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Mahindra 2810, Service Manual

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Mahindra 2810 Service Manual Download Page 141

2)Right Turn

When the steering control valve shaft is rotated to the right,the control valve moves off center.This 
connects the inlet port (P) to one port of each metering pump section and also connects the other port of 
each metering pump section to the cylinder.The amount that the spool moves off center depends on 
how fast the steering wheel is rotated and also how much effort is required to turn the wheel. 

Fig.8-3 Right turn position

8-4

Summary of Contents for 2810

Page 1: ...t 02 Chapter 3 Engine accessories 03 Chapter 4 Clutch system 04 Chapter 5 Transmission 05 Chapter 6 Front axle 4WD 06 Chapter 7 Rear axle and Brakes 07 Chapter 8 Power steering system 08 Chapter 9 Hyd...

Page 2: ...ETY DECALS 1 11 UNIVERSAL SYMBOLS 1 14 SECTION 1 TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS 1 15 SECTION 2 SPECIFICATIONS 1 17 SECTION 3 GEAR TRAIN DIAGRAMS 1 20 SECTION 4 PRECAUTIONS FOR TRACTOR...

Page 3: ...ed consequently complete disassembly and reassembly are outlined The mechanic is relied upon to decide how far disassembly must be carried when complete overhaul is not required Study unfamiliar servi...

Page 4: ...Wear safety goggles when handling battery electrolyte It contains sulfuric acid which is a poison and can cause blindness Avoid it contacting eyes skin or clothing sulfuric acid will eat through cloth...

Page 5: ...g clothing Stop the engine and be sure PTO driveline is stopped before making adjustment connections or cleaning out PTO drive equipment SERVICE TIRES SAFELY Tire changing can be dangerous and should...

Page 6: ...zard or unsafe practice that can lead in injury or death CAUTION Instructions for the correct operation of the machine which if followed will ensure that it performs at it s best IMPORTANT Hazard or u...

Page 7: ...ions are listed on CAUTION safety signs READ SAFETY INSTRUCTION Carefully read all safety instructions given in this manual for your safety Tempering with any of the safety devices can cause serious i...

Page 8: ...be worn during machine operation when the machine is equipped with a certified ROPS Failure to do so will reduce or eliminate protection for the operator in the event of a roll over PRECAUTION TO AVOI...

Page 9: ...on public roads unless prohibited by state or local regulations Use slow moving vehicle SMV sign when driving on public road during both day night time unless prohibited by law PRACTICE SAFE MAINTENA...

Page 10: ...ilated area 2 Wear eye protection and acid proof hand gloves 3 Avoid breathing direct fumes when electrolyte is added 4 Do not add water to electrolyte as it may splash off causing severe burns If you...

Page 11: ...rk on Tractor SAFETY STARTER SWITCH 1 Clutch operated safety switch is provided on all Tractors which allow the starting system to become operational only when the Clutch pedal is fully pressed 2 Do n...

Page 12: ...stop engine remove the key and apply parking brake before leaving the tractor seat Air pressures are specified by the manufacturer Before starting and operating know the operating and safety instructi...

Page 13: ...t No 1260 904 061 0 BEFORE OPERATE THE TRACTOR READ THE OPERATOR S MANUAL THOROUGHLY TO UNDERSTAND THE IMPORTANT FUNCTIONS AND CONTROLS CAUTION WARNING The cooling system operates under pressure It is...

Page 14: ...wing equipment use a Safety chain FAILURE TO FOLLOW ANY OF THE INSTRUCTIONS ABOVE CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS Location On battery bracket RH Part No 1260 904 066 0 Locati...

Page 15: ...low or minimum setting Engine coolant temperature Warning Hare fast or maximum setting Fuel level Hazard warning Transmission oil pressure Engine stop control Neutral Turn signal Lights Fan Transmissi...

Page 16: ...e number is stamped on the top of the engine block Tractor Serial Number Engine Serial Number Tractor Serial Number 1 MODEL NAME PLATE The plate indicates the model and type of the tractor Model name...

Page 17: ...3 Engine model and engine serial number plate on the head cover 1 16...

Page 18: ...n ratio 3 26inX3 64in 83mmX92 4mm 3 14inX3 64in 80mmX92 4mm Bore and Stroke 1 499 1 393 Displacement 3 Number of Cylinder 2800rpm 2 700rpm Rated Speed Vertical water cooled 4 cycle Diesel Type D1503 3...

Page 19: ...93 1 1315 51 8 3150 124 Multiple wet disk Dry single disc mechanic 2810 Rear Front Min Ground Clearance Wheel base Overall Height Overall width Overall length Axle type PTO Main MODEL Implement Posit...

Page 20: ...6 3 04 3 2 22 2 28 2 30 2 37 2 1 61 1 67 1 68 1 72 1 M 7 08 7 29 7 34 7 55 2 5 17 5 31 5 35 5 50 1 H Reverse Forward Reverse Forward 2810NEW T290 T300 T330 Main shift Range shift 12 94 9 37 13 41 9 71...

Page 21: ...SECTION 3 GEAR TRAIN DIAGRAMS FIG 1 3 GEAR TRAIN DIAGRAM 1 20...

Page 22: ...and charge light on the monitor array will light when the main switch is turned from OFF to ON All lights on the panel go out automatically when the engine is started and its speed is increased to a...

Page 23: ...MONITOR LIGHT ARRAY High Beam Lamp Low Beam Lamp PTO Monitor Lamp Cruise Control Lamp Fuel Empty Warning Lamp Oil pressure lamp Charge lamp Glow signal Lamp Turn Signal Lamp 1 22...

Page 24: ...2 CONTROLS 1 23...

Page 25: ...required Grease Clutch pedal shaft 6 32 8 453 US gal Gear oil 80 TRANSMISSION CASE 3 5 7 1 51 gal Engine oil ENGINE 2 7 Fresh clean Water L L C RADIATOR 1 33 8 717 US gal Diesel fuel FUEL TANK 8 FINAL...

Page 26: ...in deflection pushed with a finger Wash after every 100hrs and replace after 300 hrs Tank should be full Everyday and before work Clean cooling fins and cores Fill coolant up to radiator throat Replac...

Page 27: ...to 40mm Brake pedal free play Free Play 20 to 30mm Clutch pedal free play Clean hydraulic suction filter at the same time Replace after initial 50 hrs then after every 300 hrs Transmission oil Electri...

Page 28: ...ems Replace after initial 100 hrs and then after every 300 hrs Check every year by removing the plug installed in the front bottom of clutch chamber 6 0 5 5 5 0 4 5 4 0 3 5 3 0 2 5 2 0 1 5 1 0 5 Judgm...

Page 29: ...R BLOCKS 2 4 SECTION 3 SEPARATION OF MAJOR COMPONENTS 2 5 1 Separation of the front axle and axle bracket 2 5 2 Separation of the engine and front axle bracket 2 6 3 Separation of the engine and front...

Page 30: ...e stopper 5 Installed bearings should turn smoothly 2 Oil seals 1 Oil seals installer should be designed so as not to deform the oil seals 1 BEFORE OPERATION 1 Always be safety conscious in selecting...

Page 31: ...it is permanently deformed 4 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...

Page 32: ...a direction that will provide easy access for a grease gun 9 Other precautions 1 Be sure not to damage any finished surfaces or parts 2 Always refrain from forcing installation 3 Each lever knob shou...

Page 33: ...SECTION 2 OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCKS 2 4...

Page 34: ...rely with a crane or stands 2 Support the front axle with a jack 3 Remove both right hand and left hand tie rods 4 Remove the pivot metal bolts 5 Remove the front axle assembly forward FIG 2 5 Drive s...

Page 35: ...ove the upper hose lower hose and drain hose from the radiator Note The radiator should be drained of the coolant ahead of time 11 Remove the fuel filter 1 Removal 1 Hold or support the engine with a...

Page 36: ...em 4 Install the battery bracket and battery 5 Install the radiator and oil cooler on the front axle bracket 6 Connect the upper lower and drain radiator hoses 7 Install the air cleaner assembly and t...

Page 37: ...ect the linear shift control cable Disconnect the cable from both the steering lever side and transmission 10 Remove the mounting bolts and dismounting the dash panel FIG 2 15 Note Tilt the steering c...

Page 38: ...right hand pivot metal tightening bolts 3 Connect hoses 4 Assemble the engine and the front transmission Note Apply small mount of grease to each of the sliding parts Be careful not to apply excessive...

Page 39: ...he side covers LH and RH 2 Disconnect the negative battery cable 3 Detach all the wiring relevant to the removal of the floor FIG 2 23 Slow return check valve 8 Remove the diff lock pedal Remote Contr...

Page 40: ...tion control levers FIG 2 28 Rubber mounting 16 Lift up the floor slightly with a hoist 17 Disconnect the linear shift control cable fuel hoses and gauge coupler between the fuel tank and floor FIG 2...

Page 41: ...check valve 3 Disconnect the brake rods Slow return check valve FIG 2 35 Optional Note Lift up the floor gradually making sure that all relevant wiring Piping and links are disconnected FIG 2 34 Brake...

Page 42: ...th a crane or jack 9 Remove the bolts which tighten the front transmission and spacer transmission cases 10 Move the rear part of the tractor rearwards by turning the rear wheels by hand and then the...

Page 43: ...e negative battery cable 3 Remove the slow return check valve knob FIG 2 42 Remote control valve optional 12 remove the back panel 13 remove the fuel tank cover 14 Drain the fuel of fuel tank 15 Remov...

Page 44: ...oor panel 22 Drain the transmission of oil 23 Remove the assembly of the remote control valve and piping 24 Remove the suction and delivery pipe 30 Install the rear wheels LH and RH and the remained b...

Page 45: ...damage needle bearings the cut away part in the gear should be turned downward without fail so as to clear the gear to be positioned underneath 2 Install the main change shifter link and each change...

Page 46: ...3 Mount the rear wheel 4 Refill the transmission with oil up to the specified level Level up to fill the oil can be sought from the rear side of rear transmission case Window FIG 2 53 3 point linkage...

Page 47: ...ION OF THE REAR TRANSMISSION AND SPACER TRANSMISSION 1 Removal 1 Remove the operator s seat FIG 2 59 cylinder case 2 Installation Reassemble the reverse order of disassemble 1 Tighten the cylinder cas...

Page 48: ...Removal of the radiator 3 3 5 Inspection of each part 3 3 6 Radiator reassembly 3 5 7 Daily inspection 3 5 8 Trouble shooting 3 6 SECTION 2 AIR CLEANER SYSTEM 3 7 1 General description 3 7 2 Double el...

Page 49: ...ter pump only to provide a uniform and fast warm up period Once the engine has reached operating temperature the thermostat opens and coolant is pumped from the bottom of the radiator via the lower ho...

Page 50: ...side plates to install the radiator and a fan guide Fin tube type cores are used and the cores and tank is made of anti corrosive copper and Copper alloy FIG 3 3 Radiator assy Radiator cap Hose Radia...

Page 51: ...eaks 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 If any water leak should occur there repair the leak by solde...

Page 52: ...corroded cracked or badly damaged replace the radiator Also replace damaged or fatigued water hoses Retighten loose hose clamps securely if water is leaking through the hose clamps securely or replace...

Page 53: ...should be washed clean ahead of time As concerns of mixing ratio of an antifreeze follow its manufacture s instructions Antifreeze should be blended well with water before filling When the coolant le...

Page 54: ...Adjust injection timing 8 Improper injection timing 7 Clean radiator and water passages 7 Clogged water passages 6 Repair or replace 6 Poor water pump or water leaks 5 Replace 5 Poor thermostat 4 Rep...

Page 55: ...d The air cleaner Which is installed on the T series tractor is a dry cyclone type and is constructed as shown in the figure Under the influence of suction generated by the engine unfiltered air flows...

Page 56: ...ity gr 700 Filtering area sq in Outer element 1 32 2046 inner element 0 16 248 Filter material Outer element AS 42 inner element AS 44 Remarks Tested dust SAE FINE Dust density 1 0 gr 0 93gr sq ft 2 D...

Page 57: ...the dust in the element hold the element by a hand and pat the side wall with other hand Never hit the element against a stone or a concrete wall because that might cause its side wall to peel off app...

Page 58: ...ed 5 times must be replaced with a new one 5 ELEMENT INSTALLATION Install the element in the reverse order of disassembly but follow these instructions 1 Each tightening bolt must be secured and care...

Page 59: ...GENERAL DESCRIPTION 4 1 SECTION 2 SPECIFICATIONS 4 2 SECTION 3 DISASSEMBLY INSPECTION AND REASSEMBLY 4 3 1 Main clutch 4 3 2 Clutch shaft and related parts 4 6 3 Final adjustment of the clutch pedal...

Page 60: ...the input gear It can move in an axial direction but is locked in the rotational direction It transmits engine power to the transmission by means of friction Twelve coil spring are installed between...

Page 61: ...er dia inner dia Y 02 Y 07 Facing material Dry single Type Clutch disc 20 30 0 79 1 18 Clutch pedal free play in 0 7 MAX 0 028 Lateral deviation in 8 4 0 3 0 331 Disc thickness free in 21 7 0 854 Smal...

Page 62: ...to replace the clutch with assembly if pressure plate diaphragm spring are needed to be replaced 1 DISASSEMBLY Separate the engine from the front transmission referring to the paragraph SEPARATION OF...

Page 63: ...de based grease to resolving or sliding parts prior to reassembly 3 When installing the clutch disc on the flywheel turn the longer protrusion of the hub towards the flywheel The reverse installation...

Page 64: ...n should be locked securely with wire 3 Smooth movement of each part should be conformed 4 The release bearing must be installed in the correct direction 2 CLUTCH SHAFT AND RELATED PARTS 1 disassembly...

Page 65: ...96 in so that the switch will turn on only when the clutch is disengaged to allow the engine to start 3 Inspect the clutch action Inspection of clutch action and slippage While the engine is running t...

Page 66: ...ssive wear of clutch facing Adjust No play in the release bearing Repair or replace Deviation of flywheel or pressure plate Repair or replace Oil stained or hardened clutch facing Replace Broken or fa...

Page 67: ...ntermeasures Probable causes 5 PROBLEM Dashing or shifting The tractor does not starting moving smoothly but dashes or is likely to stop when the clutch is operated during a operation Repair or replac...

Page 68: ...ATIONS 5 2 1 Wheel drive system 5 2 2 PTO drive system 5 2 SECTION 3 DISASSEMBLY INSPECTION AND REASSEMBLY 5 3 1 input shaft and reverse change gear Front transmission 5 5 2 Main change sub change and...

Page 69: ...transmission produces 12 speeds forward and reverse F1 and R1 by reverse change gears 4 speeds by main change gears 3 speed by sub change gears 2 Synchromesh transmission has 3rd and 4th speed stages...

Page 70: ...a conical friction surface on its circumstance Block pin 3 prevents hub 2 from sliding until the torque imposed upon the pin due to the speed differential caused when shifting gears disappears Thrust...

Page 71: ...spring 7 without allowing the hub to clear the groove in thrust piece 6 until such time as the friction surface of synchro ring 4 comes into contact with the friction surface of synchro cup 5 1 Thrus...

Page 72: ...42 0 4398 19 30 25 36 forward reverse Speed shift range Reduction ratios Engine rated rpm 2800 RPM Speed shift range Side shift RH Main speed shift THF 500 Oil 2 PTO DRIVE SYSTEM Wet multi disc hydra...

Page 73: ...ical 30 13 Gear helical 30 14 Gear helical 25 15 Ball bearing 16 Ball bearing HL1 17 Washer 20X34X03 18 Gear helical 42 19 Snap ring 20 Needle bearing 21 Shaft shuttle 215 22 Synchronizer 23 Needle be...

Page 74: ...1 Removal of input shaft and related parts separate the engine from the front transmission referring to the paragraph 3 1 of SECTION 4 SEPARATION OF MAJOR COMPONENT in Chapter 2 a Remove input metal...

Page 75: ...assembly 0 3 0 012 in 0 0 in Stepped wear of teeth 0 5 0 020 in 0 1 0 2 0 004 0 008 in Backlash of each gear measured in meshed condition Usable limits Standard values Inspection items Inspect bearing...

Page 76: ...ll synchro hub comp 35 and above sub assemblies on reverse shaft 18 Note As each synchromesh assembly maintains a specified installed width be sure not to mix different pairs of the synchro hub comp a...

Page 77: ...mbled shaft Install each sub assembled shift into the reverse metal Support Note When installing the PTO clutch assembly apply a thin coat of grease to the seal rings and install it taking care not to...

Page 78: ...rearwards that is on the snap ring installed side b Apply adhesive to the threads of the bolts M8 20 which tighten the bearing retaining plate c Oil seals should be installed in their correct directio...

Page 79: ...coat of grease to the seal rings and install it taking care not to damage these rings When installing seal rings apply fresh oil ahead of time and install them carefully so as not to damage them PTO...

Page 80: ...plate disc assembly and driving plates d While holding return spring 43 compressed with a special tool remove snap ring e Disassemble into separate parts piston return sparing brake disc and cover as...

Page 81: ...es Inspection Items Fig 5 20 c Driven plate Inspection for deformation and burning A seriously damaged or worn disc should be replaced Fig 5 18 0 2mm 0 008 in Surface flatness Usable limit Specified v...

Page 82: ...ve a When installing seal rings apply fresh oil ahead of time and install them carefully so as not to damage them b Install the return plate with the press processed side turn towards the brake disc 4...

Page 83: ...3 MAIN CHANGE SUB CHANGE AND 4WD CHANGE GEARS 1 Synchromesh transmission version Fig 5 24 Synchromesh transmission version 5 15...

Page 84: ...Fig 5 25 Main change gear and related parts 5 16...

Page 85: ...OMPONENTS in chapter 2 With this operation the transmission is divided into parts A and B part A includes main speed shift and mechanism and part B includes speed shifting and 4WD shifting mechanisms...

Page 86: ...metal 18 b Pull out assembly of the reverse shifter metal main speed shift gears and shifters rearwards by tapping it with a plastic hammer Note Take care not allow the gear to drop as it is free whe...

Page 87: ...gears Speed range shift a Remove the sub shifter and shifter stay b Remove the space transmission case c Pull out the PTO shaft 4WD shaft and gear d Remove the snap ring from the end of the pinion gea...

Page 88: ...shed condition 0 5 mm 0 020 in Wear in each shifter 9 5Kgf 20 9 lbs 13 0 18 8Kgf 28 7 41 4lbs Synchro hub thrust for shifting Neutral Engaging 0 3 mm 0 012 in 0mm Stepped wear of teeth Usable limits S...

Page 89: ...ld be tightened to the respective specified torque in accordance with the tightening torque table Every time a gear installed its smooth rotation should be checked Every snap ring should be seated sec...

Page 90: ...reverse shift metal with RBB s of the sub assemblies of the counter gears and main change gears straight pins etc and install the reverse shift metal on the spacer transmission case Apply adhesive oi...

Page 91: ...b Pay attention to the installed direction of gear Fig 5 36 5 23...

Page 92: ...4 Rear transmission case Fig 5 38 5 24...

Page 93: ...iff case L 2 Diff case R 4 Bolt 5 Nut 6 Diff pinion 12 7 Collar 8 Lock plate 9 Bevel gear 20 10 Thrust collar 45X58X1 11 Shaft diff pinion 12 Metal Diff case L 13 Metal Diff case R 14 Shim A 15 Shim B...

Page 94: ...Pinion metal shim b The number of installed shims 14 should be written down or memorized for later reference Fig 5 42 g Release the lock of nut and remove the nut Fig 5 43 Fig 5 41 h Push out drive pi...

Page 95: ...g 8 Collar 35X50X2 9 Ball bearing 10 Shim B 11 Shim 0 5 12 Snap ring 13 Seal oil 14 Cover plate 15 PTO shaft 16 Seal a Remove the rear hitch and the trailer hitch b Remove bolt 3 and Extract PTO plug...

Page 96: ...f pinion and the dif side gear 0 1 0 2 mm 0 004 0 008 in Backlash 8 11 Kgf m 0 08 0 11KN cm Starting torque Fig 5 31 When the backlash exceeds 0 5mm also inspect the thrust collar for wear defective c...

Page 97: ...Take care not to mix them when assembling Apply multi purpose quality grease to the parts mentioned below Tooth surfaces of dif pinions and dif side gears Friction surfaces of dif pinion shafts and di...

Page 98: ...mming position h Backlash adjustment between the drive pinion and the ring pair Fig5 35 i As the drive pinion and the ring gear make a pair be sure not to mate them with other parts from differential...

Page 99: ...drive pinion support shims See Transmission REAR TRANSMISSION ASSEMBLY Setting cone center Toe contact Excessive backlash Move differential case and shims from right side to left side See Assembly an...

Page 100: ...he bearing The seal should be coated with an adhesive THREE BOND TB1215 on the circumference before installing b Install the oil seal on the PTO shaft paying attention to its installed direction c Aft...

Page 101: ...everse 2 Bolt S 3 Nut 4 Washer spring 5 Washer plain 6 Stay shifter reverse 7 Reamer bolt 8 Washer spring 9 Washer plain 10 Fork shift shuttle 11 Shifter spring 12 Steel ball 13 Arm reverse 14 Split p...

Page 102: ...ft Synchromesh transmission version 1 Fork 1 2 speed 2 Fork Main shift Synchro 3 Bolt 4 Pin A 5 Bolt 6 Washer 7 Metal Main shift 8 Shift Arm 9 Rod 10 Coupling 40 11 Set bolt 12 Main shift bracket 13 R...

Page 103: ...ng tightened Fig 5 44 1 Arm sub shift 2 Pin taper 3 Fork Sub shift 4 Shift stay Sub shift 5 Hook 6 Shifter spring 7 Steel ball 8 Oil seal D 9 Washer 10 Bolt 13 Metal sub 15 E type stop ring 16 Shim 03...

Page 104: ...2 Spring shifter 3 Steel ball 4 Bolt S 5 Packing 7 Shifter arm 8 O ring 9 Arm 4WD 10 Spring pin 11 Lever 4WD 12 Bush Chain guide 14 Grip 18 E type stop ring 19 Rod 20 Shim 03X16X26 22 Split Pin 23 Wa...

Page 105: ...ism Fig 5 48 1 O ring 2 Plug PTO 3 Bolt 4 Ball bearing HL1 5 Collar 6 Gear spur 37 7 Snap ring 8 Collar 35X50X2 9 Ball bearing 10 Shim B 11 Shim 0 5 12 Snap ring 13 Seal oil 14 Cover plate 15 PTO shaf...

Page 106: ...s processed side turned towards the outer side Be sure not to mix different pairs of the gear spur 14 Every time a gear is installed its smooth rotation should be checked a REAR PTO shaft 1 Shaft PTO...

Page 107: ...the drive pinion and related parts ahead of time Then install them and tighten the assembly to the specified torque b Be sure that the starting torque of the drive pinion meets the specified level Sta...

Page 108: ...ithout replacing the pinion gear and ring gear with new ones provide the same shimming thickness as that provided before disassembly 2 Backlash between dif pinion and dif side gear should be within as...

Page 109: ...ge and sub change 18 22 Kgf 40 49lbs 4WD change 25 29 kgf 55 64 lbs Usable limit of shifter disengaging load Main change Sub change 17 Kgf 38lbs 4WD change 24Kgf 53lbs Wearing limit of each shifter 0...

Page 110: ...foreign matter between them Replace Defective Change shift fork Replace Wear in width of gears splined hubs collars etc Repair or replace Clutch pedal play Improperly disengaged clutch Gears make a no...

Page 111: ...on return spring Replace Poor PTO clutch brake Let tractor warm up sufficiently Insufficient warming up Retighten or replace Loose joint or broken O ring of delivery valve Replace Broken or fatigues s...

Page 112: ...5 44 Fig 5 57 Power Train diagram...

Page 113: ...ON 3 DISASSEMBLY INSPECTION AND REASSEMBLY 6 3 1 Center pivot 6 3 1 1 Disassembly 6 4 1 2 Inspection 6 4 1 3 Reassembly 6 4 2 Front differential 6 6 2 1 Disassembly 6 7 2 2 Inspection 6 7 2 3 Reassemb...

Page 114: ...e power is taken off the rear transmission and transmitted to the differential in the front axle where the power is divided into right and left and to the respective final cases In the final cases the...

Page 115: ...75X80X30 50X55X20 80 Front wheel steering angles Housing R Diameter mm Housing F Diameter mm Pivot metal R bush mm Pivot metal F bush mm Pivot metal R bore mm 55 Pivot metal F bore mm Front axle 2 6...

Page 116: ...Oil cap 3 Plug 4 connector 5 Hose 820 6 Clamp worm 14 5 8 Metal pivot R 9 Bush 75X80X30 10 Bolt M16X40 11 Washer spring M16 12 O ring P 13 O ring 14 Spacer R 16 Metal pivot F 17 Bush 50X55X20 18 Space...

Page 117: ...h contact point with a micro meter or vernier calipers If the measured value is less than usable limit replace the housing front axle or bush in Metal pivot F or Metal pivot R Fig 6 6 3 Worn or damage...

Page 118: ...front axle exceeds the usable limit correct play by screwing in the adjust bolt on the top of the pivot metal F Note After correcting the pivot metal play tighten the lock nut of the adjusting bolt t...

Page 119: ...e front Diff 6 Pinion Diff 12 7 Thrust collar 8 Gear diff side 20 9 Washer thrust 10 Pin spring 11 Shaft diff pinion 12 Pin spring 13 Bearing Ball 6212 14 Snap ring 15 Snap ring hole 16 Shim A 17 Shim...

Page 120: ...prior to removal of the front axle refer to the paragraph covering disassembly of the center pivot 2 Remove both wheels 3 Remove the drain plug from the final case and drain oil from the final case 4...

Page 121: ...grease to teeth of diff pinion and dif side gear c Each parts should be washed clean and There should be no sharp edge to the surface of thrust washer d When assemble the spring pin Be sure the spring...

Page 122: ...eplaced inspect the bevel pinion assembly for thrust play in the front axle housing through drain plug hole 1 shim 2 shim 3 shim 4 Parallel pin 1 Each friction surface should be coated with grease in...

Page 123: ...g 7 Gear bevel 16 8 RBB 6207 11 Final drive case B L 13 Final drive case B R 14 Housing seal 15 Seal 16 RBB 6014 17 shaft 18 Gear bevel 12 19 RBB 6308 20 O ring 23 Cap 90 25 Shaft RH 296 26 shaft LH 4...

Page 124: ...ve the tie rod or the tie rod end 3 Remove the final drive case clamping bolts and take out the assembly of the wheel shaft 4 Remove the wheel shaft cover clamping bolts and cap 90 Note Discard the re...

Page 125: ...cover Fig 6 21 7 Remove the stop ring and the wheel shaft can be extracted 6 12 Fig 6 22 61 9 Usable limit 62 Standard value Fig 6 24 8 Remove the seal from the the wheel shaft cover Fig 6 23 2 Final...

Page 126: ...4 Adjust Back lash between bevel gear 9 2 and bevel gear 16 3 with collar 4 Apply force only to the shaded parts Fig 6 26 Take care not to deform these portions 0 1 0 2 0 004 0 008 in Back lash mm in...

Page 127: ...ure that the rods are not damaged 2 Install the pin 2 before assembling the cylinder 3 Apply an adhesive Locktite and tighten the bolts to specified torque 3 Tighten the bolts to specified torque 1300...

Page 128: ...re 2 Different tire diameters 3 Damaged final case bearing Steering wheel tends to turn to the right or left while traveling on straight paved road Adjust balance Repair or replace Adjust inflation or...

Page 129: ...1 GENERAL DESCRIPTION 7 1 SECTION 2 SPECIFICATIONS 7 2 SECTION 3 DISASSEMBLY INSPECTION AND REASSEMBLY 7 3 1 Rear axle housing and brake system 7 3 1 1 Disassembly 7 4 1 2 Inspection 7 4 1 3 Reassemb...

Page 130: ...isc mechanical operated brake system is employed Each of the brakes has 2 friction plates and can produce significant braking force with excellent durability The two actuators work to push their frict...

Page 131: ...2 5 0 09 mm 0 098 in Thickness 188mm 7 4 in Outer diameter Separator Plate 4 on each side Number of plates Paper base Lining material 3 4 0 1 mm 0 134 in Thickness 184mm 7 24 in Outer diameter Wet mul...

Page 132: ...Stop ring 18 Metal wheel shaft seal 19 Dif Lock shifter 20 Dif Lock cam 21 O ring 22 Seal shaft 23 Diff Lock Hub 24 Metal Dif Lock 25 Bolt S 26 Spring 27 Iron wire 28 Bolt 29 Pin 31 Pin spring 32 Pin...

Page 133: ...emove plate and the rubber boot 6 Remove the brake metal tightening bolts and remove brake metal 42 with wheel pinion and the disc brake assembly on it 7 Remove the snap ring 35 of wheel pinion 10 Fig...

Page 134: ...urfaces etc of the brakes are free from matter such as dust iron powder etc to avoid brake lining damage 2 When installing the brake unit on the wheel pinion friction plates and separator plates shoul...

Page 135: ...e only to the shaded parts Fig 7 11 Take care not to deform these portions 5 press in the wheel shaft 6 Install the wheel gear and bearing on the wheel shaft and retain them with nut 7 Apply adhesive...

Page 136: ...uator spring Eccentric wear of actuator Replenish Replace Replace 3 Brake overheating Insufficient oil Excessive pedal free play Improper operation Replenish Adjust Operate brakes properly 4 Brake can...

Page 137: ...eering valve 8 2 2 3 Oil tank 8 2 SECTION 3 FUNCTION 8 3 3 1 Open center non load reaction 8 4 3 2 major component of steering valve assembly 8 5 SECTION 4 DISASSEMBLY INSPECTION AND REASSEMBLY 4 1 Ma...

Page 138: ...el in neutral Generally the system is used for the vehicles that treat heavy equipment or low speed traveling Hydraulic circuit consists of Independent system The oil from tank flows into gear pump of...

Page 139: ...cc rev MODEL 2 Power steering valve Unit orbitrol UBS110B08AWD T290 T330 T330 0 2 Input torque N m 110 at 8 min Main relief pressure setting kgf 95 Max temperature 10 Max back pressure kgf 16 Rated fl...

Page 140: ...rt is connected to the reservoir T through orifices in the control spool The priority valve will only supply enough oil to the control valve to compensate for internal leakage and maintain low stand b...

Page 141: ...ts the inlet port P to one port of each metering pump section and also connects the other port of each metering pump section to the cylinder The amount that the spool moves off center depends on how f...

Page 142: ...nects the inlet port P to the one port of each metering pump section and also connects the other port of each metering pump section to the cylinder The amount that the spool shifts off center depends...

Page 143: ...nd outlet ports of the lower gyrotor pump and disconnects this pump from the system When the steering is operated manually only the upper gyrotor pump section is used to direct flow to the steering cy...

Page 144: ...22 5 3 2 Fig 8 6 1 Cover bolt 6 2 Cover bolt 1 3 End cap 1 4 Gyrotor 1 5 Spacer 1 7 Spacer plate 1 8 Driver shaft 1 9 Pump body 1 10 Sleeve 1 11 Spool 1 12 Pin 1 13 Center springs 6 15 Thrust washer...

Page 145: ...3 Disassembly STEP 1 secure the steering hand pump body in a clean soft jaw vice do not over tighten the vice Remove the fittings remove and discard the o rings Make a note of the position of the sens...

Page 146: ...rom the pump body NOTE DO NOT remove the check valve from the pump body inlet port D Assembly NOTE During assembly lubricate at all parts with clean transmission oil STEP 10 Install spool into sleeve...

Page 147: ...piral retaining ring into the the groove in the pump body Use a screwdriver to make sure the spiral retaining ring is located correctly into the groove in the pump body STEP 16 Install thrust washer t...

Page 148: ...d onto the tractor and the engine is running The steering wheel will rotate continually which may cause damage and injury STEP 21 STEP 17 For pumps equipped with cross over check valves install balls...

Page 149: ...w dust seal into seal bushing STEP 24 Install clean transmission oil into the return port and supply port Cover all the ports with a clean cloth and slowly turn the pump input shaft clockwise and coun...

Page 150: ...sembly face and spline length MAX 6 5 Replenish oil or Exchange 1 Poor assemble between steering column and unit 1 Spline of column and unit are assembled tightly 2 Spool of unit is seized by spline o...

Page 151: ...properly Deflate the air Adjust column Replace column and replenish oil 1 Worn of spline gear column 2 Depressed control set 3 Air trapped in cylinder and pipe line 4 Excessive backlash column 5 Poor...

Page 152: ...ssemble the gyrotor lower the unit 9 Steering wheel is very heavy to begin turning Replace oil 1 Oil density is too high or cool 10 External Oil leakage Replace oil seal slide ring Replace o ring Repl...

Page 153: ...ety valve main relief valve 9 8 5 Gear pump 9 9 6 Filter 9 14 SECTION 4 REMOTE HYDRAULIC CONTROL 9 15 1 Remote hydraulic control valve optional 9 15 SECTION 5 HYDRAULIC SYSTEM 9 16 1 Hydraulic cylinde...

Page 154: ...operated by a control valve which is actuated by the control lever through a link mechanism ON and OFF of the PTO is controlled by a hydraulic wet multi disc clutch whose circuit is opened and closed...

Page 155: ...very 91 efficiency litre cu in mm at 2600rpm 31 1 20 4 Fluid TDH oil or Donax TD Suction filter Rated flow min 57 41 Filtration density mesh 35 150 Filtration area 11 000 790 Line filter Rated flow mi...

Page 156: ...Rod 8 Pin spring 9 Iron wire 10 Cylinder head 11 O ring 12 Bolt 13 Washer spring 14 Lift crank 15 Plug 16 Bolt 17 Flow con valve 18 Dust seal 19 O ring P 20 O ring P 21 Knob 22 screw 23 Washer spring...

Page 157: ...divider 2 Transmission case 3 Relief Valve 4 Pressure control valve Fig 9 3 1 Solenoid This solenoid is switched on or off by operating the PTO switch With this lever operation the solenoid shifts the...

Page 158: ...ve passing through port its pressure will be set as P As passage 1 and passage 2 are interconnected then P P The force imposed upon the left hand side of the valve is P1 whereas the force imposed upon...

Page 159: ...PTO clutch that is all fluid flows to the control valve 1 Passage 1 2 Passage 2 3 Pressure reducing valve 4 Changeover valve 5 PTO clutch 6 To control valve Fig 9 5 PTO solenoid switch OFF position 1...

Page 160: ...This valve regulates the lowering speed of the lift by controlling the unloading flow from the lift cylinder to the tank Dust seal Snap ring Collar Body 0 ring Adjust screw Back up ring 0 ring Stop r...

Page 161: ...s down whereas the opening of choke C increases and the lowering speed of the lift is accelerated when the adjust screw is unscrewed counterclockwise When the adjust screw screwed in completely the po...

Page 162: ...current screwing in depth of the adjust screw should be written down or memorized for later reference 3 MEASUREMENT OF THE RELIEF PRESSURE 1 3 POINT TO TEST RELIEF PRESSURE Remove the plug in the deli...

Page 163: ...Fig 9 12 Gear pump 1 Flange 2 Housing 3 Drive gear 4 Gear 5 Bushing 6 Bushing seal 7 Bushing 8 0 ring 9 Cover 10 Cap ring 11 0 ring 12 Housing 13 Drive gear 14 Gear 15 Oil seal 16 Socket bolt 17 Wash...

Page 164: ...r kerosene Inspect all parts referring to these point and repair or replace defective parts Fig 9 16 Front and rear pump Remove the rear pump Detach the cover Remove the o ring Remove the bushing driv...

Page 165: ...ightening bolts Tightening torque 2 5 2 8 f m Fig 9 21 Cover bolt Install the oil seal snap ring and key Fig 9 19 Front and rear pump Install the front pump with rear pump After installing the cap rin...

Page 166: ...in replace the gear pump set 3 Bushing With clean working fluid surfaces are rarely scratched and should be smooth If there are many scratches on the bore walls or on parts which are in contact with...

Page 167: ...er seal lip and dust from invading by its outer dust lip Therefore if an oil seal has damaged or deformed lips it should be replaced 6 MEASUREMENT OF THE PUMP The best way to measure for the pump is t...

Page 168: ...deformation and replace defective ones When installing the filters be sure to install the O rings properly with grease applied 790 Filtration area 30 130 Working oil temperature 150 mesh Filtration d...

Page 169: ...M THF500 Recommended fluid 400 Maximum pressure kgf 26 Maximum flow min 1 Remote hydraulic control valve OPTIONAL 2 Remote control valve 3 Stay comp 5 Bolt 6 Bolt 8 Hose return 9 Adapter 10 Nut 11 Ban...

Page 170: ...utually by reference to their matching marks 5 When installing the control valve apply grease to the O rings and avoid their dislocation or binding during tightening the valve to the specified torque...

Page 171: ...h their splines using the alignment marks which were put there before disassembly 13 Hex bolt M8 20 should be locked by wiring after installation 14 Be sure the lift shaft should be moved smoothly aft...

Page 172: ...y grease to relayed drive parts 2 Drive in the roll pin into the linkage pin through the rod and lock the pin with wire 3 Be sure not to over operate within specified spool stroke 12mm between up and...

Page 173: ...3 LINKAGE EXTERNAL Fig 9 37 Linkage external 9 19...

Page 174: ...ght of the implement It consists of a feed back valve direction control valve flow control unloading valve and holding check valve 4 2 SPECIFICATIONS 10 milliliters 0 61 cu in min Fluid temp 50 pressu...

Page 175: ...ON 1 Neutral position In the neutral position convensater spool 711 in open Unload Main spool 311 and check valve 511 531 is closed and its pressure is enough to rest the force of lift arm 9 21 Fig 9...

Page 176: ...pool is moved to lifting position pump pressure is increased and open the check valve 511 531 The lift arm moved to lifting position by flowing to cylinder and operate piston Circuit diagram in the li...

Page 177: ...2 Lowering position If main spool moved to lower positions pump is unloading and the lift arm moved to lower position by flowing to tank in the cylinder Fig 9 45 9 23...

Page 178: ...aces of the spools poppets and casing for flaws like scratches Correct slight flaw with an oil stone and wash corrected parts in a cleanser Main spool and related parts When the head is disassembled i...

Page 179: ...9 in the correct direction Put the spring in and tighten the plug to the specified torque Unloading valve 20 and related parts Install the spool and confirm that the returns smoothly by the spring for...

Page 180: ...repair or replace if necessary Pay particular attention to shaft seal because a broken seal sometimes intakes air 5 Broken or poor hydraulic pump Clean 4 Clogged suction filter Tighten securely or rep...

Page 181: ...h oil stone or replace as an assembly 4 Stuck main spool Apply grease and repair or replace bushings or shaft if necessary 3 Seized lift shaft Lap after disassembling cleaning repairing flaws with oil...

Page 182: ...ed parts Broken piping Replace Poor O ring Inspect clean and eliminate dust Repair flaws with oil stone if necessary Retighten Poorly connected piping 11 Oil leaks from piping or joints Inspect transm...

Page 183: ...r correcting flaws with oil stone 7 Stuck pressure reducing valve spool Inspect and reset pressure 6 Port B regulated pressure is too high of Flow divider Replace 4 Worn friction plates or driven plat...

Page 184: ...ity 10 2 1 4 Battery testing chart 10 3 SECTION 4 Meters and switches 10 5 1 Meters 10 5 1 1 Removal 10 5 1 2 Tacho Hour meter 10 5 1 3 Fuel gauge and fuel gauge sensor 10 5 1 4 Thermometer 10 6 2 Sta...

Page 185: ...ce that enables the operator to be aware of the present operating conditions oil pressure gauge water temperature gauge thermometer fuel gauge etc are installed All the controls meters and indicators...

Page 186: ...ch 1 change in temperature Therefore when the specific gravity of the electrolyte in the battery is measured with a suction type hydrometer a temperature correction should be made using the following...

Page 187: ...ells proceed to step 2 Add water up to just above separators Charge for 15min with 15 25 amp Hydrometer test Step 2 50 points or more variation between highest and lowest cell Less than 50 points vari...

Page 188: ...ce thermometer in one cell to take temperature of electrolyte 4 Refer to voltage table Voltage below table value Voltage equal to or above table value return to service Replace 9 6 9 5 9 4 9 3 9 1 8 9...

Page 189: ...2500 1000 Engine speed rpm 1 3 Fuel gauge and Fuel gauge sensor a Construction When the fuel tank is full the float is at the top and has moved the variable resister to a position of least resistance...

Page 190: ...e high temperature side on the scale Of course as the coolant temperature become lower everything acts in reverse b Inspection Normally the thermometer resisters higher values as the coolant temperatu...

Page 191: ...elease the ring nut with a conventional screw drive and remove the combination switch 2 Inspection Each switch circuit is as shown so check each switch for a continuity across respective terminals wit...

Page 192: ...lasher 1 2 L R B2 1 OFF WG White Green G Green 2 GB Green Black Color code 5 RELAY UNIT Fig 10 16 Relay unit 1 Terminals 2 Switching positions 6 FUSE Fuses are installed in the main fuse box and one f...

Page 193: ...10 18 The circuit has 8 blade type fuses in its wiring circuit When a fuse has blown replace it with one of the same value Fig 10 19 Note Using a large capacity fuse or wire burn out the wiring system...

Page 194: ...Y Turn signal RH 5 4 AVSS 0 85 WL Stop Light 4 3 AVSS 0 85 GB Turn signal LH 3 1 AVSS 2 0 B Earth 1 7 AVSS 0 85 WG Reserve light 7 6 AVSS 0 85 YW Rear Light Number plate 6 2 AVSS 0 85 Y Small light Ta...

Page 195: ...bracket RH Earthed at upper upper tapped hole in the axle bracket A Fig 10 26 3 Right surface of the frame comp Where the battery bracket is to be installed Fig 10 25 2 Contact surfaces of the axle b...

Page 196: ...A B Fig 10 27 Hood frame 10 12...

Page 197: ...SECTION 6 WIRING DIAGRAM 10 13...

Page 198: ...act Check and renew Burnt out bulb Individual lights do not illuminate Check and renew Defective light switch Check lighting Circuit wiring and repair or renew Faulty wiring Inspect and renew Check ci...

Page 199: ...lluminate See Individual lights do not illuminate Countermeasures Causes Problems 2 INSTRUMENTATION Check and renew Loose or broken wiring Check and renew Defective switch Check and renew Burnt out fu...

Page 200: ...w plug Individual glow plug does not glow See Light system troubleshooting Defective glow monitor light or monitor and warning check unit Inspect secure repair or renew wiring Loose or broken wires Ch...

Page 201: ...otor does not spin Countermeasures Causes Problems 4 STARTING SYSTEM Check and repair or renew Defective alternator Check and renew Defective voltage regulator Inspect system tighten connections and r...

Page 202: ...fier or rectifying diodes Check and renew Faulty starter Check and renew Defective voltage regulator Warning light is normal but battery is discharged Check and renew Faulty rectifier or rectifying di...

Page 203: ...1 Engine accessories 11 1 2 Clutch damper 11 2 3 Transmission 11 2 4 Front axle 11 3 5 Rear Axle 11 4 6 Power steering system 11 4 7 Hydraulic system 11 4 8 Electrical equipment 11 7 SECTION 2 TIGHTEN...

Page 204: ...rs of operation Replace a damaged on or one which has been used more than 500 hours a Cleaning when dust is dry Apply compressed air of 7Kgf or lower to the inside of the element to blow dust outwards...

Page 205: ...or less Clutch cover Dual type Pressure plate flatness Should be measured on the hub 0 3 Play between hub spline and input gear in rotational direction 21 7 Small diameter 25 0 Large diameter 1 0 0 7...

Page 206: ...at the shifter 8 10 f PTO shift Measured at the shifters both for synchromesh and sliding select gear 4 7 f Main shift 51 17 Assembled width from neutral to engaging 9 5 f 13 0 18 8 f Synchro hub thr...

Page 207: ...0 08 0 11 m 0 5 Backlash Starting torque Available shims on drive pinion metal support Shim A 0 1 Shim B 0 2 Available shims on dif case Shim A 0 1 Shim B 0 2 Adjustment of relative positioning betwe...

Page 208: ...IAL Thrust play Play in bush Rear center pivot Front center pivot Wheel alignment Tire inflation 0 05 0 06 f m Pinion gear Adjust with adjusting bolt 0 5 0 0 2 wear limit 0 1 74 9 75 shaft dia wear li...

Page 209: ...WEAR AND CARBONIZER 2 SEPARATE PLATE 2 5 2 5 0 09 Thickness wear and damage 3 BRAKE ROD TURN BUCKLE 30 40 Pedal play at the top 6 POWER STEERING SYSTEM CHAPTER 8 1 GEAR PUMP CCW at 500 3500 rpm Direct...

Page 210: ...ity 0 9 min 18 f over Setting pressure of PTO clutch port Pressure 1 f 5 0 6 0 min Capacity of PTO clutch port 5 Flow divider assembly 2 times sec Switch over frequency limit 2 1 A Rated current 15 0...

Page 211: ...m pressure 7 MAIN CONTROL VALVE 5 min or less under a pressure of 100 f 0 01 Clearance between main spool and casing Gear oil SAE 80 90 at a temperature of 50 5 Cylinder port leaks 8 MAIN RELIEF VALVE...

Page 212: ...LECTROLITE Replace battery Cloudy fluid Correct 1 24 1 26 Specific gravity As specified on case Replace with distilled water Level 2 METER PANEL AND OTHER SWITCHES 1 STARTER SWITCH Replace a defective...

Page 213: ...l 0 1 LW LB L 6 PTO SWITCH Replace a defective switch assembly Switched on when lever is moved by about 3 mm 0 12 in across R and LR Continuity across each terminal 7 STOP LIGHT SWITCH Replace a defec...

Page 214: ...9 HAZARD WARNING SWITCH Replace a defective switch assembly Continuity across each terminal ON 11 10 9 7 6 4 3 1 2 5 8 11 OFF 11 11...

Page 215: ...ightening bolts Bevel gear case tightening bolts Dif metal support tightening bolts Ring gear dif metal support tightening bolts Bevel pinion lock nut 9 0 11 0 9 0 11 0 9 0 11 0 9 0 11 0 5 5 7 0 5 5 7...

Page 216: ...53 96 3 7795 22 0 8661 47 1 8504 72 2 8346 97 3 8189 23 0 9055 48 1 8898 73 2 8740 98 3 8583 24 0 9449 49 1 9291 74 2 9134 99 3 8976 25 0 9843 50 1 9685 75 2 9528 100 3 9370 M illimeters to inches in...

Page 217: ...308 3952 311 6760 314 9568 318 2376 321 5184 324 7992 90 100 328 0800 331 3608 334 6416 337 9224 341 2032 344 4840 347 7648 351 0456 354 3264 357 6072 100 miles 0 1 2 3 4 5 6 7 8 9 miles Km Km Km Km K...

Page 218: ...cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc 0 0 000 16 387 32 774 49 161 65 548 81 935 98 322 114 709 131 096 147 483 0 10 163 870 180 257 196 644 213 031 229 418 245 805 262 192 278 579 294 966 311 353...

Page 219: ...ers Liters Liters Liters Liters Liters Liters Liters Liters 0 0 0000 4 5460 9 0920 13 6380 18 1840 22 7300 27 2760 31 8220 36 3680 40 9140 0 10 45 4600 50 0060 54 5520 59 0980 63 6440 68 1900 72 7360...

Page 220: ...8 235 892 238 097 240 301 100 Kg 0 1 2 3 4 5 6 7 8 9 Kg N N N N N N N N N N 0 0 000 9 807 19 614 29 421 39 228 49 035 58 842 68 649 78 456 88 263 0 10 98 070 107 877 117 684 127 491 137 298 147 105 15...

Page 221: ...0 31 100 Kg cm2 0 1 2 3 4 5 6 7 8 9 Kg cm2 Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa 0 0 0 98 1 196 1 294 2 392 3 490 4 588 4 686 5 784 6 882 6 0 10 980 7 1078 8 1176 8 1274 9 1373 0 1471 1 1569 1 1667...

Page 222: ...8 9 Kg m N m N m N m N m N m N m N m N m N m N m 9 810 19 610 29 420 39 230 49 030 58 810 68 650 78 450 88 260 10 98 100 107 910 117 710 127 520 137 330 147 130 156 910 166 750 176 550 186 360 10 20...

Page 223: ...5 68 3 6 21 2 60 140 0 25 3 9 160 71 1 4 24 8 62 143 6 30 1 1 165 73 9 2 28 4 64 147 2 35 1 7 170 76 7 0 32 0 66 150 8 40 4 4 175 79 4 2 35 6 68 154 4 45 7 2 180 82 2 4 39 2 70 158 0 50 10 0 185 85 0...

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