize Agri. Tire Rear Tire type (Mechanical Transmission) Ag. Tires

Tread Width (mm) A B Not 960 Recommended Not 1067 Recommended Not 1115 Recommended Not 960 Recommended Not 990 Recommended Tread Width (mm) A B Not 1096 Recommended

Turf Tires

946

966

Wide Turf Tire

931

980

Narrow Agri. Tire

880

Oversize Agri. Tire

940

Not Recommended Not Recommended

9

TH TRACTOR SERVICE MANUAL

HYDROSTATIC TRANSMISSION MODEL: SUB MODEL:

TH4260FH MRE / ME

TH4290FH MRE / ME

TH4330FH MRE / ME

ENGINE: Make Model Type Aspiration Displacement Number of Cylinders Bore Stroke Engine Horsepower (Gross) (Net) Firing Order Compression Ratio Low Idle Speed High Idle Speed Valve Clearance (Cold) ; Intake Exhaust Air Cleaner Engine Cooling Cold Starting Aid

Iseki Diesel E3CF-VB22 E3CD-VB32 Indirect injection, overhead valve Natural 1430 cc 1463 cc 1498 cc 3 85 mm 86 mm 87 mm 84 mm 25.3 HP (18.9 kW) @ 2500 rpm 28.4 HP (21.2 kW) @ 2500 rpm 33.0 HP (24.6 kW) @ 2600 rpm 24.0 PS (17.7 kW) @ 2500 rpm 28.0 PS (20.6 kW) @ 2500 rpm 32.0 PS (23.5 kW) @ 2600 rpm 1-3-2 21.5 to 1 21.7 to 1 900-1000 rpm 930-970 rpm 980-1020 rpm 2650-2750 rpm 2650-2750 rpm 2760-2860 rpm 0.35 mm 0.35 mm Dual stage, dry element Liquid, forced circulation Glow plugs (3)

TRANSMISSION - HYDROSTATIC Type ; Primary Range Gear Speeds Clutch Brakes

Infinite Control 3 speeds constant mesh 3 gears forward, 3 reverse None Mechanically actuated sealed wet disk

E3CE-VB11

POWER TAKE-OFF (PTO): Type Control Clutch Rear PTO; Shaft Output Engine Speed @ engine rpm Mid PTO; Shaft Output Mid PTO Speed @ engine rpm

Independent, engine driven Electro-hydraulic control Hydraulically engaged, multi-plate wet disk 35 mm diameter, six spline Clockwise rotation 581/1050 @2500 rpm 604/1092 @2600 rpm 25.4 mm diameter, fifteen spline Clockwise rotation 2000 @ 2500 rpm 2080 @ 2600 rpm

HYDRAULICS: Steering System; Type Pump Maximum Output Pressure Main Hydraulic System; Pump Maximum Output Pressure Rear Linkage; Type Size Control Lift Capacity

Hydrostatic (power) Engine-mounted gear pump 9.8 l/min at 2500 rpm 11772 kPa Engine-mounted gear pump 28.0 l/min at 2500rpm Relief valve setting 14715 kPa Three-point hitch Category 1 Position (OPT draft control) 1100 kg measured at ball ends 650 kg measured at 24" behind

ELECTRICAL SYSTEM: System Voltage Battery cca @ 0 F (-18) Charging CAPACITIES: Engine Crankcase with Filter Transmission Fuel Tank Cooling system Front Drive Axle

10.2 l/min at 2600 rpm

29.2 l/min at 2600rpm

12 volt, negative (-) ground 582 cca 40 amp alternator with internal regulator/rectifier

3.6 liters

4.4 liters 29.0 liters

23 liters

30 liters 7.1 liters 4.5 liters

10

CHAPTER 1: GENERAL INFORMATION

HYDROSTATIC TRANSMISSION MODEL:

TH4260FH

TH4290FH

TREAD WIDTH SETTINGS: Front 4WD Turf Tires (24 x 8.50 - 12) Wide Turf Tires (26 x 12.00 - 12) Ag. Tires (6 - 14) Rear 4WD Turf Tires (315 / 80D - 16) Wide Turf Tires (13.6 - 16) Ag. Tires (9.5 - 22)

980 mm 985 mm 880 mm 945 mm 1040 mm 875 mm

MAXIMUM AXLE LOADING: Front Axle Rear Axle

875 kg 1000 kg

11

TH4330FH

12

960 kg

Tire size 24 x 8.50 - 12 315/80D - 16

Overall Length

Wheelbase Min. Ground Clearance Turning diameter w/o brake

Weight

Front Rear

C

D

-

-

-

Overall Width

B

200 mm

1260 mm

2350 mm

1370 mm

A2

Dimension diameter x width 614 mm x 216 mm 910 mm x 273 mm

985 kg

250 mm

1390 mm

2400 mm

1425 mm

Wide Turf Tire Front: 26 x 12.00 - 12 Rear: 13.6 - 16

Turf Tire

Turf Tire Front: 24 x 8.50 - 12 Rear: 315/80D - 16

Height of Steering Wheel Overall Height ROPS

A1

Reference

TH4260

970 kg

200 mm

1260 mm

2350 mm

1370 mm

Turf Tire Front: 24 x 8.50 - 12 Rear: 315/80D - 16

Wide Turf Tire Dimension diameter x width 660 mm x 310 mm 1009 mm x 355 mm Tire size 26 x 12.00 - 12 13.6 - 16

965 kg

245 mm

1120 mm

2395 mm

1420 mm

Agri. Tire Front: 6 - 14 Rear: 9.5 - 22

GENERAL DIMENSIONS(Hydrostatic transmission)

Tire size 6 - 14 12.4 - 16

995 kg

5600 mm

250 mm

1665 mm

2925 mm

1390 mm

2400 mm

1425 mm

975 kg

245 mm

1120 mm

2395 mm

1420 mm

Agri. Tire Front: 6 - 14 Rear: 9.5 - 22

Dimension diameter x width 653 mm x 155 mm 955 mm x 284 mm

Agri. Tire

TH4290 Hydrostatic Wide Turf Tire Front: 26 x 12.00 - 12 Rear: 13.6 - 16

980 kg

200 mm

1260 mm

2350 mm

1370 mm

Turf Tire Front: 24 x 8.50 - 12 Rear: 315/80D - 16

1005 kg

250 mm

1390 mm

2400 mm

1425 mm

Wide Turf Tire Front: 26 x 12.00 - 12 Rear: 13.6 - 16

TH4330

985 kg

245 mm

1120 mm

2395 mm

1420 mm

Agri. Tire Front: 6 - 14 Rear: 9.5 - 22

TH TRACTOR SERVICE MANUAL

Max. Speed (forward)

SHIFT POSITIONS Tire

27.44

27.86

25.09

13

19.20

17.57 18.27

7.67

17.57

7.38

8.07

19.20

8.07

18.27

7.67

3.70

7.38

3.75

3.42

3.70

3.75

3.42

27.44

11.52

High Idle 2750 rpm 27.13 30.10 28.21 Reverse

27.86

11.69

High Idle 2750 rpm 27.13 30.10 28.21

25.09

10.54

11.52

11.69

5.36

10.54

5.43

4.89

5.43

4.89

5.36

TH4290 (Engine 2500 rpm) Turf Wide Turf Agri. Forward

TH4260 (Engine 2500 rpm) Turf Wide Turf Agri. Forward

Hydrostatic transmission

28.97

12.16

5.65

28.54

11.98

5.57

18.27

7.67

3.56

19.97

8.39

3.90

19.97

8.39

3.90

High Idle 2810 rpm 28.21 31.30 30.84

26.10

10.96

5.09

TH4330 (Engine 2600 rpm) Turf Wide Turf Agri. Forward

CHAPTER 1: GENERAL INFORMATION

TH TRACTOR SERVICE MANUAL

Tire specification ( Hydrostatic transmission ) Tire type

Front Wheel

Rear Wheel

Tire size

Pressure

Tire size

Pressure

Ag. Tires

6 - 14

177 kPa

12.4 - 16

98 kPa

Turf Tires

24 x 8.50 - 12

157 kPa

315/80D - 16

98 kPa

Wide Turf Tire

26 x 12.00 - 12

118 kPa

13.6 - 16

98 kPa

Front Tire type (Hydrostatic Transmission) Ag. Tires Turf Tires Wide Turf Tire Rear Tire type (Hydrostatic Transmission) Ag. Tires Turf Tires Wide Turf Tire

Tread Width (mm) A B Not 880 Recommended Not 980 Recommended Not 985 Recommended Tread Width (mm) A B Not 875 Recommended Not 945 Recommended Not 1040 Recommended

14

CHAPTER 1: GENERAL INFORMATION

3. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION (1) BEFORE OPERATION

(c) 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.

(a) Always be safety-conscious in selecting clothes to wear and suitable tools to use. (b) Before disassembly, be sure that you familiarize yourself with the assembled condition for subsequent reference in reassembly.

(d) 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.

(c) Keep parts and tools in proper order during operations. (d) When servicing electrically live parts, be sure to disconnect the negative battery terminal.

(e) Installed bearings should turn smoothly.

(e) To prevent oil or water leaks, use the liquid gasket as required.

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

(f) When reassembling disassembled parts, discard used gaskets, O-rings, or oil seals and install new ones.

(b) During installation, be careful not to damage the lips, and assure that it is pushed in parallel to the shaft or hole.

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

(c) When oil seals are installed, there should be neither turnover of the lips nor dislocation of the springs.

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

(d) When a multi-lip seal is installed, the grooves between lips should be filled with grease, not adhesive.

(i) 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.

(e) Use a lithium-based grease. (f) There should be no oil or water leaks through the installed soil seals.

(2) PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING COMMON PARTS

3) O-rings (a) O-rings should be coated with grease before installing.

1) Roller or ball bearings (a) When a bearing is fitted in by the outer race, use an installer, which is specially designed to push only the outer race and vice versa.

(b) Installed O-rings should have no slack or twist. (c) Installed O-rings should maintain proper air tightness.

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

15

TH TRACTOR SERVICE MANUAL

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

4) Snap-rings (a) Snap-ring installers should be designed so as not to permanently deform the snap-rings.

6) Cotter pins (a) When installed, cotter pins should be bent securely at the ends as shown in the figure.

(b) Installed snap-rings should be seated securely in the groove. (c) Be careful not to overload the snap-ring to the extent that it is permanently deformed. (d) How to install the snap-ring: 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.

Fig.1-6 7) Bolts and nuts (a) Special bolts are installed at several locations, so be sure not to interchange them other bolts. (b) Bolts and nuts should be tightened to their specified torque with a torque wrench. (c) 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.

Fig.1-4

5) Spring (roll) pins (a) Spring pins should be driven in properly and tightly.

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

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

(e) Apply an adhesive (THREE BOND TB 1104) to parts through which there is any possibility of oil leaks, such as stud bolts and tapped-through parts. (f) Each lock nut must be tightened securely. (g) When tightening bolts and nuts, refer to the tightening torque table. 8) Grease fitting (a) After installation, each grease fitting should be

Fig.1-5

filled with grease.

16

CHAPTER 1: GENERAL INFORMATION

(b) 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 (a) Be sure not to damage any finished surfaces or parts. (b) Always refrain from forcing installation. (c) Each lever knob should be installed coated with an adhesive (SUPER THREE CEMENT TB1702) (d) Each contact surface should be coated with an adhesive (THREE BOND TB1215) and tightened evenly with bolts. 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, and especially from grease before application of the adhesive. (e) Precautions for applying adhesives The surface or the thread where an adhesive is to be applied should be completely free of chips and oil. The surface or the thread where an adhesive is to be applied should be completely free of oiliness.

17

TH TRACTOR SERVICE MANUAL

4. DRAWINGS OF TRANSMISSION Mechanical transmission

Fig.1-7 18

CHAPTER 1: GENERAL INFORMATION

Mechanical transmission

Fig.1-8 19

TH TRACTOR SERVICE MANUAL

HST transmission

Fig.1-9

20

CHAPTER 1: GENERAL INFORMATION

HST transmission

Fig.1-10 21

TH TRACTOR SERVICE MANUAL

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS 1. OPERATION CHART FOR DISASSEMBLING AND RE-ASSEMBLING BY MAJOR BLOCKS

22

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

2. EXTERIOR PARTS 2.1 HOOD AND FRONT GRILLE

2.2 SEAT, FENDERS, FLOOR DECK, AND RELATED PARTS a. Remove two bolts and differential lock lever (1).

(1) HOOD AND FRONT GRILLE a. Hood Turn the knob, 1, to clockwise and open the engine hood and lock it by retaining stay, 2.

Fig. 2-3 b. Remove a screw and lowering speed control Fig. 2-1

knob (2).

c. Remove two bolts and cruising speed control

b. Side Panel

lever (3).

Pull locking pins, 3, out, and then lift side panel upward to disengage and remove.

d. Remove floor mat (LH and RH).

e. Remove four bolts and center cover (4).

f.

Disconnect the wiring harness for seat switch.

g. Remove bolts that fixing the seat panel then shift the seat panel forward for avoiding mid PTO lever and 4WD lever, and remove it with the seat. FIG. 2-2 Fig. 2-2 c. Front Grill Remove locking knobs, 4, and then pull upward and outward.

23

TH TRACTOR SERVICE MANUAL

h. Remove HST pedal (1).

l. Remove hydraulic control levers (1) (2).

Fig.2-6 Fig.2-4 (E6 model) m. Remove fixing bolts and fenders. i.

Remove floor decks (LH and RH). n. Remove four screws and column cover

j.

Disconnect the couplers of wiring harness for

(forward and rearward).

combination lamps.

k. Remove four bolts per one side (total eight bolts) and ROPS (1).

Fig.2-7

Fig.2-5

24

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

o. Remove six screws and disconnect couplers

p. Remove two screws and loosen two bolts .

for related wiring harness. And remove the rear

Disconnect the coupler for meter panel and

cover .

tachometer cable.

Fig.2-8

Fig.2-10

NOTE:

q. Remove front cover.

The coupler for main switch has a lubber boot for waterproofing. When disconnecting the coupler,

r.

Remove two bolts fixing fuse box .

pull the boot off from main switch in advance.

Fig.2-9

Fig.2-11 s. Remove two bolts per one side (total four bolts) and engine hood stay.

25

TH TRACTOR SERVICE MANUAL

t.

Disconnect the throttle cable (1) (2).

w. Disconnect the fuel return hose.

Fig.2-12

Fig.2-14

u. Disconnect couplers from relays and release

x. Disconnect the hydraulic hose that connects

the wiring harness from clamp bands.

the Orbit roll with the reducing valve.

v. Close the fuel cock (1) and disconnect the fuel

y. Disconnect the hydraulic hose that connects

hose between the fuel filter and the fuel pump.

the Orbit roll with the charge filter.

Remove a bolt (2) and remove fuel filter. z. Disconnect power steering hoses at the cylinder side (1) (2). Release hoses from clamps.

Fig.2-13

Fig.2-15

26

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

aa. Remove fixing bolts and steering post

ee. Remove the front rubber mounting bolt.

assembly with the fuel tank.

Fig.2-18 ff. Remove the floor frame fixing bolts. Fig.2-16 bb. Remove a seat belt.

cc. Remove the rear panel.

dd. Disconnect the hand brake wire.

Fig.2-19 gg. Remove the floor frame. hh. Remove rear mount fixing bolts.

Fig.2-17

Fig.2-20 ii. Remove lower frame. 27

TH TRACTOR SERVICE MANUAL

2.3 REMOVE THE EXTERIOR PARTS AS ASSY The fender, frames, steering post and fuel tank can

i.

Remove the floor decks.

j.

Disconnect the hand brake wire.

be removed as assy if necessary.

a. Remove the front grille, hood and side covers. k. Close the fuel cock located on the fuel filter. b. Remove the column cover, rear cover and

Disconnect the fuel hose between fuel filter

meter panel.

and fuel pump.

c. Disconnect the throttle wire cable.

l.

d. Disconnect and release the related wiring

m. Disconnect hydraulic hose that connects the

harness.

Disconnect the fuel return hose.

Orbit roll with the reducing valve.

e. Remove the lowering speed control knob, the cruising control lever, the differential lock lever and HST pedals.

f.

Remove the center cover.

g. Remove the sheet panel with the seat.

h. Remove the hydraulic control link assembly. Fig.2-22 n. Disconnect hydraulic hose that connects the Orbit roll power steering unit with the oil cooler.

Fig.2-21

Fig.2-23

28

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

o. Disconnect power steering hoses at the

r.

cylinder side. Release hoses from clamps.

Remove the snap ring (1) and slide the PTO lever (2) outside.

Fig.2-24

Fig.2-26

p. Disconnect the brake rods.

s. Remove the neutral switch.

q. Remove the snap ring (1) and the brake pedal (2).

Fig.2-27 t.

Remove front mount fixing bolts (LH and RH).

Fig.2-25 u. Remove rear mount fixing bolts (LH and RH).

29

TH TRACTOR SERVICE MANUAL

3. RADIATOR

v. Lift up the frame set gradually making sure that

a. Remove the engine hood, front grille, etc.,

all related wirings, pipes and links are

ahead of time.

disconnected.

b. Drain the coolant.

c. Disconnect the upper hose and lower hose (1) (2).

d. Disconnect the drainpipe.

e. Remove the setting bolts from radiator stay (3). Fig.2-28

f.

Remove the setting bolts from the fun shroud (4) and shift it behind the fan.

Fig.2-29 g. Lift the radiator upward.

30

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

4. SEPARATION OF ENGINE FROM FRONT TRANSMISSION

h. Remove the suction pipe.

a. Remove the engine hood, front grille, etc., ahead of time.

b. Disconnect the negative cable from the battery.

c. Loosen clamp bolt holding telescoping the 4WD shaft cover.

Fig.2-32 i.

Remove the delivery pipe.

Fig .2-30 d. Telescope the 4WD shaft cover and slide it to expose coupler and snap ring. Fig.2-33

e. Move snap rings in toward center of shaft.

j.

Disconnect hydraulic hoses for power steering from the power steering cylinder.

Fig.2-31 f.

Slide couplers up on shaft and remove shaft. Fig.2-34

g. Drain transmission oil.

k. Disconnect the hydraulic hose that connects the oil cooler and the HST charge filter. 31

TH TRACTOR SERVICE MANUAL

m. Disconnect the hydraulic hose from the oil cooler that connects the oil cooler and the Orbit roll power steering unit.

Fig.2-35 l. Disconnect the hydraulic hose from the sub gear pump which connect the sub gear pump Fig.2-37

and the reduce valve.

n. Turn OFF the fuel tap of the fuel filter.

o. Disconnect the fuel tube from the fuel pump that connect the fuel filter and the fuel pump.

p. Remove the fuel filter from the bracket.

q. Disconnect the fuel return tube.

r. Disconnect related wiring harness (for fuel Fig.2-36

pump, engine oil pressure, water temperature, glow plug, engine stop solenoid, starter and ground).

s. Un-cramp and tear off related wiring harness from the engine.

32

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

5. REMOVAL OF ENGINE a. Separate the engine from the front

t. Remove the fuse box.

transmission .

b. Support the front axle bracket with a garage jack.

c. Drain the engine coolant.

d. Disconnect the coolant drain hose.

e. Disconnect the radiator hoses. Fig.2-38 f. Remove the bolts tightening the engine and u. Support the engine by a crane.

front axle bracket. Note:

v. Support the front transmission case by a jack.

The engine should be lifted with a chain block for safety ahead of time.

w. Disconnect wiring harnesses from the starter. Remove two bolts and remove the starter.

g. Detach the engine from the front axle bracket.

x. Remove bolts and nuts, and separate the tractor between the engine and the front transmission case.

Fig.2-40

Fig.2-39

33

TH TRACTOR SERVICE MANUAL

6. SEPARATION OF FRONT TRANSMISSION CASE

j.

FROM MIDDLE TRANSMISSION CASE

Loosen the set bolt (1) and remove the trunnion-shaft (2). (HST Type)

a. Remove the exterior parts ahead of time.

b. Drain transmission oil.

c. Remove the suction pipe.

d. Remove the delivery pipe.

e. Disconnect the hydraulic hose. Fig.2-42 f.

Disconnect the cruise control wire (1) (2). (HST Type)

k. Drive in a wedge between the axle bracket and front axle of both sides for support the engine.

g. Remove the bolt fixing the HST pedal link to trunnion-shaft (3). (HST Type)

h. Remove the HST pedal link assembly (4). (HST Type)

i.

Remove the HST metal (5). (HST Type)

Fig.2-43 l.

Support the front transmission case with a jack.

m. Support the middle transmission case with a jack. Fig.2-41

34

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

7.

n. Remove bolts and separate the tractor between

SEPARATION OF MIDDLE TRANSMISSION CASE FROM REAR TRANSMISSION CASE

the front transmission case and the middle transmission case.

a. Remove the exterior parts ahead of time.

b. Drain transmission oil.

c. Remove the suction pipe.

d. Remove the delivery pipe.

e. Disconnect brake rods (RH and LH).

f.

Remove the link plate of mid PTO (1).

g. Remove the link plate of 4WD (2).

Fig.2-44 h. Remove range change metal.

35

i.

Disconnect the wire for the cruise control (1).

j.

Remove the 4WD change arm (2).

TH TRACTOR SERVICE MANUAL

8. SEPARATION OF REAR AXLE HOUSING FROM REAR TRANSMISSION CASE a. Remove the exterior parts ahead of time.

b. Drain transmission oil.

c. Drive in a wedge between the axle bracket and front axle of both sides for support the engine. Fig.2-45

d. Support the rear transmission case with a jack.

k. Remove the stopper plate and pull the 4WD

e. Remove the plate of the stabilizer (or check

shifter to limit.

chain).

Fig.2-46

Fig.2-47

l.

f.

Drive in a wedge between the axle bracket and

Remove one side of rear tire.

front axle of both sides for support the engine. g. When remove the right hand of rear axle m. Support the rear transmission case with a jack.

housing: a) Remove the differential lock arm.

n. Support the middle transmission case with a

b) Remove the snap ring and the brake arm.

jack.

o. Remove bolts and separate the tractor between the middle transmission case and the rear transmission case.

36

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

9. REMOVAL OF CYLINDER CASE

h. When remove the left hand of rear axle housing:

a. Remove the exterior parts ahead of time.

a) Disconnect connecting rod of range change (1).

b. Disconnect the both side of lift rods from rift

b) Remove snap ring (2) and range shift arm (3).

arms.

c) Pulling off the taper pin and remove the PTO change arm (4).

c. Disconnect the delivery pipe.

Fig.2-49 Fig.2-48 d. Remove bolts and cylinder case. 10. REMOVAL OF FRONT AXLE a. Remove the 4WD shaft.

b. Disconnect hydraulic hoses from power steering cylinder.

c. Support the engine with a crane.

d. Remove four bolts which connect the front axle to the axle bracket.

37

TH TRACTOR SERVICE MANUAL

11. REMOVAL OF POWER STEERING UNIT a. Remove the floor mat (LH and RH).

b. Remove four bolts and center cover.

c. Remove four screws and column cover.

d. Remove six screws and disconnect couplers for related wiring harness. And remove the rear cover. Fig.2-50 e. Remove two screws and loosen two bolts. e. Support the front axle with a jack.

Disconnect the coupler for meter panel and tachometer cable.

f.

Lift up the front part of tractor and pull the front axle out forward.

f.

Remove front cover.

g. Remove throttle cable.

h. Disconnect four hydraulic hoses from Orbit roll power steering unit.

Fig.2-51 NOTE: The cylinder will blow oil if the wheels are given external force from a side. Fig.2-52 i. Remove four bolts and steering post with Orbit roll power steering unit.

j.

Remove bolts and power steering unit from steering post.

38

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS

39

TH TRACTOR SERVICE MANUAL

CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES For detail information about the engines, please refer to the relevant service manual which is available separately.

40

CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES

41

TH TRACTOR SERVICE MANUAL

1. RADIATOR 1.1. CONSTRUCTION

x

When the coolant level is lowered due to leaks, maintain the level by adding an antifreeze solution of the same mixing ratio.

x

Take care not to spill antifreeze on painted parts.

1.3.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. Test the radiator for leaks with compressed air in a manner as shown below.

Fig. 3-1

1.2. REMOVAL AND RE-ASSEMBLY Remove and reassemble the radiator in accordance with the instruction of "DISASSEMBLY OF FUNCTIONAL BLOCKS."

Fig. 3-2 Or check for leaks with a radiator cap tester as shown in Fig. 3-3.

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

Follow manufacturer's instructions for mixing ratio of antifreeze.

x

Antifreeze should be blended well with water before filling.

x

Fig. 3-3 Note: Never allow the test pressure to exceed 1 kgf/cm2 (14.2 psi) in both cases.

When the coolant level is lowered due to evaporation, maintain the level by adding water, not by using an antifreeze solution.

42

CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES

1.4. INSPECTION FOR RADIATOR CLOGGING

1.5. VISUAL INSPECTION OF THE EXTERIOR PARTS 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. Retighten loose hose clamps securely if water is leaking through the hose clamps, or replace them if necessary.

Inside: x

Clean the radiator inside as shown in Fig. 3-4.

2.

COOLING FAN AND BELT

Cooling fan Drive Pulley ratio

360mm Belt 1.10(TH4260) 1.20(TH4290/TH4330)

2.1 ADJUSTMENT OF BELT To adjust belt tension, loosen the alternator pivot bolt and nut and tensioning bracket bolt. Pull outward on top the alternator to correctly tension belt and tighten the bolt first and then tighten the pivot bolt.

Fig. 3-4 Clean with a detergent.

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

Outside: x

Clean the radiator screen (wire mesh). After the tractor has been operated in dusty conditions, check the screen daily and clean if necessary.

Belt deflection at “X” point

13.8 to 14.8 mm

Radiator cores x

Clean the radiator cores by applying water spray or compressed air so as to form a right angle with the radiator cores, moving water application in parallel. Note: When cleaning the radiator cores with pressurized water be sure to apply it at a right angle to the cores. Slanted applications might deform their cooling fins. Fig. 3-5

43

TH TRACTOR SERVICE MANUAL

3.

Using compressed air [not exceeding 200 kPa (30 psi)] from the inside of the element, remove loose dirt, grass, chaff, etc.

AIR CLEANER

3.1 REMOVAL AND REASSEMBLY

Be careful not to damage element pleats with air flow.

Release clips on the cover. Remove the element. Examine the element and seals for damage and brittleness. If the element is damaged in any way, it must be replaced. Reassemble in reverse order of removal and clip securely.

If the element is coated with oil or soot: a. Prepare solution of warm water and non-foaming detergent. b. Soak the element for thirty minutes. c. Agitate the element in solution until oil and soot are loosened. d. Rinse the element until rinse water is clear. e. Allow the element to completely dry. Do not dry by using compressed air or heat.

Fig. 3-6 After cleaning (or washing) the element examine for pinholes, punctures, or tears. If the element paper, canister or seal show any signs of physical damage, the element must be replaced.

3.2 INSPECTION x

Inspect the air cleaner visually for cracks, deformation, or other damage.

x

Check the rubber packing at each joint, rubber pipes and the evacuator valve.

Note: Replace an element, which has already been washed five times.

x

Inspect the paper element.

4

FUEL SYSTEM

3.3 CLEANING ELEMENT

Fig. 3-7

The element may be cleaned (if in serviceable condition) using the following procedures.

Fig. 3-8 (Fuel system diagram)

44

CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES

4.1. INSPECTION e. Loosen the air-bleeding screw (3) of the fuel injection pump and let air bubbles out of the pump.

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. 4.2. FUEL FILTER To replace the fuel filter element or clean sediment, turn the fuel valve to the OFF position (top). x

Inspect the filter element sediment bowl and O-ring.

x

Examine the small O-ring in the filter head and replace as necessary.

Fig. 3-10 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.

Fig. 3-9 4.3. AIR-BLEEDING PROCEDURE: a. Fill the fuel tank. b. Turn the fuel valve (1) to "ON". c. Turn the fuel pump "ON". d. Loosen the air-bleeding screw (2) and let air bubbles out.

45

TH TRACTOR SERVICE MANUAL

5

TROUBLE SHOOTING Problems and probable causes

Countermeasures

x

Overheating:

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

Low coolant level Fatigued pressure valve spring Loose or broken fan belt Oily fan belt Poor thermostat Poor water pump or water leaks Clogged water passages Improper injection timing Clogged air ways Fuel gas enters water jacket due to broken cylinder gasket.

x

Over-cooling:

1) 2)

Poor thermostat Excessive low atmospheric temperature

x

Loss of coolant:

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

Leaking radiator Loosely clamped or broken water hose Fatigued pressure valve spring Leaking water pump Water leakage through cylinder head gasket Cracked cylinder head or body

x

Noisy cooling fan:

1) 2) 3) 4)

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

Replenish coolant and inspect 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.

Replace. Decrease area of radiator working by masking radiator.

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

Replace. Re-tighten or replace. Replace. Replace.

46

CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES

47

TH TRACTOR SERVICE MANUAL

CHAPTER 4. CLUTCH 1. SPECIFICATIONS AND CONSTRUCTION

a b c d e f g

(mm) Ø260 Ø215 Ø150 96.5±0.7 98.5±0.7 1.4 - 15 7.8

"Difference in lever height from each other should be within 0. 7 mm.

Fig. 4-1

48

CHAPTER 4: CLUTCH

2. DISASSEMBLY (4) Disassemble the dual clutch assembly.

(1) The clutch assembly can be taken out in the same manner as the single clutch.

Fig. 4-5 Fig. 4-2 Note. When disassembling the clutch assembly, memorize the direction in which the parts are installed.

(2) Compress the pressure plates with clutch assembly setting bolts.

3. INSPECTION (1) Inspect the clutch discs in the same way as the single disc clutch. (2) Pressure plates a. Inspect the pressure plate friction surface for evenness, scratches, stepped wear, and oil stains. b. Shallow scratches may be repaired with sandpaper, but excessive wear damage must be repaired by machining the friction surface. c. Repair of friction surface Fig. 4-3

The friction surface should be ground down or machined to it to 12ɕ to 25ɕ in surface smoothness.

(3) Pull out the release lever pins.

Ground-down limit

1.0 mm (0.038 in.)

4. RE-ASSEMBLY Reassemble the dual clutch system in the same way as the single clutch. But abide by the following instructions exclusive for the dual clutch system.

Fig. 4-4

49

TH TRACTOR SERVICE MANUAL

Note: Tighten the bolts to the specified torque by two or three steps and diagonally.

(1) When assembling the clutch, install the diaphragm springs and discs in the correct direction.

(2) When installing the clutch assembly on the flywheel, use a centering tool or the input shaft to align the flywheel and clutch. loosen the PTO adjust bolts by loosening the respective lock nuts and push them out to make the PTO clutch disc free.

(5) Adjust the heights of the release levers using a height gauge.

Fig. 4-8 Fig. 4-6 (3) After centering, adjust the clearances between the PTO adjust bolts and the pressure plate.

From lining contact surface of flywheel

96.5 ± 0.7 mm (3.802 ± 0.027 in.)

From end surface of flywheel

98.5 ± 0.7 mm (3.881 ± 0.027 in.)

Difference between release lever heights

0.7 mm or less (0.027 in.)

(6) The release bearing is not made symmetrical that it has front and rear, so it should be installed properly.

Fig. 4-7 Clearance

1.4 - 1.5 mm (0.055 to 0.059 in.)

(4) Tighten the setting bolts of the clutch assembly to the specified torque. Fig. 4-9 Tightening torque

1.5 - 2.0 kgf· m (0.059 to 0.078 in.)

Note: if the bearing should be installed in reverse way, no stroke will be provided for the clutch discs.

50

CHAPTER 4: CLUTCH

(7) Adjust the free play of the clutch pedal.

Clutch pedal free play (at pedal top)

30 mm (1.18 in.)

Fig. 4-11

Fig. 4-10 5. TROUBLESHOOTING 1. PROBLEM: Clutch slippage

The initial stage of clutch slippage is very hard to notice, but the following symptoms are noticeable. (1) The tractor is not generating adequate power when performing heavy duty operations. (2) Output is not commensurate to 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.

51

TH TRACTOR SERVICE MANUAL

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

TEST METHOD: Disengage the clutch and shift the gears to LOW. Then shift the gears to NEUTRAL, accelerate the engine, and let it run for a while. Then shift the gears into REVERSE. If the gears still make noise, it is a symptom that the clutch does riot disengage properly. Probable causes

Countermeasures

a. Excessive deviation of the clutch disc

Replace. Remove rust or replace and apply

b. Worn or rusted spline section of the clutch disc hub

molybdenum disulfide grease.

c. Insufficient clutch pedal stroke

Adjust.

d. Excessive run-out or deviation of the clutch disc

Replace.

e. Fatigued diaphragm spring

Replace.

f. Excessive release bearing play

Replace.

g. Improper clearances between the PTO adjust bolts and

Adjust.

the surface of the pressure plate

52

CHAPTER 4: CLUTCH

53

TH TRACTOR SERVICE MANUAL

CHAPTER 5. TRANSMISSION 1. GENERAL DESCRIPTION (1) WHEEL DRIVE SYSTEM The wheel drive system composed of the following major components:

Input gears

Front transmission

Transmission

HST unit

Range change gears

Middle transmission

4WD change gear

Ring gear

Rear transmission

Differential gears

(2) PTO DRIVE SYSTEM a. The PTO drive system is composed of the PTO clutch pedal, the independent PTO clutch and the PTO change gears. b. The PTO change gears are housed behind the ring gear.

(3) SPEED SHIFT GEAR TRAIN DIAGRAMS

(Main change:2)

(Mechanical type) When the main change-gear is shifted, position (1,2,3,R), the gear travels the power to range gear.

(Main change:1) Fig.5-2

(Main change:3)

Fig.5-1

Fig.5-3 54

CHAPTER 5: TRANSMISSION

(Main change:R)

(Range gear:

2)

Fig.5-7 Fig.5-4

(HST Type) a. INPUT AND HST

When the range gear is shifted position (

,

1,

Drive from the engine, E, is taken from the input

2) after shifting main change, the

shaft, through the counter shaft and the HST gear travels the power to drive pinion.

(Range gear:

unit, and output to the range change section, R.

)

Fig.5-8

b. RANGE GEAR SHIFT POSITION “ONE” (

Fig.5-5

)

When the range change is shifted position “one”, the shift collar is moved rearward to

(Range gear:

1)

lock the (38T) gear to pinion shaft. Drive from HST unit, R, travels downward to countershaft, then continue rearward and upward to pinion shaft.

Fig.5-6

Fig.5-9

55

TH TRACTOR SERVICE MANUAL

When the PTO change is shifted the position

c. RANGE CHANGE SHIFT POSITION “TWO” (

“engagement”, the change gear is moved

1)

forward to engage the (13T) gear.

When the range change is shifted position

Drive

from engine, E, travels backward and

“two”, the shift collar is moved rearward to

downward through idler gear contained in the

lock the (29t) gear to pinion shaft. Drive from

input section to the independent PTO clutch

HST unit, R, travels downward to

assembly. When clutch is engaged, drive

countershaft, then continue rearward and

continuer rearward to the PTO output shaft

upward to pinion shaft.

through rear the PTO gear set.

Fig.5-10 Fig.5-12

d. RANGE CHANGE SHIFT POSITION “THREE” (

(5) MID PTO SHIFT GEAR TRAIN DIAGRAMS

2)

When the range change is shifted position

a. MID PTO CHANGE

“three”, the shift collar is moved forward to

When the mid PTO is shifted position

lock the (21T) gear to the pinion shaft. Drive

“engagement”, the change gear (21T) is

from the HST unit, R, travels downward to

moved forward to engage the (49T) gear.

countershaft, then rearward and upward to

Drive from engine, E, travels backward and

the pinion shaft.

downward through the idler gear contained in the input section to the independent PTO clutch assembly. When clutch is engaged, drive continuer rearward and downward to mid PTO output shaft through the mid PTO gear set.

Fig.5-11

(4) PTO SHIFT GEAR TRAIN DIAGRAMS a. PTO CHANGE SHIFT POSITION

Fig.5-13

“ENGAGEMENT”

56

CHAPTER 5: TRANSMISSION

2. REMOVAL AND INSTALLATION

d.

Remove bolts (2) that fix the metal (support) of the gear (15T).

(1) REMOVAL AND INSTALLATION OF INPUT SECTION

e.

Pull the input shaft, the (15T) gear and the metal (3) out evenly.

Removal a.

Separate the tractor between the engine

f.

Pull the (24T) gear out.

g.

Pull the PTO clutch out.

and the front transmission case.

b.

Remove bolts that tightening input metal. Remove the input metal as an assembly

Installation

using push bolts.

a. Installation is reverse order of disassemble. –

NOTE: Be sure to screw in the bolts evenly.

When the PTO clutch is installed, projections of brake disks of the PTO clutch should be installed in the groove of the front transmission case certainly.

Fig.5-14

c.

Fig.5-16

Remove bolts and a plate (Fig.4-8-1) that fixing the bearing of input shaft. –

If the oil seal is replaced, install it in correct direction. And apply grease between rips of it before assembling to gear.

Fig.5-15 Fig.5-17

57

TH TRACTOR SERVICE MANUAL

–

d.

When the input metal is installed, apply grease to O-ring beforehand. And input

Remove (33T) gear with a support metal (1) if necessary.

metal should be installed evenly. –

When the input metal is assembled to the front transmission case, turn the input shaft for adjusting the spline of the input shaft to the coupling to the HST unit, and shift the PTO change to engagement position and turn the PTO shaft for adjusting the spline of the PTO clutch to the coupling for the PTO drive shaft. Fig.5-19

(2) REMOVAL AND INSTALLATION OF HST UNIT Installation Removal a.

Installation is reverse order of removal. –

Separate the tractor between the front

When the front transmission case and the

transmission case and the middle

rear transmission case are assembled, both

transmission case.

side of contact surfaces are cleaned and liquid gasket should be applied beforehand.

b.

Remove delivery pipe (1). –

c.

Remove tightening bolts (2) and pull the

When the trunion shaft is installed, the setting bolt should be applied adhesive.

HST unit out forward.

Fig.5-20 Fig.5-18

–

When the trunnion metal is installed, both side of contact surfaces are cleaned and liquid gasket should be applied beforehand.

58

CHAPTER 5: TRANSMISSION

(3) REMOVAL AND INSTALLATION OF RANGE

d. Slide the third gear and the coupling forward

CHANGE SECTION

and pull the shift fork out.

Removal a. Separate the tractor between the middle transmission and the rear transmission case.

b. Pull the 4WD shaft out.

Fig.5-23

e. Pull the counter gear out with PTO drive shaft.

Fig.5-21

c. Remove a snap ring from the pinion shaft.

Fig.5-24

f.

Pull gears, needle roller bearings and hub out from pinion shaft.

Fig.5-22

g. Remove snap ring and take out the pinion shaft with bearings if necessary. Installation Installation is reverse order of removal. –

The direction of the 4WD drive gear is checked when installing it.

–

The direction of the hub ring is checked when installing it.

59

TH TRACTOR SERVICE MANUAL

Fig.5-25

–

–

Fig.5-27

–

When the front transmission case and the

When the range change metal is installed,

middle transmission case are assembled,

both side of contact surface should be clean

both side of contact surface should be

and liquid gasket should be applied

cleaned and liquid gasket should be applied

beforehand. The shift arm should be

beforehand.

installed to the groove of shift fork certainly.

When the front transmission case and the middle transmission case are assembled, shift the range change to neutral position and turn the counter gears using screw driver for adjusting the spline of the (33T) gear to the spline of the HST output shaft.

Fig.5-28

–

When the 4WD change metal is installed, both side of the contact surfaces are cleaned and liquid gasket should be applied beforehand. Before assembly of them, set the 4WD change gear to the engagement position. And shift the 4WD change arm to

Fig.5-26

the engagement position and pull it until the –

If the 4WD shaft is caught and assembly of

shifter ball falling in the depression for

the front transmission and the middle

assembly. Assemble the change metal to

transmission is difficult, remove the oil seal,

the middle transmission case, tighten the

snap ring and bearing from the front

bolts and push the change arm until the

transmission. After assembly of them, install

shifter ball falling in the depression of the

the bearing, snap ring and new oil seal.

normal position. Confirm the shift arm is

When the oil seal is installed, apply grease

installed in correct position then install the

between rips and the girth of it.

check plate. 60

CHAPTER 5: TRANSMISSION

d. Remove bolts and shifter stay locking plate.

Fig.5-29 Fig.5-31

(4) REMOVAL AND INSTALLATION OF PTO CHANGE SECTION

e. Pull the PTO shaft out rearward.

Removal

f.

Pull the PTO counter shaft out rearward.

a. Remove the cylinder case. g. Pull the shifter stay out and take the shift fork b. Remove the oil seal and snap ring of the

off.

PTO shaft. NOTE: Pay attention not falling parts into MID PTO

c. Remove the seal cap and snap ring of PTO

case.

counter shaft.

Installation Installation is reverse order of removal. When the oil seal is installed, apply grease between rips of the oil seal and spline part of the PTO shaft. Put the shift arm into groove of the shift fork Fig.5-30

certainly.

61

TH TRACTOR SERVICE MANUAL

(5) REMOVAL AND INSTALLATION OF MID PTO SECTION Removal a. Drain transmission oil using a drain plug (1) it’s located on the PTO gearbox.

Fig.5-34

e. Remove bolts and remove the oil seal guard (3). Fig.5-32

f.

Remove the oil seal and remove the snap ring.

b. Remove fixing bolt and remove mid PTO gear box (2).

g. Pull the mid PTO shaft off forward with turning the change lever clockwise.

h. Cut the fixing wire (4).

i.

Remove the spring pin (2) and pull the mid PTO lever out.

j.

Remove the bolt and plate (3).

k. Push the shift arm into the mid PTO case Fig.5-33

and remove it. Installation

c. Remove fixing bolt (1) and remove the plate.

Installation is reverse order of removal. d. Remove the idler gear shaft and take the

When the oil seal is installed, apply grease

idler gear off.

between rips of the oil seal and spline part of the PTO shaft. Put the shift arm into groove of the change gear certainly.

62

CHAPTER 5: TRANSMISSION

Reference Transmission (Mechanical type)

Fig.5-35 63

TH TRACTOR SERVICE MANUAL

(HST type)

Fig.5-35 64

CHAPTER 5: TRANSMISSION

65

TH TRACTOR SERVICE MANUAL

CHAPTER 6. HYDROSTATIC TRANSMISSION 1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS

Fig.6-1

66

CHAPTER 6: HYDROSTATIC TRANSMISSION

PARTS list 1

PUMP CASE

24

SPRING

45

PLUG

2

MOTOR CASE

25

SPRING HOLDER

46

PIN

3

PORT BLOCK

26

SNAP RING

47

O-RING

5

CYLINDER BLOCK

27

BALL BEARING

49

SOCKET HEAD BOLT

6

SLANT BOARD

28

NEEDLE BEARING

50

SOCKET HEAD BOLT

7

PUMP SHAFT

29

VALVE

51

WASHER

8

MOTOR SHAFT

30

SPRING

52

SOCKET HEAD BOLT

9

VALVE PLATE

31

OIL SEAL

53

PIN

10

VALVE PLATE

33

GASKET

54

DRIVE SCREW

11

PISTON ASSEMBLY

34

GASKET

55

SNAP RING

12

THRUST PLATE

35

O-RING

56

VALVE ASSEMBLY

13

RETAINER PLATE

36

O-RING

57

NAME PLATE

14

RETAINER HOLDER

37

SNAP RING

59

THRUST PLATE

15

COVER

38

O-RING

61

PIN

16

COVER

39

BUSH

67

SHIPPING PLUG

18

COVER

40

SCREW

68

SHIPPING PLUG

19

COVER

41

PLUG

70

O-RING

22

PIN

42

POPPET

23

SPRING HOLDER

43

SPRING

67

TH TRACTOR SERVICE MANUAL

2.

DISASSEMBLY

2.1. PRECAUTIONS FOR DISASSEMBLY a.

b.

Cover all ports to prevent dust from entering and clean the exterior of the casing completely.

c.

Select a clean, dust-free place to work in to prevent dust affecting precision parts.

d.

Be fully careful not to damage the parts and not to make scratches and dents by dropping or contacting.

Drain oil in the case.

2.2. REQUIRED TOOLS Tools

Size / Specified

Plastic hammer

0.3 kg with light alloy core

Screwdriver (+)

NO.2

Screwdriver (-)

Nominal dimension: 100 mm

Snap ring pliers(for hole)

H-2,H-3

Snap ring pliers(for shaft)

S-1 5 mm

Setscrew wrenches

Width across flat (WAF)

6 mm 8 mm 10mm

Torque wrench

Set values

Torque screwdriver Torque wrench socket

Width across flat:

7.85 N-m

(0.8 kgf-m)

17.7 N-m

(1.8 kgf-m)

29.4 N-m

(3.0 kgf-m)

36.8 N-m

(3.8 kgf-m)

49.0 N-m

(5.0 kgf-m)

6.86 N-m

(0.7 kgf-m)

26mm 5 mm

Torque wrench hexagonal bits

Width across flat:

6 mm 8 mm 10mm

Monkey wrench

68

CHAPTER 6: HYDROSTATIC TRANSMISSION

2.3. DISASSEMBLY (1) Removal of the cover b. Remove case (1) from port block (3). Attention not to drop valve plate (9) from port block (3).

a. Remove four socket head bolts (52) (M8, WAF: 6mm). b. Remove cover assembly(C) and O-ring (36) from case (1). c. Remove two pins (46) from case (1).

Fig.6-4

c. Remove valve plate (9) from port block (3). Valve plate may be put on cylinder block side.

Fig.6-2

Note: When valve plate (9) remains on port block (3), lift up one side of it with a screwdriver (-) and then it will be separated easily.

(2) Disassembly of the pump a. Remove four socket head bolts (50) (M10, WAF: 8mm).

Fig.6-3

69

TH TRACTOR SERVICE MANUAL

Fig.6-7 Fig.6-5

(4) Removal of the cylinder block assembly (3) Disassembly of the motor a. a. Remove four socket head bolts (50) (M10, WAF: 8mm).

Pull off the cylinder bock assembly from pump shaft (7).

b. Remove motor case assembly from port block. Attention not to drop from valve plate (10). Note: Be careful not to lose Valve (29) and spring (30) because they will drop easily.

Fig.6-8

b. Remove thrust plate from slant board (6).

Fig.6-6

c. Remove valve plate (10) Note: Valve plate may be put on cylinder block side. When valve plate (10) remains on port block (3), lift up one side of it with a screwdriver (-) and then it will be separated easily. Fig.6-9 70

CHAPTER 6: HYDROSTATIC TRANSMISSION

c. Remove cylinder block assembly from motor shaft (8). Note: When removing cylinder bock assembly, be careful not to lose six pins (22) of pump and motor.

Fig.6-12

(5-2) Removal of the motor shaft a. Remove three socket head bolts (49) (M6, WAF: 5mm). b. Remove cover assembly (D) and O-ring (35) from case (2).

Fig.6-10

(d) Remove thrust plate (12) from case (2).

c. Tap the end of shaft (8) by plastic hammer and remove motor shaft assembly.

Fig.6-13 Fig.6-11

(6) Removal of the slant board of pump (5) Removal of the shaft (5-1) Removal of the pump shaft a.

Remove snap ring (55) from case (1).

b.

Tap the end of shaft (7) by plastic hammer and remove pump shaft assembly.

a. Remove six screws (40) (M6) by screwdriver (+). b. Remove cover assembly (A) and cover assembly (B). Note: The cover is removed by hitting the trunnion with plastic hammer.

71

TH TRACTOR SERVICE MANUAL

Fig.6-14

Fig.6-16

d. Remove slant plate (6). e. Remove two pins (61) from slant plate (6).

Fig.6-15

(7) Disassembly of the port block a. Remove plug (41) (PF/8, WAF: 8) and remove poppet (42) and spring (43). b.

Remove valve (56) (PF1/2, WAF26).

c.

Remove for plugs (45) (PF1/4, ,WAF6).

72

CHAPTER 6: HYDROSTATIC TRANSMISSION

CRITERIA FOR REPLACING WORN PARTS Parts names

Inspection items a. Clearance between shoe and piston shoe seat:e

PISTON ASSEMBLY

b.

c.

VALVE PLATE THRUST PLATE

Usable limit

e: 0.03mm

e < 0.03mm

D-d: 0.02mm

D-d < 0.04mm

t: 3.0mm

t > 2.9mm

0.2a

< 0.8a

0.2a

< 0.8a

Clearance between piston diameter and cylinder block bore:D-d

Shoe thickness: t

d. CYLINDER BLOCK

Standard value

Smoothness of shoe friction surface Smoothness of friction surface with valve plate Smoothness of friction surface with cylinder block Smoothness of friction surface with piston assembly

Note: Slight flaws on friction surfaces can be corrected by lapping. But lapping down limit is 0.01mm. If more than specified lapping is required, replaced the part with a new one.

73

TH TRACTOR SERVICE MANUAL

3. REASSEMBLY 3.1. PRECAUTION FOR REASSEMBLY

(2) Installation of the pump shaft

a. Wash disassembled parts in fresh cleansing oil and blow them with clean compressed air.

a. Install pump shaft assembly into case (1) so that shaft end becomes flush with bearing casing.

b. Handle the cleansed parts carefully not to damage such as dents, scratches, etc. c. All removed sealing parts should be discarded and replaced with new ones. d. All fasteners should be tightened to specified values. e. Apply lithium-based grease to oil seals and O-ring, especially to the lips of the oil seals.

3.2. REASSEMBLY (1) Installation of the slant board a.

Put slant board (6) into case (1). Fig.6-19

b. Install snap ring(55) into case(1).

Fig.6-17

b.

Install cover assembly (A and B) into case (1) and tighten 6 screws (40) (M6) to the specified torque (0.07kgf-cm).

Fig.6-20

(3) Installation of the slant plate a.

Install thrust plate (59) into slant plate (6). Note: Align the two holes in the thrust plate with the two pins.

Fig.6-18 74

CHAPTER 6: HYDROSTATIC TRANSMISSION

(6) Installation of the cover a.

Set O-ring (35) on cover assembly and install cover on case (2).

Fig.6-21

(4) Installation of the cylinder block a. Install cylinder block (5) into shaft (7). Be careful not to drop pins (22).

Fig.6-24

b.

Tighten three socket head bolts (49) (M6, WAF: 5mm) to the specified torque (80.1kgf-cm).

Fig.6-22

(5) Installation of the motor shaft a.

Install motor shaft assembly into case (2) so that shaft end becomes flush with bearing casing. Fig.6-25

Fig.6-23 75

TH TRACTOR SERVICE MANUAL

(7) Installation of cylinder block on motor shaft a.

c.

Apply lithium-based grease to spring (29) into case (2).

Install cylinder block assembly into motor shaft (8).

Fig.6-28 Fig.6-26

d.

Install valve plate (10) into port block assembly. Motor side valve plate has four notches, pay attention not to mistake parts.

e.

Install valve (29) into port block assembly.

(8) Assembly of motor case and port block a.

Install two pins (46) into case (2).

Fig.6-27 Fig.6-29

b.

f.

Apply lithium-based grease to gasket (34) and install gasket (34) into case (2).

Assemble motor case (2) and port block (3). Note: When assembling motor case (2) and port block (3), check to see that valve of port block (28) and spring (29) of case are properly assembled with each other.

76

CHAPTER 6: HYDROSTATIC TRANSMISSION

(9) Assembly of pump case and port block a.

Apply lithium-based grease to gasket (33) and install gasket (33) into case (1). Note: Install gasket (33) into gasket so that projection side of gasket (33) unites case (1).

Fig.6-30

g.

Tighten four socket head bolts (50) (M10, WAF: 8) to the specified torque (500kgf-cm).

Fig.6-32

b.

Install valve plate (9) into port block assembly and assemble pump case assembly and port block assembly. Note: Pump side valve plate has two notches, pay attention not to mistake parts.

Fig.6-31

Fig.6-33

77

TH TRACTOR SERVICE MANUAL

c.

Tighten four socket head bolts (50) (M10, WAF: 8) to the specified torque (500kgf-cm).

Fig.6-36

Fig.6-34

(10) Assembly of the cover a. Install two pins (46) and O-ring (36) into case (1). b. Assemble cover assembly (C) and case (1), and tighten four socket bolts (52) (M8, WAF: 6mm) to specified torque. (180.6kgf-cm).

Fig.6-35

78

CHAPTER 6: HYDROSTATIC TRANSMISSION

CYLINDER BLOCK ASSEMBLY

Fig.6-37

SHAFT ASSEMBLY PUMP SHAFT

MOTOR SHAFT

Fig.6-38

79

TH TRACTOR SERVICE MANUAL

PRESS-INSTALLATION OF BEARING

PRESS

Fig.6-39

Note: Install bearing into shaft so that bearing becomes end of the shaft. When installing bearing into shaft, use jig such as picture.

80

CHAPTER 6: HYDROSTATIC TRANSMISSION

PORT BLOCK ASSEMBLY

Fig.6-40

Note: Install needle bearing into port block so that a carved seal of needle bearing becomes outside. When installing needle bearing into port block, make sure that the distance is 3.5mm between needle bearing and end of port block. Install pin onto port block, such as a picture.

81

TH TRACTOR SERVICE MANUAL

COVER ASSEMBLY COVER ASSEMBLY (A)

COVER ASSEMBLY (B)

Joint of bush

Fig.6-41

Note: Install bush into cover so that the joint of bush becomes port block side.

82

CHAPTER 6: HYDROSTATIC TRANSMISSION

COVER ASSEMBLY(C)

COVER ASSEMBLY (D)

Fig.6-42 Note: Install oil seal (71) into cover so that the distance is 2mm between end of oil seal and end of cover(C). Install oil seal (31) into cover so that the distance is 2.5mm between end of oil seal and end of cover (D).

83

TH TRACTOR SERVICE MANUAL

Reference (1) HST Link Assembling

Fig.6-43 84

CHAPTER 6: HYDROSTATIC TRANSMISSION

85

TH TRACTOR SERVICE MANUAL

CHAPTER7 . FRONT AXLE

1.

CONSTRUCTION

2.

DISASSEMBLY Fig.7-1

86

CHAPTER 7:FRONT AXLE

2.

DISASSEMBLY

e.

Divide the final case assembly into the final case (A) and final case (B).

f.

Remove the wheel gear bearing using a puller.

g.

Remove the snap ring and drive out the wheel shaft with a plastic hammer.

(1) Final case and related parts. a.

Remove the tire on the side of which final case is to be disassembled. Note: Support the tractor front with a garage jack.

b.

In this stage, the wheel shaft oil seal can be checked.

Remove the final case from the axle end.

(2) Differential and related parts Caution: Take care not to damage the O-ring. Never attempt to insert the blade of a screwdriver between the contact surfaces of the final case and axle end. c.

Separate the wheel cover from the final case.

a.

Separate the front axle from the front axle bracket referring to 8 of chapter 2.

b.

Pull off the right and left shafts.

c.

Remove the oil seal for the input shaft.

d.

Remove the snap ring and pull off the input shaft.

Fig.7-2

d.

Remove the cap and snap ring. Fig.7-4

Note: - The bearing for the input shaft may be too tightly fitted to remove easily. In such a case, as a tapped hole is provided in the end of the input shaft, use a slide hammer to remove the shaft.

Fig.7-3 Fig.7-5

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TH TRACTOR SERVICE MANUAL

- When removing the input shaft check to see how many adjusting shims are installed (at 2 points).

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 plays to the axis.

(3) The differential assembly can be taken out along with the bearing. (4) Before disassembling the differential, pull out the spring pin. Then it is disassembled easily.

(5) Check the bushings for the front and rear pivot metals (supports) for wear. When they are worn out exceeding the usable limit, replace them.

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

Front bushing bore Rear bushing bore

(2) Check the bevel gears and trust collars of the differential for wear. (3)

Make sure that each bearing turns smoothly.

(4) Check the oil seal lips and the seal contacting surfaces of the shafts for damage.

Ɏ62+0.186 mm or Ɏ62+0.116 mm Ɏ62+0.186 mm or Ɏ62+0.116 rum

0.2 mm

0.2 mm

Note: Bushing bore should be measured when the bushings are installed.

Fig.7-6

88

CHAPTER 7:FRONT AXLE

4.

PRECAUTIONS FOR REASSEMBLY

(1) When replacing the shaft seals of the rotating parts of the final drive case and wheel shaft, never hit the flange surface of the sleeve. Damaged flange surfaces will cause oil leaks.

(3) Tighten the lock nut so that the sub-assembled input shaft has the specified starting torque. Starting torque: Spring balance reading upon obtaining the specified torque

5 – 7 kgf-m (43 – 51 ft-lb)

Fig.7-7

(2) When sub-assembling the differential, inset the spring pin so the seam is installed in the direction of external force applied. After inserting the spring pin, retain it with wire. Note: Seam of roll pin should face in direction which load is applied.

Fig.7-9

(4) After adjusting the starting torque, make sure to tighten the lock nut.

Fig.7-8

Fig.7-10

(5) After installing the differential assembly and input shaft into the front axle housing, make sure that the shaft between the differential assembly and the final case turns smoothly. Note: Re-install the shims for the input shaft of the same number of shims and in the same position as before.

Fig.7-11

89

TH TRACTOR SERVICE MANUAL

-

When replacing the ring gear and input shaft with new ones, backlash adjustment is impossible because of design, so make sure that they turn smoothly by turning the shaft between the differential and the final case. When they are excessively heavy to turn, add the number of shims at T2 and vice versa. After T2 shimming, add shims at T1 until the snap ring has no play against the collar.

(6) After installing the front axle on the axle bracket, adjust the fore-and-aft play of the front axle to the specified vale. End-float is measured with axle raised off the ground. Loosen the lock nut (1) and turn the adjusting bolt (2) as needed to achieve correct measurement. Tighten the lock nut (1).

Fig.7-12

Fore-and-aft play of front axle

0-0.2 mm (0-0.008 in.)

(7) After installing the front axle, adjust the toe-into the specified value.

Toe-in

2-6mm (0.08 - 0.23 in.)

90

CHAPTER 7:FRONT AXLE

5.

TROUBLE SHOOTING Problems and probable causes x

x

x

x

x

x

Countermeasures

Steering wheel hard to turn: 1) Too low tire inflation 2) Broken thrust bearing 3) Stuck or broken ball joint of tie-rod end 4) Seizure or poor lubrication of axle end bush Vibrating or pulling steering wheel: 1) Unbalanced wheels 2) Wheel deflection 3) Unequal diameter of both tires 4) Loose, worn, or damaged wheel axle bearing 5) Loose, worn, or damaged wheel steering wheel shaft 6) Worn final case bush 7) Loose final case--front axle tightening 8) Loose front wheel (tire) tightening nuts Steering wheel tends to turn to the right or left while travelling on straight paved road: 1) Deflected wear of tire 2) Different tire diameters 3) Damaged final case bearing Excessive or eccentric wear of tire: 1) Improper tire inflation 2) Worn front wheel shaft bearing 3) Poorly adjusted toe-in 4) Front wheel drive (4WD) is always engaged. Noise: 1) Loose fasteners 2) Worn or damaged final case bearing 3) Worn bush 4) Wear or poor movement of tie-rod end 5) Excessive backlash of differential and bevel gear Different steering angles in both directions: 1) Lengths of RH and LH tie-rods are different.

91

Inflate to specified pressure: 1.8 kgf/cm2 (25.6 psi) Replace. Grease or replace. Grease or replace. Adjust balance Repair or replace Adjust inflation or replace. Repair or replace. Retighten or replace. Replace. Retighten. Retighten.

Replace. Adjust inflation or replace. Replace. Adjust. Replace. Readjust correctly: 2 - 6 mm (0.08 - 0.24 in.) Engage 4WD only when required. Tighten correctly to specified torque. Replace. Replace. Lubricate or replace. Adjust.

Adjust.

TH TRACTOR SERVICE MANUAL

CHAPTER8 . STEERING SYSTEM 1. CONSTRUCTION The steering system of this tractor is a hydrostatic type. The steering unit (mini-orbit roll) controls hydraulic power and activates the front wheel 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 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 works.

Fig.8-1

92

CHAPTER 8:STEERING SYSTEM

2. STEERING HYDRAULIC CIRCUIT

Fig.8-2

93

TH TRACTOR SERVICE MANUAL

3. INTEGRAL ORBIT ROLL

Fig.8-3

3.1.

COMPONENTS

94

CHAPTER 8:STEERING SYSTEM

4. DISASSEMBLY x x x

When repairing the steering unit, a clean work place 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 ofal2 the illustrations below for easy viewing do not show a vice

d.

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

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.

4.1. DISASSEMBLY OF ROTOR SIDE 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. Over tightening may damage the unit. Fig.8-6

h.

Remove drive (11).

i.

Remove spacer plate (10) and then remove Oring (31) from housing (13).

Fig.8-4

b.

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

c.

Remove the end cap.

Fig.8-7

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.

4.2. DISASSEMBLY OF CONTROL SIDE a.

Fig.8-5

95

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.

TH TRACTOR SERVICE MANUAL

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.8-8

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.8-12

g.

Fig.8-9

c.

Pull off pin (16).

Fig.8-13

Remove oil seal (27) from seal bushing (30).

h.

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

Fig.8-10

d.

Fig.8-14

Remove dust seal (28) with a screwdriver taking care not to damage the seal bushing. i.

e.

Remove two bearing races (24) and thrust needle bearing (25).

Pull off spool (15) out of sleeve (14). Note: Pull off the spool in the direction shown by the arrowhead while turning it right and left.

Fig.8-11

Fig.8-15

96

CHAPTER 8:STEERING SYSTEM

j.

Note: Make sure that the spool turns smoothly by holding the spool 's splined part.

Remove O-ring (26) from housing (13).

b.

Align the spring grooves of the spool and sleeve and insert centering springs (17) and flat springs (18) using a jig #600057. Set the spring ends flush with the sleeve circumference.

Fig.8-16

Note: Never adjust the relief valve. When it is defective, replace control valve assembly (12).

4.3. INSPECTION Fig.8-18

Check the contact surfaces of all components. Replace defective ones. Wash all metal parts in clean solvent and dry them with pressurized air. 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: Set the four centring springs (1 7) and the two flat springs (18) together with the cut-away parts turned downward. c.

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

Note: Apply fresh grease to O-rings ahead of time. We recommend used O-rings and seals be replaced with new ones whenever possible. Fig.8-19

5. RE-ASSEMBLY d. 5.1. RE-ASSEMBLY OF CONTROL SIDE a.

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

Insert the spool (15) into sleeve (14) while turning the spool slowly.

Fig.8-20

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

Fig.8-17

97

TH TRACTOR SERVICE MANUAL

e.

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

f.

Insert the two bearing races (24) and thrust needle bearing (25). Note: The thrust needle bearing should be sandwiched with the bearing races.

Fig.8-23

Note: Push open the retaining ring with a screwdriver so that it is seated completely and fully expanded in the groove. Fig.8-21

g.

5.2. RE-ASSEMBLY OF GEROTOR SIDE

Set dust seal (28) into seal bushing (30).

a.

Insert ball (5) into the bolthole and make sure that the ball is seated in the proper position.

Fig.8-22

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.

i.

Insert seal bushing (3) into spool (15) while turning the bushing. Note: Drive the bushing into the spool securely using a plastic hammer

j.

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

Fig.8-24

Note: Make sure that the spool/sleeve assembly is deformed a little when the ball is installed.

98

CHAPTER 8:STEERING SYSTEM

b.

Insert O-ring (31) into housing (13).

B: guideline for the pin axis C: Pin axis D: Port surface A, B, and C should be parallel to each other.

Fig.8-25

c.

Place spacer plate (10) as shown and align the oil holes. Note: The bolt hole and oil holes are different.

d.

Insert drive (11).

Fig.8-28

h. Fig.8-26

Note: Provide a guideline on the drive end face parallel with the pin axis with a felt pen for correct installation. e.

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 boltholes of the gerotor and placer plate do not align to each other; turn the gerotor housing alone.

Insert O-ring (31) on gerotor (7). i.

Insert O-ring (31) on end cap (6).

j.

Place end cap (6) on gerotor (7) and align boltholes.

Fig.8-27

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

Fig.8-29

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TH TRACTOR SERVICE MANUAL

k.

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

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.

Fig.8-30

6. CYLINDER SYSTEM

Fig.8-31

100

CHAPTER 8:STEERING SYSTEM

7. TROUBLE SHOOTING 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. Pump a. It is not operating. b. Worn or damaged pump c. It is rotating in reverse. d. Insufficient pump delivery 3. Relief valve a. Defective b. Too low set pressure 4. Cylinder a. Insufficient pressure receiving area 5. Priority valve (load sensing) a. Seized spool b. Clogged damping orifice c. Insufficient control pressure of spring d. Low regulation pressure of relief valve Steering wheel does not return to 1. Orbit roll neutral position when it is released a. Seized spool/sleeve assembly or it has a tendency to turn by b. Back pressure too high itself. c. 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 3. Cylinder a. Trapped air b. Broken piston seal

101

Countermeasure Repair. (If bolts, which tighten column on orbit-roll are loosened 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. Replace. Correct regulation pressure. Replace with proper cylinder.

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

Replace. Correct. Correct.

Bleed. Increase delivery rate.

Bleed. Replace.

TH TRACTOR SERVICE MANUAL

Problems

Steering wheel operates in reverse.

Oil leakage 1. Through shafts (circumference of splined part) 2. Contact surfaces between housing, spacer plate, gerotor, and end cap.

Presumable causes 4. Overload/anti-cavity valves a. Leaking 1. Orbit roll a. Incorrect valve timing 2. Piping a. Mistake in port connection Worn oil seal (X-ring) a. Contaminated working fluid b. Back pressure too high Broken O-rigs a. Pinched rings

102

Countermeasures Replace valves.

Correct. Correct. Provide proper countermeasure to prevent oil contamination Correct. Replace.

CHAPTER 8:STEERING SYSTEM

103

TH TRACTOR SERVICE MANUAL

CHAPTER9 . HYDRAULIC SYSTEM GENERAL DESCRIPTION 1. HYDRAULIC SYSTEM DIAGRAM (Mechanical type)

Fig.9-1

104

CHAPTER 9:HYDRAULIC SYSTEM

(HST Type)

Fig.9-2

105

TH TRACTOR SERVICE MANUAL

2.

HYDRAULIC CIRCUIT DIAGRAM (Mechanical type)

Fig.9-3

106

CHAPTER 9:HYDRAULIC SYSTEM

(HST type)

Fig.9-4

107

TH TRACTOR SERVICE MANUAL

3. PTO control valve Function This solenoid valve controls hydraulic flow and pressure to engage PTO clutch smoothly without shock. When the solenoid valve is in neutral position, the PTO clutch is disengaged. (1) Hydraulic oil flows into P (pump) port of the solenoid valve. (2) When electric input goes in solenoid A side from control unit, spool moves to the right and oil flows to B port. This solenoid valve has structure that A and B port are connected and hydraulic clutch is engaged. Clutch piston moves and oil flows to drain port to be controlled half engaging pressure as clutch meets. (3) After 1.1 seconds, control unit signals solenoid B, spool moves to the left. Oil flows into A port (B port is blocked). Hydraulic pressure rises up and PTO clutch is engaged completely. Clutch half engaging pressure: 7.5 – 9.0 kgf/cm2 (0.735 – 0.883 MPa), solenoid A operated Clutch full engaging pressure: 16.0 – 18.0 kg/cm2 (1.57 – 1.77 Mpa), solenoid B operated

Fig.9-5

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Maintenance

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

Tightening torque of solenoid valve: 120 – 150 kgf-cm (11.8 – 14.7 Nm) Tightening torque of hydraulic pipe: 600 – 800 kgf-cm (58.9 – 78.5 Nm) Oil seal: soft type and new seal must be installed as disassembly. Pushing A port of solenoid valve operates half engaging pressure of clutch. Pushing B port of solenoid valve operates full engaging pressure of clutch. Operating hydraulic pressure is measured in inspection port. Pressure gauge: 50kgf/cm2 Plug: PT1/8 Engine: Full speed Hydraulic oil temperature: 40 – 50 cent-degree

Fig.9-6

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4. SPECIFICATIONS

Oil Piston and cylinder inch(mm) Piston diameter Cylinder bore Piston stroke Lift (at lower link end) lbs.(kg) Main control valve Maximum flow rate (p-c) Maximum pressure (port c) C-port leak Relief valve Cracking pressure Relief pressure Leak Safety valve Cracking pressure Relief pressure Leak Flow-control valve Operating fluid temperature Maximum pressure Leak when closed fully Gear pump Working oil temperatures Theoretical delivery Maximum pressure Suction filter Rated flow rate Filtering density Filtering area

TH4260 TH4290 TH4330 Gear oil SAE 80 (in common with transmission) 2.95(75) 2.95(75) 4.22(107) 2425 (1100) 30 l/m @ engine 32.1 l/m @ engine 2750rpm 2860rpm 2987psi(210kgf/cm2) 10cc(0.61 cu.in.) / min. or less 1849psi (130kgf/cm2) 2133psi (150kgf/cm2) 0.1cc(0.006 cu.in.) / min. or less 2347psi (165kgf/cm2) 2774psi (195kgf/cm2) 0.1cc(0.006 cu.in.) / min. or less -20֣100͠ 3982psi (280kgf/cm2) 1cc(0.061 cu.in.) / min. or less -20֣90͠ 9.8 l/m @ engine 2500rpm 2133psi (150kgf/cm2) 43.3 l/min 400mesh 650cm2(100.8sq.in.)

110

10.2 l/m @ engine 2600rpm

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MAJOR COMPONENTS OF HYDRAULIC SYSTEM 5. CYLINDER 5.1. CONSTRUCTION

Fig.9-7

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e. Disassemble the lift crank in the following way:

5.2. DISASSEMBLY a. Separate the cylinder case from the rear transmission case referring to 8 of chapter 2.

x

Remove the bolts from the control lever bracket ahead of time.

x

Remove the snap rings from the right side and centre of the lift shaft.

x

Drive off the lift shaft leftward.

Fig.9-8

b.Remove the sub control valve cover. c. Remove the spring, which retains the spool of the main control valve. Fig.9-11

Note: Make sure that the lift shaft and lift crank have aligning marks. x

Disconnect the right end of the lift arm from the lift shaft.

Note: Before disassembly, put aligning marks on the lift arm and lift shaft.

Fig.9-9

d. Pull off the cotter pin from the spool link and remove the main control valve.

Fig.9-12

f. Fig.9-10

112

Remove the cylinder head.

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Fig.9-13

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k. Assemble the lift shaft and lift crank in accordance with the aligning marks.

Fig.9-14

g. Remove the piston. Fig.9-17

l.

Install the lift arm into the lift shaft by aligning the splines so that the lowest position of the lift arm is 10° below horizon.

Note: Aligning marks should be provided on both parts before disassembling. m. The control valve bolts should be tightened to the specified torque. (Fig. 9-13)

Fig.9-15

5.3. PRECAUTIONS FOR RE-ASSEMBLY Note: Excessive tightening or uneven tightening will lead to irregular movement of the control valve spool. After installation, make sure that the spool moves smoothly.

g. Wash especially hydraulic circuit parts and keep them away from dust. h. During re-assembly, be sure to check each part for damage, especially sealing parts like O-rings. i.

Apply grease to O-rings and friction surfaces in advance.

j.

Be sure to install the O-ring and back-up ring in position correctly.

Fig.9-18

Tightening torque Fig.9-16

114

130 - 180 kg·cm (9.34 - 13.01 ft·lb)

CHAPTER 9:HYDRAULIC SYSTEM

n.

Set the position arm and support link correctly.

Fig.9-21 Fig.9-19

o. Hook the spring on the end of the main control valve spool so that the spring becomes level paying attention to the installed direction of the spring.

Fig.9-22 Fig.9-20

Top clearance

Note: If the spring is not level, the smooth movement of the spool will deteriorate. p.

Standard length of 50 mm (3.07 in.) position rod Note: After assembly, shift the hydraulic control lever to the highest position to make sure that the relief valve is not activated.

Tighten the bolts for each valve to the specified torque. Main control valve Safety valve Slow return valve

4-5mm (0.158-0.20 in.)

130-1 80 kgf-cm (9.3 -13.0 ft-·lb) 600- 700 kgf-cm (43.4 - 50.6 ft-lb) 1000-1200 kgf-cm (72.3 - 86.8 ft-lb)

l.

Adjust the clearance between the flow control valve and shaft as specified.

k. After installing the cylinder case on the rear transmission case, adjust the top clearance of the lift arm (the play of the lift arm in the highest position) as specified by adjusting the effective length of the position rod. Fig.9-23

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Clearance

16 mm (0.63 in.)

m. Adjust the operating load of the position control lever as specified with the lock nut. Lever operating load

3 - 4 kgf (6.6 - 8.8 Ib)

5.4. AUXILIARY HYDRAULIC VALVE

Fig.9-24

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6. MAIN CONTROL VALVE 6.1 CONSTRUCTION

Fig.9-25

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6.2 FUNCTION This valve composed of the main spool (sequential control), relief valve (pressure control), compensator (flow control), and check valve (sequential control). It is housed in the cylinder case.

Fig.9-26

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a.

Main control valve

The up and down movement of the lift is controlled by switching over the flowing channel of the pressurized fluid from the pump between the two routs: P to C or C to T.

b.

Fig.9-27 c. Check valve

Compensator

This valve bypasses all the pressurized flow from the pump to the tank while the main spool is in the neutral position or in the down position. This leads to engine power economy and prevention of fluid temperature rise. While the main spool is in the up position, this valve allows the flow to go only through the opened area of the passage from P to C in the main spool: to the cylinder, and causes the surplus to instantaneously bypass to the tank, which allows the operator to perform delicate lift operation such as "Inching."

This valve controls fluid flowing directions by main spool shifting, that is, it controls the flow to the cylinder, while the reverse flow from the cylinder is blocked when the spool is in the neutral position.

Fig.9-29

Fig.9-28

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6.3 OPERATIONS a.

Neutral position Chamber (9) in the compensator is drained through passage (10) and chamber (5), while all fluid from port P2 goes to compensator chamber (1) and to main spool chamber (2), but all pressure is applied to chamber (1) because main spool chamber (2) is closed. Then pressure difference is generated between chamber (1) and chamber (9) because force in chamber (9) is that of spring (14) alone: chamber (1) > chamber (9), which causes the compensator spool to shift leftwards so as to compensate the pressure difference. Then the fluid is all unloaded through cut-away (19) and chamber (8) to port T2. On the other hand, unloading of the cylinder pressure is sustained because the ball in the check valve is in tight contact with the seat, and unloading route through passage (12) and chamber (6) is also blocked by the main spool. Thus the cylinder pressure is held to hold the piston still.

Fig.9-30

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b.

Up position The pressurized fluid from the pump flows to chamber (2) through chamber (1). Then it flows into chamber (21) through orifice (3) in the main spool. In chamber (21) the flow is divided in two directions. One flow goes to chamber (9) through passage (4), chamber (5), and passage (10), where the compensator spool is shifted rightward by the fluid pressure and the force of the spring: pump pressure in chamber (9) plus spring force > pump pressure in chamber (1). (the fluid is not unloaded to port T2.) The other branched flow (pump pressure) goes through passage (11) to the check valve. It pushes the valve to open and goes into the cylinder to activate the piston. When the piston is pushed to a designate position, the main spool is returned to the neutral position by the link mechanism and following pressurized fluid from the pump is unloaded. When the piston is pushed to a specified level: the lift rises, the main spool is shifted to the neutral position, by means of the link mechanism. Then the fluid is unloaded to port T2 as explained in a neutral position.

Fig.9-31

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c.

Down position As chamber (9) in the compensator is drained through passage (10) and passage (10) to port Dr, the compensator spool is held only by spring (14). The pressurized fluid from the pump all goes to chamber (4) as chamber (2) in the main spool is blocked. In chamber (4) it shifts the compensator spool leftwards and unloads itself passing through chamber (1), chamber (14), and passage (11). On the other hand the cylinder pressure is unloaded to port T1 through cut-away (7), chamber (18), and passage (13). Thus the piston returns: the lift lowers. When the piston returns to a designated position, the main spool is shifted to the neutral position by means of the link mechanism. Then the cylinder pressure unloading is blocked at chamber (6), the check valve, and chamber (21) in the main spool. Thus the piston stops.

Fig.9-32

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- Minor flaws can be corrected with an oilstone. - Clearance between compensator spool and body:

6.4 INSPECTION OF MAIN CONTROL VALVE Inspect the disassembled parts for damage and wash them clean in fresh kerosene or light oil. Repair or replace damaged parts. a.

Usable limit

Main spool - The spool should smoothly move in the body. - All passages in the spool should be free from clogging. - Minor flaws on the spool surface can be corrected with an oilstone. - Specified clearance between main spool and body. Usable limit

b.

- Measure the free length of the spring. If the measured value is deviated from the specified values or it is deformed, replace it.

Free length

0.01 mm (0.0004 in.)

Check valve - Mutual bearing surfaces of the check valve guide and the body should have no flaws. - Measure the outer diameter of the check valve guide. If the measured value exceeds the usable limit, replace the guide. After the installation of a new guide, tap the seat surface with the steel ball lightly to make sure of the ball's tight seating. Ɏ 11.92 mm (Ɏ0.4693 in.)

Usable limit

- There should be no flaws on the seat surface and steel ball surface. - Minor flaws can be corrected with an oilstone. - Measure the free length of the spring. If the - measured value is deviated from the specified values or it is deformed, replace it.

Free length c.

0.016 mm (0.00063 in.)

Specified value

Usable limit

19 mm (0.75 in.)

18mm (0.71 in.)

Compensator spool - Mutual bearing surfaces of the compensator spool and body (surfaces and edges) should have no flaws.

123

Specified value

Usable limit

26 mm (1.02 in.)

25mm (0.98 in.)

TH TRACTOR SERVICE MANUAL

7. FLOW CONTROL VALVE 7.1.GENERAL DESCRIPTION This valve controls the flow returning from the cylinder while the lift arm is lowering and as a result regulates the maximum lowering speed of the lift.

Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12

Part Names O-ring Back-up ring Ring C Spring Poppet Body O-ring O-ring Snap ring (hole) Dust seal Bush Adjusting screw

Quantity 1 1 1 1 1 1 1 1 1 1 1 1 Fig.9-33

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7.2.Operations

b.

a.

The flow from port A, overcoming the force of spring (4), pushes up poppet (5) and choke (O) is fully opened regardless of the position of adjusting screw (12). Thus the fluid flows to port B and the cylinder, which results in raising the lift arm.

DOWN position

The fluid from port C pushes up stop ring C (3) of poppet (5) until the ring comes into contact with adjusting screw (12), as it reaches chamber (R). Consequently, the extent choke (O) is opened is determined by the positioning of adjusting screw (6): that is, when adjusting screw (12) is screwed in clockwise, the opening of choke (O) decreases and the lowering speed of the lift arm slows down; whereas the opening of choke (O) increases and the lowering speed of the lift is accelerated when the adjusting screw is unscrewed counter clockwise. When the adjusting screw is screwed in completely, the poppet comes into contact with body seat (S) and the choke is closed completely, so the lift arm stops.

Up position

Fig.9-35

8. SAFETY VALVE 8.1.CONSTRUCTION With the choke closed completely by turning the adjusting screw tightly clockwise, the implement mounted on the lift is held at a specified height. While the tractor is travelling on roads in this condition, there is a possibility that the cylinder pressure will raise excessively when the implement bounces. In such a situation the cylinder pressure can rise so high as to break the cylinder. To prevent such an accident, the relief valve works

Fig.9-34

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TH TRACTOR SERVICE MANUAL

to leak off the fluid in the cylinder to the tank via port P and port T to decrease the cylinder pressure.

Part Names

Quantity

Valve body Seat Steel ball Spring seat Spring retainer Relief valve spring Relief setting bolt Lock nut

1 1 1 1 1 1 1 1

Ref. No. 1 2 3 4 5 6 7 8 Fig.9-36

9. RELIEF VALVE 9.1. CONSTRUCTION

Ref No. 1 2 3 4 5 6 7 8 9 10

Part Names Relief valve body Seat Steel ball Relief valve spring seat Sleeve Relief valve spring Adjusting screw Lock nut O-ring O-ring

Quantity 1 1 1 1 1 1 1 1 1 1

Fig.9-37

8.2.OPERATIONS This valve is installed in the slow-return check valve circuit. When the adjusting screw of the slow return check valve is closed completely, the slow return check valve is completely closed. In this condition, when the cylinder pressure exceeds the regulated pressure of the relief valve: Cracking pressure 165 kgf/cm2, the fluid pushed up steel ball (4), overcoming the force of spring (10). Then the surplus fluid is bled off to the tank via port P and port T. Cracking pressure

Tightening torque of lock nut (8)

9.2. OPERATIONS The operation principle of the relief valve is the same as that of the safety valve.

9.3. MEASUREMENT OF CRACKING PRESSURE OF RELIEF VALVE Install the valve on a nozzle tester as shown and adjusting the cracking pressure to the specified value by turning the adjusting screw with a screwdriver.

165 kg/cm2 (2347 psi) [under a leaking rate of 0.3 lit. (0.32 US qt)/min.]

Cracking pressure

3.5 -4.0 kgf-m (28.9 - 36.2 ft-lbs)

126

130 kg/cm2 (under a leaking rate of 0.3 lit. /min.)

CHAPTER 9:HYDRAULIC SYSTEM

After adjustment, be sure to tighten the adjusting screw with the lock nut and then stake the nut without fail. Tightening torque to tractor

650r50 kgf-cm

Tightening torque of lock nut

400 - 500 kgf-cm

Fig.9-38

10. GEAR PUMP 10.1.GENERAL DESCRIPTION This pump is composed of two gears meshed in the casing, which take in and deliver fluid by turning.

Ref. No. 1 2 3 4 5 6

Part Names Pump body Pump gear A Pump gear B Metal A (support) Metal B (support) Pump cover

Quantity 1 1 1 2 2 1

Ref. No. 7 8 9 10 11 12 Fig.9-39

127

Part Names Oil seal O-ring (G50) O-ring (P22) O-ring (P6) Bolt Spring washer

Quantity 1 1 4 1 6 6

TH TRACTOR SERVICE MANUAL

10.2. OPERATIONS

10.4. INSPECTION

The maximum delivery pressure of the pump is 150 kgf/cm2 (2133 psi), and the theoretical delivery volume is 8.78 cc/rev (10.00 cc/rev for 25 HP model). The practical delivery volume under specified revolving speeds and volume efficiencies are as follows:

Check all disassembled parts for damage and wash undamaged or usable parts except for rubber parts in clean diesel fuel or kerosene. Inspect all parts referring to these points, and repair or replace defective parts. a.

Pump body (1)

2

Delivery pressure: 150 kgf/cm (2133 psi) with fluid heated at 50°C Speed (rpm)

Delivery (liter/min.)

Volume efficiency (%)

26.0

91.0

10.0

81.0

2600 1000

The gear pump is originally designed so that the gears come into light contact with the side of the pump body. Maximum efficiency is attained only after sufficient break-in. Therefore some evidence of contact can be found around the in-take port of a pump once used. The normal contact tracing is less than half the length of the gear housing bore and less than 0.05 mm (0.002 in.) in width. If width A is more than 0.1 mm (0.004 in.), replace the gear pump set.

10.3. DISASSEMBLY a.

Before disassembling the pump, wash clean its exterior. Put disassembled parts on clean paper or cloth and take care not to smear or damage them.

b.

Turn the pump with the flange turned downwards and holds the flange in a vice.

c.

Remove bolts (Il) and remove pump cover (6). Fig.9-40

d.

Remove O-ring (8). b.

e.

Push pump gear A (2) a little up from the oil seal (7) installed side to raise top metals (A and B) a little above the cover installing surface. Remove the metals.

f.

Remove pump gears (2 and 3).

g.

Remove the bottom metals.

With clean working fluid, the shaft and gear surfaces are rarely scratched and should be smooth. However, if roughness can be felt by a finger nail, they are darkened, or the shaft diameter is less than 13.88 mm (0.5465 in.), replace the gear pump set. c.

Note: When the metals are hard to be removed, give light shocks to the pump body with a mallet. h.

Pump gear A (2) and B (3)

Metal A (5) and B (4): Supports If there are many scratches on the bore walls, or on parts, which are in contact with the gears, which can be readily felt or when the latter parts are darkened, the gear pump set should be replaced.

Check if a O-ring remains in the bottom of pump body (1).

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CHAPTER 9:HYDRAULIC SYSTEM

d.

Note: Incorrect installation will lead to seizure because of pressure imbalance.

Oil seal (7)

Inspect its sealing lips for damage, deterioration, deformation, etc., and replace a defective one. Reassemble the parts in reverse order of disassembly, referring the following the reassembling precautions.

f.

They should also be assembled gently without forcing and misalignment should be avoided.

10.5. RE-ASSEMBLY Reassemble following the next precautions: a.

Make sure that all seal installing and baring surfaces are all free from damage like scratches or dents.

Fig.9-43

g. b.

The oil seal and O-rings should first be coated with working fluid (Gear oil SAE80) and installed without any deformation or damage.

c.

The oil seal should be caulked at four points as illustrated.

Assemble pump cover (6) and pump body (1) so that their drain holes are aligned with each other. Improper assembly will cause abnormally high pressure rise, which will break the oil seal.

Fig.9-44

h. Fig.9-41

d.

e.

Apply working fluid to the metals (A and B) and pump gears (A and B) before installation.

Tightening sequence and torque of the pump cover tightening bolts.

Tightening torque

Install the metals (A and B): supports in correct places and correct directions.

x

Fig.9-42

Tightening sequence

Fig.9-45

129

300 - 350 kgf-cm (22 - 25 ft-lbs)

TH TRACTOR SERVICE MANUAL

i. Inspection after re-assembly The gears should turn smoothly without hitching.

Turning torque

0.3 kgf-m (2.17 ft-lbs) or less

11. TROUBLE SHOOTING 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 poor hydraulic pump if necessary. Pay particular attention to shaft seal because a broken seal sometimes intakes air.

Inspect pump and repair or replace

Poor link mechanism if necessary.

Inspect, adjust, repair, or replace

Excessive load on lift

Decrease load.

Broken cylinder

Replace.

Too low viscosity of transmission oil wear, replace with gear oil of SAE 80.

As it will cause oil leaks or internal.

Maladjusted relief valve

Readjust.

Excessive internal leaks damaged seals, and repair. (Check each part systematically.) Broken control valve (Even when spool is shifted to up position, lift does not rise.) x Stuck compensator plunger stone x Clogged orifices or slanted orifices in pilot passage x Broken or fatigued relief valve spring x Bitten or stuck check valve plunger Broken flow-control valve x Stuck poppet.

130

Inspect cylinder and valves. Replace

Lap after repairing flaws with oil Clean them with compressed air or a sharp point. Replace spring. Lap after repairing flaws with oilstone. Lap after disassembling, cleaning, and repairing flaws with oilstone.

CHAPTER 9:HYDRAULIC SYSTEM

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

Above 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 x

Stuck poppet

x

Poor poppet seat

Lap after disassembling, cleaning, repairing flaws with oilstone. Replace valve.

x Poor O-ring Safety valve x Oil leaks due to poor sealing x Poor seating

Lift does not lower.

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

Stuck poppet of slow-return check valve Broken control valve x Stuck main spool

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

Above mentioned causes can also be possible.

Lap lightly after disassembling, cleaning, and repairing flaws with oilstone or replace as an assembly. Repair or adjust according to instructions mentioned above.

Insufficiently lowered control lever

Lower lever sufficiently.

Excessively closed flow-control valve When hydraulic control lever is raised, Maladjusted lever stopper check valve relief valve beeps. Poor link mechanism Fluid overheating

Inspect and re-tighten each joint. Replace valve.

Flow-control valve knob is turned to the Turn knob to down position. lock position. Seized lift shaft

Too slow lift lowering speed

Replace.

Open valve sufficiently.

Excessively high working pressure

Readjust lever stopper gu/de position. Inspect, readjust, repair, or replace link mechanism if necessary. Inspect and adjust.

Too high or low viscosity of working fluid

Replace with fluid of adequate viscosity.

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Problems Fluid overheating

Pump noise

Excessive wear, deflection or damage of pump

Causes

Countermeasures

Insufficient fluid

Maintain specified level by replenishing.

Too high internal friction of pump

Replace.

Partially clogged suction-filter or suction piping. Air inhaled through suction piping connections Air inhaled through intake pipe connection for pump

Clean. Inspect and re-tighten. 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 lf necessary.

Oil less 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. Oil leaks from piping or joints

Broken or fatigues oil seal or O-ring

Replace.

Poorly connected piping

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

Poor O-rings Replace. Replace with a new one after washing clean related parts.

Broken piping Poor oil seal

Replace oil seal or bushing if necessary.

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CHAPTER10 . ELECTRICAL ACCESSORIES 1. CABLE LAYOUT Main Fuse Box, A – Located at right side of engine.

134

CHAPTER 10:ELECTRICAL ACCESSORIES

135

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2. WIRE HARNESS LAYOUT 2.1. Around engine

Fig.10-1

136

CHAPTER 10:ELECTRICAL ACCESSORIES

2.2. Around dash board

Fig.10-2 137

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2.3. Around left rear of chassis

Fig.10-3

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CHAPTER 10:ELECTRICAL ACCESSORIES

3. TROUBLE SHOOTING 3.1. BATTERY Inspection items a. Exterior parts Container, cover, and sealing parts Vent plugs

Pole plates (only when housed in a transparent casing)

Deposit (only when housed in a transparent casing)

b. Voltage c. Electrolyte

d. Specific gravity of electrolyte

Problems

Countermeasures

Fluid leaks due to cracks

Repair or replace battery.

Corrosion or breakage

Repair or replace battery.

Excessive resistance between Measure voltage drop with a terminal post and clamp brings voltmeter while turning starter with about a voltage drop and results in fuel shut off. faulty starter operation. When voltmeter reading is more than 0.2 to 0.3, it is excessive. Clean post and clamp, and tighten them securely. Whitened (sulphated) Replace battery. Positive plates should be dark brown and negative ones should be grey. Positive plate grids are broken. Accumulated up to lower ends of Perform charging test and judge pole plates, shorting them battery condition.

Total voltage is less than 12V battery condition. Pole plates appear above electrolyte. battery condition by applying charging test. Specific gravity of some cells is less than 1.200 and variation among cells is over 0.05.

Perform charging test and judge Maintain electrolyte level and judge

Perform charging test and judge battery condition.

3.2. METERS, GAUGES, AND SWITCHES a. Tacho /hour meter and meter cable Pointer does not work. Pointer moves but is very unstable.

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

139

Replace meter assembly. Replace cable assembly. Replace. Lubricate. Replace.

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Inspection items Problems b. Fuel gauge and sensor unit (switch) Pointer does not move. Open circuit Faulty sensor assembly Faulty gauge assembly Faulty battery Faulty earth Faulty pointer movement Poorly contacted terminals Faulty sensor assembly Faulty gauge assembly c. Turn signal and hazard warning switch Both lamps do not flash. Open circuit Burnt-out bulbs Faulty turn signal switch Faulty battery Faulty flasher unit d. Head lamp switch Lamps do not light up as Burnt-out bulbs indicated when switch is Open circuit turned to each position (Small, Faulty battery Low, High) Faulty battery grounding Faulty starter switch Faulty light switch Blown-out fuse Headlamps are dim with Faulty battery capacity switch turned to Low or High. Poorly contacted terminals Faulty bulbs Faulty light switch

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

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

140

Countermeasures Repair. Replace sensor assembly. Replace gauge assembly. Recharge or take necessary countermeasures. Repair. Repair. Replace sensor assembly. Replace gauge assembly. Repair Replace Replace switch assembly. Recharge or take necessary countermeasures. Replace unit. Replace. Repair. Recharge or take necessary countermeasures. Repair. Replace switch assembly. Replace switch assembly. Replace. Recharge. Repair. Replace. Re place switch assembly.

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

CHAPTER 10:ELECTRICAL ACCESSORIES

Inspection items

Problems

Countermeasures

Starter does not work when starter switch is turned to start.

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

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CHAPTER11 . LUBLICATION & MAINTENANCE 1. SPECIFICATIONS & CAPACITIES Use engine oil of the appropriate SAE viscosity. Oil must meet or exceed; MIL-L-2104C requirements, API Service “CD”. TH4260 TH4290 TH4330 Engine oil Capacity U.S.qts. (Litres) 3.8 (3.6) 5.3 (5.0) Recommended Viscosity: 78 qF (25 ͠) and above SAE 30W, 10W-30 32 – 78 qF (0 – 25 ͠) SAE 20W, 10W-30 Below 32 qF (0 ͠) SAE 10W, 10W-30 Recommended Change Intervals: Initial Oil and Filter Change 50 hours Oil and Filter Change, Thereafter Every 100 and 300 hours Engine Coolant Freezing Protection (Original factory Fill) -30qF (34͠) Recommended Coolant 50 / 50 mixture ethylene glycol and water System Capacity U.S.qts. (Litres) 7.5(7.1) Fuel tank Capacity (litres) U.S.gals. (Litres) 6.1 (23.0) 7.9 (30.0) Fuel recommended, Above 39qF (4͠) No.2 or No.2-D Fuel recommended, Below 39qF (4͠) No.1 or No.1-D Transmission & Differential Housing (Including Hydraulic System) Capacity U.S.gals. (Litres) 7.7 (29) Recommended Change Lubricant Shell Donax TD or equivalent Recommended Change Interval First 50 hours every 300 hours thereafter Front axle Capacity U.S.qts. (Litres) 4.7 (4.5) Recommended Lubricant SAE 80 GL-4 Recommended Change Interval Every 300 hours Grease Fittings Greasing Interval Every 50 hours Recommended Grease 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 of muddy), change intervals may need to be more frequent.

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2. LUBRICATION & FILL POINTS General layout of lubrication, fill and drain locations on the tractor: 1 2 3 4 5 6 7 8 9 10

Crankcase Radiator Fuel Tank Rear Housing Front Axle (4WD) Power Steering Rod Axle Pivot Point Brake Pivot Draft Pivot (Accessory) Levering turnbuckle

11 12 13

Engine Oil Engine Coolant Diesel Fuel Hydraulic Oil Hydraulic Oil Grease Grease Grease Grease Grease

Fig. 11-1

143

HST Pedal Pivot Mid PTO Lever Pivot Tie-rod End

Grease Grease Grease

TH TRACTOR SERVICE MANUAL

3. PERIODIC INSPECTION TABLE 䂾:Inspection, replenishment, and adjustment ٌ:Cleaning and washing 䃂:Replacement 䃨:Consult your dealer Check points

Engine oil

Pre-ope

Inspection and servicing intervals hours of operation

ration

50

䂾

䃨

100

150

200

䃂

250

300

䃂

Intervals after that 350

Judgement standard

400

䃨

Replace after initial 50 h and then

Maintain the specified level.

every 100 h 䂦

Air cleaner

䂦

䂦

䂦

Clean after every 100 h. Replace element after it has been clean

Engine coolant

䂾

Fuel

䂾

Fuel filter

䂾

Fan belt

Replace every year

Fill up to radiator throat Keep fuel tank always full.

䂦

䂦

䃂

䂦

Clean after every 100 h. Replace

There should be no dust or water

element after every 300 h.

in filter.

䂾

Deflection:13.8 to 14.8mm (0.54 to 0.58in.) at 10kgf. 䃨

Engine oil filter

䃨

Replace after initial 50 h. Replace after every 300 h

Transmission oil

䂾

䃂

䃂

Replace after initial 50 h. And then

Maintain the specified level.

after every 200 h 䂦

Transmission oil filter

䂦

䂦

䂦

Clean after initial 50 h. And ten after every 100 h.

Clutch pedal play

䂾

Brake pedal play

䂾

Brake performance

䂾

Steering wheel

䂾

Adjust after initial 50 h.

20 to 30 mm ( 0.8 to 1.2in. ) 20 to 30 mm ( 0.8 to 1.2in. )

Free pay: 30 to 60 mm ( 0.79 to 1.18 in. ) on circumference 䃨

Throttle lever and foot throttle

Check after every 300 h.

Loose ball joints should be re-tightened

Control lever performance

䂾

Tire pressure

䂾 䃨

Toe-in Wheel tightening bolts

Adjust after every 300 h

䂾

2 to 6mm (0.08 to 0.24in.) There should be no loose nuts.

䂾

Front axle oil

䂾

䃂

䂾

Inspect after every 100 h Replace after every 300 h

䂾

Grease-up

䂾

䂾

䂾

䂾

䂾

䂾

䂾

Inject grease after every 50 h

Radiator screen

䂦

There should be no clogging

Radiator

䂦

There should be no clogging

Electrical apparatus

䂾

All should work properly

Electrical wiring

䂾

Bolts & nuts

䂾

Rubber pipes

Inspect every year

All should work properly There should be no loose ones

䂾

䂾

䂾

䂾

Check after every 100 h

Important: 䊶㩷 Above mentioned service intervals should be used as reference standard. If working conditions are harder, earlier service is recommended. 䊶㩷 When special technology and special tools are required, consult your dealers.

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CHAPTER 11:LUBLICATION & MAINTENANCE

4. SERVICE STANDARDS Part names and inspection items

Type

1.BRAKE AND RELATED PARTS Brake disk thickness Seperator thickness Brake pedal play Parking brake lever play 2.TRANSMISSION AND RELATED PARTS Backlash between drive pinion and ring gear Backlash between dif-side gear and dif-pinion 3.STEERING SYSTEM AND 4WD SYSTEM Free play of steering wheel (on circumference) Front wheel steering angles Toe-in Fore-and-aft play of front axle Up-and-down play of final case A Front axle bush play Final case bush play 4.HYDRAULIC SYSTEM Safety valve assembly (Tightening torque) Control valve bolts (Tightening torque) Flow-control valve (Tightening torque) Relief set pressure Lift capacity (at lower link end) Lift arm top clearance Standard length of position

Standard value for reassembly

Usable limits

3.5㫧0.1 (0.14㫧0.004)

2.9(0.11)

3.2㫧0.8 (0.13㫧0.03) 20 to 30 (0.79-1.18) 20 to 30 (0.79-1.18)

3.0(0.12)

Measure in the middle. Measure at pedal top. Measure at lever top.

0.1 to 0.2 (0.004 to 0.008) 0.1 to 0.2

Powerassisted

(0.004 to 0.008)

30 or less (1.18 or less) 55.1㫧1㫦(inner) 2 to 6 (0.08 to 0.24) 0.02 (0.008) 0.05 (0.020) 0.12 to 0.20 (0.005 to 0.008) 0.12 to 0.20 (0.005 to 0.008)

50 (1.97)

Adjust with adjusting bolt.

2 (0.08) Replace. Replace.

6.0 to 7.0 kgf-m(51 to 58 ft-lbs) 1.3 to 1.8 kgf-m(9.4 to 13.0 ft-lbs) 10.0 to 12.0 kgf-m(72 to 87 ft-lbs) 150 kgf/cm2 (2134 psi) 1100 kgf (2425 lbs) 4 to 5 (0.16 to 0.20) Set just prior to relief valve opening

5.ENGINE ACCESSORIES Antifreeze density of engine coolant

Fan belt tension

Operation force of throttle lever

Unit: mm (in.) Service instruction and remarks

13.8 to 14.8

4 to 6 kgf (9 to 13 lbs)

145

Should be determined in accordance with local conditions Depress(10kgf) belt at a point between alternator pulley and crankshaft pulley Adjust

TH TRACTOR SERVICE MANUAL

Unit: mm (in.) 6.POWER-ASSISTED STEERING SYSTEM (INTEGRAL ORBIT ROLL) Cylinder 7.GEAR PUMP Gear contacting trace around intake port Contact trace width Clearance between metal bore and gear shaft Clearance between metal shaft diameter and metal bore Clearance between metals Gear’s offset projection against metal diameter Pump cover tightening torque Gear pump starting torque 8.ELECTRICAL ACCESSORIES Electrolyte capacity (Specific gravity) Terminal voltage

Dimension between rod ends: 355㫧2 (13.98㫧0.08) Less than 1/2 of gear housing bore diameter 0.05 (0.002) or less

Adjust

0.1 (0.004)

Replace pump body

10.8V

Charge

0.07 to 0.08 (0.0027 to 0.0030) 0.015 to 0.025 (0.0006 to 0.0009) 0.010 to 0.020 (0.0004 to 0.0008) 0.005 to 0.015 (0.0002 to 0.0006) 3.0 to 3.5 kgf-m (21.7 to 25.3 ft-lbs) 0.3kgf-m (2.2 ft-lbs) 1.240 to 1.260 12V

146

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INTRODUCTION This manual has been prepared to provide information concerning the servicing and overhaul of the ISEKI engines, assuming that trained mechanics perform this work at workshops outfitted with the required equipment. E3CD E3CE E3CF This manual does not apply to fieldwork where adequate service tools and equipment are not available. The contents of this manual cover all of the necessary information, which would be required for operations in a workshop. These include construction, the functions of major components, specifications, disassembly and reassembly instructions, inspection and adjustment instructions, troubleshooting, etc. Figures mentioned in this manual are standard values established by ISEKI for the E3CD series, E3CE, and E3CF engines. Consequently, when a non-ISEKI part has been installed on the engine or adjustments and repairs have been made in a manner other than as specified in this manual, the values mentioned herein are inapplicable and useless. Consequently, ISEKI does not assume responsibility for any problems or damage caused by a value deviation due to maladjustment or by the use of unauthorized parts. Be sure to follow the instructions mentioned in this manual when servicing the engines in a workshop. Values necessary for servicing the engines are mentioned in each instruction section, besides which all of the service reference values are summarized in the SERVICE STANDARDS TABLE. Please refer to this table before commencing service work to assure efficient maintenance and operation. Prompt and reliable servicing is a critical factor in following the operating Procedures and precautions included in this manual, while keeping safety in mind at all times. The ultimate objective of this manual is to provide you with adequate information to service the engines most effectively and economically, and in the end to gain a favorable reputation for ISEKI products among its users.

All information, illustrations, and specifications contained in this technical manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

2

ISEKI TRACTORS

CONTENTS INTRODUCTION ..........................................................................................................................

2

CONTENTS ..................................................................................................................................

3

CHAPTER 1. GENERAL INFORMATION AND SPECIFICATIONS ............................................ 6 1. SPECIFICATIONS ................................................................................................................ 6 2. PERFORMANCE CURVES .................................................................................................. 8 3. EXTERIOR VIEWS & IDENTIFICATION NUMBERS ............................................................ 9 4. SECTIONAL VIEWS.............................................................................................................. 10 CHAPTER 2. SERVICE STANDARDS ........................................................................................ 1. PRECAUTIONS FOR SERVICE OPERATION .................................................................... 1.1. ALWAYS KEEP SAFETY IN MIND. ................................................................................ 1.2. CLOTHING .................................................................................................................... 1.3. PREPARATION FOR OPERATION................................................................................ 1.4. PRECAUTIONS DURING OPERATION ........................................................................ 2. SERVICE STANDARDS ........................................................................................................ 3. TIGTENING TORQUE OF MAJOR FASTENERS ................................................................ 4. TROUBLESHOOTING ..........................................................................................................

12 12 12 12 12 12 13 20 21

CHAPTER 3.INSPECTION AND ADJUSTMENT ........................................................................ 1. INSPECTION AND ADJUSTMENT ...................................................................................... 1.1. INSPECTION OF ENGINE OIL...................................................................................... 1.2. INSPECTION OF FAN BELT.......................................................................................... 1.3. INSPECTION AND ADJUSTMENT OF VALVE CLEARANCES .................................... 1.3.1. Remove the cylinder head cover............................................................................. 1.3.2. Turn the crankshaft by hand so that the piston in No.1cylinder reaches at TDC: align the TDC notch in the crankshaft pulley with the projection on the gear case .............. 1.3.3. Insert a feeler gauge of a specified thickness and adjust the clearance with the adjusting screw ...................................................................................................... 1.4. INSPECTION AND ADJUSTMENT OF NOZZLE OPENING PRESSURE AND INJECTION TIMING ...................................................................................................... 1.4.1. Adjustment of the valve opening pressure of the injection nozzles ........................ 1.4.2. Inspection of oil tightness of valve seats ................................................................ 1.4.3. Spraying condition of injection nozzle .................................................................... 1.4.4. Inspection and adjustment of injection timing ........................................................ 1.5. COMPRESSION AND UNLOADED IDLING SPEEDS .................................................. 1.5.1. Inspection of compression ...................................................................................... 1.5.2. Inspection and adjustment of the idling speeds ...................................................... 1.6. INSPECTION OF WATER PUMP .................................................................................. 1.6.1. Inspection of the pump and pulley .......................................................................... 1.6.2. Inspection of the bearing unit .................................................................................. 1.7. INSPECTION OF THERMOSTAT .................................................................................. 2. ENGINE BODY...................................................................................................................... 2.1. CYLINDER HEAD .......................................................................................................... 2.1.1. REMOVAL OF THE CYLINDER HEAD .................................................................. 2.1.2. DISASSEMBLY ...................................................................................................... 2.1.3. INSPECTION .......................................................................................................... 2.1.4. ASSEMBLY OF THE CYLINDER HEAD ................................................................

28 28 28 28 29 29

3

29 29 29 29 30 30 30 32 32 32 32 32 33 33 33 33 34 35 35 38

TH TRACTOR SERVICE MANUAL

2.1.5. DISASSEMBLY AND INSPECTION OF THE ROCKER ARM SHAFT.................... 2.1.6. INSPECTION OF THE PUSH RODS...................................................................... 2.1.7. INSTALLATION OF THE CYLINDER HEAD .......................................................... 2.2. GEAR CASE .................................................................................................................. 2.2.1. EXPLODED VIEW .................................................................................................. 2.2.2. REMOVAL OF THE GEAR CASE .......................................................................... 2.2.3. RE-INSTALLATION OF THE GEAR CASE ............................................................ 2.3. CYLINDER BLOCK ........................................................................................................ 2.3.1. EXPLODED VIEW .................................................................................................. 2.3.2. DISASSEMBLY OF THE CYLINDER BLOCK ........................................................ 2.3.3. INSPECTION OF CYLINDER BLOCK, CRANKSHAFT, CAMSHAFT, AND TAPPETS ...................................................................................................... 2.3.4. DISASSEMBLY AND INSPECTION OF PISTONS AND CONNECTING RODS .... 2.3.5. INSPECTION OF PISTONS AND CON- NECTING RODS .................................... 2.3.6. ASSEMBLY OF PISTON AND CONNECTING ROD .............................................. 2.3.7. REPLACEMENT OF GEAR CASE OIL SEAL ........................................................ 2.3.8. INSTALLATION OF CRANKSHAFT........................................................................ 2.3.9. INSTALLATION OF PISTON/CONNECTING-ROD ASSEMBLIES ........................ 2.3.10. INSTALLATION OF REAR OIL SEAL .................................................................. 2.3.11. INSTALLATION OF STRAINER AND OIL PAN .................................................... 2.3.12. INSTALLATION OF REAR PLATE AND FLYWHEEL .......................................... 2.3.13. INSTALLATION OF FRONT PLATE AND GEARS................................................

39 40 40 42 42 42 43 44 44 45

CHAPTER 4. LUBRICATION SYSTEM ........................................................................................ 1. GENERAL DESCRIPTION .................................................................................................... 1.1. LUBRICATION DIAGRAM.............................................................................................. 1.2. RELIEF VALVE .............................................................................................................. 1.3. OIL FILTER .................................................................................................................... 1.4. EXPLODED VIEW OF OIL PUMP ................................................................................ 2. REMOVAL, DISASSEMBLY, INSPECTION AND RE-INSTALLATION OF OIL PUMP .......... 2.1. REMOVAL OF OIL PUMP .............................................................................................. 2.2. DISASSEMBLY OF OIL PUMP ...................................................................................... 2.3. INSPECTION ................................................................................................................ 2.4. INSTALLATION OF OIL PUMP ...................................................................................... 3. OIL FILTER............................................................................................................................ 3.1. REMOVAL OF OIL FILTER ............................................................................................ 3.2. INSTALLATION OF OIL FILTER ....................................................................................

62 62 62 63 63 64 65 65 65 65 66 66 66 66

CHAPTER 5. COOLING SYSTEM................................................................................................ 1. COOLING SYSTEM DIAGRAM ............................................................................................ 2. THERMOSTAT ...................................................................................................................... 2.1. REMOVAL OF THERMOSTAT ...................................................................................... 2.2. INSTALLATION OF THERMOSTAT .............................................................................. 2.3. INSPECTION OF THERMOSTAT .................................................................................. 3. WATER PUMP ...................................................................................................................... 3.1. REMOVAL OF WATER PUMP ...................................................................................... 3.2. INSTALLATION OF WATER PUMP .............................................................................. 3.3. INSPECTION OF WATER PUMP ..................................................................................

68 68 68 68 68 68 69 69 69 69

CHAPTER 6. FUEL SYSTEM ...................................................................................................... 1. INJECTION PUMP CONSTRUCTION .................................................................................. 2. REMOVAL, DISASSEMBLY, INSPECTION, RE-ASSEMBLY, AND INSTALLATION ............ 2.1. REMOVAL OF INJECTION PUMP ................................................................................

70 70 71 71

4

46 51 52 54 55 55 57 58 58 58 59

ISEKI TRACTORS

2.2. DISASSEMBLY OF INJECTION PUMP ........................................................................ 2.3. INSPECTION OF INJECTION PUMP ............................................................................ 2.4. RE-ASSEMBLY OF INJECTION PUMP ........................................................................ 2.5. ADJUSTMENT OF INJECTION VOLUME AND ADJUSTMENT CONDITIONS ............ 3. INJECTION NOZZLES AND HOLDERS .............................................................................. 3.1. REMOVAL OF INJECTION NOZZLES AND HOLDERS................................................ 3.2. INSPECTION OF INJECTION NOZZLES...................................................................... 3.3. DISASSEMBLY AND WASHING OF INJECTION NOZZLES ........................................ 3.4. INSTALLATION OF INJECTION NOZZLES AND HOLDERS ........................................ 3.5. INSTALLATION OF INJECTION NOULES AND HOLDERS.......................................... 4. GOVERNOR.......................................................................................................................... 4.1. GOVERNOR CONSTRUCTION .................................................................................... 4.2. GOVERNOR OPERATION ............................................................................................ 5. ANGLEICHUNG DEVICE ...................................................................................................... 5.1. ANGLEICHUNG OPERATION ......................................................................................

71 72 72 75 76 76 76 77 78 78 79 79 80 80 80

CHAPTER 7. ELECTRICAL SYSTEM .......................................................................................... 1. STARTER .............................................................................................................................. 1.1 CONSTRUCTION .......................................................................................................... 1.2. REMOVAL AND DISASSEMBLY STARTER .................................................................. 1.2.1. REMOVAL OF STARTER ...................................................................................... 1.2.2. DISASSEMBLY OF STARTER................................................................................ 1.3. INSPECTION OF COMPONENTS ................................................................................ 1.4. REASSEMBLY OF STARTER........................................................................................ 1.5. INSPECTION OF THE STARTER AFTER REMOVAL FROM THE TRACTOR ............ 1.6. PERFORMANCE TEST ................................................................................................ 1.7. INSTALLATION OF THE STARTER .............................................................................. 2. ALTERNATOR ...................................................................................................................... 2.1. EXPLODED VIEW, SPECIFICATIONS, AND PERFORMANCE CURVES.................... 2.2. TROUBLESHOOTING .................................................................................................. 2.3. REMOVAL AND DISASSEMBLY.................................................................................... 2.4. INSPECTION ................................................................................................................ 2.5. RE-ASSEMBLY .............................................................................................................. 3. GLOW PLUGS ...................................................................................................................... 3.1. SEDTIONAL VIEW ........................................................................................................ 3.2. REMOVAL, INSPECTION, AND RE-ASSEMBLY ..........................................................

82 82 82 82 82 82 83 86 87 88 88 89 89 90 90 92 95 96 96 96

5

TH TRACTOR SERVICE MANUAL

CHAPTER 1. GENERAL INFORMATION AND SPECIFICATIONS 1. SPECIFICATIONS 䎷䏕䏄䏆䏗䏒䏕䏖 䎨䏑䏊䏌䏑䏈䎃䏐䏒䏇䏈䏏䏖 䎷䏜䏓䏈 䎦䏒䏐䏅䏘䏖䏗䏌䏒䏑䎃䏆䏋䏄䏐䏅䏈䏕 䎱䏒䎏䎃䏒䏉䎃䏆䏜䏏䏌䏑䏇䏈䏕䏖 䎥䏒䏕䏈䐙䎶䏗䏕䏒䏎䏈䎃䎋䏐䏐䎌 䎷䏒䏗䏄䏏䎃䏇䏌䏖䏓䏏䏄䏆䏈䏐䏈䏑䏗䎃䎋䎯䎌 䎦䏒䏐䏓䏕䏈䏖䏖䏌䏒䏑䎃䏕䏄䏗䏌䏒 䎵䏄䏗䏈䏇䎃䏒䏘䏗䏓䏘䏗䎃䎋䎳䎶䎋䏎䎺䎌䎌䎃 䏄䏗䎃䏈䏑䏊䏌䏑䏈䎃䏖䏓䏈䏈䏇䎃䎋䏕䏓䏐䎌 䎩䏘䏈䏏䎃䏆䏒䏑䏖䏘䏐䏓䏗䏌䏒䏑䎃䎋䏊䎒䏎䎺䯂䏋䎃䎋䏊䎒䎳䎶䯂䏋䎌䎌 䏄䏗䎃䏈䏑䏊䏌䏑䏈䎃䏖䏓䏈䏈䏇䎃䎋䏕䏓䏐䎌 䎸䏑䏏䏒䏄䏇䏈䏇䎃䏐䏄䏛䏌䏐䏘䏐䎃䏖䏓䏈䏈䏇䎃䎋䏕䏓䏐䎌 䎸䏑䏏䏒䏄䏇䏈䏇䎃䏐䏌䏑䏌䏐䏘䏐䎃䏖䏓䏈䏈䏇䎃䎋䏕䏓䏐䎌 䎩䏘䏈䏏 䎧䏕䏜䎃䏚䏈䏌䏊䏋䏗䎃䎋䏎䏊䎌 䎧䏌䏐䏈䏑䏖䏌䏒䏑䏖䎃䎋䏐䏐䎌䎃䎋䎯䐙䎺䐙䎫䎌 䎩䏘䏈䏏䎃䏌䏑䏍䏈䏆䏗䏌䏒䏑䎃䏒䏕䏇䏈䏕 䎧䏌䏕䏈䏆䏗䏌䏒䏑䎃䏒䏉䎃䏕䏒䏗䏄䏗䏌䏒䏑 䎶䏘䏓䏈䏕䏆䏋䏄䏕䏊䏈䏕䎃䏖䏜䏖䏗䏈䏐 䎩䏘䏈䏏䎃䏌䏑䏍䏈䏆䏗䏌䏒䏑䎃䏖䏜䏖䏗䏈䏐䎒䏓䏘䏐䏓 䎳䏘䏐䏓䎃䏐䏒䏇䏈䏏 䎳䏏䏘䏑䏊䏈䏕䎋䏇䏌䏄䎑䐙䏖䏗䏕䏒䏎䏈䎌䎃䎋䏐䏐䎌 䎬䏑䏍䏈䏆䏗䏌䏒䏑䎃䏑䏒䏝䏝䏏䏈 䎪䏒䏙䏈䏕䏑䏒䏕 䎤䏌䏕䎃䏆䏏䏈䏄䏑䏈䏕䎃 䎯䏘䏅䏕䏌䏆䏄䏗䏌䏒䏑䎃䏖䏜䏖䏗䏈䏐 䎲䏌䏏䎃䏓䏘䏐䏓 䎩䏌䏏䏗䏈䏕䏌䏑䏊䎃䏐䏈䏗䏋䏒䏇 䎦䏒䏒䏏䏌䏑䏊䎃䏖䏜䏖䏗䏈䏐䎒䏐䏈䏗䏋䏒䏇 䎦䏒䏒䏏䏌䏑䏊䎃䏉䏄䏑䎃䎋䏐䏐䎌 䎧䏕䏌䏙䏌䏑䏊䎃䏐䏈䏗䏋䏒䏇 䎳䏘䏏䏏䏈䏜䎃䏕䏄䏗䏌䏒䎃䎋䏆䏕䏄䏑䏎䎒䏉䏄䏑䎌 䎶䏗䏄䏕䏗䏈䏕䎃䏐䏒䏗䏒䏕 䎃䎃䎃䎹䏒䏏䏗䏄䏊䏈䎃䎋䎹䎌 䎃䎃䎃䎲䏘䏗䏓䏘䏗䎃䎋䏎䎺䎌 䎨䏑䏊䏌䏑䏈䎃䏖䏗䏒䏓䏓䏌䏑䏊䎃䏖䏜䏖䏗䏈䏐 䎳䏕䏈䏋䏈䏄䏗䏌䏑䏊䎃䏖䏜䏖䏗䏈䏐 䎪䏈䏑䏈䏕䏄䏗䏒䏕䎃䏙䏒䏏䏗䏄䏊䏈䎃䎋䎹䎌 䎃䎃䎃䎲䏘䏗䏓䏘䏗䎃䎋䎤䎌 䎵䏈䏊䏘䏏䏄䏗䏒䏕

䎷䎫䎗䎕䎙䎓䎩 䎷䎫䎗䎕䎜䎓䎩 䎷䎫䎗䎕䎙䎓䎩䎫 䎷䎫䎗䎕䎜䎓䎩䎫 䎨䎖䎦䎨 䎨䎖䎦䎩 䎹䏈䏕䏗䏌䏆䏄䏏䎏䎃䎺䏄䏗䏈䏕䎐䏆䏒䏒䏏䏈䏇䎏䎃䎗䎐䏆䏜䏆䏏䏈䏇䎏䎃䎧䏌䏈䏖䏈䏏 䎶䏚䏌䏕䏏䎃䏆䏋䏄䏐䏅䏈䏕䎃䏗䏜䏓䏈 䎖 䎛䎘䐙䎛䎗 䎛䎙䐙䎛䎗 䎔䎑䎗䎕䎜 䎔䎑䎗䎙䎖 䎕䎔䎑䎘 䎕䎔䎑䎚 䎕䎗䎑䎓䎋䎔䎚䎑䎚䎌 䎕䎛䎑䎓䎋䎕䎓䎑䎙䎌 䎕䎘䎓䎓 䎕䎚䎕䎋䎕䎓䎓䎌 䎕䎚䎜䎋䎕䎓䎘䎌 䎕䎘䎓䎓 䎕䎙䎘䎓䎐䎕䎚䎘䎓 䎜䎓䎓䎐䎔䎓䎓䎓 䎜䎖䎓䎐䎜䎚䎓 䎧䏌䏈䏖䏈䏏䎃䏉䏘䏈䏏 䎔䎕䎓䎋䎷䎫䎗䎕䎙䎓䎩䎌 䎔䎕䎓䎋䎷䎫䎗䎕䎜䎓䎩䎌 䎔䎕䎛䎋䎷䎫䎗䎕䎙䎓䎩䎫䎌 䎔䎕䎛䎋䎷䎫䎗䎕䎜䎓䎩䎫䎌 䎘䎙䎛䐙䎗䎚䎘䐙䎙䎘䎓䎋䎷䎫䎗䎕䎙䎓䎩䎌 䎘䎙䎛䐙䎗䎚䎘䐙䎙䎘䎓䎋䎷䎫䎗䎕䎜䎓䎩䎌 䎘䎛䎗䐙䎗䎚䎘䐙䎙䎘䎓䎋䎷䎫䎗䎕䎙䎓䎩䎫䎌 䎘䎛䎗䐙䎗䎚䎘䐙䎙䎘䎓䎋䎷䎫䎗䎕䎜䎓䎩䎫䎌 䎔䎐䎖䎐䎕 䎦䏏䏒䏆䏎䏚䏌䏖䏈䎃䏙䏌䏈䏚䏈䏇䎃䏉䏕䏒䏐䎃䏉䏄䏑 䎱䏒䏑䏈 䎥䏒䏖䏆䏋䎒䎳䎩䎵䎃䏗䏜䏓䏈䎃䏓䏘䏐䏓 䎱䎳䎐䎳䎩䎵䎖䎮䎻 䎙䎑䎓䐙䎚 䎮䎦䎤䎒䎧䎱䎐䎳䎧 䎦䏈䏑䏗䏕䏌䏉䏘䏊䏄䏏䎏䎃䏄䏏䏏䎐䏖䏓䏈䏈䏇䎃䏊䏒䏙䏈䏕䏑䏒䏕 䎶䏌䏑䏊䏏䏈䎃䏇䏕䏜 䎩䏒䏕䏆䏈䏇䎃䏏䏘䏅䏕䏌䏆䏄䏗䏌䏒䏑 䎷䏕䏒䏆䏋䏒䏌䏇䎃䏗䏜䏓䏈 䎩䏘䏏䏏䎃䏉䏏䏒䏚䎃䏗䏜䏓䏈 䎺䏄䏗䏈䏕䎃䏆䏒䏒䏏䏌䏑䏊 䎖䎙䎓 䎥䏈䏏䏗䎃䏇䏕䏌䏙䏈 䎔䎑䎕䎓 䎔䎑䎔䎓 䎨䏑䏊䏄䏊䏌䏑䏊䎃䏐䏄䏊䏑䏈䏗䎃䏗䏜䏓䏈䎋䏕䏈䏇䏘䏆䏗䏌䏒䏑䎌 䎔䎕 䎔䎑䎗 䎩䏘䏈䏏䎃䏆䏘䏗䎐䏒䏉䏉䎃䏗䏜䏓䏈 䎶䏋䏈䏄䏗䏋䏈䏇䎃䏊䏏䏒䏚䎃䏓䏏䏘䏊䏖 䎔䎕 䎗䎓 䎷䏕䏄䏑䏖䏌䏖䏗䏒䏕䎃䏗䏜䏓䏈

6

䎷䎫䎗䎖䎖䎓䎩 䎨䎖䎦䎧

䎛䎚䐙䎛䎗 䎔䎑䎗䎜䎛 䎕䎔䎑䎚 䎖䎕䎑䎓䎋䎕䎖䎑䎘䎌 䎕䎙䎓䎓 䎕䎚䎜䎋䎕䎓䎘䎌 䎕䎙䎓䎓 䎕䎚䎙䎓䎐䎕䎛䎙䎓 䎜䎛䎓䎐䎔䎓䎕䎓 䎔䎖䎘 䎙䎓䎘䐙䎗䎚䎘䐙䎙䎚䎖

䎙䎑䎘䐙䎚

CHAPTER 1. GENERAL INFORMATION AND SPECIFICATIONS 䎷䏕䏄䏆䏗䏒䏕䏖

䎷䎫䎗䎕䎙䎓䎩 䎷䎫䎗䎕䎙䎓䎩䎫

䎷䎫䎗䎕䎜䎓䎩 䎷䎫䎗䎕䎜䎓䎩䎫 䎖䎑䎙

䎲䏌䏏䎃䏓䏄䏑䎃䏆䏄䏓䏄䏆䏌䏗䏜䎃䎋䎯䎌 䎹䏄䏏䏙䏈䎃䏗䏌䏐䏌䏑䏊䎃 䎃䎃䎃䎬䏑䏗䏄䏎䏈䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎲䏓䏈䏑䏌䏑䏊 䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎦䏏䏒䏖䏌䏑䏊 䎃䎃䎃䎨䏛䏋䏄䏘䏖䏗䎃䎃䎃䎃䎃䎃䎃䎃䎃䎲䏓䏈䏑䏌䏑䏊 䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎦䏏䏒䏖䏌䏑䏊 䎹䏄䏏䏙䏈䎃䏆䏏䏈䏄䏕䏄䏑䏆䏈䎃䎋䏐䏐䎌 䎩䏘䏈䏏䎃䏌䏑䏍䏈䏆䏗䏌䏒䏑䎃䏗䏌䏐䏌䏑䏊 䎬䏑䏍䏈䏆䏗䏌䏒䏑䎃䏑䏒䏝䏝䏏䏈䎃䏒䏓䏈䏑䏌䏑䏊䎃䏓䏕䏈䏖䏖䏘䏕䏈䎃䎋䏎䏊䏉䎒䏆䏐䎕䎌 䎕 䎦䏒䏐䏓䏕䏈䏖䏖䏌䏒䏑䎃䏓䏕䏈䏖䏖䏘䏕䏈䎃䎋䏎䏊䏉䎒䏆䏐 䎌䎃䏄䏗䎃䎕䎓䎓䏕䏓䏐 䎷䏋䏈䏕䏐䏒䏖䏗䏄䏗䎃䏖䏗䏄䏕䏗䎃䏗䏒䎃䏒䏓䏈䏑䎃䏗䏈䏐䏓䏈䏕䏄䏗䏘䏕䏈䎃䎋䛐䎌 䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䏉䏘䏏䏏䎃䏒䏓䏈䏑䎃䏗䏈䏐䏓䏈䏕䏄䏗䏘䏕䏈䎃䎋䛐䎌

䎛䏲䎥䎷䎧䎦 䎗䎓䏲䎤䎥䎧䎦 䎗䎛䏲䎥䎥䎧䎦 䎔䎕䏲䎤䎷䎧䎦 䎓䎑䎖䎘 䎔䎚䏲䎥䎷䎧䎦 䎔䎕䎓 䎖䎔 䎚䎙䎑䎘 䎜䎓

7

䎷䎫䎗䎖䎖䎓䎩 䎗䎑䎚

䎕䎓䏲䎥䎷䎧䎦

TH TRACTOR SERVICE MANUAL

2. PERFORMANCE CURVES (1) TH4260-E3CE

(2) TH4290-E3CF

Fig. 1-1

Fig. 1-2

(3) TH4330-E3CD

Fig. 1-3

8

CHAPTER 1. GENERAL INFORMATION AND SPECIFICATIONS

3. EXTERIOR VIEWS & IDENTIFICATION NUMBERS

Fig. 1-4

9

TH TRACTOR SERVICE MANUAL

4. SECTIONAL VIEWS

Fig. 1-5

10

CHAPTER 1. GENERAL INFORMATION AND SPECIFICATIONS

Fig. 1-6

11

TH TRACTOR SERVICE MANUAL

CHAPTER 2. SERVICE STANDARDS 1. PRECAUTIONS FOR SERVICE OPERATION 1.1. ALWAYS KEEP SAFETY IN MIND. • When jacking up the tractor, be sure to chock the grounded wheels. • After jacking up, support specified parts with something sturdy. • When more than two persons work together, keep each other's safety in mind. • Before starting the engine, make sure that there is no danger. 1.2. CLOTHING • Wear suitable work clothes, a head gear, and safety shoes. 1.3. PREPARATION FOR OPERATION • Prepare all tools, gauges, jigs, etc, which are required before starting operation. • Also prepare all parts, which are supposed to be replaced during operation. 1.4. PRECAUTIONS DURING OPERATION • Removed parts should be placed in order of disassembly so as to prevent interchanging or miss assembling. • Separate the parts to be discarded and the ones to be used again from each other to prevent confusion when re-assembling. • Before re-assembling, wash or clean the parts completely and remove oil from the surfaces to which liquid packing is to be applied. • When servicing the electric system, disconnect the negative (-) terminal of the battery beforehand. • When pulling off an electrical connector, be sure to hold the connector body. Never pull the wire. When disconnecting a connector which has a lock, be sure to release the lock ahead of time.

12

CHAPTER 2. SERVICE STANDARDS

2. SERVICE STANDARDS

13

TH TRACTOR SERVICE MANUAL

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CHAPTER 2. SERVICE STANDARDS

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TH TRACTOR SERVICE MANUAL

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CHAPTER 2. SERVICE STANDARDS

17

TH TRACTOR SERVICE MANUAL

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CHAPTER 2. SERVICE STANDARDS

19

TH TRACTOR SERVICE MANUAL

3. TIGTENING TORQUE OF MAJOR FASTENERS

20

CHAPTER 2. SERVICE STANDARDS

4. TROUBLESHOOTING

21

TH TRACTOR SERVICE MANUAL

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CHAPTER 2. SERVICE STANDARDS

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TH TRACTOR SERVICE MANUAL

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CHAPTER 2. SERVICE STANDARDS

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TH TRACTOR SERVICE MANUAL

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CHAPTER 2. SERVICE STANDARDS

27

TH TRACTOR SERVICE MANUAL

CHAPTER 3. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT

a. REPLACEMENT OF OIL FILTER

1.1. INSPECTION OF ENGINE OIL • Draw out the level gauge (dip stick) and wipe the end clean. Then insert and draw out it again. Check to see if the level is between the upper and lower limits. If the level is low, refill oil through the filler to the upper level.

Remove the oil filter cartridge from the cylinder block, using a cartridge wrench. b. INSTALLATION OF OIL FILTER Inject a small amount of engine oil into the cartridge. Apply engine oil to the O-ring of the cartridge.

Fig. 3-1

Fig. 3-2

Note: -When checking oil level, place the machine on level ground. -Before checking oil level, stop the engine and wait three minutes at least. -When replenishing oil, use the same king of oil as that in the engine.

Tighten the cartridge by hand until the O-ring comes into contact with the cylinder block surface and then give it three-fourth turn.After filling with new oil, operate the engine more than three minutes. Then check for oil leaks.

• Oil capacities E3CE & E3CF

3.6 litres

E3CD

4.7 litres

• Grades and viscosities of usable oil Temperatures C (° F) °

SAE No.

API Classifications

-20-30 (-4 -86)

10w-30

CC or over

Below 0 (32)

10

↑

0 - 25 (32 - 77)

20

↑

Above 25 (77)

30

↑

Fig. 3-3 1.2. INSPECTION OF FAN BELT • Check belt deflection by apply a force of about 10 kg to the center of the belt between the fan pulley and alternator. Also check the belt for damage such as cracks, peeling, wear, etc. 28

CHAPTER 3.INSPECTION AND ADJUSTMENT Specified deflection

1.3.3. Insert a feeler gauge of a specified thickness and adjust the clearance with the adjusting screw.

13.8 - 14.8 mm

Specified valve clearance (cold): Intake

0.35mm

Exhaust

0.35mm

Fig. 3-4 • Adjustment: When the deflection is more than specified, tension the belt properly by moving the alternator. 1.3. INSPECTION AND ADJUSTMENT OF VALVE CLEARANCES Fig. 3-6 1.3.1. Remove the cylinder head cover. 1.4. INSPECTION AND ADJUSTMENT OF NOZZLE OPENING PRESSURE AND INJECTION TIMING

1.3.2. Turn the crankshaft by hand so that the piston in No.1 cylinder reaches at TDC: align the TDC notch in the crankshaft pulley with the projection on the gear case.

1.4.1. Adjustment of the valve opening pressure of the injection nozzles. • Measure the pressure of initial fuel injection on a nozzle tester. Specified pressure

Fig. 3-5 Note: When it is difficult to distinguish between TDC in compression stroke and TDC in exhaust stroke, use height difference among the push rods as a criterion for judgment. When the heights of the push rods (No.1, 2,3, and 6 viewed from the fan) are about 5 mm lower than those of No.4 and 5, the piston in No.1 cylinder is at TDC in compression stroke.

Fig. 3-7

29

120 kg/cm2

TH TRACTOR SERVICE MANUAL

• When the pressure is too high, adjust by reduceing shimming thickness for the nozzle, or replace the nozzle assembly.

(2) Remove the injection pipes. Note: To keep away dust, cap the openings of the injection nozzle, injection pump, and injection pipe.

• When the pressure is too low, adjust by increasing shimming thickness, or replace the nozzle assembly. 1.4.2. Inspection of oil tightness of valve seats Set a nozzle on a nozzle tester, and apply and maintain a pressure of 100 - 110 kg/cm2 . Check it see if fuel leaks through the seat. If fuel oozes out apparently, the nozzle is defective. If a nozzle is not oil tight, disassemble it and remove carbon deposit. If this is insufficient to stop the oil leaking, replace the nozzle assembly.

Fig. 3-9

1.4.3. Spraying condition of injection nozzle

(3) Remove the delivery valve holder. (4) Remove No.1 delivery spring and install a delivery holder.

Fig. 3-8 1.4.4. Inspection and adjustment of injection timing • Confirmation of injection timing, using No.1 cylinder Fig. 3-10

(1) Bring the piston in No.1 cylinder to TDC in com- pression by aligning the marking on the crank- shaft pulley with the one on the timing gear case, turning the crankshaft by hand.

(5) Turn the crankshaft by hand to the point about 。 10 before the injection timing (turning the crank- shaft in either direction will do).

Note: Be sure not to take TDC in exhaust for that in compression by checking for the opening and closing of the valves.

(6) Open the fuel cock and turn the key switch to the “ON”position to activate the fuel pump.

30

CHAPTER 3.INSPECTION AND ADJUSTMENT

(7) Make sure that fuel ejects from the delivery holder. Turn the crankshaft slowly in correct direction (clockwise viewed from the fan) until fuel ejection stops. The injection timing is just before fuel ejection stops.

Tightening torque

1.5 - 2.5 kgf･m

Note: -Supply fuel only when fuel injection timing is measured (only for operation 6)]. -It is impossible to measure the fuel injection timing by turning the crankshaft in reverse (counterclockwise viewed from the fan). -During this operation, be sure to keep dust out of the fuel system.

• When fuel ejection stops, the injection timing point is passed. Turn the crankshaft in reverse and repeat operation (6). • Even when the injection timing point is passed, there is no sign of fuel ejection stopping. The point is BTDC in exhaust stroke. Turn the crankshaft fully by 360" and start operation. • As a criterion of “just before fuel stops," use the time to take to refill the fuel in the end of the delivery holder after blowing it off. When it takes 1 to 2 seconds to refill, it is the fuel injection timing point.

• Adjustment of injection timing When the injection timing is improper, it should be corrected. The injection timing can be adjusted by changing the distance between the camshaft and pump-mounting surface with shims. a. Remove the injection pump cover. b. Remove ~he control link and starting spring from the control rack. c. Remove the injection pump. -Shimming Available adjusting shims: 0.1, 0.2, 0.3, 0.4 and 0.5 mm thick.

Fig. 3-11

For reference: Injection timing shift with 0.1 mm thick shimming by crank angle:

(8) Check to see the timing mark on the flywheel or the crankshaft pulley is aligned. For reference: The crank angle 1°is about 1mm on the crankshaft pulley and about 2.5 mm on the flywheel.

Shimming +0.1 mm 1°delay Shimming -0.1 mm 1°advance

(9) Turn the key switch to“OFF”and close the fuel cock.

d. Install the injection pump. e. Confirm that the injection timing is proper by the operation mentioned above. Until the proper fuel injection timing is attained, repeat steps from c. to e.

(10)After checking to see the fuel injection timing is correct, remove the delivery holder and install the delivery spring and stopper. Then re-tighten the delivery holder to the specified torque.

f. Install the control link and starting spring on the control rack and then the injection pump cover.

(11)Install the injection pipe and tighten the nut to the specified torque.

Note: During this operation, be careful to keep dust out of the fuel system. 31

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1.5. COMPRESSION IDLING SPEEDS

AND

UNLOADED

1.5.2. Inspection and adjustment of the idling speeds

1.5.1. Inspection of compression

(1) Check for idling speeds.

(1) Remove the injection pipes.

E3CE, E3CF

930∼970rpm

E3CD

980∼1020rpm

(2) Remove an injection nozzle.

(2) When the measured value deviates from the specified value, correct with an adjusting bolt.

Note: Cap the injection nozzles, injection pump, and injection pipes to avoid dust. (3) Install a compression gauge using an adaptor.

Fig. 3-13 1.6. INSPECTION OF WATER PUMP 1.6.1. Inspection of the pump and pulley

Fig. 3-12 (4) Activate the starter and measure the compression.

Check the pump for noise or hitching by turning the water pump pulley, applying load vertically to the pump axis.

Kg/cm2 at 200 rpm Standard

Limit

Difference between cylinders

31

22

3

When noise or hitching occurs, replace the pump assembly.

Note: • Use a fully charged battery. • Be sure to remove the fuel pipes in advance to avoid fuel injection. • Remove only the nozzle for the cylinder whose compression is to be measured. Other nozzles should be left installed.

Fig. 3-14 Caution: When cranking the engine, take care not to touch rotating parts.

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CHAPTER 3.INSPECTION AND ADJUSTMENT

1.6.2. Inspection of the bearing unit Check the bearing unit for run-out. If the run out is more than 0.2 mm (0.008 in.), replace the pump assembly. 1.7. INSPECTION OF THERMOSTAT • Inspection of activating temperatures at which the valve starts to open and opens fully. Put the thermostat in water and heat the water gradually by stirring. Check for the temperature at which the valve starts to open and that at which the valve opens fully.

Fig. 3-15

2. ENGINE BODY 2.1. CYLINDER HEAD

Fig. 3-16 (Exploded view of cylinder head) 33

Starts-to-open temperature

76.5±2° C

Full open temperature

90° C (194° F) [lift: more than 8 mm ]

TH TRACTOR SERVICE MANUAL

2.1.1. REMOVAL OF THE CYLINDER HEAD

(5) Removal of the rocker shaft assembly.

(1) Removal of the cylinder head cover.

(6) Removal of the push rods. (7) Removal of the water by-pass hose. (8) Removal of nozzles.

Fig. 3-17 (2) Disconnection of the injection piping. • When the piping has been removed, cap the delivery pipe holders, injection nozzles and injection pipes at once to avoid dust.

Fig. 3-20 • Remove the cap. • Remove fuel-return pipes. • Draw out the nozzle along with the gasket. Note: Be careful to keep the nozzle free from dust. (9) Removal of glow plugs. (10)Removal of the cylinder head. • Loosen the cylinder head bolts in the sequence shown in the figure. • After the removal of the cylinder head, remove the dowels and tappets.

Fig. 3-18 (3) Removal of the fan belt. (4) Removal of the oil pipe.

Fig. 3-19 Fig. 3-21

34

CHAPTER 3.INSPECTION AND ADJUSTMENT

2.1.2. DISASSEMBLY (1) Removal of the inlet manifold. (2) Removal of the exhaust manifold. (3) Removal of the thermostat housing. (4) Removal of the valves. Fig. 3-23 (2) Inspection of the cylinder head for distortion • Measure the flatness of the bottom surface of the cylinder head by putting a straight rule diagonally across the four corners on the bottom face and check for clearance with thickness gauges.

Distorition

Fig. 3-22

Standard value

Usable limit

0.075mm

0.15mm

• When the distortion exceeds the usable limit, correct on a surface grinder. • As the ground-down limit is 0.4 mm (0.016 in.), replace a cylinder head assembly, which required more than the ground-down limit to correct.

• Compress the valve spring along with the spring seat with a spring compressor, and remove the cotter spring seat retainer. Note: Removed valve and related parts should be put aside in order of valve numbers. (5) Removal of the valve oil seals. Note: Discard removed valve oil seals. 2.1.3. INSPECTION (1) Inspection of the cylinder head for cracks.

Fig. 3-24 (3) Inspection of the clearance between the valve guide and valve stem.

• Remove carbon deposit from the bottom surface of the cylinder head. • Inspect the bottom surface and inlet and exhaust ports using "COLOR CHECK."

35

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• Check the valve for play with a dial indicator. If the play exceeds 0.15 mm (0.0059 in.) for the inlet valve and 0.2 mm (0.008 in.) for the exhaust valve, replace both the valve and valve guide as an assembly. Measure the play at a point 10 mm (0.39 in.) apart above the valve oil seal when the valve lift is 0 mm (0 in.).

• Press in so that the distance from the cylinder head top to the valve guide end becomes 0∼ 0.2mm.

between valve guide and cylinder head

0∼0.2mm

Fig. 3-27

Fig. 3-25

(5) Inspection and correction of valve seats.

(4) Replacement of the valve guide.

• Check for valve contacting width and depresssion.

• Drive out the valve guide upwards from the cylinder head bottom. • Press in a new valve guide from the cylinder head top, taking care not to damage the guide.

When the contact width is wider than specified, correct with a 45° valve seat cutter. When the subsidense is more than specified, replace the cylinder head assembly. Standard value

Usable limit

Contact width

1.3-1.6mm

2.0mm

Subsidense

0.7mm

1.4mm

Fig. 3-28 Fig. 3-26

• Apply polishing compound to the valve seat surface and lap with the valve while tapping the valve to secure sufficiently contact with the whole circumference.

Note: Apply oil to the new valve guide ahead of time.

36

CHAPTER 3.INSPECTION AND ADJUSTMENT

Fig. 3-31 (7) Inspection of valve springs. • Measure the free length of each valve spring with calipers. Standard value

Usable limit

Free length

36mm

35.0mm

Tension

8.3kgf

7.35kgf

Fig. 3-29 Note: After lapping, remove the polishing compound completely.

when compressed to 31mm

(6) Inspection of valves.

• Put a spring upright on a surface table and measure deviation from vertical.

• Measure the valve stem diameter with a micrometer. Standard value

Usable limit

Inlet valve

7.00mm

6.90mm

Exhaust valve

7.00mm

6.89mm

Usable limit Deviation from vertical

1.0mm

Fig. 3-30 Fig. 3-32 • Check for valve thickness.

Valve thickness

Standard value

Usable limit

1.0mm

0.75mm

(8) Inspection of intake and exhaust manifold contact surfaces for flatness. • Measure flatness with a straight rule and thickness gauges.

When the valve thickness is less than the usable limit, replace the valve.

37

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Fig. 3-33

Fig. 3-35 Usable limit

(2) Install valves. Surface flatness (both for intake and exhaust manifolds)

0.2mm

• Apply oil to all valve stems before inserting them into valve guides. • Install valve springs. • Install valve spring seats. • Compress each valve spring along with the valve seat and install the cotter spring seat retainer.

When the deviation exceeds the usable limit, replace the manifold. 2.1.4. ASSEMBLY OF THE CYLINDER HEAD (1) Install valve guides and oil seals. • Be sure to use new valve guides. Press them in on a press.

Fig. 3-36 (3) Install the inlet manifold. • Be sure to install a new gasket before installing the manifold. Fig. 3-34 • Be sure to use new valve oil seals and drive in or press them in on a press.

(4) Install the exhaust manifold. • Also be sure to use a new gasket before installing the manifold. (5) Install the thermostat housing. • Also use new packing.

38

CHAPTER 3.INSPECTION AND ADJUSTMENT

2.1.5. DISASSEMBLY AND INSPECTION OF THE ROCKER ARM SHAFT Diameter

Standard value

Usable limit

16.00mm

15.85mm

(1) Disassembly of the rocker arm shaft assembly. • Put an identification mark on the front side top of the rocker arm shaft for later reference. • Remove snap rings C and remove arm brackets. • Put away the brackets in order.

Fig. 3-39 (4) Inspection of the clearance between the rocker arms and rocker arm shaft Fig. 3-37

• Measure the bore diameter of each rocker arm and calculate the difference from the diameter of the rocker arm shaft.

(2) Inspection of the rocker arm shaft for bending.

When the difference exceeds the usable limit, replace the assembly of the rocker arm shaft and rocker arms.

• Check for bending with a dial gauge. Usable limit Shaft bending

0.5mm Clearance

Fig. 3-38

Fig. 3-40

(3) Inspection of the rocker arm shaft for wear. • Measure diameter at four points where the shaft bears respective rocker arms. • When wear is in excess of the usable limit, replace the shaft.

39

Standard value

Usable limit

0.01-0.05mm

0.2mm

TH TRACTOR SERVICE MANUAL

(5)Reassembly of the rocker arm shaft assembly

2.1.7. INSTALLATION OF THE CYLINDER HEAD

• Arrange the rocker arms so that the sides where identification markings were put when disassembled are turned forward. Make sure that the shaft is placed with the end having an off-set positioning tapped hole turned forward.

(1) Installation of the cylinder head • Clean the bottom surface of the cylinder head and the top surface of the cylinder block. • Drive in dowels. • Insert tappets. • Put a new gasket with its "TOP" mark turned upward. • A gasket of different models has a different identification marking: notches in the left top corner as shown below.

Fig. 3-41

2.1.6. INSPECTION OF THE PUSH RODS • Check both ends of each push rod for wear. Replace excessively worn rods with new ones. • Check push rods for bending. Place a rod on a surface table and measure bending with thickness gauges. Usable limit Push-rod bending

0.3mm

Fig. 3-43

Fig. 3-42

40

CHAPTER 3.INSPECTION AND ADJUSTMENT

• Place the cylinder head softly on the cylinder block. • Apply engine oil to the threads of the cylinder head bolts.

(4) Installation of the leak hoses.

• Tighten the cylinder head bolts in the sequence as shown in Fig.IV-31 to the specified torque. • Be sure to tighten the bolts step by step: first to 2 kg•m (14 ft-lbs), second to 4 kg•m (29 ft-lbs), and then lastly to the following torques. Specified torque

6.0 - 7.0kg･m

Fig. 3-46 (5) Installation of the push rods

Fig. 3-44 Fig. 3-47

(2) Installation of the glow plugs. (3) Installation of the injection nozzles.

(6) Installation of the rocker arm assembly

• Be sure to use new packing and tighten the nozzles to the specified torque. Specified torque

• Loosen all rocker arm adjusting screws. • Install the rocker arm assembly and tighten it to the specified torque.

4.0 - 5.0 kg･m Specified torque

Fig. 3-45 Fig. 3-48

41

1.4-2.4 kg･m

TH TRACTOR SERVICE MANUAL

(7) Installation of the injection pipes.

sure to adjust the valve clearances.

• Install injection pipes for respective cylinders and tighten them securely.

(10) Installation of the head cover. Note: The head cover seal and gasket is made of rubber, so take care not to tighten the head cover excessively.

(8) Install water by-pass hose. (9) Adjustment of the valve clearances. When the cylinder head has been removed, be 2.2. GEAR CASE 2.2.1. EXPLODED VIEW

Fig. 3-49

2.2.2. REMOVAL OF THE GEAR CASE

• Remove the return spring from the control lever. • Remove the hydraulic pump if installed. • Remove the hydraulic pump drive gear. • Remove the gear case.

• Remove the cooling fan. • Remove the fan belt. • Remove the crankshaft pulley. • Remove the alternator. • Remove the injection pump cover and then remove the starting spring, setting spring, and control link from the rack.

Fig. 3-51 Fig. 3-50 42

CHAPTER 3.INSPECTION AND ADJUSTMENT

Note: Note which bolt is to be installed in which place for later reference and remember to remove the bolts which also tighten the case from behind.

Fig. 3-54 • Install the gear case. Specified torque

1.4 - 2.4 kg･m

Fig. 3-52

Fig. 3-53 Fig. 3-55 • Discard removed packings and oil seals and use new ones during re-assembly.

• Connect the rack of the injection pump and the control link with a setting spring. After installation, confirm their smooth working by moving the rack several times. • Install the starting spring. Take care not to drop the spring. • Install the injection pump cover, using new packing. • Install the crankshaft pulley and tighten to the specified torque.

Note: It is recommended not to disassemble the oil pump assembly, relief valve, governor, and related parts, which are installed inside the gear case except when required. 2.2.3. RE-INSTALLATION OF THE GEAR CASE • Install the idle gear. • • Apply oil to the bore surface of the idle gear and install taking care to align the timing marks with those of other gears.

Specified torque

17.0 - 20.8 kg･m

• Install the alternator. • Install the fan belt and cooling fan.

43

TH TRACTOR SERVICE MANUAL

2.3. CYLINDER BLOCK 2.3.1. EXPLODED VIEW

Fig. 3-56

44

CHAPTER 3.INSPECTION AND ADJUSTMENT

(10) Remove the water pump spacer.

2.3.2. DISASSEMBLY OF THE CYLINDER BLOCK

(11) Remove the oil filter. (1) Install the engine on an engine stand. (12) Remove the oil pan and oil strainer. (13) Clean the cylinder bores of carbon deposit. Remove carbon deposit from the upper part of the cylinder bore with a scraper, taking care not to damage the cylinder walls.

Fig. 3-57 (2) Drain engine oil. (3) Remove the cylinder head (Refer to page 32). Fig. 3-59

(4) Remove the tappets.

(14) Removal of the pistons and connecting rods.

(5) Remove the gear case (Refer to page 41).

• Remove the nuts, which tighten the connecting bearing cap.

(6) Remove the camshaft.

• Remove the piston/connecting rod assembly toward the cylinder head.

Fig. 3-58 (7) Remove the injection pump and then remove the pump cam.

Fig. 3-60 • Put aside removed piston/connecting rod assemblies, connecting rod bearing caps, and bearings in order in accordance with respective cylinders.

(8) Remove the solenoid. (9) Remove the water pump.

45

TH TRACTOR SERVICE MANUAL

(15) Removal of the flywheel. • Chock the flywheel.

2.3.3. INSPECTION OF CYLINDER BLOCK, CRANKSHAFT, CAMSHAFT, AND TAPPETS

• Removal of the flywheel.

(1) Inspection of the cylinder block • Inspect the cylinder block for damage. Check for damage visually. Use "COLOR CHECK" if necessary to check for cracks and other damage. Repair damage if possible or replace. • Inspect the cylinder block top surface for flatness. Check the top surface for distortion with a straight rule and thickness gauges in diagonal ways as shown in the figure.

Fig. 3-61 (16) Remove the rear plate. (17) Removal of the crankshaft. • Remove bearing caps.

Fig. 3-63 Standard value

Usable limit

0.08 mm or less

0.15 mm

If distortion exceeds the usable limit, correct on a surface grinder. But the ground-down limit is 0.4 mm (0.016 in.). A cylinder block, which cannot be corrected within the ground-down limit, should be replaced with a new one.

Fig. 3-62 • Put aside removed bearing caps and bearings in order of bearing numbers. • Remove the crankshaft.

• Check the cylinder bores for wear.

(18) Remove the oil pressure switch.

46

CHAPTER 3.INSPECTION AND ADJUSTMENT

Fig. 3-66 (2) Inspection of the crankshaft

Fig. 3-64

• Check the crankshaft journals for oil clearance.

- Measure cylinder bore diameter at a point of 12 to 14 mm (0.47 - 0.55 in.) below the cylinder block top surface in two directions: one is in alignment with the crankshaft axis and the other is at right angles to the crankshaft axis. Wear limit

a. Clean the journals and bearings. b. Install the upper bearings and crankshaft on the cylinder block.

0.2 mm

c. Put plasti-gauge over the journal width. - If wear is in excess of 0.2 mm (0.008 in.), correct by honing. - Honing should be done to fit an oversize piston, which should be done at a specialist's workshop. Oversize

0.5; 1.0 mm

- Honing accuracy should be to the extent that bore diameters measured in two directions at A and B and in three levels at a, b, and c differ less than 0.02 mm (0.0008 in.) from each other.

Fig. 3-67 d. Install the bearings on respective bearing caps. Install the assembled and tighten them to the specified torque. Specified torque

8.5∼9.0 kg･m

While tightening, the crankshaft should be held securely so as not to turn. e. Loosen the tightening bolts and remove the bearing caps carefully. Then measure the most stretched parts of the plasti-gauges. Fig. 3-65

47

TH TRACTOR SERVICE MANUAL

c. Tighten the bearings on the connecting rods to the specified torque.

Fig. 3-68 Standard value

Usable limit

0.029 - 0.090 mm

0.12 mm

f. If the oil clearance of a journal is in excess of the usable limit, replace the bearings with new ones and check for oil clearance again. When the clearance exceeds the usable limit ever after new bearings have been installed, polish the journal and use undersize bearings. Undersize bearings

Fig. 3-70 Specified torque

8.5 - 9.0 kg･m

Note: Hold the crankshaft securely so as not to turn while tightening.

0.5, 1.0 mm

When the ground-down limit of 1.0 mm (0.039 in.) is not enough for correction, replace both crankshaft and bearings with new ones.

d. Loosen the tightening bolts and remove the connecting-roil bearing caps carefully.

• Check the pins on the crankshaft for oil clearance.

e. Measure the most stretched parts of the plastigauges.

a. Clean the crankshaft pins, connecting-rod big ends, and bearings. b. Place plasti-gauge over the pin width.

Fig. 3-71 Standard value

Usable limit

0.027 - 0.075 mm

0.12 mm

Fig. 3-69 f. If the oil clearance exceeds the usable limit, replace the bearings with new ones and check for 48

CHAPTER 3.INSPECTION AND ADJUSTMENT

oil clearance again. When the clearance exceeds the usable limit ever after new bearing have been installed, polish the pin and use undersize bearings. Undersize bearings

0.5; 1.0 mm

When the ground-down limit of 1.0 mm (0.039 in.) is enough for correction, replace both crankshaft and bearings with new ones.

Fig. 3-73 • Replacement of the ring gear

• Thrust clearance

Hammer the circumference of the ring gear evenly via a holding rod to remove the ring gear.

Install the connecting rod on the crank pin and measure the thrust play with thickness gauges. If the play exceeds the usable limit, replace the connecting rod. Standard value

Usable limit

0.175 - 0.030 mm

0.35 mm

Fig. 3-74 Heat up a new ring gear with a torch, and then drive it onto the flywheel.

Fig. 3-72 (3) Inspection of the flywheel Check the friction surface for cracks and other damage. If defective, correct or replace with a new flywheel. Check the ring gear teeth for excessive wear and other damage. If defective, replace the ring gear with a new one.

Fig. 3-75 Note: - Install the ring gear with the chamfered side turned toward the starter. - After installation, make sure the ring gear is in tight contact with the flywheel.

49

TH TRACTOR SERVICE MANUAL

• Inspection of the pilot bearing. Check for noise or hitching by turning it. Replace a defective bearing with a new one. • Removal of the pilot bearing. Remove the flywheel and drive out the bearing from front to rear.

Fig. 3-78 • Measurement of journal wear Measure the diameter of each journal. Standard value

Usable limit

48 mm

47.6 mm

If wear is in excess of the usable limit, replace the camshaft with a new one.

Fig. 3-76 • Installation of the pilot bearing Drive in the bearing evenly, taking care not to allow it installed slanted. Be sure not to apply load upon the inner race. (4) Inspection of the camshaft • Check the journals and cams for wear and other damage. A worn or defective shaft should be replaced with a new one.

Fig. 3-79 Measure the bore diameter of each bearing. And calculate the difference between the cam journal diameter and bearing bore diameter. Clearance between journal and bearing:

Fig. 3-77

Measure the height with a micrometer.

IN

40.42 mm

EX

40.60 mm

Usable limit

0.05 - 0.105 mm

0.120 mm

If the clearance exceeds the usable limit, replace the camshaft with a new one.

• Cam height

Standard value

Standard value

Usable limit 40.02 mm 40.20 mm 50

CHAPTER 3.INSPECTION AND ADJUSTMENT

Fig. 3-82 • Check the outer diameter for wear. Fig. 3-80

Standard value

Usable limit

25 mm

24.95 mm

• Thrust play of the camshaft Install the thrust plate and cam gear on the camshaft. Push the thrust plate fully against the cam gear and measure the clearance between the thrust plate and journal with thickness gauges. Standard value

Usable limit

0.05 - 0.174 mm

0.3 mm

Replace the tappets having diameters less than the usable limit. • Clearance of the tappets with the cylinder block Measure the bore diameter of each tappet hole in the cylinder block and the outer diameter of each tappet. Then calculate the difference. Replace the tappets, which have clearances in excess of the usable limit.

If the clearance exceeds the usable limit, replace the thrust plate.

Standard value

Usable limit

0.02 - 0.062 mm

0.1 mm

2.3.4. DISASSEMBLY AND INSPECTION OF PISTONS AND CONNECTING RODS (1) Disassembly of the piston/connecting-rod assemblies • Remove the piston rings Remove the piston rings using a piston ring expander. Put aside the remove piston rings in order of removal and piston numbers to avoid confusion during re-assembly.

Fig. 3-81 (5) Inspection of tappets • Check the contact surface with the camshaft for pitting, cracks, etc. Defective tappets should be replaced with new ones.

Fig. 3-83 51

TH TRACTOR SERVICE MANUAL

• Removal of a piston pin Remove the snap ring using snap ring pliers (for holes).

2.3.5. INSPECTION OF PISTONS AND CONNECTING RODS. • Push a piston ring into the cylinder, using a piston as a pushing tool, to a point past the position where the ring would be during operation i.e. to the lower end of the cylinder wall.

Fig. 3-84 Note: Take care not to contract the snap ring excessively during removal. Fig. 3-87

Pull out the piston pin.

Measure the gaps of each piston ring with thickness gauges.

Fig. 3-85 Put a mark on the piston pin to identify its front and rear ends for later reference. Fig. 3-88 Replace the rings whose gaps are in excess of the usable limit.

Fig. 3-86 Put aside the removed pistons, piston pins, and connecting rods in order of cylinder numbers. 52

CHAPTER 3.INSPECTION AND ADJUSTMENT Standard value

Usable limit

No.1 compression ring

0.25 - 0.40 mm

1.5 mm

No.2 compression ring

0.40 - 0.60 mm

1.5 mm

Oil ring

0.20 - 0.40 mm

1.0 mm

• Inspection of piston ring clearance in ring grooves.

Fig. 3-90 When the pin has excessive play in the hole at room temperature, replace the piston or the piston pin. • Inspection of the clearance between the connecting-rod small end and piston pin

Fig. 3-89 Clean ring grooves using a used piston ring. Measure the clearance at the outer circumference with thickness gauges as shown in the figure. Standard value

Usable limit

No.1 compression ring

0.08 - 0.12 mm

0.3 mm

No.2 compression ring

0.03 - 0.07 mm

0.3 mm

Oil ring

0.02 - 0.06 mm

0.15 mm

Fig. 3-91

Fig. 3-92 Calculate the difference between the bore in the small end and piston pin diameter.

When the clearance exceeds the usable limit, replace both piston and rings as an assembly.

Standard value

Usable limit

0.008 - 0.02 mm

0.05 mm

• Inspection of the piston pin Clearance

The interference between the piston-pin and piston-pin hole should be such that the pin can be pushed in smoothly at room temperature.

When the clearance exceeds the usable limit, replace the connecting rod or the piston pin.

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TH TRACTOR SERVICE MANUAL

• Connecting-rod twist

• Install a snap ring in one end of the piston pin hole.

Find the twist and parallelism between the big end and small end of the connecting rod. Standard value

Usable limit

Twist

0.05 or less

0.2 mm

Parallelism

0.05 or less

0.15 mm

• Set the piston and the connecting rod so that the front mark on the piston and "ISEKI" marking on the connecting rod are turned in the same direc- tion. • Apply engine oil to the piston pin and push it into the hole by hand.

[Per 100 mm]

If either of the measured values exceeds the specified value, replace the connecting rod.

Fig. 3-95 • Install the other snap ring securely in the groove. Fig. 3-93

Fig. 3-96 (2) Installation of piston rings Fig. 3-94

• Install the rings using a piston ring expander with their "T" marks turned upwards. But the oil rings have no markings, so they can be installed with either side up.

2.3.6. ASSEMBLY OF PISTON AND CONNECTING ROD (1) Assembly of the piston and connecting rod

54

CHAPTER 3.INSPECTION AND ADJUSTMENT

• The gaps of the ring and ring expander of the oil ring should be set apart 180" from each other. Note: As No.1 and No.2 compression rings have dif- ferent cross sections, take care not to install them in wrong order.

Fig. 3-99 • Apply engine oil to the lips of a new oil seal. • Drive in the new oil seal evenly to avoid slanted installation. • Drive in the oil seal until the oil seal end reaches the stepped part of the gear case. Further driving should be avoided. Fig. 3-97 • Install the rings with their gaps 120" apart from each other as shown in the figure.

Fig. 3-100 2.3.8. INSTALLATION OF CRANKSHAFT (1) Install the upper bearings, which have oil grooves or oil holes, in cylinder block. Note: Bearings and bearing fitting surfaces on the cylinder block should be free from any foreign matter.

Fig. 3-98 2.3.7. REPLACEMENT OF GEAR CASE OIL SEAL

The projection of each bearing should be securely seated in its notch in the cylinder block.

• Place wooden block under the gear case. • Drive out the oil seal rearwards with a screwdriver. 55

TH TRACTOR SERVICE MANUAL

Fig. 3-103 • Apply engine oil to lower bearing surfaces. Fig. 3-101

• Install the bearing caps.

(2) Apply engine oil to upper bearing surfaces and bring the crankshaft in contact with them.

The bearing caps (F) and (R) should be installed so that their outer faces are flush with respective cylinder block walls: within +0.05 mm (0.002 in.). • Install the bearing caps with their arrowhead marks turned forwards. Install the bearing cap with "T" mark on No.3 journal.

Fig. 3-102 (3) Install the lower bearings, which have no oil grooves or holes, on bearing caps. Note: Bearings and bearing fitting surfaces on the bearing caps should be free from any foreign matter.

Fig. 3-104 Note: After installation, make sure that the crankshaft turns smoothly.

The projection of each bearing should be securely seated in its notch in the bearing cap.

Bearing cap tightening torque

(4) Install the thrust bearing on No.3 journal with the oil groove turned towards the crankshaft. Apply silicone compound (Three Bond #1215B: liquid seal) to the shaded parts on the bearing caps O and (R) as illustrated.

8.5∼9.0 kg･m (61.5 - 65.1 ft･lbs)

• Install bearing cap seals (A) Apply silicone compound (Three Bond #1215B) on the shaded part as illustrated, and install it with chamfered part "a" turned outwards. 56

CHAPTER 3.INSPECTION AND ADJUSTMENT

2.3.9. INSTALLATION OF PISTON/CON-NECTING-ROD ASSEMBLIES • Install bearings on the connecting-rod big end and bearing cap with the bearing projections seated securely in respective notches in the big end and bearing cap. Apply engine oil to the bearing surfaces. • Clean the cylinder bores and crankshaft, and apply engine oil to them. • Set the crankshaft at BDC. • Turn the front mark on the piston head towards the front and make sure that the piston ring gaps are 120°apart from each other. Then insert the piston/connecting rod assembly, compressing the piston rings with a piston ring compressor, into the cylinder until the connecting rod bearing comes into contact with the crankpin.

Fig. 3-105 First, push it until it depresses 1 - 2 mm (0.04 0.08 in.) below the bearing cap top, and then drive it in further until it depresses 0.3 - 0.5 mm (0.012 - 0.02 in.), using a punch with care not to damage the seal end. Fill the gap with silicone compound.

Fig.3-108

Fig. 3-106

• Install the connecting rod bearing cap having the same number that the connecting rod has.

(5) Then install bearing cap seals (B). Drive them in until they subside 0 - 0.3 mm (0 - 0.012 in.) from the cylinder block end. Fill the gaps with silicone compound. Tighten the journal bearing cap to the specified torque. Specified torque:

8.5 - 9.0 kg･m

Fig. 3-109 • Tighten the connecting rod bearing cap to the specified torque.

Fig. 3-107 57

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2.3.11. INSTALLATION OF STRAINER AND OIL PAN • Install the O-ring in the groove in the hole for oil strainer installation. • Apply engine oil to the outer surface of the strainer pipe and install it by turning to avoid dislocation of the O-ring. Fig. 3-110 Specified torque:

3.5 - 4.5 kg･m

The crankshaft should turn smoothly. 2.3.10. INSTALLATION OF REAR OIL SEAL

Fig. 3-113 Note: Be careful not to damage the O-ring. 2.3.12. INSTALLATION OF REAR PLATE AND FLYWHEEL

Fig. 3-111 • Apply silicone compound to the outer circumference of the rear oil seal and drive it in evenly to avoid slanted installation.

• Installation of the rear plate Set the rear plate guided by the straight pins and tighten it to the specified torque.

• Make sure that the crankshaft turns smoothly.

Specified torque

• The projection of the rear oil seal after installation should be 1.5 mm (0.059 in.).

M10:

3.5 - 4.7 kg･m

M12:

7.6 - 9.2 kg･m

Fig. 3-114 • Installation of the flywheel Apply engine oil to the seats and threads of tightening bolts.

Fig. 3-112 58

CHAPTER 3.INSPECTION AND ADJUSTMENT

• Install the crankshaft gear on the crankshaft with the side bearing the front mark turned forward. • Apply engine oil to the camshaft bearing parts and install the camshaft assembly. Then tighten to the specified torque. Specified torque

0.6 - 1.0 kg･m

Fig. 3-115 Temporarily tighten the flywheel. Chock the flywheel, and then tighten the bolts to the specified torque. Specified torque

Fig. 3-117

8.5 - 10.5 kg･m

• Sub-assemble the pump cam and the thrust plate in advance, paying attention to thrust plate direction.

2.3.13. INSTALLATION OF FRONT PLATE AND GEARS • Install the front plate. Apply silicone compound to the contact surfaces of the cylinder block and bearing cap. Install new packing and tighten the front plate to the specified torque. Specified torque

1.4 - 2.4 kg･m

Fig. 3-118 • Insert the starting spring pin into the cylinder block and install the starting spring.

Fig. 3-116 • Install key on the crankshaft. 59

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Fig. 3-119

Fig. 3-121

• Install the injection cam gear assembly. • Installation of the injection pump. • Retain the injection pump cam shaft with the thrust plate and tighten the gear to the specified torque. Specified torque

Tighten the bolts to the specif ied torque in sequence as shown in the figure.

0.6 - 1.0 kg･m

Specified torque

1.4 - 2.4kg･m

Note: Remember to install adjusting shims.

Fig. 3-120 • Install the idle gear. Fig. 3-122

Apply engine oil to the bore of the gear in advance. Align respective timing marks with those of other gears.

• Installation of the oil pan Apply liquid gasket (THREE BOND1207D) to the cylinder block surface in shape of a string of φ3 - 3.5 mm (φ0.12 - 0.14 in.) as illustrated. Then install the oil pan and tighten to the specified torque. Specified torque

60

0.8 - 1.2 kg･m

CHAPTER 3.INSPECTION AND ADJUSTMENT

• Install the water by-pass hose. • Install the generator. • Install the fan. Set the fan belt on the fan pulley. Install the spacer and the fan.

Fig. 3-123 • Install the oil pan with the recessed part turned forward.

Fig. 3-124 • Install the gear case referring. • Install the cylinder head referring. • Install the water pump spacer. • Install the water pump with new packing and tighten to the specified torque. Specified torque

1.4 - 2.4 kg･m

Fig. 3-125

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CHAPTER 4. LUBRICATION SYSTEM 1. GENERAL DESCRIPTION 1.1. LUBRICATION DIAGRAM

Fig. 4-1

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CHAPTER 4. LUBRICATION SYSTEM

1.2. RELIEF VALVE

through the oil gallery to the outside circumference chamber in the oil filter. The oil is cleaned while passing through the element and goes out through the central port, passing through the oil gallery and lubricates the crankshaft journals and other engine parts.

The lubrication oil from the oil pump should properly lubricate all engine parts throughout all engine speed ranges. A relief valve is installed to maintain constant oil pressure to the oil for this purpose. Excessively high regulation pressure will lead to oil leaks while too low regulation pressure to seizure of parts due to poor lubrication. This picture shows the construction of the relief valve. It is installed in the inside of the gearbox. Leaked oil through the valve is sprayed inside the gearbox and also lubricates gears.

Fig. 4-3 Oil filter When an element is clogged with dust, the oil reaching the outside circumference chamber in the oil filter is not allowed to pass smoothly through the element. As a result oil supply to the central port becomes insufficient, which will lead to seizure of engine parts due to poor lubrication. To prevent seizure caused by poor lubrication, the overflow valve opens and supplies oil bypassing the filter element. * Oil filter cartridge should be replaced with a new one after every 300 hours of operation.

Fig. 4-2 Relief valve 1.3. OIL FILTER SPECIFICATIONS

CONSTRUCTION AND OPERATION This filter is a cartridge type as shown in Fig. V3. The oil from the oil pump is fed into the relief valve where oil pressure is maintained a constant level by the relief valve and delivered

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1.4. EXPLODED VIEW OF OIL PUMP

Fig. 4-4

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2. REMOVAL, DISASSEMBLY, INSPECTION AND RE-INSTALLATION OF OIL PUMP 2.1. REMOVAL OF OIL PUMP • Drain oil. • Remove the gear case. • Remove the oil pump.

Fig. 4-6 • Measure the clearance between the inner rotor and outer rotor.

When the clearance exceeds the usable limit, replace the pump assembly. Fig. 4-5 2.2. DISASSEMBLY OF OIL PUMP • Remove the oil cover tightening bolts. Then the cover, inner rotor, and outer rotor are disassembled. 2.3. INSPECTION • Remove the oil pump gear and cover. • When the inner rotor or outer rotor is worn or damaged, replace the pump assembly with a new one. Fig. 4-7

• Clearance of the inner and outer rotors with the cover.

• Measure the clearance between the pump body and outer rotor with thickness gauges.

When the clearance exceeds the usable limit, replace the pump assembly. When the clearance exceeds the usable limit, replace the pump assembly.

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Fig. 4-10 Fig. 4-8 3.2. INSTALLATION OF OIL FILTER 2.4. INSTALLATION OF OIL PUMP • Inject a small amount of engine oil into the cartridge.

• Inject a small amount of engine oil into the oil pump and the oil passage in the gear case and install the oil pump on the gear case.

• Apply engine oil to the O-ring of the cartridge.

Fig. 4-9

Fig. 4-11 • Tighten the cartridge by hand until the O-ring comes into contact with the cylinder block surface and then give it three-fourth turn.

• Install the gear case on the cylinder block.

• After filling with new oil, operate the engine more than three minutes. Then check for oil leaks.

3. OIL FILTER 3.1. REMOVAL OF OIL FILTER Remove the oil filter cartridge from the cylinder block, using a cartridge wrench.

Fig. 4-12 66

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CHAPTER 5. COOLING SYSTEM 1. COOLING SYSTEM DIAGRAM

Fig. 5-1 2.3. INSPECTION OF THERMOSTAT

*In this section, only the thermostat and the water pump, which are directly mounted on the engine, are explained. About the radiator.

• Inspection of activating temperatures at which the valve starts to open and opens fully. Put the thermostat in water and heat the water gradually by stirring. Check for the temperature at which the valve starts to open and that at which the valve opens fully.

2. THERMOSTAT 2.1. REMOVAL OF THERMOSTAT • Drain coolant. • Remove the radiator hoses. • Remove the water outlet. • Remove the thermostat. 2.2. INSTALLATION OF THERMOSTAT • Discard the removed O-ring and install a new one.

Fig. 5-2

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CHAPTER 5. COOLING SYSTEM

Replace the thermostat whose specified temperatures deviate from specified values. Note: - Keep in mind that the valve reaction to temperature change is sometimes delayed by 3 to 5 minutes. - Be careful not to heat the thermostat directly. Place something under the thermostat in the water container or hang it in the water.

• Remove the cooling fan and pulley. • Install the pulley, belt, and cooling fan. 3.3. INSPECTION OF WATER PUMP • Inspection of the pump and pulley

3. WATER PUMP Check the pump for noise or hitching by turning the water pump pulley, applying load vertically to the pump axis.

3.1. REMOVAL OF WATER PUMP

When noise or hitching occurs, replace the pump assembly.

Fig. 5-3 • Drain coolant. Fig. 5-4 • Remove the cooling fan and pulley. • Inspection of the bearing unit • Remove the water by-pass hose Check the bearing unit for run-out. If the run out is more than 0.2 mm (0.008 in.), replace the pump assembly.

• Remove the water pump. • Remove the water pump spacer. 3.2. INSTALLATION OF WATER PUMP • Install the water pump spacer with new packing. • Install the water pump with new packing and tighten to the specified torque.

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CHAPTER 6. FUEL SYSTEM 1. INJECTION PUMP CONSTRUCTION

Fig. 6-1

Specifications E3CE , E3CF

E3CD

Pump type

NP - PFR3KX

NP - PFR3KX

Pre - stroke

2.05 - 2.15 mm (with rack at 8 mm)

2.05 - 2.15 mm (with rack at 16 mm)

Plunger lift

7 mm

7 mm

Rack stroke

16 mm

16 mm

Np = 2000 rpm

Np = 2000 rpm

Allowable max. speed

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2. REMOVAL, DISASSEMBLY, INSPECTION, RE-ASSEMBLY, AND INSTALLATION 2.1. REMOVAL OF INJECTION PUMP • Remove the injection pipes. • Open the injection pump side cover and remove the control rack along with the starting spring and control link. Fig. 6-3 • Remove the tightening bolts. • Remove the control rack. 2.2. DISASSEMBLY OF INJECTION PUMP • Remove the tappet and pin. Hold the pump in a vise. Release the lock plate and pull out the pin. Then the tapped springs out, so take care not to allow it fall.

Fig. 6-4 • Removal of the delivery valve Remove the delivery holder. Take out the valve spring and delivery valve with tweezers. Fig. 6-2 Discard removed O-rings. • Removal of other parts With the tapped removed, the lower spring seat, plunger, spring, upper spring, seat, and plunger control sleeve are removed. Note: Take care not to damage the plunger without fail.

Fig. 6-5

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• Removal of the cylinder. Push up the bottom of the cylinder to remove.

Fig. 6-8 2.4. RE-ASSEMBLY OF INJECTION PUMP Fig. 6-6

• Installation of the cylinder Install the cylinder into the pump housing, aligning the groove in the cylinder with the knock pin in the housing. Make sure that the knock pin is securely seated in the cylinder groove.

2.3. INSPECTION OF INJECTION PUMP • Inspection of movement of the plunger/cylinder assembly: element After washing well in clean fuel, place the assembly slanted at 600 and then pull up the plunger, and then give it a spin. When the plunger comes down without any hitch, the assembly is normal.

Fig. 6-9 • Installation of the delivery valve. Install the delivery valve, valve gasket, valve spring, and O-ring, and then temporarily tighten the delivery holder.

Fig. 6-7 • Wash the delivery valve sufficiently in clean fuel. While it is still wet after washing, close the opening with a finger and pull up the valve and release it in midway. If the valve comes down smoothly without any hitching and stops at the relieve valve, the delivery valve is normal.

Note: Take care not to damage the O-ring by other parts such as the threads of the valve holder.

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Fig. 6-10

Fig. 6-12

• Installation of the control sleeve and plunger

• Locking of the pins

Install the control sleeve aligning the center tooth with the groove in the control rack as illustrated.

Bend tangs of the plate as illustrated to lock the pins securely. Note: Discard the removed lock plate and install a new one.

Note: Plungers are designed not to allow inverted installation. Install the plunger into the sleeve.

Fig. 6-13 Fig. 6-11 • Tighten the delivery holders to the specified torque.

• Installation of the tappet Install the tappet by feeling for the position where the groove in the control sleeve is aligned with the trapping face of the plunger while depressing the tappet by hand.

Note: Be sure to tighten to the specif ied value. Excessive tightening may lead to seized plungers

After installing the tappets, install the lock plate and pins.

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Fig. 6-14 • Control rack movement After installation, make sure that the control rack moves smoothly.

Fig. 6-15

Presumable causes of not smooth movement are listed below: - Defective plunger-rack movement - Foreign matter caught in teeth of the control rack or control sleeves. - Too tight delivery holders Disassemble and inspect the pump again.

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2.5. ADJUSTMENT OF INJECTION VOLUME AND ADJUSTMENT CONDITIONS • Injection volume E3CE , E3CF

E 3CD

Injection volume for adjustment (reference)

34 mm3 / stroke

28 mm3 / stroke

Pump speed

NP = 1300 rpm

NP = 1000 rpm

Rack position

9.2 mm

10 mm

E3CE/E3CF

E3CD

Fig. 6-16 • Adjustment conditions E3CD

E3CF , E3CF Injection nozzle

NP - DN12SD12T 120 kgf / cm2

Nozzle opening pressure

Ф6 ×Ф2 − 600 mm

Injection pipe

0.5 kgf / cm2

Oil delivery pressure

Diesel fuel

Oil used

refer figure as following

Cam profile

E3CD,E3CE,E3CF Fig. 6-17

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3. INJECTION NOZZLES AND HOLDERS 3.1. REMOVAL OF INJECTION NOZZLES AND HOLDERS • Removal of the injection pipes and leak-off pipes. After removing the injection pipes, cap the openings of the delivery holders, nozzles, and injection pipes. Fig. 6-19 • Injection-starting pressure Injection-starting pressure should be 120 kgf/cm2 (1707 psi). If it is not so, adjust by shimming. • Visual inspection After washing the nozzles, check the needle valve seat for damage, or carbon deposit, and the injection orifice for clogging.

Fig. 6-18 • Loosen the retaining nuts. Use a box wrench or open-end wrench of 22 mm (0.866 in.). Note: Be careful not to loosen the hexagonal part [19mm (0. 748 in.)] of the holder body. If done so, the holder becomes disassembled. 3.2. INSPECTION OF INJECTION NOZZLES • Spraying test Use fuel with a specific gravity of 0.82 - 0.84 and a temperature of approximately 20°C (68° F). Wash the holder and nozzle in clean fuel. Also wash a nozzle tester and install the nozzle and nozzle holder on it as shown in Fig. 7-18. Inject fuel and observe spraying. It is the best to use a stroboscope to judge accurately. But it can be considered to be normal if the spraying pattern is focused and free from scattering.

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3.3. DISASSEMBLY AND WASHING OF INJECTION NOZZLES

When a nozzle is found functioning poorly through spray test, wash it. If washing does not restore its original function, replace it. • Nozzle washing First wash the nozzle in clean gasoline, and then wash it again in clean diesel fuel before assembling it. If the nozzle is seized, soak it in carbon cleaning liquid after washing. Then wash it again. • Nozzle replacement Replace the assembly of the needle valve and nozzle body. Before installing a new nozzle, move the needle valve sufficiently in the nozzle body in clean diesel fuel warmed up at 50 - 60° C (122 - 140° F) to remove the anti-corrosive completely.

Fig. 6-20

• Needle valve sliding

• Removal of the packing ring.

Move the needle valve in and out of the nozzle body several times in clean diesel fuel to make sure of its smooth movement. Slant the nozzle body by about 60°c, pull out the needle valve by about one-third of its length, and release it. When it comes down smoothly, it is normal. Perform three tests with the needle valve turned by 120°at each test.

Loosen the joint nut without removing the nozzle from the engine. Note: Take care not to damage the packing ring and the washer-contacting surface of the nozzle holder. • Hold the nozzle/holder assembly in a vice by the hexagonal part [19 mm (0.75 in.)] of the nozzle body with the nozzle turned upwards. Then loosen the retaining nut with a box wrench [21 mm (0.83 in.)].

If the needle valve does not move smoothly, replace the assembly of the needle valve and nozzle holder.

• Remove the retaining nut while holding the nozzle by hand. • Remove the nozzle assembly and distance piece. • Remove the holder body from the vise and remove other parts. Note: Handle the nozzle, distance piece, and nozzle holder body carefully not to damage their end surfaces, as they are made tight for high-pressure fuel.

Fig. 6-21

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3.4. INSTALLATION OF INJECTION NOZZLES AND HOLDERS

• When using an air tool to tighten the nut, make its tightening speed as slow as possible.

• Before installation, wash all parts in clean diesel fuel or cleansing oil.

• Be careful not to hit the nozzle body with a wrench, which may cause fuel leakage.

• Put the adjusting shim, spring, pressure pin, and distance piece on the nozzle holder body in this order. Lastly place the nozzle assembly and retain with the retaining nut.

• Place the packing ring in position and tighten the joint nut to the specified torque.

Note: When installing the pressure pin and distance piece, pay attention to their directions.

• Install the injection pipe and leak-off pipe and tighten them to the specified torque.

• Hold the nozzle holder body in a vise and tighten the retaining nut to the specified torque.

Incorrect tightening torque will lead to fuel leakage or nozzle seizure. • Remove the assembly from the vise and install a new washer, the packing ring, and nut. (Be sure to discard the removed washer and install a new one.) • Check each assembly on a nozzle tester for spraying, valve-opening pressure, etc. Valve-opening pressure should be adjusted with an adjusting shim. 3.5. INSTALLATION OF INJECTION NOULES AND HOLDERS • Install the nozzle gasket into the cylinder head. • Screw in the retaining nut by hand. • Tighten the retaining nut to the specified torque, using a box wrench [21 mm (0.83 in.)].

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4. GOVERNOR

(5) The floating arm end is connected with a pin to the control link, which is connected with the control rack of the injection pump.

4.1. GOVERNOR CONSTRUCTION

(6) A tension arm end is connected with the governor spring, which is connected with a control arm. The control arm is further connected with a control lever.

(1) Flyweights are installed on the injection pump cam gear and turn along with the injection pump camshaft. (2) A thrust piece is installed on the camshaft and can slide along the shaft.

(7) An "Angleichung" (adaptation) device, which will be explained later, is installed on the tension arm. The Angleichung pin end is in contact with the control link pin, which is connected with the control lever. (8) A starting spring is installed on the control link. (9) A return spring is installed on the control lever, which is limited in movement with two adjusting screws.

Fig. 6-22 (3) A tension arm and a floating arm are installed to turn on a common pin. (4) A sintered piece is cast in the center of the floating arm and in contact with the thrust piece, which slides as the injection pump camshaft turns.

Fig. 6-23

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4.2. GOVERNOR OPERATION

(3) When the control lever is set in the full load position, tension of the tension spring is increased and the tension arm is in contact with the full load stopper. Meanwhile, the floating arm, control link, and control rod work to control fuel supply so as to avoid exceeding a preset maximum engine speed. Thus full-load, maximum speed operation is possible. When load is eliminated during loaded operation, engine speeds increase, which lead to increased centrifugal force of the flyweights. Then the trust piece pushes the floating arm and the control rod is shifted to decrease fuel. Thus over-racing is prevented.

(1) The control lever is released in the engine starting position and is set in the idling position by the return spring. In this state no centrifugal force is applied to the governor, so the control rack of the injection pump is shifted by the starting spring to the position for increased fuel supply. (2) Once the engine is stated, the governor controls engine speeds automatically. When engine speeds exceeds preset value, the thrust plate moves by means of the centrifugal force of the flyweights and shifts the control rack to decrease fuel supply providing smooth rotation. When engine speeds come down below the specified value, the force of the governor spring and starting spring surpasses the centrifugal force and the thrust peace is pushed back. Then the control rack is shifted to increase fuel and thus restore engine speeds. Engine speeds are maintained at a constant level in this way.

5. ANGLEICHUNG DEVICE 5.1. ANGLEICHUNG OPERATION The Angleichung device works to provide: a. Averaged ratio of intake air and fuel injection volume. b. Increased torque at low speeds. The Angleichung device is installed on the tension arm. It is in contact with the floating arm pin and the control link. (1) When the full-load stopper is in contact with the tension arm and centrifugal force of the flyweights is weaker than force of the Angleichung spring during full-load, low speed operation, the spring pushes the thrust piece and shifts the control rack to increase fuel supply and thus provide more torque.

Fig. 6-24

Fig. 6-25

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CHAPTER 6. FUEL SYSTEM

(2) When engine load is released, engine speeds increases. The centrifugal force increases, which pushes out the thrust piece. The thrust peace pushes the floating arm, which results in compression of the Angleichung spring, which makes the control rod shift to decrease fuel supply. Angleichung operation is completed when the control link and control rod are in direct contact with each other due to the complete compression of the spring.

Fig. 6-26

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CHAPTER 7. ELECTRICAL SYSTEM 1. STARTER 1.1 CONSTRUCTION Nominal voltage

12V

Nominal output

1.4KW

Pinion teeth

9

Direction of rotation

Clockwise(as viewed from pinion)

Fig. 7-1 1.2. REMOVAL AND DISASSEMBLY 1.2. STARTER

1.2.2. DISASSEMBLY OF STARTER (1) Removal of the lead from terminal C.

1.2.1. REMOVAL OF STARTER (1) Remove the negative (-) battery cable. (2) Remove the starter wiring. • Disconnect the wire harness from terminal 30 by removing the nut. • Remove the connector from terminal 50. • Remove the starter from the engine.

Fig. 7-2 82

CHAPTER 7. ELECTRICAL SYSTEM

(2) Removal of the starter yoke/armature assembly.

(6) Removal of the brush holder

• Remove the starter yoke/armature assembly and O-ring by removing the two through bolts. • Removal the commutator end frame and an Oring.

• Lift up the brush spring and take out the brush.

Fig. 7-6 • Disconnect the brush holder from the starter yoke.

Fig. 7-3 (3) Removal of the starter housing

(7) Removal of the armature

• Disconnect the starter housing from the magnetic switch. • Remove the drive pinion. • Remove the idle gear and retainer with roller.

• Removal the armature from the starter yoke. 1.3. INSPECTION OF COMPONENTS (1) Inspection of the armature coil grounding • Check continuity across the commutator and an armature coil core. If there is no continuity, the armature coil is normal.

Fig. 7-4 (4) Removal of the clutch assembly. • Remove the clutch assembly from the magnet switch.

Fig. 7-7 (2) Inspection of armature coil for short circuit

(5) Removal of the steel ball and spring

• Turn the armature coil on a armature coil tester while holing a piece of iron closely above the armature. If the iron piece does not vibrate nor is attached to the armature, the armature is normal. Note: The armature coil surfaces should be cleaned ahead of time. Fig. 7-5

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Measure mica depth against segment top. Standard value

Usable limit

0.5-0.8mm

0.2mm

Fig. 7-8 (3) Inspection of the commutator • Inspect the commutator for dirt, burning, damage, etc. Minor damage can be corrected with sandpaper of #400 or higher no. • Inspect the commutator for run-out with a dial gauge on a V-block. Standard value

Usable limit

0.02mm

0.05mm

Fig. 7-11 (4) Inspection of field coils for short circuit • Inspection for continuity across the lead from terminal C and field coil brush. If there is continuity, the coils are normal.

Fig. 7-12

Fig. 7-9

(5) Inspection of field coils for grounding

• Measure the commutator diameter with vernier calipers. Standard value

Usable limit

30mm

29mm

• Inspect continuity across the field coil brush and field coil. If there is no continuity, the coils are normal.

Fig. 7-13 Fig. 7-10

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CHAPTER 7. ELECTRICAL SYSTEM

(6) Inspection of the brushes

holder is normal.

• Measure brush length in the middle. Standard value Usable limit Standard value

Usable limit

15.0mm

10.0mm

Fig. 7-16 (9) Inspection of the clutch • Inspect the gear for wear and damage. • Make sure that the gear locks when turned in driving direction and turns smoothly in the reverse direction.

Fig. 7-14 • Correct the contact surfaces of the brushes on the sandpaper wrapped around the commutator. (7) Inspection of brush spring tension • Measure spring tension with a spring balance and read the balance at the moment when the spring is about to leave the brush.

Fig. 7-17 (10) Inspection of the bearing • There should be no hitching when the bearing is turned manually by applying some force to it with fingers. • It should not make abnormal noises when turned abruptly. • Remove the bearing or install it as illustrated.

Fig. 7-15 Standard value

Usable limit

1785-2415 gr

1200 gr

(8) Inspection of the brush holder.

Fig. 7-18

• Inspect for insulation across positive (+) side and negative (-) side of the brush holder. If there is no continuity, the brush

(11) Replacement of the bearing • Remove the bearing or install it as illustrated. 85

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1.4. REASSEMBLY OF STARTER (1) Installation of the armature • Apply grease to the armature bearing and then install the armature on the starter yoke. (2) Installation of the brushes and brush holder • Lift up and hold the spring and install the brush.

Fig. 7-19

Fig. 7-23

Fig. 7-20

• Install the commutator end frame using an Oring.

(12) Inspection of the magnetic switch • Inspect for continuity across terminal 50 and terminal C. If there is continuity, the switch is normal.

(3) Installation of the starter yoke/armature • Install the starter yoke on the magnetic switch using an O-ring.

Fig. 7-21 Fig. 7-24

• Inspect for continuity across terminal 50 and magnetic switch body. If there is continuity, the switch is normal.

(4) Installation of the steel ball and spring • Apply grease to the ball ahead of time and install the ball and spring.

Fig. 7-22 86

CHAPTER 7. ELECTRICAL SYSTEM

Fig. 7-27

Fig. 7-25

(2) Coil holding test

(5) Installation of the gear and clutch

• In the state of the pull-in test, the gear should remain pushed out when the lead is disconnected from terminal C.

• Install the clutch assembly on the starter housing. • Apply grease to the roller/retainer assembly and idle gear and them install. • Install the drive pinion on the armature shaft. Apply grease to each gear.

Fig. 7-28 (3) Plunger-return test Fig. 7-26

• In the state of the coil holding test, the pinion should retract when the connection is removed as illustrated.

(6) Installation of the starter housing • Install the starter housing on the magnetic switch. • Install the two through bolts. (7) Connection of the lead of terminal C 1.5. INSPECTION OF THE STARTER AFTER 1.5. REMOVAL FROM THE TRACTOR Note: Each step should be performed within three to five seconds to prevent damage.

Fig. 7-29

(1) Pull-in test • Make sure the pinion is pushed out when the starter is connected as illustrated.

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1.6. PERFORMANCE TEST Note: Hold the starter securely in a vise. In unloaded test use thick wires because of high current.

Voltage

11.5V

Current

230A or less at 1180 rpm or over

Torque

0.65 kgf･m or over

1.7. INSTALLATION OF THE STARTER (1) Connect the wiring.

(1) Unloaded test Drive the starter independently with a specified battery without any load and check for spinning speed, voltage, and current. Values should be as shown below: Voltage

11.5V

Current

90A or less

Speed

3000 rpm or more

• Connect the lead to terminal 30 and tighten it with the nut. • Install the starter on the engine. (2) Install the starter on the engine. (3) Connect the negative (-) battery cable.

Fig. 7-30 (2) Braking test Install the starter on a test bench and apply brake. Measure each value while the starter is thus prevented from spinning. Each value should be as shown below:

Fig. 7-31

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CHAPTER 7. ELECTRICAL SYSTEM

2. ALTERNATOR 2.1. EXPLODED VIEW, SPECIFICATIONS, AND PERFORMANCE CURVES • Exploded view

Fig. 7-35

• Specifications

• Output performance curves

Nominal voltage

12V

Nominal output

40A

Rated speed

5000 rpm

Starting speed

1350 rpm

Allowable maximum speed

15000 rpm

Allowable surrounding temperatures

-30~+90˚C

Direction of rotation

Clockwise (as viewed from pulley)

Polarity

Negative earthing

Regulated voltage

Usable limit

Fig. 7-36

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TH TRACTOR SERVICE MANUAL

2.2. TROUBLESHOOTING

b. Removal of the rear end cover

2.3. REMOVAL AND DISASSEMBLY

Remove the three rear end cover tightening bolts and nut for terminal B. Then the rear cover is removed.

REMOVAL • Remove battery wiring. • Remove the fan and fan belt. • Remove the tightening bolts and remove the generator. DISASSEMBLY a. Removal of the pulley Hold the hexagonal part of the shaft with a socket wrench and remove the pulley nut with an open end wrench.

Fig. 7-38 c. Removal of the brush holder Remove the two screws which tighten the brush holder and rectifier. Then the brush is removed.

Fig. 7-37

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CHAPTER 7. ELECTRICAL SYSTEM

d. Removal of the IC regulator

Fig. 7-41 f.

Fig. 7-39 Remove the three screws which tighten the IC regulator. Then the regulator is removed.

Removal of the brushes Remove the four nuts and bushes which tighten the drive end frame and rear end frame. Then the brush assembly is removed.

Note: As screws of different length are used for respective terminals, they should be set aside in order for later reference after disassembly. A wrongly used screw may come into contact with the end frame and couse the regulator out of control, which will lead to battery overcharging and result in serious damage in the end.

Fig. 7-42 Note: When removing the bushes, take care not to strech the wire from the startor. g. Removal of the rear end frame Remove the rear end frame using a puller as illustrated.

Fig. 7-40 e. Removal of the rectifier Remove the four screws which tighten the leads for the rectifier and stator. Then the rectifier is removed.

Fig. 7-43 h. Place the drive end frame on blocks as illustrated to make it level and push out the rotor on a press. 91

TH TRACTOR SERVICE MANUAL

Note: The bearing is a high speed type, so be sure to use a specified one by ISEKI when replaceing. Never give it shock. k. Removal of the bearing which is installed on the slip ring side Remove the bearing using a puller as illustrated.

Fig. 7-44 Note: Take care not allow the rotor to fall to avoid damaging the slip ring and fan. i.

Removal of the retainer plate Remove the four screws which tighten the retainer plate. Then the plate is removed Fig. 7-47 2.4. INSPECTION a. Inspection of the rotor slip rings Measure the outer diameter of the rings. If the measured value exceeds the usable limit, replace with a new one. Standard value

Usable limit

14.4mm

14.0mm

Fig. 7-45 j.

Removal of the bearing which is installed on the drive end side. Place the dive end frame level on blocks as illustrated and put a jig on the bearing. Then push out the bearing on a press.

Fig. 7-48 • Make sure that the slip ring surface is smooth, clean, and free from oil. If the surface is roughened, polish with a f ine sand paper (#500 #600). Fig. 7-46

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CHAPTER 7. ELECTRICAL SYSTEM

If it is smeared with oil, clean with alcoholsoaked cloth

e. Continuity test of the stator coils Check for continuity across respective coil terminals with a tester. If there is no continuity, replace the stator.

b. Continuity test of the rotor coil Check for continuity across the slip rings. If there is no continuity, replace the rotor.

Fig. 7-52 f.

Fig. 7-49 c. Insulation test of the rotor coil

Insulation test of the stator coils Check continuity across one of the stator terminals and stator core. If there is continuity, replace the stator.

Check for continuity across a slip ring and the rotor core or the shaft. If there is continuity replace the rotor.

Fig. 7-53 g. Inspection of the rectifier

Fig. 7-50 d. Inspection of the bearings

Set the tester at KΩ range and check continuity across respective terminals. The diode should show continuity only in one direction.

Noisy or hitching bearings should be replaced with new ones.

Fig. 7-54

Fig. 7-51 93

TH TRACTOR SERVICE MANUAL

the brush holder. If the length is less than the usable limit, replace.

Note: The rectifire cannot be judged by the resistance value shown in forward direction, because the diode shows greatly defferent forward current flow in accoedance with voltage applied, that is, the tester type and resistance range applied greatly affect resistance reading. Consequently the diode should be considered normal when the resistance difference between the forward direction and reverse direction is large enough. Never apply MΩrange of the tester, which may damege the diode. h. Inspection of the brushes

Fig. 7-55

Measure the length of the brush exposed above i.

Specified tightening torques and servise standards

Fig. 7-56 94

Standard value

Usable limit

10.5mm

4.5mm

CHAPTER 7. ELECTRICAL SYSTEM

J. Inspection of the IC regulator

Fig. 7-57 • Connect the removed IC regulator, variable DC power supply, voltmeter, and a lamp as illustrated. (Keep SW1 and SW2 turned off.) • Set the power supply at 12V. • Turn on SW1. Make sure that L1 (in place of the charge lamp) is lit bright and L2 (in place of the rotor coil) is also lit. • Then turn on SW2 with SW1 on. Make sure that L1 is turned off and L2 remains lit. • When the power supply output is changed gradually from 12V until 14.5±06. at about 25℃ with both SW1 and SW2 turned on, L2 should turn off and L1 should remain turned off.

Fig. 7-58 2.5. RE-ASSEMBLY Re-assemble in reverse order of disassembly, following the next precautions.

After above test, check the diode between terminal B and F.

a. Pressing in the bearings

• Set the tester at KΩ range and check for continuity across terminals B and F. Check by changing the polarity of the tester. There should be continuity in one directions and no continuity in the other direction.

Press in the bearing with a hand press carefully to avoid slanted installation. At room temperature, it is very hard to press in the bearing due to interference. So it is recommendable to heat up the whole frame at about 100℃ Note: When installing the bearing use a jig which is designed to press only the outer race. Support the frame at the bearing box not at the stay.

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Fig. 7-59 (2) Installation of the brush holder

Fig. 7-60 Note: - The clearance between the brush holder and the connector should be 1 mm or more. - Rubber packing for the brush holder should not be deformed or pinched. - As the terminals have screws different in length, be sure not to confuse them when installing.

Installation the brush holder sideways along with the IC regulator 3. GLOW PLUGS 3.1. SEDTIONAL VIEW

Fig. 7-61 3.2. REMOVAL, INSPECTION, AND RE-ASSEMBLY a. Troubleshooting

electrode. If there is no resistance, it indicates a short circuit, so replace the glow plug. If the resistance is infinite, it shows that pre-heating coil is burnt out, so replace the glow plug.

b. Removal • Remove the connector by loosening the glow pulg nut installed on the cylinder head. • Remove the glow plug.

Standard value

c. Inspection

1.2-2.5Ω

d. Re-installation

• Check for continuity across the sheath and center

• Install the glow plug. • install the nut on the glow plug and connect the connector. 96

WIRING DIAGRAM

WIRING DIAGRAM TH4260F

WIRING DIAGRAM

TH4260FH

WIRING DIAGRAM

TH4290F

WIRING DIAGRAM

TH4290FH & 4330FH

TH4330 TH4290 TH4260

Overseas Business Department 3-14, Nishi-Nippori, 5-chome, Arakawa-ku, Tokyo 116-8541, Japan Phone: (03) 5604-7658 Fax: (03) 5604-7703

SM-TH4330/-EN-10 0402-01-100 Printed in Japan