Mitsubishi Heavy Industries BD2G Service Manual Download Page 348

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Summary of Contents for BD2G

Page 1: ...SERVICE MANUAL MITSUBISHI DIESEL ENGINE for BD2G BS3G CONTENTS CONSTRUCTION AND FUNCTION SPECIAL TOOLS MAINTENANCE STANDARDS DISASSEMBLY AND REASSEMBLY ...

Page 2: ...I j I I I I ...

Page 3: ...mension to be attained at the time of reassembly or the standard performance Its value is rounded to the nearest whole number needed for inspection and is different from the design value STANDARD CLEARANCE Indicates the clearance to be between mating parts at the reassem bly obtained time of REPAIR LIMIT A part which has reached this limit must be repaired SERVICE LIMIT A part which has reached th...

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Page 5: ...nd Removal and installation of fuel injection pump alternator 6 installation starter etc Disassembly inspection and reassembly of engine proper Engine proper Cylinder head valve mechanism flywheel timing gears 7 camshaft pistons connecting rods crankshaft crankcase I Intake and exhaust systems Inspection of exhaust manifold 8 Disassembly inspection and reassembly of lubrication Lubrication system ...

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Page 7: ...gine External views 2 2 1 2 S4E2 diesel engine Sectional views 4 1 3 Engine serial number location 6 1 4 Engine model and application codes 6 2 SPECIFICATIONS 7 3 TIPS ON DISASSEMBLY AND REASSEMBLY 10 3 1 Disassembly 10 3 2 Reassembly 10 ...

Page 8: ...GENERAL 1 1 S4E2 diesel engine External views CD Fuel filter V Fan Water pump Fuel injection pump Fuel feed pump Fan belt j Intake manifold Stop solenoid Governor j Flywheel j Starter Left hand side view 2 402884 ...

Page 9: ...2 o o CD Exhaust manifold Oil filter Alternator P T O Gear Right hand side view GENERAL 4 402885 3 ...

Page 10: ...GENERAL 1 2 S4E2 diesel engine Sectional views 4 CD Rocker arm Piston Compression ring Oil ring Connecting rod Camshaft j Oil pump G ow plug Fuel injection nozzle Transverse view I 402886 ...

Page 11: ...Oil ring Fan j Camshaft gear Camshaft Connecting rod j Crankshaft gear Crankshaft Intake valve Exhaust valve Rocker shaft Longitudinal view GENERAL 402887 Rocker shaft bracket Cylinder head Valve pushrod Crankcase Valve pushrod Flywheel Oil strainer 5 ...

Page 12: ...rankcase number Iu II Engine s erial n I 9 J1 O t_ 1 4 Engine model and application codes SO 0 l _ 6 Series codes E2 Swirl combustion chamber type Piston displacement per cylinder 739 cc 45 1 cu in Bore x stroke 98 mm x 98 mm 3 86 in x3 86 in No of cylinders code 2 3 4 or 6 Sagamihara Machinery Works ...

Page 13: ...all height mm in 750 29 53 Weight dry kg Ib 270 595 Rated output PS rpm 40 2400 Maximum torque kgf m lbHt N m1 rpm 15 5 112 1 152 01 1200 Compression pressure kgf em psi MPa1 rpm 27 384 2 61 150 200 Maximum speed rpm 2620 20 Minimum speed rpm 870 10 Type of cylinder sleeves Dry special cast iron No of piston Compression ring 2 rings Oil ring 1 w spring expander B T D C 300 Open 0 Intake valves Clo...

Page 14: ... 4 6 1 2 Type Centrifugal Water pump Speed ratio to crankshaft 1 3 Delivery capacity 115 liter U S gal min at 2000 engine rpm 30 4 E Fan belt Type Low edge cog B type V belt 1 Manufacturer MITSUBOSHI Type Wax pellet 5 Thermostat 0 Valve opening temperature c F 0 76 5 2 169 7 3 6 u Radiator Type Corrugated fin Type Polypropylene blade circular arc type No of blades 6 Fan 440 Diameter mm in 17 32 Sp...

Page 15: ... negative ground Model M002T65271 dry Starter Manufacturer MITSUBISHI ELECTRIC Type Pinion shift Output V kW 24 3 2 No of pinion teeth No of ring gear teeth 11 110 Type 3 phase with rectifier S Manufacturer MITSUBISHI ELECTRIC 00 Output V A 24 20 00 l Alternator Rated voltage generating speed u rpm 1100 5 u Rated output generating speed rpm 5000 iii Maximum speed rpm 13500 Speed ratio to crankshaf...

Page 16: ...isassembled and cleaned parts in the order in which they were removed to save time for reassembling work 4 Pay attention to marks on assemblies components and parts for their positions or directions Put on marks if necessary to aid reassem bly 5 Carefully check each part for any sign of faulty condition during removal or cleaning The part will tell you how it acted or what was abnormal about it mo...

Page 17: ...MAINTENANCE STANDARDS 1 MAINTENANCE STANDARDS 12 2 TIGHTENING TORQUE 19 2 1 Important bolts and nuts 19 2 2 General bolts and nuts 20 3 SEALANTS 21 ...

Page 18: ...2 43 57 psi 28 psi Oil temRerature 0 3 0 4 MPa at 1500 rpm 0 2 MPa Lube oil pressure Nominal value O 5kgf cm 60 _70 C I kgf cm2 14 psi 7 psi 140 158 F 0 1 MPa minimum at idling 0 05 MPa Values are only I 14 A T D C Valve timing In valves open for checking with 3 mm In valves close 3 A B D C valve timing and 0 I2 in Ex valves open 24 B B D C are different clearance on Ex valves close 29 B T D C fro...

Page 19: ... 0 0098 E 0 50 0 0197 and 0 75 0 0295 Thrust journal length 2 45 0 100 0 264 0 300 Replace thrust end play 0 0965 0 00394 0 01039 0 01l8 J plate Inside diameter 22 000 22 021 22 100 0 86614 0 86697 0 87008 g on 0 10 If repair limit is Clearance on 22 0 035 0 086 0 120 0 0039 p 0 00138 0 00339 0 00472 J reached replace p tappets 0 87 as inside diameter tappets If repair limit is a Clearance on 0 04...

Page 20: ...1 6 angle 0 047 0 063 sinkage Refacing is Valve margin 2 13 0 0839 permissible up to 1 2 0 047 48 85 47 60 Free length S 1 9232 1 8740 g u c Squareness 1 27 0 0500 maximum Test force length 19 1 42 2 15 33 under test force 186 10 147 kgf lbl N 43 1 69 43 1 69 Inside diameter of 20 000 20 021 rocker bushings 0 78740 0 78823 E Diameter of rocker 19 984 19 966 shafts 0 78677 0 78606 Clearance of 20 0...

Page 21: ...d crankpin length c Out of roundness 0 01 0 0004 0 03 ofjournals and maximum 0 0012 crankpins k U Taper of journals om 0 0004 0 03 and crankpins maximum 0 0012 1 _ k Fillet radius of 3R 0 journals and 0 2 0 008 0 12 crankpins 0 _ __ E If repair limit is S I reached replace thrust plates If repair limit is I exceeded use over End play 37 0 100 0 264 0 300 I size thrust plates 1 46 0 00394 0 01039 1...

Page 22: ... 00098 0 00236 J 0 00591 1 piston 0 177 0 35 0 50 1 50 End gap 00 0 0138 0 0197 0 0591 e 0 S Outside 28 000 27 994 diameter 1 10236 1 10212 E If repair limit is 5 Clearance in Ireached replace pin e 28 0 0 016 0 050 0 piston 1 10 0 0 00063 J 0 00197 1 If repair limit is ex ceeded replace piston a __ Clearance in 28 0 020 0 051 Replace pin or 0 080 bushing Ream if bushing 1 10 0 00079 0 0020I J 0 0...

Page 23: ...4 1 8nos g g 0 26315 0 24346 Cam lift D I D 45 94 g D D iD D Exhaust 7 344 f 6 844 0 11 80881 g 0 28913 I 0 26945 I E No 54 53 96 53 94 I 53 90 0 Diameters 1 2 2 13 2 1244 2 1236 21 220 of journals 53 52 96 52 94 52 90 No 3 i 2 Q9 2 0850 2 0842 2 0827 IReplace thrust 5 0 050 0 112 0 300 f End play 0 20 0 00197 0 00441 1 0 01181 1 plates _ Clearance of shaft in 36 0 Q25 0 D75 0 100 Replace bushing ...

Page 24: ...psi MPa l 0 29 0 02 psi O oIS MPa per OJ I mm 0 04 in thickness of shim Fit of bearing Front 17 O OlT 0 017T inner races on 0 67 1 0 0004T 0 00067T 1 pump shaft Rear 47 1Replace pump case Fit of bearing Front 1 85 or pump assembly outer races in 0 0IlL 0 02SL pump case 40 1 0 00043L 0 00098L 1 Rear 1 57 c 0 010 0 Q25 Replace bearings e Radial clearance of 17 0 010 0 022 0 045 if they fail to rotat...

Page 25: ...onnecting rod caps I 12 1 25 17 8 5 0 5 61 4 83 5 Flywheel 12 1 25 17 8 5 0 5 61 4 83 5 Camshaft thrust plate 8 1 25 12 1 8 13 18 Front plate 10 1 5 14 I 7 10 Timing gear case bolts 10 1 5 14 1 7 10 Crankshaft pulley 24 1 5 36 40 0 5 289 4 392 5 Idler thrust plate 10 1 25 14 3 5 25 34 Oil pan 8 1 25 12 0 7 5 7 Oil pan drain plug 12 1 25 19 10 0 5 72 4 98 5 Oil pump mounting bolts 12 1 75 17 5 5 0 ...

Page 26: ...f m Ibf ft N m 8 1 0 1 8 13 18 2 2 16 22 1 25 1 8 13 18 2 1 15 21 10 1 25 3 6 26 35 4 2 30 41 1 5 3 4 25 33 4 0 29 39 12 1 25 6 5 47 64 7 6 55 75 1 75 6 0 43 59 7 1 51 70 14 1 5 10 4 75 102 12 2 88 120 2 0 9 8 71 96 11 5 83 113 16 1 5 15 8 114 155 18 6 135 182 2 0 15 0 108 147 17 6 127 173 18 1 5 22 9 166 225 26 9 195 264 2 5 20 7 150 203 24 4 176 239 20 ...

Page 27: ...Cylinder head installing plugs cylinder head Screw plug for crankcase main oil gallery taper Crankcase Loctite 271 Apply to threads plug Water bypass hose and pipe Thermostat cover Loctite 271 Apply to threads elbow and water pump Bearing caps front Apply to crankcase Front and rear bearing cap before installing side seals of crankcase and rear side seal ThreeBond I 105D front and rear contact sur...

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Page 29: ...SPECIAL TOOLS SPECIAL TOOL LIST 24 II ...

Page 30: ... 30691 04500 31391 13010 For Intake 34491 01300 For exhaust 34491 02100 Piston ring pliers 31391 12900 Piston guide 34491 02200 24 Shape 670228 670230 ItJ l 401793 670232 670236 670240 Use Valve guide installation Valve guide removal Valve spring removal installa tion Valve seat installation Cylinder sleeve installation Piston ring removal installa tion Piston installation ...

Page 31: ...1 Universal 30091 01101 extension Cranking handle 30691 11800 Shape 670237 670242 670235 401822 670239 670238 SPECIAL TOOLS Use Idler shaft removal Idler bushing removal installa tion Camshaft thrust plate removal installation Cartridge type oil filter removal PE A type fuel injection pump removal installa tion Engine cranking 25 ...

Page 32: ... 26 Part No 30691 21100 64309 12900 33391 02100 30691 13010 Shape 670233 670241 40t609 Use Engine compres sion pressure measurement Crankshaft gear camshaft gear crankshaft pulley and water pump pulley removal Compression pressure measurement Oil seal sleeve on crankshaft rear side installation ...

Page 33: ...I OVERHAUL INSTRUCTIONS I DETERMINING WHEN TO OVERHAUL THE ENGINE 28 2 TESTING THE COMPRESSION PRESSURE 29 II ...

Page 34: ...er b Increase in fuel consumption c Increase in lubricating oil con sumption d Excessive blowby through breather due to worn cylinder sleeves pistons etc e Excessive seating of valves blowby due to poor worn inlet and exhaust f Hard starting g Excessive abnormal noise In most cases these troubles occur concurrently Some of them are directly caused by low compression pressure but others are not Amo...

Page 35: ...air limit overhaul the engine CAUTION J a Be sure to measure the compres sion pressure on all cylinders It is not a good practice to measure the compression pressure on two or three cylinders and judge the compression pressure of the remaining cylinders therefrom b The compression pressure varies with change of engine rpm This makes it necessary to check engine rpm at the time of measuring the com...

Page 36: ...re at periodical intervals to obtain the da ta on the gradual change of the pressure b The compression pressure would be slightly higher than the Assembly standard in a new or overhauled engine owing to breaking in of the piston rings valve seats etc It drops as the engine parts wear down ...

Page 37: ... speed and maximum speed setting inspection and adjustment 1 5 Fan drive belt inspection and adjustment 2 BENCH TEST 2 1 Starting up 2 2 Inspection after starting up 2 3 Bench test dynamometer test conditions 2 4 Inspection and adjustment after bench test 3 PERFORMANCE TESTS 3 1 Standard equipment 3 2 Test items 3 3 Test methods 32 32 33 34 36 42 43 43 43 43 43 43 II 43 43 44 ...

Page 38: ...ft by the specified crank angle in normal direction at a time to bring the piston to its top dead center on compression stroke No of cylinders Firing order Crank angle 4 3 4 2 180 b The top dead center on compression stroke of the piston is identified by the timing mark 0 on the crankshaft pulley being aligned with the pointer on the gear case With the piston so located either intake and exhaust v...

Page 39: ...y turning it about 1 5 rotations b Unlock turning operate priming pump handle by it counterclockwise and the priming pump c Tighten the air vent plug when fuel flows from the vent hole without bubbles 2 Fuel injection pump a Loosen air vent plug on the injection pump by turning it about 1 5 rotations If the pump has two air vent plugs prime at these plugs b Operate the priming pump handle c Tighte...

Page 40: ...ts output speed and specification Be sure to verify the timing by referring to the specifications of each model 1 Bringing No 1 piston to top dead center on compression stroke 34 a Using turning bar 30691 11800 at the crankshaft pulley turn the crankshaft in normal direction clockwise as viewed from the front side of the engine b Stop cranking the engine when the timing mark 0 on the crankshaft pu...

Page 41: ...e priming pump to allow fuel to flow from the delivery valve holder crank the engine in normal direction Reduce cranking speed when the fuel just starts to stop flowing Stop cranking when the fuel stops flowing d Make sure that the timing mark on the crankshaft pulley is aligned with the pointer 3 Adjusting fuel injection timing a If the timing is retarded tilt the injection pump toward the crankc...

Page 42: ...rized service shop only b When inspecting and adjusting these settings be on standby to operate the engine stop lever manually in the event of engine overrun For inspection and adjustment warm up the engine thoroughly until the coolant and oil temperature rises to 70 C 158 F RSV type governor 1 Engine starting a Pull speed control lever to high speed side Operate starter switch to crank the engine...

Page 43: ...er or higher idling level b Turning the set bolt clockwise raises the idling speed c If engine speed tends to fluctuate at a lowest idling speed set as above turn the idle sub spring adjusting screw clockwise to push in this spring making it come in slight contact with tension lever With idle sub spring exerting some force to the lever the speed will rise slightly but will stop fluctuating 1CAUTIO...

Page 44: ...levers in order to find out just where the engine produces the rated output e Having positioned the stopper bolt properly for the rated output back it off slowly while observing the speed Stop backing it off just when the speed begins to fall from the rated level Secure the stopper bolt rack set bolt in that position with its lock nut f At that time the speed control lever should be at the positio...

Page 45: ...mning in no load condition subsequent to the condition mentioned in 1 b above and with the speed control lever left in the same position as above put the prescribed load instantaneously on the engine the speed will decrease once and increase as shown and settle at a new steady level Read the lowest speed N5 occurring in this transition and the speed N6 after settling and the time t2 from N4 to N6 ...

Page 46: ...o gain access to the adjusting screw remove the plug at the top of governor housing and turn speed control lever all the way to the low idling set bolt this will turn up the swivel lever pointing the head of the adjusting acrew toward the plug hole Insert a flat tip screwdriver through the hole to catch the screw head c Tightening the adjusting screw increases the pre tension of governor spring to...

Page 47: ... by using an injection pump tester or an engine test bench in the final stage of manufacture prior to shipment from the factory All these stoppers visible on the injection pump are sealed with wires and punched pellets b After authorized adjustment of the governor which has to be effected by breaking the seals be sure to re seal all visible stoppers making them appear as if they were sealed at the...

Page 48: ...ction and adjustment Apply thumb pressure to the belt midway between the pulleys to inspect the belt tension If the tension is incorrect make an adjustment by means of bolt 1 Item Fan drive belt tension deflection 42 Unit mm in Assembly standard 10 15 3 8 518 300481 ...

Page 49: ...e and investigate for the cause 1 Lubricating oil pressure It should be 3 to 4 kgf cm 2 43 to 57 psi 0 3 to 0 4 MPa at rated speed or 1 kgf cm 2 14 psi 0 1 MPa at idling speed 2 Coolant temperature It should be 75 C to 85 C 167 F to 185 F 3 Lubricating oil temperature It should be 60 C to 80 C 140oF to 176 F when measured in oil pan 4 Leakage of oil coolant and fuel ADJUSTMENTS BENCH TEST PERFORMA...

Page 50: ... maximum speed 3 No load minimum speed test a The control lever should be set to the stable minimum speed position By stable minimum speed is meant a minim urn speed to which the engine rpm can be quickly dropped from the maximum rpm without stalling b The no load minimum speed is specified to be 870 10 rpm 4 Others 44 During the performance test inspect for leakage of gases coolant lubl icating o...

Page 51: ...ENGINE ACCESSORY REMOVAL AND INSTALLATION 1 PREPARATORY STEPS 46 2 ENGINE ACCESSORY REMOVAL 46 3 ENGINE ACCESSORY INSTALLATION 50 ...

Page 52: ...TEPS a Shut off fuel supply and disconnect the starting system from the engine b Loosen the drain cock on left rear side of crankcase and drain coolant c Loosen the oil pan drain plug and drain engine oil WARNING Hot engine oil can cause personal injury if it contacts the skin Use caution when draining the oil 2 ENGINE ACCESSORY REMOVAL 1 Removing stop solenoid 46 Disconnect and remove stop soleno...

Page 53: ...nscrew lock nut 3 and remove leak off pipe 4 CAUTION j Be sure to fit rubber caps to the openings of the injection pumps and nozzle holders to prevent dust from getting inside the fuel system 4 Removing fuel injection nozzles Using a box wrench loosen nozzle retaining nut and remove nozzle 1 complete with gasket 2 r NOTE Remove nozzle gaskets from the cylinder head using a piece of wire or screwdr...

Page 54: ... Disconnect oil feed pipe 1 and remove cover 2 Remove injection pump 4 from the timing gear case by unscrewing two mounting bolts 3 7 Removing thermostat a Disconnect bypass hose 1 b Unscrew elbow attaching bolts and remove elbow 2 thermostat 3 and gasket 4 1NOTE At reassembly install thermostat with its air vent hole facing upward 8 Removing water pump 48 a Remove fan 1 Slacken fan belt 2 and rem...

Page 55: ...nting bolts 2 11 Removing oil filter Remove oil filter 2 complete with its bracket by unscrewing mounting bolts 1 12 Removing oil pan and oil pump a Remove oil pan 2 by unscrewing mounting bolts 0 b Remove oil pump 4 by unscrewing mounting bolt 3 NOTE Camshaft skew gear might interfere with pump drive gear Remove pump by turning crankshaft slightly ENGINE ACCESSORY REMOVAL AND INSTALLATION 401317 ...

Page 56: ...espectively as shown 1 NOTE l With these matching marks are all aligned No 1 cylinder piston is at top dead center on compression stroke b Refill the engine with recommended oil up to the specified level c Refill the cooling system with coolant d Check each pipe connection for oil or coolant leaks e Prime the fuel system f After installing the fuel injection pumps inspect and adjust the injection ...

Page 57: ...1 2 Inspection and repair 54 1 3 Reassembly 62 2 FLYWHEEL TIMING GEARS AND CAMSHAFT 66 2 1 Disassembly 66 2 2 Inspection and repair 69 2 3 Reassembly 75 3 PISTONS CONNECTING RODS CRANKSHAFT AND CRANKCASE 78 3 1 Disassembly 78 3 2 Inspection and repair 80 3 3 Reassembly 94 D ...

Page 58: ...kness CD Rocker cover Eye bolt Oil pipe Adjusting screw Bolt short Bolt long IJ Valve cap Snap ring Washer 52 Cracks oil leaks o l J Worn valve cap contact face clogged Qil hole QID Intake rocker arm Rocker shaft bracket Exhaust rocker arm Rocker shaft spring Rocker shaft Valve pushrod Cylinder head bolt Cylinder head Valve cotter Upper retainer Valve spring Valve Valve stem seal 401323 Cylinder h...

Page 59: ...e disassembled rockers in the order removed and install them in that order at the time of reassembly This is for reproducing the same rocker shaft to rocker arm clearance as before 3 Removing cylinder head Unscrew the cylinder head bolts and lift the head off the crankcase NOTE a When removing the gasket from the crankcase be careful not to damage the mounting face of crankcase b If any cylinder h...

Page 60: ...ker bushing inside diameter and rocker shaft diameter Compute the clearance between the bushing and shaft on the basis of the measurements If the Repair limit is reached replace the bushing If it is exceeded replace both bushing and shaft Unit mm in Item Nominal Assembly Repair value standard limit 20 000 Rocker bushing 20 021 inside diameter 0 78740 0 78823 19 984 Rocker shaft 19 966 diameter 0 7...

Page 61: ...ce standard limit 7 955 Intake 7 940 7 900 0 31319 0 31102 Valve stem 0 31260 diameter 7 940 Exhaust 7 920 7 850 0 31260 0 30905 0 31181 2 Measuring valve stem to guide clearance The valve guide wears more rapidly at its both ends than at any other parts Measure the guide at its ends and in two directions at right angles to each other If the Service limit is exceeded replace the guide ENGINE PROPE...

Page 62: ...for replacement b To install a replacement guide use valve guide installer 8 34491 00400 CAUTION As installed depth of the valve guide is specified be sure to use the valve guide installer to insure this depth 4 Inspecting valve face Coat the valve face lightly wi th red lead and using valve lapper check the valve contact with its seat If the contact is not uniform or if the valve is defective or ...

Page 63: ...0 051 1 2 0 14 rn 1 6 Width 0 047 0 0055 0 063 2 13 Up to 1 2 Valve margin 0 0839 0 047 by refacing 5 Refacing valves If the valve face is badly worn reface it with a valve refacer _ _ _ _ NOTE a Set a valve refacer at an angle of 300 b If the valve margin seems to be less than the Repair limit when ground replace the valve ENGINE PROPER Good Bad 400059 Valve contact with its seat Valve seat angle...

Page 64: ...plate of about 5 mm 0 20 in thickness to the valve seat Insert a shaft into the valve guide hole from the upper side of cylinder head and drive the seat off the head as shown ___ CAUTION When welding the plate be careful not to permit spatters to come in contact with the machined surfaces of cylinder head b Measure dimensions of valve seat holes in the cylinder head before installing valve seats a...

Page 65: ...Intake 31391 13010 Exhaust 34491 01300 8 Lapping valves in valve seats Be sure to lap the seats after the replaced valves in the valve seats have been a Coat the valve face lightly with a lapping compound NOTE J a Do not permit the compound to come in contact with the valve stem b Use the compound of 120 to 150 mesh for initial lapping and the compound of finer than 200 mesh for finish lapping c M...

Page 66: ...n lap the valve e Check the valve face for contact Valve springs Measuring squareness and free length If the squareness or free length exceeds the Service limit replace the spring Unit mm in Item Assembly Service standard limit Free length 48 85 47 60 1 9232 1 8740 Squareness 1 27 0 0500 maximum Test force length 19 1 42 2 15 33 under test force 186 IOJ 43 147J kgf lbf NJ mm 1 69 43 1 69 in 60 401...

Page 67: ... rod of about 6 mm 0 24 in diameter into the glow plug hole and give light blows to the periphery of the ject through the rod b To install align the spray hole of the jet with the center line of cylinder Valve pushrods If the runout exceeds the Assembly standa rd replace the pushrods Item Valve pushrod runout Unit mm in Assembly standard 0 4 0 016 maximum ENGINE PROPER 670067 Measuring cylinder he...

Page 68: ...ENGINE PROPER 1 3 Reassembly IReassembling sequence I 62 I r ICrankcase I I I I D I I I I I I CV III t t I 401336 I ...

Page 69: ...ure initial lubrication of the stem seal lip 2 Installing valves and valve springs a Install the valve spring and retainer to the valve guide Using valve spring pusher A 30691 04500 install the valve cotters r I NOTE In case of the double spring comprising inner and outer springs install the outer spring with its smaller coil pitch end on the cylinder head side b Using a soft hammer give light blo...

Page 70: ... as guided by the two guide bolts Apply engine oil to the threads of cylinder head bolts and insert the bolts into the head Lt CAUTION J 64 Do not apply any sealant to the cylinder head bolts c Tighten the cylinder head bolts to the specified torque in the sequence shown Front side l r 402894 Unit kgf m lbf ft N m Tightening torque 12 0 5 87 3 6 118 4 9 ...

Page 71: ...the arms make sure that they move freely 5 Installing rocker shaft assemblies Tighten the long bolt and short bolt in that order by following reverse of loosening order 6 Adjusting valve clearance Refer to 1 1 Group No 5 ENGINE PROPER 24 5 mm 0 965 in 22 5 mm 0 886 in Exhaust Intake _ _ 670364 1 5 0 5 kgf m 10 8 3 6Ibf ft 14 7 4 9 N m 65 ...

Page 72: ...assembly 66 CD Flywheel Flywheel housing Oil seal Oil pan Oil pump Crankshaft pulley J Timing gear case Oil seal Baffle plate P T O gear Idler gear P T O Bearing case Thrust plate Idler gear Camshaft gear Thrust plate Camshaft Tappet Front plate 402891 402897 ...

Page 73: ...ving flywheel housing Unscrew the housing mounting and remove the housing 3 Removing oil pan and oil pump bolts Unscrew the oil pan mounting bolts and remove the oil pan Then remove the oil pump by unscrewing its bolt Refer to 2 Group No 6 4 Removing timing gear case Remove the crankshaft pulley and timing gear case ENGINE PROPER 401344 fJJ jJ 1 r 1 jt ll 401345 67 ...

Page 74: ...Removing camshaft Position the camshaft gear so that its two jacking bolt holes come to top and bottom Using socket A 34491 00300 unscrew the thrust plate bolts and remove the camshaft from the crankcase After removing the camshaft remove the tappets 8 Removing camshaft gear Using a puller remove the gear from the camshaft Now the thrust plate can be removed II N OT El It is not necessary to remov...

Page 75: ...rd limit D In 46 916 gj D D D D take I 84708 0 004 6 684 6 184 Cam 0 012 0 26315 0 24346 lift D Ex 45 944 g D D Dl D2 7 344 6 844 haust I 80882 0 004 0 28913 0 26945 0 012 3 Measuring camshaft runout If the runout exceeds the Repair limit straighten the camshaft by means of a press or replace it with a new one J CAUTION 1 Set up a dial gauge on the camshaft and turn the camshaft Take one half 1 2 ...

Page 76: ...2 0827 0 15 Camshaft journal to 0 04 0 09 0 0059 bushing clearance 0 0016 0 0035 Repair limit 5 Replacin i camshaft bushings To install bushings align their oil holes with those from oil gallery and drive bushings in Tappets 1 Inspection 70 Check the cam contact face of each tappet for abnormal wear and replace it if necessary 670439 Measuring camshaft journal diameter S Removal W S Installation 4...

Page 77: ...ove one gear back and forth to measure the backlash between the gears If the backlash exceedS the Repair limit replace the gears Unit mm in Item Assembly Repair standard limit Timing gear backlash 0 07 0 0028 0 15 0 0059 Idler idler bushing and idler shaft I Measuring idler end play Measure the end play with a feeler gauge or dial gauge If the end play exceeds the Repair limit replace the thrust p...

Page 78: ...ntil its end face is flush with that of gear boss 4 Replacing idler shaft To remove the idler shaft for replacement use idler shaft puller A 34491 02300 Flywheel and ring gear 1 Measuring flywheel radial runout Set the flywheel on the surface plate and measure the radial runout of the friction surface by moving a dial gauge on and along thatsurface If the radial runout exceeds the Repair limit ref...

Page 79: ...oceed as follows Removal a Heat the ring gear uniformly with an acetylene torch b Using a bar give light hammer blows to the periphery of ring gear Installation Heat a replacement ring gear up to about 100 C 212 F in a piston heater and press the gear onto the flywheel with its unchamfered teeth foremost Crankshaft pulley Inspecting V belt groove Inspect the groove for wear Wrap a new belt around ...

Page 80: ...op surface of the belt is uniformly above the top of the pulley all the way around it is not necessary to replace the pulley If the top surface of the belt sinks into the groove more than 1 6 mm 1 16 in replace the pulley 74 ...

Page 81: ...2 3 Reassembly B Section A A 402892 5 Section B B 402903 IReassembling sequence I III1 III r ICrankcase I CV CD r r i ENGINE PROPER 402906 402887 75 ...

Page 82: ...te installed in advance 2 Installing camshaft Carefully insert the camshaft into the crankcase 3 Installing idler Install timing install the idler while aligning marks each pair of gears the thrust plate with bolt 4 Installing oil seal the and To install the oil seal use the installer 76 Camshaft gear 400456 ...

Page 83: ...Using a 3 mm 0 12 in thick smooth steel plate add 3 mm 0 12 in clearance to the intake and exhaust valves of No 1 cylinder Then insert a 0 05 mm 0 0020 in feeler gauge into between the top of valve cap and rocker and slowly turn the crankshaft trying to find a position where the feeler gauge is firmly gripped the valve starts opening and a position where the gauge is just ungripped the valve start...

Page 84: ...n ring Second compression ring Oil ring j Snap ring 78 Scratches cracks wear carbon deposit on outside Chipping abnormal wear Scratches flaking metal to metal contact Piston pin Piston Connecting rod Bearing cap bolt Main bearing cap Side seal Thrust plate WeaJ scratches rust Scale deposit corrosion damage Scratches cracks pitting clogged oil hole wear 401766 Main bearing lower shell Crankshaft Ma...

Page 85: ...g pistons a Lay the crankcase on its side b Remove all carljon deposits from the upper areas of cylinder sleeves with cloth or oil paper Carbon deposits if any will make it difficult to pull the pistons upward 3 Removing pistons Bring the piston assembly from which the connecting rod cap has been removed to top dead center position Put the hammer handle to the big end of the rod and push the assem...

Page 86: ...removing the caps and bearings mark each combination for its location so that it is installed to the same crankshaft journal as before at the time of reassembly 7 Removing crankshaft Slowly lift the crankshaft off the crankcase 3 2 Inspection and repair Crankcase and cylinder sleeves 1 Measuring warpage of crankcase gasketed surface Meas 1re the warpage with a straightedge and fee ler ga tige If t...

Page 87: ...maximum 0 05 Taper 0 0020 maximum b If the inside diameter reaches the Repair limit within the Service limit bore the sleeve to the specified oversize c Hone the sleeve to 0 25 mm 0 0098 in or 0 5 mm 0 0197 in oversize accurate within 0 to 0 035 mm 0 00138 in Use the piston and pistori rings of the same oversize d If any sleeve is unevenly worn determine the oversize on the basis of the maximum we...

Page 88: ...kcase by aligning it with the center of the less worn area of the sleeve at the bottom b Bore the sleeve until its stock thickness is about 0 5 mm 0 02 in c Break and remove the sleeve being careful not to damage the inside surface of the crankcase Installing a new cylinder sleeve a Use cylinder sleeve installer 34491 02100 b Press the sleeve into the crankcase leaving a protrusion of 0 3 to 0 5 m...

Page 89: ... pistons per engine is within the Assembly standard Unit mm in Item Assembly Service standard limit Standard 97 875 97 845 97 660 3 85334 3 85216 3 84487 0 25 98 125 98 095 97 910 Piston 0 0098 3 86318 3 86200 3 85472 diameter oversize 0 50 98 375 98 345 98 160 0 0197 3 87302 3 87184 3 86456 oversize Variance in weight 3 O l per engine gram oz b Piston weight is stamped on the top of each piston E...

Page 90: ...ce standard limit Piston ring end gap 0 30 0 50 1 50 0 0118 0 0197 0 0591 3 Measuring piston ring side clearance Insert new piston rings into the ring grooves in the piston and measure the clearance of each ring with a feeler gauge and straightedge as shown Unit mm in Item Nominal Assembly Repair value standard limit 0 030 2 5 0 070 0 200 0 No I ring 0 098 0 00118 0 00787 M 0 00276 l 2 0 0 No 2 ri...

Page 91: ... a Determine the top dead center of piston with a dial gauge b Set up the dial gauge at the top of crankcase and set the gauge pointer to zero 0 c Measure the protrusion at three places on the piston head and average the three measurements to determine the protrusion Subtract the protrusion from the as installed thickness of cylinder head gasket to determine the clearance between the piston top an...

Page 92: ...rance exceeds the Repair limit replace the bearing If the crankpin is worn excessively or unevenly grind the crankpin and use undersize bearing The two bearing undersizes are 0 25 mm 0 0098 in and 0 50 mm 0 0197 in I NOTE To measure the bearing inside diameter install upper and lower shells to the connecting rod properly and tighten the cap bolts to the specified torque Unit mm in Item Assembly Re...

Page 93: ...onnecting rod bushing puller as shown b Align the oil holes in the bushing and connecting rod c Press the bushing from the chamfered side of connecting rod d After installing the bushing insert the piston pin to make sure that the pin rotates freely 4 Inspecting connecting rods for bend and twist a Measure e and V If the measurement at e is larger than 0 05 mm 0 0020 in per 100 mm 3 94 in of strai...

Page 94: ... place the piston on a surface plate insert a round bar corresponding to the crankpin in diameter into the big end bore and measure the heights A and B of the bar 5 Inspecting connecting rod bearings 88 Inspect each bearing shell for wiped overlay scratching burning pitting and other defects If any of these defects is present replace the shell r Checking connecting rod on aligner 0 cr L T J A B II...

Page 95: ... rods per engine is within the Assembly standard shown below Item Assembly standard Variance in weight per 5 g 0 2 oz engine maximum Crankshaft 1 Measuring journal diameter Using a micrometer measure the journal in two positions 1 and 2 and in two directions A and B to determine the wear out of round and taper If any of the Repair limits is exceeded regrind the journal to the undersize or replace ...

Page 96: ...00217 Crankpins Out of om round 0 0004 0 Q3 Taper maximum 0 0012 3 Grinding crankshaft If the crankshaft is ground to any of the undersizes and refinished to a dimension which is 0 100 to 0 120 mm 0 00394 to 0 00472 in smaller than the undersize it is not necessary to check the bearing contact pattern Crankshaft grinding dimensions Unit mm in Undersize Refinishing dimension 0 25 74 65 74 63 Cranks...

Page 97: ...hrust plates Unit mm in Item Nominal Assembly Repair value standard limit 0 100 Crankshaft end 37 0 264 0 300 play 1 46 0 00394 0 01039 0 01181 5 Measuring crankshaft runout Support the crankshaft on its front and rear journals in V blocks and ineasure the runout at the center journal using a dial gauge Depending on the amount of runout repair the crankshaft by grinding or straightening with a pre...

Page 98: ...he seal shows a sign of oil leaks replace it with a replacement oil seal with sleeve To install the sleeve apply oil to the inside surface of the sleeve and drive it onto the crankshaft using crankshaft sleeve installer A 30691 13010 as shown Main bearings 1 Inspection 92 Inspect each bearing shell for abnormal contact scratching corrosion wiped overlay and other defects Also check for a sign of p...

Page 99: ...en the journal diameter and this inside diameter to determine the clearance Unit mm in Item Assembly Repair standard limit Main bearing to 0 050 0 115 0 200 journal clearance 0 00197 0 00453 0 00787 3 Replacing main bearings If the clearance exceeds the Repair limit replace the bearings or refinish the crankshaft and use undersize bearings If the crankshaft is refinished in compiance with any of t...

Page 100: ...earings 94 a Install each upper shell in the crankcase by fitting its locking lip in the recess Tlie oil holes in the shell and crankcase will be aligned when the shell is so installed b Apply a thin coat of engine oil to the inside surface of each shell c Install the thrust plate in position Installing main bearing upper shell 401788 ...

Page 101: ...to only front and rear caps to which side seals are to be installed c Install the bearing caps to the crankcase making sure that they are flush with the crankcase walls on the front and rear sides d Coat the side seals with potash soapy water and insert them into the grooves in each bearing cap Using the face of a screwdriver push in the seals bringing their rounded corners on the outer side and t...

Page 102: ...mbly standard replace the thrust plates Unit mm in Item Assembly Repair standard limit 0 100 Crankshaft end 0 264 0 300 play 0 00394 0 01181 0 01039 6 Lay the crankcase on its side 7 Installing piston rings a Using piston ring 31391 12900 install the rings on the piston pliers piston NOTE 1 96 Each piston ring is marked R on the side to be up when installed on the piston H t lu 1O 4 O S kgf m 75 2...

Page 103: ...e with a clean cloth and apply engine oil to that surface 9 Installing connecting rod bearings and caps a Insert the bolts into the cap by settling the flat of bolt head in place on the cap b Install the upper shell of the bearing in the rod by fitting its locking lip in the groove and apply engine oil to the inside surface of the shell ENGINE P ROPER ingexpander gap r Spring expander Teflon tube ...

Page 104: ...into the crankcase with the matching mark of the connecting rod on the camshaft side c After resting the big end of connecting rod on the crankpin turn crankshaft by 180 and install the cap 11 Installing connecting rod caps a Install the lower shell of the bearing in the cap apply engine oil to the inside surface of the shell b Install the cap by tightening the nuts to the specified torque 98 Cams...

Page 105: ...INTAKE EXHAUST SYSTEMS I DESCRIPTION 100 2 EXHAUST MANIFOLD 100 Inspection 100 ...

Page 106: ...t flanges for cracks b Inspect flanges for warpage If 100 the warpage exceeds the Assembly standard repair the flanges Unit mm C fl Item Assembly standard Warpage of exhaust 0 2 0 008 manifold flanges maximum Air cleaner Cylinder 401800 Inspecting exhaust manifold flanges for warpage ...

Page 107: ...LUBRICATION SYSTEM 1 DESCRIPTION 102 2 OIL PUMP 103 2 1 Disassembly 103 2 2 Inspection and repair 104 2 3 Reassembly 106 3 OIL FILTER 107 Disassembly and inspection 107 4 RELIEF VALVE 107 Inspection 107 ...

Page 108: ...LUBRICATION SYSTEM 1 DESCRIPTION Fuel injection pump Water pump Crankshaft 102 Valve mechanism Piston Oil filter Relief valve Oil pump Oil strainer 402910 ...

Page 109: ...2 OIL PUMP 2 1 Qisassembly D Oil pump case cover Outer rotor Taper pin _ G Worn or broken gear teeth U 21r 8 Pump drive gear Pin Inner rotor LUBRICATION SYSTEM 401803 J Main shaft Oil pump case 103 ...

Page 110: ...the pin and separate the inner rotor from the main shaft 2 2 Inspection and repair 1 Measuring outer rotor to inner rotor clearance If the clearance exceeds limit replace the outer rotors as an assem bly Item Assembly standard 0 013 Outer rotor to 0 150 inner rotor clearance 0 00051 0 00591 104 the Service and inner Unit mm in Service limit 0 250 0 00984 670144 670148 Measuring ouler rolor la inne...

Page 111: ... 20 Outer rotor to pump 0 28 0 50 case clearance 0 0079 0 0197 0 0110 4 Measuring main shaft to pump case clearance Measure the diameter of main shaft and the inside diameter of pump case to determine the clearance between the two If the clearance exceeds the Service limit replace the main shaft or the pump assembly Unit mm in Item Assembly 8 ervice standard limit 13 000 Diameter ofmain 12 985 sha...

Page 112: ...gear at the time of reassem bling the pump drill dowel pin hole in and through the shaft and gear b When tightening the cover bolts be sure to make sure that the rnatching marks on the cover and case are aligned A failure to match the marks will result in malfunction 106 4 3 7 8 402907 401219 Matching marks on pump case and cover ...

Page 113: ...akness and breakage 2 Measure the relief valve opening pressure If it exceeds the Assembly standard make an adjustment by tightening or loosening the adjusting screw varying the setting of the spring Unit kgf cm psi MPa Item Assembly standard Relief valve opening 3 0 0 2 42 7 2 8 pressure 0 29 0 02 LUBRICATION SYSTEM Filter case Relief valve Hydraulic pressure outlet Apply engine oil to O ring whe...

Page 114: ... ...

Page 115: ...COOLING SYSTEM 1 DESCRIPTION 110 2 WATER PUMP 110 2 1 Disassembly 110 2 2 Inspection 111 2 3 Reassembly 112 3 THERMOSTAT 113 Inspection 113 4 FAN AND FAN BELT 114 Inspection 114 ...

Page 116: ...y 110 CD Cover Impeller Nut Pump pulley Spacer Cooling fan Radiator Thennostat Bypass pipe Water pump I Rotation I Oil seal J Snap ring Shaft Bearing Bearing CD Corrosion feathering due to rubbing contact damaged threads Oil seal Unit seal Case 402911 670196 ...

Page 117: ...ion replace the bearings b Visually inspect the impeller for corrosion or broken blade Replace the impeller if defective Also check the impeller for sign of rubbing cont lct with the pump case and regr cover If such a contact is evident replace the impeller and bearings c Inspect the unit seal for condition Replace the seal if any sign of leakage is noted during operation Unit mm in Item Assembly ...

Page 118: ...g the pump operate it by means of the pulley and belt making sure that it runs smoothly without any sign of rubbing contact with the pump case or cover 1 Installing unit seal To install the seal use a unit seal installer Do not reuse a unit seal which has been removed from the pump case 2 Installing oil seal To install the seal use an oil seal installer 112 670197 400475 ...

Page 119: ...WORKSHOP THEORY I PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 116 1 1 Oil seals 116 1 2 O rings 117 1 3 Bearings 117 1 4 Lockplates 118 1 5 Split pins and spring pins 118 II ...

Page 120: ... to the surface of oil seal to be fitted into housing bore c Using a tool of the type shown to guide seal lip drive oil seal squarely Never give any hammer blows directly to oil seal since this will damage the seal resulting in oil leakage 2 Driving oil seals onto shafts a Apply a thin coat of grease to oil seal lip b Use an oil seal guide of the type shown when driving oil seal over stepped porti...

Page 121: ...ase to O ring 1 3 Bearings 1 When installing a rolling bearing be sure to give a push to the race inner qr outer by which the bearing is fitted Be sure to use a bearing driver of the type shown WORKSHOP THEORY 400249 O ring guide 400250 q 2 Use a press whenever possible to minimize shock to bearing and to assure proper installation Bearing installation by a press 400251 117 ...

Page 122: ...pring pins Generally split pins are to be replaced at the time of disassembly Be sure to insert the split pin fully and spread it properly Drive each spring pin into position so that it may not get out of place after subsequent installation of parts has been completed 118 m rrp fIlS I Right Right Wrong Bending lock plates ...

Page 123: ...in Item Assembly standard Temperature at which 76 5 2 C valve starts opening 169 1 3 6 F Temperature at which 90 2 C valve opens fully 194 3 6 F Valve stroke 9 0 35 NOTE l a Stir the water in the bath with a stick to maintain its temperature uniform during test b At reassembly install thermostat with its air vent hole facing upward COOLING SYlnEM mm in 9 O 35 o 76 5 2 90 2 US9 7 3 6 194 3 6 Tempef...

Page 124: ...COOLING SYSTEM 4 FAN AND FAN BELT Inspection 114 Distorted or cracked blade Ch e in length detenoration cracks 401811 ...

Page 125: ...I j I I I I ...

Page 126: ...DEC 86 Printed in Japan Pub No 99879 00120 1 ...

Page 127: ...SERVICE MANUAL MITSUBISHI DIESEL ENGINE for BD2G BS3G CONTENTS FUEL SYSTEM ELECTRICAL SYSTEM ...

Page 128: ...I j I I I I ...

Page 129: ...fications Equipment S4E2 BD2G BS3G Injection nozzle Type of nozzle holder ND DNOSD Type of nozzle tip Fuel Feed pump ND EP KS22A system Injection pump PES4A65B Governor ND EP RSV Electrical Starter M002T65271 system Alternator AOOlT70770 TABLE OF CONTENTS Group Contents Group No Disassembly inspection reassembly and maintenance Fuel system standards of fuel system I Fuel fIlter fuel injection nozz...

Page 130: ......

Page 131: ...y 4 FUEL FEED PUMP 4 1 Disassembly 4 2 Inspection and adjustment 5 FUEL INJECTION PUMP 2 3 3 3 6 7 7 8 9 9 5 1 Disassembly 5 2 Inspection 5 3 Reassembly 11 13 5 4 Testing and adjustment 15 6 RSV GOVERNOR 20 6 1 Disassembly 20 6 2 Reassembly 22 6 3 Testing and adjustment 23 7 MAINTENANCE STANDARDS 29 7 1 Maintenance standards 29 7 2 Tightening torque 31 I ...

Page 132: ...embly and inspection Cartridge type paper element filter 2 CD Element assembly 2 Fuel injection nozzle Fuel leak off pipe _ To fuel tank _ From fuel tank f Air vent plug Bracket Clacks damaged threads Apply engine oil when installing Clogged or torn element Replace every 500 hours 401812 401814 ...

Page 133: ...ogged spray hole Spring Washer J Nozzle holder FUEL SYSTEM 401816 300542 b Slowly operate the handle all the way up and down completing each cycle in about a second while observing the pressure gauge indication Testing injection nozzle c As the nozzle beings to spray fuel the needle of the gauge being deflected will start oscillating Read the pressure right then as the injection pressure Item Valv...

Page 134: ... 0 0020 in 2 Spray pattern a At the time of testing the injection pressure inspect each nozzle for clogged spray hole and fuel leaks from the hole Also examine spray pattern b To test the nozzles move the tester handle at it rate of about 1 stroke per second to make sure that it sprays fuel in good straight pattern 3 Washing or replacing nozzle tip a Loosen the retaining remove the nozzle tip need...

Page 135: ...ining nut to the specified torque d If the spray pattern is still bad after the nozzle has been adjusted and cleaned replace the nozzle tip r CAUTION J Never attempt to touch the sliding surface of needle valve 1NOTE To replace the nozzle tip remove the sealpeel plastic covering and wash the new tip in clean gasoline by sliding the needle valve in the nozzle to remove the rust preventive oil compl...

Page 136: ...FUEL SYSTEM 3 3 Reassembly 5 0 5 kgf m 36 4 lbf ft 49 5 N m 2 fR ssembling sequenceI 6 670038 ...

Page 137: ...alve support Check valve spring II 0 I 6 I II j Check valve outlet Piston chamber plug Piston spring Piston Ring Tappet 401543 Pushrod Hollow screw Filter gauze Nipple Pump housing Remove the parts in the order numbered for disassembly To reassemble follow the reverse of disassembling order FUEL SYSTEM 7 ...

Page 138: ...ly airtight if the amount of this leakage with no leakage from any other part of the pump is not greater than the value specified Specification Item Standard Not greater than 50 cc 3 1 cu in minute with Feed pump airtightness bubbles not larger than 2 mm 0 08 in in size at an air pressure of 2 kgf cm 28 psi 0 2 MPa If the airtightness is poor repair the pushrod bore in pump housing wi th a burnish...

Page 139: ...t roller Roller bushing Shim Lower spring seat Plunger Plunger spring Upper spring seat Control sleeve Control pinion Lock plate Delivery valve holder Delivery valve spring Delivery valve Pump cylinder Rack guide screw Control rack Pump body Fuel injection pump Disassembled view Remove the parts in the order numbered for disassembly 670191 9 ...

Page 140: ...ve the tappet insert 3 To remove tappet 7 insert the tappet clamp c through bearing hole to pinch the tappet take off the roller clamp b and remove the tappet 1NOTE Tilt down the top delivery valve holder side of the pump so that the plungers and springs will not come off 4 To remove plunger 14 pinch the lower portion of the plunger with plunger clamp d and draw out the plunger together with its l...

Page 141: ...unger from the barrel about two thirds of the way while holding the barrel horizontal then angle up the barrel slowly by about 60 This should cause the plunger to slide out all the way by its own weight to evidence a proper fit If the plunger goes outward in a free falling manner or becomes stuck on the way then the pump element assembly must be replaced 4 Pull up the delivery valve piston cover t...

Page 142: ...ng a greater force to overcome than the assembly standard Unit gf ozf N Item Assembly standard Sliding resistance Not more than 120 4 2 1 2 of control rack as starting pull 6 Measure the overall radial play of tappet roller 10 roller bushing 11 and pin 9 with a dial gauge as shown If it exceeds the assembly standard replace the whole tappet sub assembly 8 12 670176 401584 ...

Page 143: ...5 3 Reassembly IReassembling sequence I FUEL SYSTEM Tightening torque 3 0 0 5 kgf m 21 7 3 61bf ft 29 4 4 9 N m Tightening torque 6 5 1 0 kgf m 47 0 7 21bf ft 63 7 9 8 N m 670194 13 ...

Page 144: ... feed the tappet into the camshaft chamber and insert it into the bore with roller clamp b 3 To install camshaft 3 match the driving face of plunger and the slot in pump cylinder push the tappets and hold them with tappet inserts a r NOTE Each time when the above step is completed on one cylinder check the control rack if it slides smoothly 4 Check the sliding resistance of control rack 25 The rac...

Page 145: ...71 in and 0 50 min 0 0197 in NOTE So that the camshaft will not be so displaced by shimming to one side as to offset the cams from the tappets try to use equal amounts of shim on both sides 5 4 Testing and adjustment o Control rack sliding resistance test o Injection timing adjustment a Pre stroke adjustment b Checking position injection and adjusting the angular of the beginning of c Tappet clear...

Page 146: ...e selector lever of the pump tester into injection quantity position and turn on the motor switch to start up the motor Next produce the prescribed delivery pressure by means of the pressure adjusting valve Loosen the air bleeder screw on the pump to let out the trapped air if any 1NOTE It is not necessary to run the pump in order to bleed air out 2 Control rack sliding resistance test 16 Run the ...

Page 147: ...mshaft just when the fuel ceases to overflow and read the distance traversed by the tappet from its lowest position Unit mm in Item Standard 1 9 2 0 0 Q75 0 079 If the pre stroke is out of standard bring the tappet to its top dead center position insert spring holder into between the lower spring seat and tappet and turn the camshaft in normal direction Now there will be a clearance between the sp...

Page 148: ...t and bring the tappet to its top dead center position Keeping the tappet in this position lever up the tappet with a screwdriver and measure the clearance Unit mm in Item Standard Tappet clearance 0 2 0 008 min 18 This clearance is prescribed to be not less than the value specified above and normally should not require any adjustment Thus the purpose of this measurement just for making sure that ...

Page 149: ...gf cm 2 28 4 psi 0 2 MPa on tester gauge run the injection pump at the specified speed by the tester keep the control rack at the standard position and measure the injection quantity by a measuring cylinder for each pump element Adjust it to bring its injection quantity into the specified range NOTE For specified injection quantity refer to the Maintenance standards If injection quantity of any cy...

Page 150: ... Screw plug Lever supporting shaft Adjusting lever Snap ring Lever bushing Control spring Swiveling lever Guide lever Sleeve Ball bearing Plate washer 402914 Tension lever Adjusting set assembly Stop lever Spring cover Return spring Bearing bushing Governor shaft assembly Control lever Cover plate Governor cover Governor Disassembled view Remove the parts in the order numbered for disassembly 20 ...

Page 151: ...ion between control rack and shackle 2 2 Unhook the start spring 3 Remove the governor cover complete with the lever mechanism 3 Remove round flyweight 5 by round nut wrench nut 4 loosening A securing it with 4 Run the flyweight extractor B into the threaded hole as shown and force the flyweights 5 off the camshaft by jacking action FUEL SYSTEM 402915 402916 21 ...

Page 152: ...FUEL SYSTEM 6 2 Reassembly 402917 Governor Sectional view For the parts not numbered refer to the disassembled view IReassembling sequence I 22 ...

Page 153: ...and adjustment After assembling the governor properly the adjustments described below should be effected on the test bench 1 Fuel injection pump injection quantity adjustment Before adjusting the governor be sure to carry out the required injection timing and injection quantity adjustments on the fuel injection pump For the adjustments refer to 5 4 Testing and adjustment Fuel Injection Pump Instal...

Page 154: ...pump at the speed corresponding to Nc turn the adjusting lever to give the control spring a fairly tight tension and secure the adjusting lever there temporarily Turn the full load stopper with the screwdriver until the rack comes to the position corresponding to Rc and secure the stopper there with lock nut Turning the full load stopper clockwise as seen from the rear of the governor increases th...

Page 155: ... as adaptor stroke Tightening or driving inward adaptor screw 4 elongates this spring to increase the stroke and vice versa 3 Run the pump at Na This should move the control rack to Ra if not change the thickness of shim plate 3 indicated in this illustration preload adjustment of adaptor spring Na rpm Ra mm Nd rpm Rd mm Inner 250 12 7 400 11 2 spring Outer 500 10 4 700 9 8 spring Low speed contro...

Page 156: ...ermine the maximum speed to be controled by the governor The maximum speed stopper sets this position of the adjusting lever Slowly raise the speed from Nc Upon locating that position of adjusting lever at which the control rack begins to move in from Re at Ne speed bring the maximum speed stopper into contact with the lever thereby setting the maximum speed position of adjusting lever Secure the ...

Page 157: ...e For the maximum speed position of adjusting lever speed regulation is represented by that portion of the characteristic curve from point Re to point Rf for the differential speed from Ne to Nf In the present governor the regulation can be changed by means of the adjusting screw provided in the swiveling lever Tightening this screw increases the tension of control spring to reduces the value of r...

Page 158: ...Ne to a proper level by repeating the process described in 1 above NOTE In the table of standard adjustment data the angular position of the adjusting lever assumes that 400 is vertical Turning the adjusting lever from this position to the maximum speed stopper side increases degree and vice versa Matching the pump to the engine After adjusting the governor according to the procedures set forth ab...

Page 159: ...f 20 kff cm 284 psi 2 0 Wash or replace needle valve seat MPa lower than valve open nozzle tip ing pressure for 10 seconds Outside diameter of E tappets 7 0 1 3 Inside diameter of 0 276 0 004 tappet holes 0 Outside diameter of 15 o 0 0 075 tappet roller 0 591 0 027 0 00106 0 00295 Deliverr pressure 1 8 2 2 Injection pump Po 25 6 31 3 E kgf cm psi MPa 0 18 O 22J speed 600 rpm p Check displacement w...

Page 160: ... Plunger 49 1 0 039 0 5 Free spring 1 929 o 0 0 020 8 length Delivery I 8 32 0 5 0 020 valve spring 1 260 0 039 2 c 8 Cam height g 1 tg 0039 0 2 32 major diam 1 260 0 0078 8 t Inside diameter of 24 0 15 tappet holes in pump t 0 945 0 0059 housing Pre stroke 1 95 0 05 0 0020 0 0768 Beginning of injection 90 30 Tappet clearance 0 2 0 008 min Injection quantity adjustment Pump speed Rack position Plu...

Page 161: ...1 0 008 E Set by torque spring 2 0 Medium speed 53 SO 9 0 O I 0 354 0 004 850 control Set by full load stopper 0 300 8 3 0 1 0 354 0 004 u Low speed control 25 5 200 11 0 0 433 min 400 5 3 O I 0 209 0 004 Set by idle sub spring 400 52 2 3 17 0 12 500 47 I 2 87 0 06 by means of Angleich Matching to engine 53 so spring 900 39 2 2 38 0 12 1200 29 1 1 77 0 06 by means of torque spring 7 2 Tightening t...

Page 162: ... ...

Page 163: ...y 34 1 2 Inspection and repair 35 1 3 Reassembly 39 2 ALTERNATOR 42 2 1 Disassembly 42 2 2 Inspection and repair 42 2 3 Reassembly 44 3 GLOW PLUGS 44 Inspection 44 4 MAINTENANCE STANDARDS 45 4 1 Maintenance standards 45 4 2 Tightening torque 45 I ...

Page 164: ...ture Ball bearing Pole and field coil installation J Ball bearing Cover set Center bracket Gear jJ Spring set Lever Roughness burning grooved wear worn or damaged gear Brush dust buildup uneven wear brush movement in holder Pinion set Pinion shaft Oil seal Ball bearing QD Front bracket 670248 ...

Page 165: ...pport the armature in V blocks and measure the runout of commutator with a dial gauge If the runout exceeds the Repair limit repair the commutator by turning it in a lathe within Service limit for the outside diameter If the commutator surface is rough smoothen it with a sandpaper pf 300 to 500 Unit mm in Item Assembly Repair Service standard limit limit Commutator 0 03 0 05 0 05 runout 0 0012 0 0...

Page 166: ...n and the yoke assembly should be replaced b Testing for grounded circuits If there is continuity between the yoke and positive brush check the insulation and repair or replace the yoke assembly 3 Brushes and holders a Wear of brushes Measure the brush length and if it is less than the Service limit replace the brushes If the brushes are unevenly worn or rough recondition them with a sandpaper of ...

Page 167: ...mit Brush spring 3 5 7 7 34 3 2 3 5 1 22 6 tension c Testing brush holders for insulation If there is continuity between the positive brush holder and negative holder plate replace the brush holder assembly 4 Overrunning clutch Make sure that the pinion shaft turns smoothly when turned in the direction of driving clockwise and that it locks when turned in the opposite direction If not replace the ...

Page 168: ...t into the center bracket and lock the shaft with the washer and ring Under this condition move the shaft in the axial direction and measure the thrust gap b When the pinion is installed Install the pinion shaft and gear between the front and center brackets and temporarily tighten the bolt Under this condition move the shaft in the axial direction and measure the thrust gap Item Unit mm in Assemb...

Page 169: ... ELECTRICAL SYSTEM 1 3 Reassembly Apply grease to sliding surface of lever IReassembling sequence I Replace packing Apply grease 670044 39 ...

Page 170: ...ed to the magnetic switch Increasing the packings decreases the pinion gap Unit mm in Item Assembly standard Pinion gap O S 2 0 0 020 0 079 Lt CAUTION Do not test the starter continuously for more than 20 seconds to prevent the switch coil from overheating 2 No load test After adjusting the pinion gap hook up the starter as shown and test it for no load characteristics NOTE Use wires as thick as p...

Page 171: ... and body ground replace the switch b lnspecting contactors for fusion If there is continuity between Band M terminals replace the switch c lnspecting contactors for poor contact action Inspect for contactors excessive defective voltage drop between If voltage drop is the contactors are ELECTRICAL SYSTEM B leonina L 401837 41 ...

Page 172: ...racket Stator Replace the brushes if they are worn down to the wear limit line Unit mm in Item Assembly Service standard limit Brush length 18 0 71 8 031 42 Bearing rotation Dirty or burned slip rings worn oil seal contact surface of shaft Brush movement jJ Brush holder set Rectifier assembly Plate Rear bracket 670213 r r Service IimJiJ8 mm 0 31 in 18 rom 0 71 in L 670216 ...

Page 173: ... any continuity is noted the coil is grounded 4 Rectifier Inspect the resistance between the lead wire and heat sink on each diode by connecting the positive side lead wire and negative side lead wire of the tester to the diode If the resistance is infinite in both cases the diode is open circuited If it is nearly zero in both cases the diode is short circuited If the diode is open or short circui...

Page 174: ... 0 08 in diameter wire into the hole in the brush Then install the rotor Remove the wire after installing the rotor 3 GLOW PLUGS Inspection If the glow plug glows red when the positive wire is connected to the portion A with the portion B grounded the plug is in satisfactory condition 44 670054 rrnt Brush Wire lli I ff l Rotor 670220 Testing glow plug ...

Page 175: ...ad characteristics Locked characteristics Magnetic switch operating voltage t Torque Switch in Voltage Current Speed Voltage Current iil kgf m lbf f voltage Switching off V A rpm V A N m V 80 730 4 5 32 5 Shall turn off upon 23 3400 8 16 max lurning off of slarter max max 44 1 min switch Brush spring 210 tension 0 5 gf lbf N 2 1 0 Outside diameter 33 32 4 of slip ring 1 30 1 276 Brush length 18 8 ...

Page 176: ......

Page 177: ...uel cut soleno d l 2R 2R BTT l 0 85 G 0 75 G ON I Y L 2 L 2l SOL SBR L __ 9 GND __ J I 81 HHhlel w ro 1 __ 1 I I I I 0 858 1 25BR 1 25G FGiJ 1 3412TI36 1 l G OWP l f 1 f I gine 1 1217111141171 hol l T r Tl OldI L 011315 I L L L o 5RL II l w Head lamps i I 0 8 5 G 8 1 8 l S rt I S O 85WR J i i w O SSWR I r I 8 ___ 0 I i j _ l i 58 w __ Q Cl l I I C 4 15 0 I I I _ J J 0 J 0 1 8 L g _ ci O 85W Hom ci...

Page 178: ...DEC 86 Printed in Japan Pub No 99879 00120 2 ...

Page 179: ...SERVICE MANUAL MITSUBISHI TRACTOR BD2Gi TRACTOR SHOVEL HSaG CONTENTS POWER TRAIN HYDRAULIC SYSTEM MAINTENANCE STANDARDS ...

Page 180: ...I j I I I I ...

Page 181: ...l valve 17 BD2G with power angling tilt blade 17 BD2G with power tilt blade 19 BS3G 22 Cylinders 25 Lift cylinders BD2G with power angling tilt blade and power tilt blade 25 Angling cylinders BD2G with power angling tilt blade 26 Tilt cylinder BD2G with power angling tilt blade 27 Tilt cylinder BD2G with power tilt blade 28 Lift cylinders BS3G 29 Dump cylinders BS3G 30 Power angling tilt blade BD2...

Page 182: ... ...

Page 183: ...0 4 0 016 Botb sides O 0 031 0 7 0 028 min 0 30 0 0118 20 2 0 795 0 19 7 0 776 max 0 05 0 15 0 0020 0 0059 10 20 c 10 25 0 4016 0 4 35 13 0 0 5 I2 0 05 0 10 0 0020 0 0039 70 6 2 780 o 43 5 2 2 95 9 4 9 426 6 21 6 48 2 1 898 0 30 0 01l8 10 50 0 4134 See Remarks 12 5 0 492 max 0 20 0 0079 68 5 2 697 39 2 86 4 384 4 48 2 1 898 3 min Unit mm in Remarks Bushing are said to have reached tbe service limi...

Page 184: ...FLYWHEEL CLUTCH 4 2 8 000 00 2 602165 7 602279 ...

Page 185: ...d sliding gear 0 0047 0 0118 7 8 9 10 Shift rails shifter shafts Shift forks Detent springs poppet springs Sliding gears Countershaft end securing II bolts bevel pinion shaft securing bolts Fit in forks Bend Clearance of shift fork in groove Free length Test force length under test force kgf lbf N min Width of shifter fork gr ooves Tightening torque kgf m lbf ft N m 0 020 0 062 0 00079 0 00244 0 1...

Page 186: ...DIRECT DRIVE TRANSMISSION 9 60Z242 o 602167 602243 4 ...

Page 187: ...BRAKE Unit mm in Ref Group No Item Assembly standard Service limit Remarks Outside diameter 252 9 92 250 9 84 I Drum Clearance in linings 0 8 0 031 Thickness 6 5 0 256 4 5 0 177 2 Linings 2 602244 5 ...

Page 188: ...ates splines 0 0055 O oJ 18 0 0236 c Total thickness of 69 66 friction plates 6 pes 2 72 2 60 V and disc plates 6 pes 6 Shlfter Fit in flange 0 200 0 324 0 00787 0 01276 Inner drum Tightening torque 3 5 0 3 7 25 3 2 2 securing bolts kgf m lbf ft N m 34 3 2 9 Outer drum and Tightening torque 3 5 0 3 8 pinion securing 25 3 2 2 bolts kgf m Ibf ft N m 34 3 2 9 Drive shaft 16 19 9 clutch shaft Tighteni...

Page 189: ...STEERING CLUTCHES AND FINAL DRIVES 602177 7 ...

Page 190: ... Remarks No Free length 66 2 60 I Valve springs Test force length under 9 8 l 21 6 2 2 test force 96 1 9 8J 56 kgf Ibl Nl mni in 2 20 c Free length 36 5 1 44 Test force length under 0 9 0 1 2 0 0 2 en 2 Return springs test force 8 8 1 0 32 9 kgf Ibl Nl mm in 1 30 2 602278 8 ...

Page 191: ...ng clearance Lower 1 8 2 8 0 039 mount 0 071 0 110 Engine front Tightening torque 15 9 1 6 3 mount attach I15 0 11 6l e ing bolts kgf m lbf ft N m 155 9 15 7 f Flywheel hous Tightening torque 15 9 1 6 4 ing mounting kgf m lbf ft N m 115 0 11 6l bolts 155 9 15 7 Standard models 1200 47 1 4 Center to center Swamp models 1400 55 1 8 Difference 5 of tracks Super swamp models 1590 62 5 8 10 3 8 between...

Page 192: ...25 1 40 4 Axial play 0 0079 0 0098 0 0551 5 0 155 0 235 1 000 s 5 Shafts Fit in bushing 0 00610 0 00945 0 03937 0 7 6 0 8 It 6 Filler plugs Tightening torque 55 5 8 kgf m lbf ft N m 74 5 7 8 Bearing shaft Tightening torque 6 5 0 7 7 securing taper 47 5 1 pin bolts kgf m lbHt N m 63 7 6 9 8 Guides track Lateral clearance I 0 04 3 0 12 I 9 frames Vertical clearance I 0 04 3 0 12 3 2 8 9 602187 10 ...

Page 193: ... length under 2610 210 5755 463 test force 25 6 2 I kgf lbf kN nlin in 326 12 83 0 075 0 164 Fit on piston 0 00295 0 00646 Tightening torque 26 2 188 14 kgf m lbHt N m 255 20 Tightening torque 3 5 0 5 25 3 3 61 kgf m lbf ft N m 34 3 4 9 Adjustment limit 370 14 57 14 7 2 2 Tightening torque kgf m lbf ft N m 106 3 15 9 144 1 21 6 I L o iO il T r J 1 L1J I I I a IG J 0 6 d Service limit 2300 5072 22 ...

Page 194: ... Diameter 104 4 Q9 Rollers Width 30 1 18 35 1 38 3 i l r 0 2 0 5 1 0 ll e 4 Axial play 0 008 0 020 0 039 II 0 185 0 226 1 600 5 Roller shafts Fit in bushings 0 00728 0 00890 0 06299 a Tightening torque 4 2 0 4 6 Filler plugs 30 4 2 9 kgf m lbf ft N m 41 2 3 9 12 2 1 2 7 Roller shaft Tightening torque 88 2 8 7 securing bolts kgf m lbHt N m 119 6 11 8 12 ...

Page 195: ...r 132 5 20 r Rollers Flange width 9 0 35 4 0 16 0 30 0 90 1 40 4 Axial play 0 0118 0 0354 0 0551 I 1 60 e 0 20 0 25 5 Roller shafts Fit in bushings 0 0079 0 0098 0 0630 7 6 O S 6 Filler plugs Tightening torque 55 0 5 Sl kgf m Ibf ft N m 74 5 7 S Tightening torque 6 0 6 7 Roller mount 43 4 4 3 ing bolts kgf m Ibf ft N m 5S 5 5 9 3 4 2 7 602250 5 602188 13 ...

Page 196: ...ins Fit in bushings 0 450 0 734 2 5 0 01772 0 02890 0 098 Standard models 38 5 1 516 BD2G II 0 43 11 Standard models 30 1 18 BS3G 10 0 39 Grouser Swamp models 67 5 2 657 55 5 2 185 Repair limit 4 Shoes height 57 5 2 264 Super swamp models 57 5 2 264 52 5 2 067 Repair limit not Ultra super swamp 57 5 2 264 52 5 2 067 specified models 5 Tracks Sag 20 30 3 4 1 1 8 Tightening torque 17 20 6 Sho bolts ...

Page 197: ...TRACKS 2 b 2 a 6 4 602253 Standard model track 2 b 2 a 4 6 Swamp model super swamp model ultra super swamp model track 15 ...

Page 198: ...Pump Delivery pressure 180 2560 17 7 1 kg eI11 psi IMPa performance _ Capacity 54 3295 liter eu in min 3 a Tightening torque 4 7 5 0 2 Through bolts kgf m lbFft N m 34 0 36 2 46 1 49 0 3 Pump mount Tightening torque 4 2 30 4 41 2 ing bolts kgf m lbf ft N m 1 2 r I I L t F n t J1 r I f 3 601501 16 ...

Page 199: ...g Test force length under 24 3 2 4 springs test force 107 9 10 8J kgf Ibf NJ mm in 10 5 00413 1il Free length 57 2 24 13 8 1 0 Test force length under 30 4 2 2l test force 35 3 9 8 N kgf lbf NJ mm in 10 5 0 413 Q 35 1 38 Free length E 7 0 7 Plunger Test force length under 0 4 detent 1504 l 5l spring test force 68 6 6 9 kgf lbf NJ mm in 27 1 06 0 u Free length 26 1 02 Relief valve Test force length...

Page 200: ...securing bolts kgf m lbf ft N m 10 8 1 0 2 7 0 3 Tigbtening torque 11 Tie rods 19 5 2 2 kgf m lbf ft N m 26 5 2 9 0 Control lever Operating N Raise 1 5 3 0 3 3 6 6 With engine force 14 7 29 4 shut off kgf lbl N N Lower 1 0 2 0 2 2 4 4 N 9 8 19 6 Q Lower 4 5 5 0 9 9 11 0 Float 44 1 49 0 1 Float 2 5 3 0 5 5 6 6 OJ Lower 24 5 29 4 E1 N RH angling 2 0 3 0 4 4 6 6 0 N LH 19 6 29 4 u angling N RH tilt F...

Page 201: ...41 l 0 S Free length 57 2 24 13 8 1 0 Test force length under 30 4 2 21 0 j test force 135 3 9 8 c Plunger kgf lbf N mm in 27 6 1 09 4 centering 51 2 01 Free length 8 springs 11 0 J Test force length under 24 3 2 4 test force 107 9 10 8 i kgf Ibf N mm in 27 6 1 09 0 35 1 38 Free length 0 7 0 0 7 u Plunger detent Test force length under 15 4 1 5 5 spring test force 68 6 6 9l kgf lbf N mm in 27 6 1 ...

Page 202: ...19 6 2 0 plug 10 I Tightening torque 72 3 7 21 0 12 Plugs kgf m lbf ft N m 98 1 9 8 oS 1 1 0 1 1 Seal cover Tightening torque 8 0 0 7 D 13 plates cap kgf m lbf ft N m 10 8 1 0 M securing bolts Q 2 7 0 3 Tightening torque 19 5 2 2l i 14 Tie rods kgf m lbf ft N m 26 5 2 9 1 5 3 0 3 3 6 6 With engine Control lever Operating N Raise 14 7 29 4 shut off force 0 1 0 2 0 2 2 4 4 u kgf lbf N Lower 9 8 19 6...

Page 203: ...CONTROL VAlVE 14 602206 602208 602207 2 1 ...

Page 204: ...t force length under 0 20 0 02 3 0 44 6 04 springs test force 2 0 0 2 C kgf lbf N mm in 10 5 O 4i3 e 57 2 24 Free length Test force length under 13 8 I 8 30 4 2 21 test force 135 8 9 8 kgf lbf N mm in 27 6 1 09 0 Plunger u 4 centering Free length 51 2 01 springs p 11 0 1 1 S Test force length under 24 3 2 4 A test force 107 9 10 8 1 kgf lbf NJlmm in 27 6 1 09 Free length 21 0 83 Makeup valve Test ...

Page 205: ... lbf ft N mJ 49 0 4 9 G 2 0 0 2 M Plunger plug Tightening torque 14 5 1 4 e li plunger detent kgf m lbf ft N m 19 6 2 0J plug 1l Seal cover 1 1 0 1 Tightening torque 8 0 0 7 0 12 plates cap kgf m lbf ft N mJ 10 8 1 0 securing bolts 8 2 7 0 3 Tie rods Tightening torque 19 5 2 21 13 kgf m lbf ft N m 26 5 2 9 1 5 3 0 3 3 6 6 With engine Control valve Operating N Raise 14 7 29 4 shut off force 1 0 2 0...

Page 206: ...CONTROL VALVE 24 6 7 3 9 1 2 13 602214 11 602215 602199 ...

Page 207: ...ng on 0 Q75 0 139 0 350 0 piston rod _ 0 00295 0 00547 0 01378 S Tightening torque 50 0 2 5 k Piston securing k 3 361 7 lS I nut kgf m Ibf ft N m 0 490 3 24 5 0 15 0 1 5 t o S C Tightening torque 0 tI 4 Gland screw 108 5 10 8 kgf m Ibf ft N m 147 1 PI 7 o o Center to center of 4 Q Jes 5 pins with cylinder 640 25 20 Piston rod fully retracted r 6 Stroke 370 14 57 3 602256 25 ...

Page 208: ... bushing om5 0 139 0 350 on piston rod 0 00295 0 00547 0 01378 on 50 0 2 5 5 Piston securing Tightening torque Ch 3 361 7 18 11 a nut kgf m Ibf ft N m 490 3 24 5 k Il 15 0 1 5 Tightening torque 0 4 Gland screw 108 5 10 81 kgf m Ibf ft N m 147 1 14 7 Center to center of gp0 579 5 M 5 pins with cylinder 22 815 gpo Piston rod fully retracted e 6 Stroke 321 12 64 602255 26 ...

Page 209: ...0 139 0 350 2 Guide bushing on piston rod 0 00295 0 00547 0 01378 bo 70 0 3 5 Piston securing Tightening torque b 3 506 3 25 3 nut kgf m lbf ft N m 686 5 34 3 i Tightening torque 24 0 2 4 0 4 Gland screw 173 6 17 4 kgf m lbf ft N m 235 4 23 5 0 _ 5 t Center to center of 0 UN 5 pins with cylinder 390 15 35 Piston rod fully retracted f 7 Stroke 110 4 33 4 2 3 6 5 602257 27 ...

Page 210: ...0 1 39 0 350 2 Guide bushing on piston rod 0 00295 0 00547 0 01378 S Piston securing Tightening torque 50 0 2 5 3 361 7 18 11 nut kgf m lbf ft N m 490 3 24 5 45 0 4 5 5 Tightening torque 4 Gland screw 325 5 32 51 S kgf m lbf ft N m 441 3 44 1 UN Center to center of t Q 5 pins with cylinder 500 19 69 f Piston rod fully retracted r Stroke 115 4 53 _ 4 2 3 o 5 602258 28 ...

Page 211: ...ng Fit of guide bushing 0 075 0 139 0 350 on piston rod 0 00295 0 00547 0 01378 95 0 5 0 Piston securing Tightening torque 3 687 1 36 2 nut kgf m Ibf ft N m 931 6 49 0 OJ 75 0 8 0 4 Gland screw Tightening torque 542 5 57 9 kgf m Ibf ft N m 735 5 78 5 l Center to center of 5 pins with cylinder 700 27 56 Piston rod fully retracted 6 Stroke 386 15 20 4 602259 29 ...

Page 212: ...of guide bushing 0 075 0 139 0 350 on piston rod 0 00295 0 00547 0 01378 50 0 2 5 Piston securing Tightening torque 3 361 7 18 1l 1 nut kgf m Ibf ft N ml 490 3 24 5 Tightening torque 45 0 4 5 4 Gland screw 325 5 32 5 kgf m Ibf ft N ml 441 3 44 1 8 Center to center of 0 5 pins witil cylinder 866 5 34 11 Piston rod fully retracted t 6 Stroke 423 5 16 67 602260 30 ...

Page 213: ...low 47 0 5 11 CI bolts kgf m lbf ft N m 63 7 6 9 e 38 43 Cap mounting Tightening torque 274 311 l 3 bolts kgf m lbf ft N m 373 422 Outer and 12 14 Tightening torque 4 inner plates kgf m lbf ft N m 87 lOll 01 118 137 mounting bolts 12 2 14 8 Tightening torque i 5 Swing bracket 88 2 107 0 0 mounting bolts kgf m lbf ft N m 119 6 145 1 7 6 9 2 6 Plate mounting Tightening torque 55 0 66 5l bolts kgf m ...

Page 214: ... hole to edge 75 2 95 end bits tip bit tip Cutting edge Tightening torque 6 5 0 7 2 mounting plow 47 0 5 11 kgf m Ibf ft N m bolts 63 7 6 9 lOA 1 0 0 Tightening torque 3 Trunnion 75 2 7 21 mounting bolts kgf m Ibf ft N m 102 0 9 8 15 8 1 6 0 Tightening torque 4 Trunnion cap fI14 3 11 6 mounting b olts kgf m IbHt N m 154 9 15 7 602264 602268 32 ...

Page 215: ...311 kgf m lbf ft N m 284 314 I 3 Cutting edges Width 159 6 26 120 4 72 e 3 5 0 3 j 4 Lock plate Tightening torque 25 3 2 2 mounting bolts kgf m lbf ft N m 34 3 2 9 g 0 100 0 175 0 600 5 35 1 38 0 00394 0 00 89 0 02362 Clearance of 0 600 0 200 0 275 J Q 6 each pin in 45 1 77 0 00787 0 01083 0 02362 bushing 0 130 0 219 0 600 7 50 1 97 0 00512 0 00862 0 02362 602261 2 3 602262 33 ...

Page 216: ...t 24 1 5 55 8 72 5 102 6 65 6 85 3 120 7 s 27 1 5 81 0 105 3 148 0 95 3 123 9 174 1 30 1 5 112 2 145 9 205 2 132 0 171 6 241 4 33 1 5 149 6 194 5 273 3 176 0 228 8 321 6 36 1 5 195 6 254 3 356 6 230 1 299 2 419 6 39 1 5 251 0 326 2 455 8 295 3 383 8 536 2 Nominal With spring washer Without spring washer size Pitch mm mm lw IW lW lw nw lW 10 1 5 3 4 4 4 6 9 4 0 5 2 8 1 12 1 75 6 0 7 8 11 8 7 1 9 2 ...

Page 217: ...I j I I I I ...

Page 218: ...DEC 86 Printed in Japan Pub No 99879 00120 3 ...

Page 219: ...SERVICE MANUAL MITSUBISHI TRACTOR B TRACTOR SHOVEL BS3G DIRECT DRIVE MODEL CONTENTS POWER TRAIN OPERATING PRINCIPLE TESTING AND ADJUSTMENTS ...

Page 220: ...I j I I I I ...

Page 221: ...annot be bought or manufactured they must be learned through the job you do By learning what CAUTION or WARNING symbol emphasizes know what is safe what is not safe Consult your forem an if necessary for specific instructions on a job and the safety equipment required NOTES CAUTIONS and WARNINGS NOTES CAUTIONS and WARNINGS are used in this manual to empha size important and critical instructions T...

Page 222: ... ...

Page 223: ...Transmission control 9 Steering clutches brakes and final drives 10 Steering clutch and brake controls I I Undercarriage J3 TESTING AND ADJUSTMENT Adjusting the steering clutches and brakes 18 19 19 20 Adjusting the brake pedal Adjusting the clutch pedal Adjusting the clutch brake Adjusting the tracks Troubleshooting guide w 21 ...

Page 224: ......

Page 225: ...OPERATING PRINCIPLE ...

Page 226: ...5 steering clutches 6 and final drives 7 including sprockets The engine and flywheel clutch are bolted together and are mounted on the frame 2 602163 I I 4 5 Bevel gear drive 6 Steering clutch 7 Final drive 602164 by a total of four mounts fitted with barrel shaped vibration insulating rubber pads The transmission selection of three reverse speeds is which provides a forward and two housed in an t...

Page 227: ... N W N 0 0 u j ii 1 1 i p OC W 0 ...

Page 228: ...I j I I I I ...

Page 229: ...l connected through a linkage to the release lever Clutch discs driven members 2 have checkered oil grooves to increase the torque capacity of the clutch in oiJ sprayed condition This wet clutch unlike a dry clutch tends to grab in disengagement due to presence of oil film between the driving and driven members To prevent this grabbing and to facilitate smooth engagement the discs are slightly dis...

Page 230: ...g the clutch discs and related parts Oil drawn by gear pump 2 through strainer 1 flows through relief valve 3 into oil cooler 4 where it is cooled and then into the oil bypass drilled in clutch main shaft 5 From this bypass the oil is sprayed over the friction surfaces of clutch discs 6 5 4 Oil eooler 5 Clutch main shaft 6 To and from steering valve 602166 ...

Page 231: ...ard and two reverse speeds The arrangement of its shifting and gearing is as shown above The bevel pinion shaft third carries three sliding gears These gears are shifted into mesh with three gears mounted on the countershaft second for forward ratio selection or with two gears on the input I shaft first for reverse ratio selection 7 1st speed drive gear 8 1st speed sliding gear 9 2nd speed sliding...

Page 232: ...ar 5 Counlershaft 6 Q Q I l l 2nd speed tH 1 i5 sliding gear 9 TBevel pinion I shaft 12 L _ _ _ 602170 Forward 3rd speed position I 8 Inputsha L I IftInpUI gear 4 1 I tL counter o I I hi gear 10 II J JLt e arII 00 r 1 1 0 _ I T TBevel pinion I _ J shaft 12 I 1 4 10 11 12 602171 Reverse 1st speed position 1 2 o T 0 602172 Rev rse 2nd speed position Input shaft 1 2nd speed I reverse gear 3 r IiiI 1 ...

Page 233: ...e forks is moved to shift the desired sliding gear on the third shaft into mesh with the gear on the countershaft or input shaft The control is provided with an interlocking mechanism involving spring loaded steel detent balls Because of this interlocking mechanism it is only possible to engage one gear reduction at a time For instance when 1st speed shift rail 7 is moved 2nd speed shift rail S an...

Page 234: ...disc steering clutch outer driven drum 9 is bolted to the flange of final drive pinIOn Inner driving drum 6 to the flange of drive sha ft 3 Friction plates 8 are engaged with the outer drum and disc plates 7 with the inner drum The stack of these plates is normally kept compressed by 10 spring loaded pressure transmit the power to involving pinion 11 and disengaged the pressure away from the stack...

Page 235: ...ngage the clutch When the lever is further pulled brake band 7 is contracted to brake outer drum 8 to interrupt the flow of power to the final drive 7 602178 Steering clutch in disengaged position 602180 6 Friction plate 7 Brake band 8 Outer drum 9 Brake pedal 10 Ratchet brake lock It is possible to disengage the steering clutch without braking for gradual turn or to disengage jt with braking for ...

Page 236: ...NG PRINCIPLE Steering clutch control hydraulic circuit 4 602181 2 6 7 602182 1 Relief valve 4 Oil cooler hose 6 Oil pump 2 Steering valve 5 Steering clutch lever 7 Steering clutch 3 Steering clutch cylinder 12 ...

Page 237: ...er 9 guides the track into position in front of the track rollers It rolls around and on shaft 3 which is rigidly held at both ends by bearings 4 Wear strips 7 are welded to the bearings they can be replaced when they are worn down to the limit The whole idler assembly is capable of sliding forward and backward on the rail strips on the top of track frame The idler is filled with gear oil which is...

Page 238: ...I j I I I I ...

Page 239: ...ting seal 9 Standard shoe 10 Master seal 11 Seal 12 Curved apex shoe Track roller 1 Collar 2 Floating seal 3 Thrust washer 4 Bushing 5 Shaft 6 Roller 602188 OPERATING PRINCIPLE Carrier roller 1 Fill vaJve 2 Stopper bolt 3 Cylinder 4 Cylinder shaft 3 6021 1 Cover 5 Shaft 2 Washer 6 Floating seal 3 Roller 7 Seal support 4 Bl shing Recoil spring and hydraulic adjuster cylinder 4 5 Spring retain er 6 ...

Page 240: ... I ...

Page 241: ...TESTING AND ADJUSTMENT ...

Page 242: ...ering clutch lever by means of clevis 5 so that it is 6 5 to 7 5 cm 2 9 16 to 2 15 16 in as measured from the end of instrument panel 18 B Adjusting the clearance between brake band and outer drum 1 Screw adjusting nut 6 all the way 2 Flack off the nut 2 2 3 rotations C Adjusting the stroke of steering clutch levers 1 Loosen lock nut 7 2 Set the stroke by means of clevis 8 so that it is 20 to 22 c...

Page 243: ...he pedal by means of clevis 4 so that it is 0 5 to LO cm 3 16 to 3 8 in NOTE Make sure that the RH and LH brakes are applied simultaneously TESTING AND ADJUSTMENT ADJUSTING THE CLUTCH PEDAL 4 3 5 1 1 Loosen lock nut 1 Unit em in 20 7 7 8 1 5 9 16 602194 2 Set the released position of the pedal by meanS of stopper bolt 2 so that it is 20 cm 7 7 8 in as measured from the dashboard wall 3 Loosen lock...

Page 244: ...oes not appear at the vent hole and the vent hole appears to be open and the track appears to have tension start the engine and move the machine back and forth slightly 4 If the track still appears to have tension even after such a backward and forward movement of the machine insert a wood block into between the sprocket and track and move the machine backward slightly This will strain the track t...

Page 245: ...d dutch shaft repair or replace 5 Dirty friction surfaces of Clean by washing clutch discs Clutch chatterS when Release bearing seized poorly Disassemble and repair disengaged lubricated or damaged lubricate Of replace Incomplete djsengage Oil is too viscous Change with oil of ment resulting in proper viscosity hard shifting Hard gear shifting on Clutch brake maladjusted or Adjust or replace trans...

Page 246: ...clutch 2 Shift lever or forks loose or Repair or replace worn 3 Foreign matter lodged Clean by washing between gears 4 Oil Viscosity too high Change with oil of proper viscosity 5 End faces of gear teeth Repair or replace damaged 6 Distorted or broken forks Repair or replace Noisy 1 Not enough oil or oil is dirty Add or change 2 Too much backlash Change gears 3 Worn damaged or rattling Adjust or r...

Page 247: ...too tight too loose Adjust or replace Raceways could be or damaged in cracked spalled or otherwise damaged condition 4 Bearings out of alignment Adjust Oil leakage I Too much gear oil or oil Remove excess oil Leakage of oil into viscosity too low to hold oil level as steering clutch side prescribed or change incapacitates this oil by one meeting device viscosity specification 2 Defective oil seal ...

Page 248: ...of disc plates 5 Weakened or broken clutch Replace Habitual half clutch springs operation tends to overheat clutch and thus weakens springs 6 Disc plates and friction plates Repair or replace Warped plates are warped usually a result of overheating for which habitual half clutch operation is usually to blame 7 Defective clutch cylinder See the topic Steering clutch cy1inder Clutch drags I Clutch o...

Page 249: ...brake J Maladjustment Adjust as prescribed Uneven or inade I quate band to drum clearance is likely to I result in overheating I Readjustment is necessary if pulling steering clutch lever just a little causes machine to turn 2 Return spring weakened Readjust or replace 3 Brake band distorted Repair or replace Steering valve Complaint Possible caUse Remedy Remarks Jerky movement 1 Foreign particles...

Page 250: ...g oil sampled out of drain point 2 Too much backlash Repair or replace Loose bearings or worn shaft promotes tooth wear resulting in excessive backlash 3 Worn or damaged shaft or Repair or replace teeth Overheating I Not enough gear oil wrong Add or change klnd of oil or dirty oil 2 Damaged bearings Replace Damage here means spalled or chipped bails rollers or race ways or broken cages Inspect bea...

Page 251: ...d front idler or of the track frame When check ing these for align ment check track frame too for mis alignment particu larly at its front end Side faces of sprockets I Track frame misalignment Realign frame wear relative to sprocket 2 Front idler mispositioned in Reposition and adjust Front idler track place or its wear strips idler or replace wear rollers and sprocket excessively worn strips whe...

Page 252: ... wavy fashion to rub roilers and sprocket if pins and bushings are worn down 5 Front idler and track rollers Repair or replace Track chain will oscil have too much axial play late sidewise to promote wear of flange parts of rollers if idler and rollers have too much sidewise play 6 Track links worn Repair or replace This rnalcondition Sec ure specified allows roller flanges linkheight to rub link ...

Page 253: ...tc 6 Bolts securing roller shaft Disassemble and bushings broken repair Abnormal noise from I Loose shoe bolts Retighten This retightening undercarriage should be carried out as early as possible otherwise the whole shoe assembly would fail beyond repair 2 Bolts securing roller shaft Retighten collar loose 3 Bolts securing roller shaft Disassemble and bushing broken or missing repair 4 Track pitch...

Page 254: ...ispositioned Relocate idler to correct position 3 Recoil spring insufficiently Adjust or replace preloaded or broken 4 Roller flanges worn Repair or replace Refer to Complaint Pront idlers track rollers and carrier rollers wear abnor mally 5 Abusive steering by operator Avoid backing and sharp turning on rough ground 6 Sprocket teeth worn Repair by welding 30 ...

Page 255: ...I j I I I I ...

Page 256: ...DEC a6 Printed in Japan Pub No 99879 00120 4 ...

Page 257: ...SERVICE MANUAL MITSUBISHI TRACTOR BD20 TRACTOR SHOVEL BS3G CONTENTS DIRECT POWERSHIFTTRANSMISSION OPERATING PRINCIPLE TESTING AND ADJUSTMENTS MAINTENANCE STANDARDS DISASSEMBLY AND REASEMBLY ...

Page 258: ...I j I I I I ...

Page 259: ...cannot be bought or manufactured they must be learned through the job you do By learning what CAUTION or WARNING symbol emphasizes know what is safe what is not safe Consult your foreman if necessary for specific instructions on a job and the safety equipment required NOTES CAUTIONS and WARNINGS NOTES CAUTIONS and WARNINGS are used in this manual to empha size important and critical instructions T...

Page 260: ......

Page 261: ...NG AND ADJUSTMENT DPS transmission 24 Adjusting the inching pedal 31 Adjusting the transmission control lever 31 Troubleshooting guide 32 MAINTENANCE STANDARDS DPS transmission 38 Transmission control valve 40 DISASSEMBLY AND REASSEMBLY DPS transmission 44 Removal and installation Disassembly and reassemb ly Transmission control valve 44 47 61 Transfer Bevel gear Damper 63 65 66 ...

Page 262: ... ...

Page 263: ... OPERATING PRINCIPLE ...

Page 264: ...OWER TRAIN 2 1 Engine 2 Damper 3 Universal joint 4 Transmission 5 Transfer 6 Bevel gear GENERAL DESCRIPTION 2 3 7 Steering clutch 8 Final drive gear 9 Track 10 Hydraulic pump 602306 602307 11 Transmission oil pump Power train ...

Page 265: ...eds and three reverse From the transmission output shaft power flows to the final drives right and left through transfer bevel gear and steering clutches right and left The tracks are driven by the sprockets of final drives The engine and damper are coupled together integrally and are mounted on the frame by four mounts fitted with barrel shaped vibration insulating rubber pads The transmission an...

Page 266: ......

Page 267: ...OPERATING PRINCIPLE POWER TRAIN Universaljolnt 3 Engine 1 Transmission 4 Damper 2 clutch 7 Transmission oil pump 1 Final drive 8 602308 j d T O 4 f 1 J ...

Page 268: ...I j I I I I ...

Page 269: ...e shaft and one of the friction plates is bolted to the flywheel The combination of coil springs and friction plates absorbs power impulse from the engine which would otherwise be transmitted directly to the gears in the transmission as when the engine is quickly accelerated or decelerated and shocks from the ground through power train OPERATING PRINCIPLE 002309 7 ...

Page 270: ...tch 8 Sun gear 15 Friction plate 2 Forward clutch 9 Planet gear 16 Return spring 3 3rd speed clutch 10 Ring gear 17 Bevel pinion 4 2nd speed clutch 11 Carrier 18 Gear pump 51st speed clutch 12 Piston housing 19 Oil filter 6 Input shaft 13 Piston 7 Output shaft 14 Mating plate 8 ...

Page 271: ...netary gear train each having a hydraulically controlled clutch pack control valve oil pump oil filter and their related parts The two planetary gear sets on the input side are for directional control forward or reverse drive and the remaining three sets on the output side are for speed selection 1st speed 2nd speed or 3rd speed drive plate Each planetary gear set comprises sun gear 8 planet gears...

Page 272: ...lates In forward 1st speed position forward clutch 2 and 1st speed clutch 5 are engaged Because forward ring gear 10 is locked power from input shaft 6 flows to carrier 11 through sun gear 8 From this carrier 11 the power flows to the sun gear of 1st speed clutch through carrier and then to output shaft 117 f1 In reverse position reverse clutch 1 is engaged In this case the reverse carrier is lock...

Page 273: ...ifferential valve IDifferential pressure 2 kgf cm 28 4 psi 0 20 MPa 8 Directional selector valve 9 Inching valve 10 5 kgf cm 0 71 psi 0 0 49 MPa 6 7 OPERATING PRINCIPLE 10 16 15 2 602318 10 Main relief pressure test port M 11 Speed clutch pressure test port liSII 12 Directional clutch pressure test port liDII 13 Oil cooler 14 Oil filter IBypass pressure 1 kgf cm 14 2 psi 0 10 MPa 1 15 Lubrication ...

Page 274: ...ross it exceeds 1 0 kgf cm 2 14 2 psi 0 10 MPa to maintain constant flow of oil to the lubrication circuit Lubrication relief valve 15 maintains the oil pressure in the lubrication circuit at 1 to 2 kgf cm2 14 2 to 28 4 psi 0 10 to 0 20 MPa for protection 4 6 12 The oil in the oil sump is lifted by oil pump 2 through suction strainer 1 Oil from the pump flows into two circuits one leading to the s...

Page 275: ...he directional clutch and the directional clutch serves to transmit the power 3 Directional selector valve 4 directs the oil to either forward clutch o OPERATING PRINCIPLE o 5 Inching valve 6 Differential valve 7 Neutral switch 602320 piston chamber or reverse clutch piston chamber 4 Speed selector valve 3 directs the oil to any of the 1st speed 2nd speed and 3rd speed clutch ports 5 Inching valve...

Page 276: ...mulator valve pressure chamber 4 14 Speed selector valve 3 is in neutral position covering the port leading to the 1st speed clutch piston chamber As the pressure rises in the chamber 4 accumulator valve 1 moves to the left to cover main port 2 Now a circuit through main orifice 5 is formed to allow the oil from the pump to flow into the chamber 4 for pressure accumulation This pressure accumulati...

Page 277: ...ion the pressure is being applied to the 1st speed clutch piston chamber but it is not applied to the forward clutch piston chamber yet Neutral 1st speed 2nd speed 3rd speed Reverse Forward OPERATING PRINCIPLE The moment the oil in accumulator valve pressure cham ber 4 enters the 1st speed clutch piston chamber for prefilling accumulator valve 1 returns to the right end to uncover main port 2 Now ...

Page 278: ...ves differential valve 7 to the left end allowing the speed clutch pressure oil to enter forward clutch pressure port CP through inching valve 8 11 Since accumulator valve 1 does not move yet keeping main port 2 uncovered the oil from the pump flows into the forward clutch piston chamber without being metered 1st speed JI 7 16 Main pressure Speed 1st clutch pressure 1i 1 Directional forward clutch...

Page 279: ...e 1st speed clutch circuit to move accumulator valve I slowly and to increase both forward and 1st speed clutch pressures gradually This is called modulation action 1st speed Fonvard OPERATING PRINCIPLE Since the speed clutch pressure is always higher than the directional clutch pressure the 1st speed clutch and forward clutch are engaged in that sequence This means that shock produced during shif...

Page 280: ...ating position This keeps the forward clutch pressure lower than the 1st speed clutch pressure by 2 kgf cm2 28 4 psi 0 20 MPa 7 18 In the operation for shifting into other speeds too differential valve 7 is returned to the right end of its stroke for draining the directional clutch pressure because the speed clutch pressure decreases in advance Susequent actions are the same as those described for...

Page 281: ... pushed to the left end of its stroke by return spring 2 Under this condition prImary pressure in passage 3 is admitted into secondary pressure passage 4 thus maintaining 21 kgf cm 2 299 psi 2 06 MPa pressure there 7 5 3 4 6 o 8 1 Plunger 2 Return spring 3 Primary pressure passage from differential valve o 4 Secondary pressure passage to directional selector valve OPERATING PRINCIPLE 2 5 Valve 21 ...

Page 282: ...anded is builtin the pressure chamber 6 1 r l C BIIID draining oil from passage 4 to the oil sump through passage 8 to reduce the directional clutch secondary pressure down to 5 kgf cm 2 71 psi 0 49 MPa 4 mm 0 16 in 5 kgf cm2 71 psi 0 49 MPa oL c _ 5 10 15 S Ioke mm 602327 decreasing secondary pressure PD2 Thus secondary pressure PD2 varies from 5 to o kgf cm 2 71 to 0 psi 0 49 to 0 MPa within the...

Page 283: ...the machine is brought into a complete stop as in neutral 4 6 7 o 8 o OPERATING PRINCIPLE In summary the inching pedal may be used like the clutch pedal of a direct drive model The machine can be started smoothly by depressing the inching pedal quickly all the way to the end of its stroke and then releasing it gradually to a position within the range of 4 to 16 5 mm 0 16 to 0 65 in of the stroke o...

Page 284: ......

Page 285: ...TESTING AND ADJUSTMENT ...

Page 286: ...hing pedal and transmission control lever linkages for adjustment 3 Operating the machine Get on the machine and operate it for testing During the test shift the transmission into all gears forward and reverse and operate the inching pedal If the machine fails to start smoothly or if inching or shifting is hard see Troubleshooting guide which follows Testing the clutches for slippage 1 Start the e...

Page 287: ...rt by All low not higher than strainer and pump between pump flushing or repair leaking point 10 kgf cm 142 psi and line fIlter or between filter 0 98 MPa 1 3 and control valve or leakage Main relief valve sticking Disassemble and clean No shift to all gears Neutral safety valve in malcondition Disassemble clean by washing and M port pressure Normal due to weakened spring foreign repair or replace...

Page 288: ... Accumuiator valve sticking Wash valve body check bore for I and from N to 2 but is normal damage and 3S necessary repJace in shifting from 1 to 2 and 2 to I valve and bore if they do not Indicating hand takes 2 seconds move sliding smoothly or more in deflecting from 0 to 2 Accumulator valve spring Replace 21 kgf cm 299 psi 2 06 MPa weakened Indicating hand takes longer I Accumulator valve sticki...

Page 289: ...sing causes machine NOTE If S mm 0 31 in dia rod Replace 3 piece spool as necessary to jerk in standing start is positioned the other way Be sure g mm 031 in dia rod is 1M and S port pressures around clulch valve will correctly positioned Normal D port pressure Rises but I not function properly not smoothly as pedal mOves in releasing direction Releasing inching pedal quickly Pilot valve sticking ...

Page 290: ...ssion parts 6 If output power is not enough Complaint Possible cause Remedy M D and US port pressures Oil level too low Add oil are low 1M D and S port pressures 1 Engine lacks power Tune up engine are normal 2 Mechanical trouble inside Overhaul and replace defective transmission parts 7 If oil pressures are high Complaint Possible cause Remedy M D and S port pressures I Main relief valve sticking...

Page 291: ...ansmission and control valve on the bench in order to break them in be sure to form an oil cooler bypassing circuit by connecting two rubber hoses one leading to the cooler inlet and the other from the cooler outlet 1 Main pressure M port 2 Speed clutch 1st speed 2nd speed and 3rd speed pressure S port 3 Directional clutch forward and reverse pressure D port TESTING AND ADJUSTMeNT 602330 29 ...

Page 292: ...F 1 8 connection with With engine running at high idling speed this clutch pressure O ring pressure is required to take the follOwing value okgf cm2 for both clutches with control lever in neutral 2 Not lower than main pressure by 2 kgflcm 28 4 psi 0 20 MPa with control lever in 1st 2nd or 3rd speed pOSition Speed clutch Sport PF 1 8 connection with Measure time required for pressure to change pre...

Page 293: ...rning clevis 5 so that lever 4 starts moving when the inching pedal is depressed 5 Loosen lock nut 6 6 Reposition stopper bolt 7 so that the pedal stroke is 14 5 cm 5 11 16 in TESTING AND ADJUSTMENT ADJUSTING THE TRANSMISSION CONTROL LEVER a a Clearance lever 1 0 02 to position 5 3 602332 NOTE a between guide 2 and should be 0 5 to 2 0 mm 0 08 in in any lever 1 Loosen lock nut 3 2 Turn rods 4 and ...

Page 294: ...s SAE lOW B Mechanical failure 1 Transmission shaft damaged Disassemble and replace 2 Seized or bound clutch piston Disassemble repair or replace friction plates or mating plates resulting in reduced clutch capacity 3 Friction plates or mating plates Disassemble and replace worn or damaged 4 Bevel gears or other gears defective Disassemble and replace C Neutral safety valve malfunctions Overhaul o...

Page 295: ...adjusted Readjust into neutral or remains 2 Burnt clutches Disassemble and replace burnt parts 3 Clutch piston friction plates or Disassemble repair or replace mating plates binding 4 Clutch valve seized resulting in no Disassemble repair or replace pressure drop 5 Oil level too high or too low Adjust to the prescribed level Abnormal oil temperature rise I Air being drawn into oil circuit Retighte...

Page 296: ...tions replace gaskets or add oil to oil pan 6 Not enough oil Add oil 7 Oil leakage from loose joint or Inspect and repair replacing connection O rings and seals as necessary Clutch oil pressure is abnormally 1 Main pressure too low Refer to the procedure imrne low when inching pedal is in I diately above released condition I Transmission responds too This is not a symptom it shows I slow to shifti...

Page 297: ...e I I 4 Shaft splines worn 0 Replace i 5 Gear tooth contact ineer 0 Readjust or replace I rect or teeth worn or I I damaged I Oil leakage i I Oil level too high i 0 Lower oilleve I i I 2 O rings damaged 0 Replace i 3 Oil seals damaged 0 Replace I I 4 Transfer case installation 0 Retighten or replace loose or packing defective packing Overheating i 1 Oil level too low 0 Add oil 2 Backlash too large...

Page 298: ......

Page 299: ...MAINTENANCE STANDARDS ...

Page 300: ...ss of fRfN Th k t 2 95 0 JO 2 4 I hf t Pressure plate IJl C2__ _1 1 o e os IC ness new par s I 0 1161 0 0039 0 0965 I eac nc IOn I thm 3 I plate 1 F r ee le ng t h 41 1 61 D ia m e te r j Return springs 13 5 0 531 5 of reverse clutch piston Test force length under 6 6 0 5 36 5 5 36 test force 14 6 1 1 1 42 12 1 142 kgf Ibf NJ mm in 64 7 4 9J 54 0J I I j 6 Free length Test force length under test f...

Page 301: ...MAINTENANCE STANDARDS 5 6 602311 602333 39 ...

Page 302: ...5 9 Accumulator Free length 151 0 5 945 4 valve spring Test force length under 50 4 5 0 1200 Diameter inner test force 111 1 11 47 24 I I 22 0 87 kgf Ibf N mm in 494 3 49 Free length 132 0 5 197 Accumulator 5 valve spring Test force length under 61 1 6 1 780 Diameter outer test force 134 7 13 5 3 071 31 1 22 kgf Ibf N mm in 599 2 59 8 Free length 78 0 3 071 6 Inching valve Test force length under ...

Page 303: ...MAINTENANCE STANDARDS I 8 602320 41 ...

Page 304: ......

Page 305: ...DISASSEMBLY AND REASSEMBLY ...

Page 306: ... 2 Drain the oil from the transmission 11 liters 2 9 U S gal approx 3 Drain the oil from the transfer arid bevel ger cases 7 liters 1 8 U S gal approx 1 Remove the following parts 1 Floor plates platform 3 pes 2 Electrical wire between battery switch and battery 3 Clamp for electrical wire between battery and starter 44 ...

Page 307: ...6 Steering clutch levers 7 Steering control rods 8 Brake control rods 31 kg 68Ib approx 9 Steering clutch oil pipes 2 pcs 10 Oil cooler pipe 11 Oil cooler hose 12 Springs 2 pcs 13 Inching control rod 14 Electrical wire for neutral switch DISASSEMBLY AND REASSEMBLY 602336 6 10 13 602338 45 ...

Page 308: ...rox Before lifting off the transmission shift it forward to pull the pInIOn back out of mesh with the bevel gear Installation To install the transmission follow the reverse of removing procedure and proceed as follows 1 Make sure that the electrical wires pipes and hoses are connected properly 2 Adjust the inching pedal Refer to the topics Adjusting the inching pedal TESTING AND ADJUSTMENT 3 Fill ...

Page 309: ...il filler and oil level gauge Remove the groups in the order listed below for disassembly A TransmissIon case and flange group B Reverse clutch group C Forward clutch group and 3rd speed clutch group D 2nd speed clutch group E 1st speed clutch group and cover group When disassembling the transmission place it on a workbench having a hole for admitting the output shaft and cover mounting bolts with...

Page 310: ...ansmission case NOTEl To remove transmission case 6 attach the hangers to its front face and lift it off with that face up Thread size of hangers MIO x 1 25 mm 2 Remove the following parts from case 5 7 Flange 8 Oil seal 9 Retaining ring 10 Ball bearing 11 Snap ring 12 Oil pump driven gear 13 Ball bearing 14 Retaining ring 15 Ball bearing 16 Retaining ring 48 t 4 6 5 602343 602344 7 8 i t l0 60234...

Page 311: ...Piston 13 Piston seal 14 Piston seal 15 Input shaft DISASSEMBLY AND REASSEMBLY 16 Ball bearing 17 Ring gear 18 Reverse planet carrier 26 602346 to be removed as an assembly including 19 thru 24 19 Seal ring 20 Spring pin 3 pes 21 Pin 3 pes 22 Planet gear 3 pes 23 Thrust plates 6 pes 24 Needle roller bearing 3 pcs 25 Ball bearing 26 Reverse clutch piston housing Remove the parts in the order number...

Page 312: ... 27 Piston 9 Snap ring 28 Piston seal 10 Bolt 9 pes 29 Piston seal 11 Forward 3rd speed clutch piston housing 30 Pin 5 pes to be removed as an assembly including 31 Ball bearing 12 thru 30 32 Ball bearing 12 Spring pin 3 pes 33 Snap ring to be removed as an assembly including 34 Pressure plate 13 thru 23 35 Return spring 5 pes 13 Pin 3 pes 36 Friction plates 3 pes 14 Planet gear 3 pes 37 Mating pl...

Page 313: ...ssure plate 6 Return spring 5 pcs 7 Friction plates 2 pcs 8 Mating plates 2 pcs 9 Snap ring 10 Snap ring 11 2nd speed planet carrier to be removed as an assembly including 12 thru 17 12 Spring pin 3 pcs 13 Pin 3 pcs 14 Planet gear 3 pcs 15 Thrust plate 6 pcs 16 Needle roller bearing 6 pcs 17 Ball bearing 18 Ring gear Remove the parts in the order numbered for disassembly 602348 51 ...

Page 314: ...pes 8 Mating plates 2 pes 9 Oil seal retainer 10 Oil seals 2 pes 11 Retaining ring 12 Snap ring 13 Output shaft 14 Ball bearing 602349 15 Retaining ring 16 1st speed planet carrier to be removed as an assembly including 17 thru 23 17 Ring gear 18 Spring pin 3 pes 19 Pin 3 pes 20 Planet gear 3 pes 21 Thrust plates 6 pes 22 Needle roller bearing 3 pes 23 Seal ring 24 Ball bearing 25 Cover Remove the...

Page 315: ...tch I 21 57 0 62 plates 0 8492 O 0244 Friction plates 3 pcs 20 40 0 8031 Mating plates 3 pcs il Pressure plate 1 pc Assembled totai I thickness of 2nd and 1st speed clutch plates Friction plates 2 pes Mating plates 2 pes Pressure plate 1 pc Thickness of friction plate 2 Thrust plates 15 44 O 44 14 60 0 6079 O OI73 0 5748 2 95 0 10 2 45 0 1 161 0 0039 0 0965 Measure the thickness plate Replace the ...

Page 316: ...nsmission install the groups in the reverse order IIE thru A E 1st speed clutch group and cover group 19 1B 21 20 23 25 Reassembling order I 12 14 I 24 I 23 r 21 22 20 54 13 L r r16 19 18 9 10 12 11 15 14 24 4 3 10 9 LL2 rrLrrrrrL 15 11 17 8 7 6 5 602352 1 25 1 ...

Page 317: ...DISASSEMBLY AND REASSEMBLY D 2nd speed clutch group 7 18 17 14 13 602353 Reassem bling order 18 L r r r r r r r r r r Transmission case r r r r 11 17 10 9 8 7 5 2 1 15r14 13 1 2 4 r 16 I 55 ...

Page 318: ...and 3rd speed clutch group 543287623 11 24 J1 25 26 28 29 27 34 35 Reassem bling order 23 22 33 9 14 6 2625 LL24 12 8 20 602354 21 19 16 14 rrrrrrrrr rLrrrrrrrrrI gsmission rrrrrLrrrLrr22389 137363534 30 87611105234 2332333120 181715 1312 rr27 2829 56 ...

Page 319: ...DISASSEMBLY AND REASSEMBLY B Reverse clutch group 602333 Reassem bling order Transmission case rrrrrrrrrrrrrrrrr 15 rrr r18 16 24 I 11 17 9 8 10 2 I 25 4 5 3 6 1 23 I 21 26 rr12 19 7 20 22 14 13 57 ...

Page 320: ...p 602368 Reassembling order r rrr rrrTransmission case rrrrrrr r6 7 2 1 3 5 4 9 10 8 14 15 16 13 I 11 12 Tips for reassembly 1 Apply a coat of engine oil to the 0 ring of oil filter screw 2 Bend each lock washer properly against the flat of bolt 58 4 602333 602356 ...

Page 321: ... oil SAE lOW to the sliding surface of each piston seal before installing the seal to the clutch piston 5 Piston housing installation Install the piston housings 5 pcs with their recessed portions alined as shown This illustration shows the piston housings viewed from the engine side 6 Oil seal installation to retainer Install the oil seal to the retainer as shown I DISASSEMBLY AND REASSEMBLY o x ...

Page 322: ...the transmission case to make sure that the clutch pistons move smoothly in the housings A Oil hole for reverse clutch B Oil hole for forward clutch C Oil hole for 1st speed clutch D oii hole for 2nd speed clutch E Oil hole for 3rd speed clutch Air pressure 60 2 3 kgf cm 28 4 42 7 psi 196 294 kPa 602361 ...

Page 323: ...body 2 Roller pin 3 Plug 4 Relief valve 5 Slug 13 Outer spring 25 Inching valve 14 Inner spring 26 Slug 15 Pin 3 pcs 27 Spring 16 Plug 2 pcs 28 Cover 17 Spring 2 pcs 29 Spring 602362 6 Inner spring 7 Outer spring 8 Roller pin 18 Detent ball 2 pcs 30 Inching valve plunger 9 Plug 10 Cover 11 Accumulator piston 12 Seat 19 Cover 31 Roller pin 20 Speed selector plunger 32 Plug 21 Spring 33 Oil seal 2 p...

Page 324: ... seals by alkali washing before installing them for reassembly 8 9 o 7 6 4 5 o 0 32 0 0 Reassembling order 62 15 1 35 19 r r r r r 1 1 9 8 7 6 4 5 2 3 II r rrri 1011121314 c J 33 20 16 15 17 18 r r r r r 33 23 32 31 22 21 rrrrrr 30 29 27 25 26 24 34 28 12 1 10 33 23 28 29 602320 ...

Page 325: ...er 2 Washer 3 Cover 4 Bearing cage 5 Shims 1 set 6 Shim 1 set 7 Snap ring 8 Roller bearing 4 8 3 DISASSEMBLY AND REASSEMBLY 12 11 14 9 Driven gear 10 Bevel pinion 11 Roller bearing 12 Drive gear 13 Ball bearing 14 Ball bearing 15 Case 602364 Remove the parts in the order numbered for disassembly 63 ...

Page 326: ...DISASSEMBLY AND REASSEMBLY Reassembly 3 15 13 t IC 1 14 12 4 9 2 1 10 8 7 5 6 11 602369 Reassem bling order r qrrrTfTTT 10 11 rr4 8 7 64 ...

Page 327: ...his distance into 0 1 mm 0 004 in of the specification the thickness of shims 58827 10900 and 58827 11000 must be adjusted The shims are available in these thicknesses Unit mm in Part number Shim thicknesses 58827 10900 0 1 0 004 0 4 0 016 1 0 0 039 58827 11000 0 1 0 004 0 4 0 016 1 0 0 039 Shim DISASSEMBLY AND REASSEMBLY Value of urn marked here thickness i JI Specifi d distance 46 2 mm m 100 0 1...

Page 328: ... DISASSEMBLY and REASSEMBLY volume except for the following items 1 Clutch control rod 2 Rubber hose for steering clutch oil 3 Rubber hose for oil cooler flywheel clutch group InstaIlation To install the damper follow the reverse of removing procedure Disassembly 7 8 1 Drain plug 2 Flange 5 Damper cover 6 Shaft 66 3 Air breather 4 Connector 7 Ball bearing 8 Snap ring 5 9 Oil seal 10 Damper 602367 ...

Page 329: ...DISASSEMBLY AND REASSEMBLY Reassembly 9 2 602309 Reassem bling order J PTfEngine rrr5 3 4 8 7 9 67 ...

Page 330: ... ...

Page 331: ...I j I I I I ...

Page 332: ...DEC a6 Printed in Japan Pub No 99879 00120 5 ...

Page 333: ...SERVICE MANUAL MITSUBISHI TRACTOR D G TRACTOR SHOVEL CONTENTS HYDRAULIC SYSTEM OPERATING PRINCIPLE TESTING AND ADJUSTMENTS ...

Page 334: ...I j I I I I ...

Page 335: ...not be bought or manufactured they must be learned through the job you do By learning what CAUTION or WARNING symbol emphasizes know what is safe what is not safe Consult your forem an if necessary for specific instructions on a job and the safety equipment required NOTES CAUTIONS and WARNINGS NOTES CAUTIONS and WARNINGS are used in this manual to empha size important and critical instructions The...

Page 336: ... ...

Page 337: ... valve 19 19 20 TESTING AND ADJUSTMENT BD2G Tractor 24 Testing cylinder rods for drift 24 Testing lift cylinders for blade holding ability BD2G PAT PT 25 Testing cylinders for actuating speed 25 BS3G Tractor Shovel 27 Testing cylinder rods for drift 27 Testing cylinders for holding ability 29 Testing cylinders for actuating speed 29 Adjusting main relief valve 31 Adjusting safety valve 31 Troubles...

Page 338: ... ...

Page 339: ...OPERATING PRINCIPLE ...

Page 340: ...ng valve plunger Check valve Tilt valve plunger Makeup valve Check valve Lll Hydraulic Hlter 602195 BD2a PAT hydraulic circuit diagram Tilt cylinder Lift cylinder Lift valve plunger Tilt valve plunger v v Check valve Makeup valve Safety valve 200kgf cm 2844 psi 19 6 MPaJ J 2 Check valve Lift cylinder Main relief valve M 180kgf cm 2560 psi 17 7 MPaJ Hydraulic filter Hydraulic pump 602196 BD2a PT hy...

Page 341: ...ve lr B2lf Ii Safety valve A2 4 1IIIDi I f _160 kgf cm Lift cylinder B1 2275 psi 15 7 MPa Dump cylinder Check valve A1 tJ Makeup valve Check valve Lift valve plunger Main relief valve M 180 kgf cm 2560 psi 17 7 MPa A U _ Hydraulic ftiter Hydraulic pump 602197 BS3a hydraulic circuit diagram 3 ...

Page 342: ...g valve plunger section 4 End plate 5 Main relief valve 180 kgf cm 2 2560 psi 17 7 MPa 6 Makeup valve 3 1 4 T Tank port P Pump port A1 Lift cylinder rod side B1 Lift cylinder head side A2 Tilt cylinder head side B2 Tilt cylinder rod side A3 Angling cylinder 602198 RH rod side and LH head side B3 Angling cylinder RH head side and LH rod side ...

Page 343: ...OPERATING PRINCIPLE Control valve sections 602199 Lift valve plunger section A2 A3 o o 602200 Tilt angling valve plunger section 1 Plunger 3 Makeup valve 2 Main relief valve 5 ...

Page 344: ...OPERATING PRINCIPLE I Lift valve plunger in pulled out RAISE position tAl 602201 l Lift valve plunger in pushed in LOWER position 602202 6 ...

Page 345: ...OPERATING PRINCIPLE Lift valve plunger in pushed in FLOAT position 602203 7 ...

Page 346: ...lung r in pushed in RIGHT TILT position Angling valve plunger in pushed in LEFT ANGLING position o o Tilt valve plunger in pulled out LEFT TILT position Angling valve plunger in pulled out RIGHT ANGLING position 82 83 o o 602204 602205 ...

Page 347: ...ion 3 End plate 4 Main relief valve 1180 kgf cm 2560 psi 17 7 MPaJ 5 Safety valve 200 kgf cm 2844 psi 19 6 MPaJ 6 Makeup valve OPERATING PRINCIPLE 1 3 5 T Tank port P Pump port 2 A1 Lift cylinder rod side B1 Lift cylinder head side A2 Tilt cylinder head side B2 Tilt cylinder rod side 602206 9 ...

Page 348: ...OPERATING PRINCIPLE Control valve sections Lift valve plunger section A2 82 o o Tilt valve plunger section 1 Plunger 2 Main relief valve 3 Safety valve 4 Makeup valve 10 602207 602208 ...

Page 349: ...OPERATING PRINCIPLE It Lift valve plunger in pulled out RAISE position Q Bl 602209 J f Lift valve plunger in pushed in LOWER position 602210 11 ...

Page 350: ...OPERATING PRINCIPLE k Lift valve plunger in pushed in FLOAT position t 602211 I j 12 ...

Page 351: ...OPERATING PRINCIPLE Tilt valve plunger in pushed in RIGHT TILT position o o 602212 Tilt valve plunger in pulled out LEFT TILT position B2 o o 602213 13 ...

Page 352: ...ion 3 End plate 4 Main relief valve 180 kgf cm 2560 psi 17 7 MPa j 5 Safety valve 1160 kgf cm 2275 psi 15 7 MPa 1 6 Safety valve 1200 kgf cm 2844 psi 19 6 MPa 1 7 Makeup valve 6 T Tank port P Pump port A1 Lift cylinder head side B1 Lift cylinder rod side A2 Dump cylinder rod side B2 Dump cylinder head side 602214 ...

Page 353: ...Control valve sections A1 81 Lift valve plunger section Dump valve plunger section 1 Plunger 2 Main relief valve 3 Safety valve 4 Makeup valve OPERATING PRINCIPLE 2 602199 4 602215 15 ...

Page 354: ...OPERATING PRINCIPLE Lift valve plunger in pulled out RAISE position 602201 Lift valve plunger in pushed in LOWER position 602202 16 ...

Page 355: ...OPERATING PRINCIPLE Lift valve plunger in pushed in FLOAT position 602203 17 ...

Page 356: ...OPERATING PRINCIPLE Dump valve plunger in pulled out ROLLBACK position 602216 Dump valve plunger in pushed in DUMP position 602217 18 ...

Page 357: ...k port creating a large pressure difference across valve 1 OPERATING PRINCIPLE Relieving action P T BAD 600057 Because of the pressure difference drop of the pressure in cham ber A occurring because pilot valve port D is larger than orifice B valve 1 slides to the right thereby opening tank port T through which a large amount of oil flows into the tank to lower the line pressure SAFETY VALVE This ...

Page 358: ...r from moving erratically a Makeup valve for dump cylinder Normal closed state 2 600401 1 Valve 2 Spring 20 C Cylinder port T Tank port Making up action T 600402 Valve I is kept clo sedby the force of spring 2 and hydraulic pressure acting on it When an external force acts on the cylinder to move it faster as in LOWER position the pressure in the circuit leading to cylinder port c drops lower than...

Page 359: ...afety valve 1 in that port will be forced to open thereby bleeding out the excess pressure Now such a pressure rise means that the cylinder piston is moved by an external force and that B 1 Safety valve 2 Makeup valve 602272 because the piston will move slightly the pressure in port A drops to create a vacuum condition Under this condition the makeup valve on that side acts to admit some make up o...

Page 360: ......

Page 361: ...TESTING AND ADJUSTMENT ...

Page 362: ...602221 With the front end of the machine raised as in Test 1 stop the engine move the control lever to LOWER and observe the retraction of each lift cylinder rod 24 B Blade tilt cylinder BD2G PTA PT Test 1 Raise the front end of the machine with the blade tilted left move the control lever to NEUTRAL stop the engine and observe the retraction of tilt cylinder rod Test 2 Raise the front end of the ...

Page 363: ...er rod TESTING AND ADJUSTMENT TESTING LIFT CYLINDERS FOR BLADE HOLDING ABILITY BD2G PAT PT NEUTRAL o o e o 602222 Raise the blade until the C frame is parallel to the ground move the control lever back to NEUTRAL stop the engine and measure the extension of lift cylinder rod Rod extension 20 nun 0 8 in max in 5 minutes at oil temperature 30 to 40 C 86 lb 104 F TESTING CYLINDERS FOR ACTUATING SPEED...

Page 364: ...ling circuit actuating speed test Specification Time required for alteriog raised blade from right or left angling to left or right angliog 5 4 sec D Blade lift cylinders BD2G PT Test 1 lift circuit actuatiog speed test I Time required for raisiog blade to maximum height from ground Test 2 Lift circuit actualiog speed lest 2 Time required for allowing blade 10 lower to ground from maximum height w...

Page 365: ...engine move the control lever back to NEUTRAL and observe the retraction of lift cylinder rod Test 4 602229 Fill up the bucket with material raise the bucket to maximum height stop the engine move the control lever to RAISE and observe the retraction of lift cylinder rod Test results Possible cause In Test I alone lift Makeup valve in rod side cylinders yield to load circuit is leaky and extend In...

Page 366: ...ngine move the control lever to DUMP and observe the retraction of dump cylinder rod 28 Test 3 G Zt R e traction 602232 Fill up the bucket with material raise the bucket until the arms become nearly parallel to the ground move the control lever to NEUTRAL stop the engine and observe the retraction of dump cylinder rod Test 4 Retraction 602233 Fill up the bucket with material raise the bucket until...

Page 367: ... FOR HOLDING ABILITY A Bucket lift cylinders Retraction 602234 Raise the bucket fully move the control lever to NEUTRAL stop the engine and measure the retraction of ift cylinder rod Rod retraction 5 mm 0 20 in max in 5 minutes at oil temperature 30 to 40 C 86 to 104 F TESTING AND ADJUSTMENT B Bucket dump cylinders 602235 Raise the bucket fully dump it until its cutting edge is parallel to the gro...

Page 368: ...lowering empty bucket to ground from maximum height with control lever in LOWER 30 Specification IS 7 sec 602237 Specification 3 9 sec 602238 Specification S 3 sec B Bucket dump cylinders Run the engine at minimum speed low idling speed 602277 Dump circuit actuating speed test D Specification Time required for dumping empty bucket fully from full rollback position with lift cylinders fully extende...

Page 369: ...FETY VALVE Safety valve location Setting BI 2G PT AI port in lift 200 kgf cm 2844 psi cyJinder rod side circuit 19 6 MPa BS3G B2 port in dump 160 kgf cm 2275 psi cylinder head side circuit 15 7 MPa BS3G A2 port in dump 200kgf cm cylinder rod side circuit 2844 psi 19 6 MPa 2 0000 600399 1 Install a test pressure gauge on each port Pressure gauge range 2 Loosen lock nut 1 oto 250 kgf cm 0 to 3555 ps...

Page 370: ... in tank Add enough oil 2 Oil viscosity too heavy Change oil 3 Pump speed low Disassemble and inspect 4 Pump performance low Disassemble and inspect 4 Cylinder motion slow I Pump not delivering enough oil because of a Worn pump parts Replace b Improperly assembled pump Reassemble 2 Cylinder piston seals defective Replace 3 O ring seals in circuits defective Replace 5 Cylinder motion erratic 1 Pist...

Page 371: ...mounting seats distorted Repair 3 Cutting edges and I Cracks distortion or dents Repair or replace end bits 2 Abnormal wear Repair or replace 4 Frame I Twist cracks distortion dents or Repair or replace broken welds 2 Pin holes and trunnion bearings pr Replace worn 5 Trunnions PT I Abnormal wear Repair or replace 2 Mounting bolts loose or damaged Retighten or replace 6 Braces PT I Distortion or we...

Page 372: ... ...

Page 373: ...I j I I I I ...

Page 374: ...DEC 86 Printed in Japan Pub No 99879 00120 6 ...

Page 375: ...SERVICE MANUAL MITSUBISHI TRACTOR B28 TRACTOR SHOV EL BS3G CONTENTS POWER TRAIN DISASSEMBLY AND REASSEMBLY ...

Page 376: ...I j I I I I ...

Page 377: ...ot be bought Or manufactured they must be learned through the job you do By learning what CAUTION or WARNING symbol emphasizes know what is safe what is not safe Consult your foreman if necessary for specific instructions on a job and the safety equipment required NOTES CAUTIONS and WARNINGS NOTES CAUTIONS and WARNINGS are used in this manual to empha size important and critical instructions They ...

Page 378: ......

Page 379: ...l clutch 7 Direct drive DD transmission Steering clutches and brakes 17 26 Steering valve 38 Final drives 40 Undercarriage 44 Front idlers 45 Recoil springs and hydraulic adjuster cylinders 47 Track rollers 51 Tracks 54 Track carrier rollers 57 Special tools 60 ...

Page 380: ...I 1 ...

Page 381: ...fted 2 Drain the coolant 13 liters 3 4 U S gal approx 3 Raise the bucket fully and support the lift cylinders there by the brackets to prevent the bucket from lowering accidentally Lower the bucket to the ground after removing the radiator guard and side covers BS3b 4 Disconnect the hoses and pipes from the blade tilt cylinder BD2G PT 1 Front guard 2 Rubber hoses 2 pcs 3 Shield rubber 4 Clamp 5 Pi...

Page 382: ...e for access to the bolts 2 Remove the following electrical wires and parts on and around the engine 8 Oil pressure switch wire 9 Thermo switch wire 10 Alternator wire 11 Hydraulic rubber hoses 2 pcs NOTEl Before disconnecting the wires mark them for the components to which they are to be reconnected at the time of installation 12 Air cleaner indicator wire 13 Glow plug wire 14 Stop solenoid wire ...

Page 383: ...arts 19 Muffler 20 Air cleaner 21 Clutch control rod 4 Remove the following parts 22 Steering clutch oil rubber hoses 2 pes 23 Oil cooler rubber hoses 2 pes 24 Electrical wire by loosening clamps ENGINE DISMOUNTING AND MOUNTING 3 ...

Page 384: ...lifting slings to the engine hitching bolts 27 Remove the castle nuts washers and bolts 28 Lift off the engine and flywheel clutch 4 NOTE To leave the engine proper alone remove the following parts a Flywheel clutch b Hydraulic pump Weight of engine and flywheel clutch assembly 602376 340 kg 750 lb approx ...

Page 385: ... side and shim 3 and washer 4 on top side 2 Check to make sure that clearance A between the bottom end of mount bracket and washer 2 is 1 8 to 2 8 mm 0 07 to 0 11 in If this clearance is zero 0 at one or more brackets replace all brackets 3 With mount bolt 5 in place see if clearance B is 1 2 to 2 2 mm 0 05 to 0 09 in if not reduce or increase the thickness of shim 3 to set the clearance within th...

Page 386: ...O 24 in thickness Shims 58611 02500 64361 74611 I mm O 04 in thickness 64361 74612 0 5 mm O 02 in thickness 64361 17516 o 5 mm O 02 in thickness 3 After mounting the engine and clutch on the frame 1 Make sure that the electrical wires pipes and hoses are connected properly 2 Adjust the clutch pedal Refer to TESTING AND ADJUSTMENT volume 3 Adjust the engine control 4 Fill the engine and clutch with...

Page 387: ...e refer to the topic ENGINE DISMOUNTING AND MOUNTING Disassembly of the clutch on the machine Preparatory steps 1 Remove the under guard 2 Drain the oil from the clutch 5 5 liters 1 5 U S gal approx 1 Remove the following parts 1 Floor plate platform center 1 pc 2 Steering clutch levers 2 pcs 3 Steering control rods 2 pcs 4 Brake control rods 2 pcs 5 Clutch control rod 1 pc 602445 7 ...

Page 388: ... top of clutch case 9 Attach hook A in that threaded hole and lift off the case 4 Unscrew the bolts securing the clutch case and move the case backward until it is possible to pull the main drive shaft out of the clutch cover 8 NOTEj Shift the lifting sling from hook A to attached to one of the bolt holes hitching point shackle B case mounting NOTEj Remove the universal joint together with the fla...

Page 389: ...ine flywheel refer to the topic Disassembly Reassembly To reassemble the clutch follow the reverse of disassembling procedure Disassembly of the clutch dismounted with the engine Relief valve removal and installation 1 Remove the following parts 1 Pipe 2 Bracket 3 Relief valve 4 Block 2 When installing the valve to the block apply a coat of oil to the O ring of the oil pump side connector FLYWHEEL...

Page 390: ...ng 5 thru 45 26 Needle roller bearing including 47 thru 56 5 Suction pipe 27 Shaft 47 Lock plate 6 Oil pump 28 Oil seal 48 Nut 7 Filter cover 29 Needle roller bearing 49 Return spring 8 Filter 30 Release lever fork 50 Pressure spring 9 Filter case 31 Bearing 51 Pin 10 Adjusting bolt 32 Bearing 52 Release lever 11 Pin 33 Release hub 53 Pin 12 Clevis 34 Bushing 54 Lever support 13 Brake band 35 Cove...

Page 391: ...t B into each clutch spring hole Tighten the guide bolts to compress the clutch springs lightly and remove the pressure plate assembly lnspection 1 Clutch discs Measure the face runout facing wear and fit of hub splines Replace the disc if any of these measurements exceeds the service limit Unit mm in Item Assembly standard Service limit 0 4 0 016 for Thickness 5 7 6 3 one side of facing 0 224 0 2...

Page 392: ...exceeds the service limit Item Assembly standard Thickness of 20 2 0 795 friction surface Flatness 0 05 0 15 0 0020 0 0059 4 Mating plates Unit mm in Service limit 68 5 2 697 39 2 86 4 384 41 48 2 1 898 3 min wear of the the pressure measurements Unit mm in Service limit 19 7 0 776 max 0 30 0 0118 Measure the flatness and wear of the friction surface Replace the rnating plate if any of these measu...

Page 393: ...n in Item Assembly standard Service limit Backlash 0 35 0 42 0 70 0 0276 0 0138 0 0165 min 6 Brake band Measure the thickness of the facing Replace the band if the measurement exceeds the service limit Unit mm in Item Assembly standard Service limit Thickness of 5 0 0 197 3 0 0 118 facing max FLYWHEEL CLUTCH 602384 602385 13 ...

Page 394: ...7 kgf m 12 3lbf ft 16 7 N m 5 602386 Reassembling order r r r r r r 56 1 1 1524950554847 L 515453 r r r r rlllr r r r r r r 1 1 r r rr l Flywheel 595857 46 765321918121011141320211716151 rr 14 r r r42 4143 r4 444544 r r r rrr 40 3539383734 1 1 33 32 31 ...

Page 395: ...eight INOTE Support the dial gauge solidly to retain the original setting 2 Install the clutch disc mating plate clutch disc and clutch cover assembly in that order on flywheel C or the jig Then remove guide bolts B 3 Point the dial gauge spindle to the tip of release lever read its indication and tighten or loosen the lever nut until the gauge indicates 0 mm After repeating this process on the ot...

Page 396: ...r to clutch cover 55 with bolt 3 Split pin installation Insert the split pin into release lever 30 in parallel with the shaft and spread its ends properly to avoid interference with the pump drive gear 4 Oil seal installation Apply a coat periphery of installation 16 of ThreeBond 1104 to the oil seal 36 before r n L0 J r 602388 ...

Page 397: ...el gear case 9 5 liters 2 5 U S gaD approx 1 Remove the following parts 1 Floor plate platform center 1 pc 2 Electrical wir e between battery switch and battery 3 Clamp for electrical wire between battery and starter 4 Operator s seat and seat plate 5 Rear cover Weight of operator s seat and seat plate 31 kg 68Ib approx 1 l 2 3 17 ...

Page 398: ...g parts 9 Steering clutch oil hoses 2 pes 3 Remove the following parts 10 Universal joint 11 Transmission Weight ofuniversal joint Weight of transmission NOTEj 2 kg 41b approx 73 kg l611b approx Before lifting off the transmission shift it forward to pull the pIllion back out of mesh with the bevel gear 18 602337 602389 602390 ...

Page 399: ...hoses are connected properly 2 Fill the transmission case and bevel gear case with recommended oil Disassembly Remove the groups in the order listed below for disassembly A Gearshift lever transmission control lever group B Main drive shaft input shaft group C Shift fork group D Countershaft group E Bevel gear shaft group DIRECT DRIVE DD TRANSMISSION 19 ...

Page 400: ...ver case A9 Transmission cover 20 89 88 J l 85 810 2J 815 86 83 813 parts in the order numbered for disassembly B1 Flange to be removed as an assembly including B2 B2 Plug B3 Cover to be removed as an assembly including B4 B4 Oil seal B5 Lock nut B6 Lock washer B7 Spacer to be removed as an assembly including BS thru B14 BS Input gear B9 2nd speed reverse B10 Spacer B11 1st speed reverse B12 Space...

Page 401: ... in the order numbered for disassembly C19 1st speed shift fork 013 Snap ring to be removed as an 014 Ball bearing assembly including C20 thru C22 C20 Spring retainer C21 Spring C22 Plunger 01 Cover 02 Washer 03 Washer 04 Spacer to be removed as an assembly including 05 thru 012 05 Counter gear 06 Spacer 07 2nd speed drive gear 08 Spacer 09 1st speed drive gear 010 Spacer 011 Roller bearing 012 Co...

Page 402: ... case in the following directions 1 Drive off input shaft main drive shaft B14 to the steering clutch case side 2 Drive off countershaft D12 to the steering clutch case side 3 Drive off bevel pinion shaft E12 to the universal joint side 3 Bevel pinion shaft bearing cage removal Using jacking bolts remove bearing cage E3 together with bearing ES and shim E4 4 Bevel pinion shaft bearing removal Remo...

Page 403: ...pring Replace the spring if any of these measurements exceeds the service limit Unit mm in Item Assembly standard Service limit Free length 62 2 44 60 5 2382 Test forcel 9 80 0 49 7 5 length under 21 61 L08 16 5 test force 96 11 4 8IJI 73 5JI kgf lbf NJI 55 2 1 7 55 2 17 mm in 3 Gear backlash Measure the backlash of gears Replace the gears if the measurement exceeds the service limit Unit mm in It...

Page 404: ...eassembling order r r r r r r r r r r r r r r r r r r E3E5 I E8 E7 E6 E2 E4 El I 01009 08 07 06 0504 014 013 03 01 II EI2 1 1 0 12 EllEl0E9 01102 r r r r r r Transmission I 87 88 89 81 0 81 1 81 2 81 3 83 84 81 82 case I I r l 8 1 4 816815 I 85 86 24 ...

Page 405: ... in NEUTRAL 2 Bevel pinion shaft installation 1 Measure dimension L from the end face of pinion to that of transmission case making sure that it is as specified below L 46 2 0 1 mm 1 819 0 004 in 2 The standard value of this dimension is indicated on the end face of pmlOn Referring to that value increase or decrease the thickness of shim E4 to be fitted to pinion shaft EI2 on the opposite side of ...

Page 406: ...e the tracks unless they engage the sprockets Refer to the topic Removal TRACKS 1 Disconnect the following electrical wires 1 Wire between battery switch I1ld battery 2 Clamp for wire between battery and starter 2 Remove the following parts i Floor plate 2 Operator s seat and seat plate 3 Rear cover 3 Remove the following parts 1 Steering control rods 2 pcs 2 Brake control rods 2 pcs 3 Springs 4 p...

Page 407: ...Steering clutch oil pipes 4 pcs 5 Levers 2 pcs 6 Bracket 7 Steering valve 8 Cover 9 Cover 10 Shaft 11 Spring 12 Steering brake mounting bolts 4 pcs 13 Bracket STEERING CLUTCHES AND BRAKES 602401 602402 27 ...

Page 408: ...shown 5 Hold the clutch pedal in depressed position and place the gearshift lever in forward 1st position 6 Unscrew bolts 14 and 15 securing the steering clutch brake assembly To do this turn the splined portion of transmission input shaft S to rotate that assembly to remove the bolts one by one 7 Remove the following parts 14 Mounting bolts 15 Mounting bolts A Steering clutch brake assembly 28 60...

Page 409: ... are connected properly 2 Fill the bevel gear case and transmission case with recommended oil Tips for steering clutch brake assembly and cylinder assembly removal These assemblies can be taken out of the steering clutch case with the operator s seat tilted forward by removing bracket 13 and its related parts without removing the operator s seat and seat plate STEERING CLUTCHES AND BRAKES 1 B 6024...

Page 410: ...9 A2 Lever to be removed as an assem bly including A3 thru A5 A3 Spring pin 30 parts in the order numbered A4 Pin A5 Roller A6 Anchor A7 Clevis A8 Adjusting nut A9 Brake band assembly AIO Outer drum A11 Bolt Al2 Plate for disassembly Al3 Plate Al4 Spring Al5 Spacer Al6 Pressure plate Al7 Disc plate Al8 Friction plate Al9 Inner drum 602407 ...

Page 411: ...J B4 Piston B5 Backup rmg B6 Cylinder 602408 assem b IY _ _______ _ C B e_v_e_l_g_e_a_r 0 1 1 C 1 Locking plate C2 Nut S t screw C 3 e b loosened to e b C2 Q I0m C7 1U C4 C4 Bearing cag ed as an to be remo d g C5 bly inclu m C7 assem ter race of and ou C5 Oil seal C5 C6 C i bearing g8 Bevel geart C9 Drive sha 602409 31 ...

Page 412: ...uter 0 16 0 52 0 80 0 0315 drum splines 0 0063 0 0205 2 Disc plates Measure the thickness fit of its teeth in inner drum splines and total thickness of friction plate and disc plates Replace the disc plate if any of these measurements exceeds the service limit Unit mm in Item Assembly standard Service limit Thickness 2 8 0 110 2 3 0 091 Fit in inner 0 14 0 30 0 60 0 0236 drum splines 0 0055 0 01 1...

Page 413: ...sembly Tightening Orallle 3 5 0 3 25 3 2 2 34 3 2 9 Tightening torque 16 19 kgf m 116 137Ibf ft 157 186 N m Al A5 A3 A4 o STEERING CLUTCHES AND BRAKES 25 3 2 2IbHt 34 3 2 9 N m 602412 A6 m A9 A7 II 602244 33 ...

Page 414: ...14 A19 A17 A16 IA10 I I I jA9 I I I I A2 A8 A6 A1 A7 A5 A4 A3 B Steering clutch cylinder assembly I r I I I Drive shaft B4 I B3 B2 Bl B5 B6 Tips for reassembly 1 Drive shaft installation 1 Before instaliing drive shaft C9 fit the inner race of left hand roller bearing C7 and collar C6 to the shaft 2 After installing shaft C9 and bevel gear CS in the steering clutch case fit the inner race of right...

Page 415: ...kgf Spring balance indication 14 44 17 641bf 64 23 78 45 N 3 Bevel gear and pinion backlash adjustment 1 Put a fuse stock into between the bevel gear and pinion at the place indicated as E roll it and measure the amount of flattening 2 Measure the backlash at a total of four places by turning the bevel gear 90 0 at a time and take the smallest measurement for comparison with the assembly standard ...

Page 416: ...pattern more visible lightly press the gear when rotating the pinion Correct tooth contact Contact indicated by the dark areas on the tooth faces is heaviest toward the toe end and extends about 30 of the tooth length on both convex and concave faces Incorrect tooth contact Pinion too far away from bevel gear 1 Contact extends toward the toe end of concave faces and toward the heel end of convex f...

Page 417: ...ontact increase the thickness of shims P and turn adjusting nuts C2 to move gear CB toward pinion G Recheck the contact pattern by brushing red lead lNOTE The foregoing tooth contact adjustments are meaningless unless the bevel gear and pinion backlash has been adjusted properly STEERING CLUTCHES AND BRAKES Pinion 00 close 0 bevel gear 602418 37 ...

Page 418: ...e Removal STEERING CLUTCHES BRAKES Disassembly 1 2 the topic AND 3 Remove the parts in the order numbered 1 Cover 6 Return spring 2 Oil seal 7 Cover 3 Pison 8 Oil seal 4 Valve spring 9 Piston 5 Plunger valve 10 Valve spring 38 602419 for disassembly 11 Plunger valve 12 Return spring 13 Valve housing ...

Page 419: ...STEERING VALVE Reassembly 10 9 8 T 11 12 13 o 3 4 6 5 602278 Reassembling order 39 ...

Page 420: ...the topic Removal Remove the parts in the order numbered 1 Cover 9 Gear case 2 Castle nut to be removed as an 3 Washer assembly including 4 Sprocket 10 thru 14 5 Seal case 10 Tapered roller bearing 6 Floating seal to be removed as an 7 Shim assem bly including 8 Screw 1111 through 14 11 Gear 40 for disassembly 12 Spacer 13 Tapered roller 14 Shaft 15 Snap ring 16 Tapered roller 17 Snap ring 18 Pini...

Page 421: ...rom the frame is not only dangerous but also harmful to the shaft subassembly Be sure to remove the case to which the shaft subassembly is installed 2 Tapered roller bearing removal 1 Remove the inner race and rollers of tapered roller bearing 10 as the components of the shaft subassembly Remove the outer race of this bearing from the steering clutch case when required 2 Similarly remove tapered r...

Page 422: ...9 17 16 15 10 Outer race 42 replace the measurement Unit mm in Service limit 1 00 0 0394 16 8 17 13 9 12 11 2 Sprockets Measure the tooth width and replace the sprocket if the measurement exceeds the service limit Unit mm in Item Assembly standard Service limit Sprocket tooth 40 1 57 36 1 42 width 18 19 14 10 ightening torque 7 6 9 2 kgf m 55 0 66 5Ibf ft 74 5 90 2 N m 602421 r rrr r Steering clut...

Page 423: ...y standard Tapered roller bearing 0 29 0 37 2 10 2 68 pinion preload 2 84 3 63 Starting torque T of pInIOn F kgf Obf N x L m in distance from center of pinion Example If L is 25 cm 9 84 in balance reading should be 1 16 kgf 2 56 Ibf 11 4 N to 1 48 kgf 3 26 Ibf 14 5 N as calculated below 0 29 kgf m 2 10 Ibfoft 2 8 N m 0 25 m 9 84 in x Xl Xl 1 16 kgf 2 56 Ibf 11 4 N 0 37 kgf m 2 68 Ipfoft 3 6 N m 0 ...

Page 424: ...er and remove the blade and blade arms 1 Remove the following parts 1 Bolts securing rigid bar 2 Bolts securing rear support 2 Lift or jack up the machine a little and securely block the rigid bars and steering clutch cases using wood blocks as shown 3 Remove the under carriage Installation To install the undercarriage follow the reverse of removing procedure 44 l ...

Page 425: ... and pull the idler assembly off the track frame 2 After installing the idler center it in the track frame Disassembly 6 7 5 4 Remove the parts in the order numbered for 1 Guide 2 Shim 3 Bearing 4 Floating seal Weight of front idler 5 Thrust washer 6 Shaft to be removed as an assembly including 711 and 11811 38 kg 84 lb approx 3 disassembly 7 Bushing 8 Idler 45 ...

Page 426: ...5 0 5 81bf ft 74 5 7 8 N m 7 Reassembling order Tips for reassembly Lubrication 1 Fill the idler with recommended oil through the plug hole in the shaft 2 Use an adaptor and volume pump for this filling Capacity approx Adaptor 60 ee 3 7 eu in SAE 90 gear oil Part name Part number 58809 15100 Volume pump 58309 03100 46 602187 ...

Page 427: ...r cylinder assembly 1 Weight of hydraulic adjuster cylinder assembly IS kg 33Ib approx 2 Remove carrier roller bracket assembly recoil spring assembly 2 Weig ht of carrier roller braci et I 42 kg 93Ib assembly with carrier roller approx 3 Remove the track carrier assembly Refer to the Removal TRACK CARRIER ROLLERS roller topic 4 After installing the track adjust its tension 602439 47 ...

Page 428: ...the to be removed as an assembly including 6 and 117 48 13 12 11 8 10 i 9 15 602426 parts in the order numbered for disassembly 6 Dust seal 14 Bracket 7 Rod packing for ultra super swamp 8 Plate model 9 Shaft 15 Carrier roller bracket 10 Ring for ultra super swamp 11 Spring retainer model 12 Spring 13 Carrier roller bracket ...

Page 429: ...o remove recoil spring 12 hold plate 8 with the arbor of a press having a capacity of 3 tons 6615 lb as shown unscrew four bolts and gradually back off the press arbor to let the spring expand Take out the plate spring retainer 11 and spring o o o 602427 4 _ 12 602428 49 ...

Page 430: ... 3 5 0 5 kgf m 25 3 3 61bf ft 34 3 4 9 N m 7 Reassembling order r l rri13 12 11 9 10 8 5 t 1 1 4 3 276 Tips for reassembly Recoil spring installation Compress spring 12 as in case of disassembly and install plate 8 to the spring 50 13 Tightening torque 26 2 kgf m 141bf ft 20 N m 602249 ...

Page 431: ...ay from the track 2 Apply the brake lock and chock the tracks at front end with blocks B 3 Remove the following parts 1 Track roller center 3 pcs 2 Track roller guard front and rear 3 Track roller front and rear Weight of track roller Installation 15 kg 33 Ib approx 1 To install the track rollers follow the reverse of removing procedure 2 Drive the machine forward out of its chocked condition Tigh...

Page 432: ... 1 TRACK ROLLERS Disassembly 4 3 Remove the parts in the order numbered for disassem bly 1 Collar 2 Floating seal 52 3 Thrust washer 4 Shaft 5 Bushing 6 Flanged roller V 602431 ...

Page 433: ...er or a sharp edged tool to fit the floating seals 2 Using a lint free cloth or a brush and washing fluid clean the surfaces of metal rings of floating seals making sure that these rings are free of any grime TRACK ROLLERS 602188 2 Lubrication 1 After reassembling the roller fill it with recommended oil through plug hole in the shaft 2 Use an adaptor and volume pump for this filling Capacity appro...

Page 434: ... steering clutch case Installation 1 To install the track follow the reverse of removing procedure 2 Insert a bar into the link and aid the track to climb over the sprocket carrier roller and front idler as the machine is moved slowly forward 3 Install the seal washers properly Drive in the master pin with its center hole outside For detail of seal washer installation refer to the topic Reassembly...

Page 435: ...Disassembly 5 5 3 5 1 10 7 Remove the parts in the order numbered for disassembly Ia Standard shoe Ib Swamp shoe curved apex shoe 2 Pin 3 Bushing 4a Seal washer 4b Seal 5 Link TRACKS 602434 55 ...

Page 436: ...der Tips for reassembly Install the seal washers and seals as shown 56 Seal washer standard and swamp models Seal 1a super swamp and ultra super swamp models 602184 Tightening torque 17 20 kgf m 123 145Ibf ft 167 196 N m 602185 602435 ...

Page 437: ...r roller 2 and remove the following parts 3 Bolts 2 pcs 2 Track carrier roller Weight of track carrier roller Installation 1 To install the track follow the reverse procedure 11 kg 24Ib approx carrier roller of removing 2 Insert the shaft into the bracket so that the arrow mark on one end points upward and the spring pin hole on the other comes to the top side 3 Adjust the tension of tracks 3 6024...

Page 438: ...ERS Disassembly 58 8 4 Remove the parts in the order 1 Cover 2 Washer 3 Floating seal to be removed as an assembly including 4 and 5 5 numbered for disassembly 4 Bushing 5 Roller 6 Snap ring 7 Seal support 8 Shaft 602438 ...

Page 439: ...h recommended oil through plug hole in the cover 2 Use an adaptor and volume pump for this filling Capacity approx 35 ee 2 1 eu in SAE 90 gear oil Part name Part number Adaptor 58609 00300 Volume pump 58309 03100 TRACK CARRIER ROLLERS ri1 ht miIlg torque 2kgf m 8 7Ibf ft 19 6 11 8 N m Tightening torque 4 2 0 4 kgf m 30 4 2 9 Ibf ft 41 2 3 9 N m 602186 59 ...

Page 440: ...100 Volume pump 58809 15600 Clutch disc arbor 60 SPECIAL TOOLS Shape 602441 602444 Use Bevel gear adjustment Carrier roller lubrication Front idler and track roller lubrication Carrier roller front idler and track roller lubrication Flywheel clutch installation clutch disc assembly aligning ...

Page 441: ...I j I I I I ...

Page 442: ...DEC 136 Printed in Japan Pub No 99879 00120 7 ...

Page 443: ...SERVICE MANUAL MITSUBISHI TRACTOR B 2G TRACTOR SHOVEL BS3Gi CONTENTS HYDRAULIC SYSTEM DISASSEMBLY AND REASSEMBLY ...

Page 444: ...I j I I I I ...

Page 445: ...nnot be bought or manufactured they must be learned through the job you do By learning what CAUTION or WARNING symbol emphasizes know what is safe what is not safe Consult your forem an if necessary for specific instructions on a job and the safety equipment required NOTES CAUTIONS and WARNINGS NOTES CAUTIONS and WARNINGS are used in this manual to empha size important and critical instructions Th...

Page 446: ... ...

Page 447: ... TABLE OF CONTENTS Hydraulic pump Control valve 4 Power angling tiit blade 14 Power tilt blade 16 Bucket and linkage 18 Hydraulic cylinders 20 Special tools 32 ...

Page 448: ... ...

Page 449: ...urely support it by external means BS30 1 Remove the following parts 1 Rubber hose suction side 2 Pipe 3 Rubber hose discharge side 4 Pipe and connector 5 Hydraulic pump Installation To install the pump follow the reverse of removing procedure Tightening torque for hydraulic pump mounting bolts 4 2 kgf m 30 41bf ft 41 2 N m 602280 ...

Page 450: ... Lay down the pump body Pull out the drive gear by hand and remove the bushings 2 Layout the disassembled parts neatly in the order in which they came out identifying each for its position Particularly the shaft and its bushings must be identified positionally by marking or otherwise so that they will be restored to their original position in reassembly 2 NOTE If the bushings will not come out tap...

Page 451: ...ULIC PUMP 7 12 601398 INOTE 1 When inserting a pair of bushings 4 and 11 hold them squarely to the bore to avoid scuffing 2 If the outside surface of the bushing is found with scratch marks remove high spots on the surface by lightly polishing with an oil stone 3 When reinstalling the gears mesh drive gear 6 with the driven gear in the same tooth position as before 4 Before installing the cover wr...

Page 452: ...or 10 0 kg 22 lb power tilt blade approx Control valve for BS3G 10 0 kg 22 lb approx Installation To install the control valve follow the reverse of removing procedure Tips for installation When installing the control valve check to make sure that the clevis of each control linkage and the plunger of control valve are properly installed The clevis and plunger should be at a right angle to the adja...

Page 453: ...Tie rod B Inlet and lift valve plunger section C Tilt valve plunger section NOTE D Angling valve plunger section E End plate F Main relief valve G Makeup valve 1 Be sure to tighten the tie rods to the specified torque or the plungers will not move smoothly and the implement will drift excessively 2 After reassembly make sure that the plungers move smoothly A Tightening torque 2 7 0 3 kgf m 19 5 2 ...

Page 454: ...u B4 B16 Spacer C3 D3 Spring guide B2 Snap ring B17 Oil seal C4 D4 Spring B3 Plate B18 Plunger C5 D5 Spring guide 602284 B4 Detent sleeve B19 Plug C6 D6 Seal cover plate B5 Steel detent balls B20 Plug C7 D7 Oil seal B6 Spring pin B21 Spring C8 D8 Seal cover plate B7 Steel detent ball B22 Check valve C9 D9 Oil seal B8 Spring B23 Housing CI0 DI0 Plunger B9 Plunger plug Cll Dll Plug BI0 Spring guide ...

Page 455: ...ening torque 2 0 0 2kgf m l4 5 1 4 Jbf ft 19 6 2 0 N m F r 819 D9 602200 B4 Bl r r r r r r r r L r r r r B23 j j j r r r r B18 B16 B11 B15 B20 B21 B22 B12 Bll Bl0 B9 B8 B7 B5 B6 B3 B2 B13 B14 C Tilt valve plunger section r r r C14j j j r r r r r r r Cl 0 C9 C8 Cll C12 C13 C5 C4 C3 C2 Cl C6 C7 D Angling valve plunger section Identical with C Tilt valve plunger section 7 ...

Page 456: ... torque 5 0 0 5 kgf m 36 2 3 6 Ibf ft 49 0 4 9 N m o A Tightening torque 2 7 0 3 kgf m 19 5 2 2 Ibf ft 26 5 2 9 N m o c B Inlet and lift valve plunger section C Tilt valve plunger section o End plate E Main relief valve F Safety valve G Makeup valve 1 Be sure to tighten the tie rods to the specified torque or the plungers will not move smoothly and the implement will drift excessively 2 After reas...

Page 457: ...3 Plate B4 Detent sleeve B5 Steel detent balls B6 Spring pin B7 Steel detent ball B8 Spring B9 Plunger plug BI0 Spring guide B11 Spring B12 Spring guide B13 Seal cover plate B14 Oil seal B21 Check valve B22 Housing Cl Cap C2 Plunger plug C3 Spring guide C4 Spring C5 Spring guide C6 Seal cover plate C7 Oil seal C8 Seal cover plate C9 Oil seal CI0 Plunger Cll Plug C12 Plug C13 Plug C14 Spring C15 Ch...

Page 458: ...bf ft 19 6 2 0 N m Tightening torque 1 1 0 1 kgf m 8 0 0 7Ibf ft C6 C7 10 8 1 0 N m Reassembling order C16 C11 C13 Tightening torque 3 5 0 4 kgf m 25 3 2 9 Ibf ft 34 3 3 9 N m C8 C10 C9 E H F 602207 602208 B Inlet and lift valve plunger section 84 81 r L r r r 822 1 1 1 818816817 815 B19820821 812 811 810 89 88 87 85 86 C Tilt valve plunger section 83 82 813 814 Cll r r C16 1 1 1 roo 1 r Cl0 C9 C8...

Page 459: ... 21bf ft 26 5 2 9 N m tG G Tightening torque 5 0 0 5 kgf m 36 2 3 61bf ft 49 0 4 9 N m B Inlet and lift valve plunger section C Dump valve plunger section INOTE D End plate E Main relief valve F Safety valve a Safety valve H Makeup valve 1 Be sure to tighten the tie rods to the specified torque or the plungers will not move smoothly and the implement will drift excessively 2 After reassembly make ...

Page 460: ...C1 Cap C 2 Plunger plug C3 Spring guide C4 Spring B2 Snap ring B3 Plate B4 Detent sleeve B5 Steel detent balls B6 Spring pin B7 Steel detent ball B8 Spring B9 Plunger plug 810 Spring guide Bll Spring B12 Spring guide B13 Seal cover plate B14 Oil seal B15 Plate B22 Check valve B23 Housing C5 Spring guide C6 Seal cover pIate C7 Oil seal C8 Seal cover plate C9 Oil seal C10 Plunger Cll Plug C12 Spring...

Page 461: ... 19 6 2 0 N m Tightening torque 1 1 0 1 kgf m 8 0 0 7 Ibf ft 10 8 1 0 N m Reassem bling order B Inlet and lift valve plunger section CONTROL VALVE 817 602199 602215 Igmenll g torque 5 0 0 5 kgf m 3 61bf ft 49 0 4 9 N m B19 rE B4 81 I I I I 823 I I I I I I r r L r r r I B18 B16 B17 B15 B20 B21 B22 812 811 Bl0 89 88 87 B5 86 B3 82 B13 B14 C Dump valve plunger section G1rF I r r C17 1 I I I I I r r I...

Page 462: ... circuits 1 Remove the following parts 1 Rubber hoses for lift cylinders 4 pcs 2 Rubber hoses for angling cylinders 4 pes 3 Rubber hoses for tilt cylinder 2 pes 4 Lock plate 5 Pin 2 Move the machine backward leaving the blade on the ground 3 The blade may be lifted off with a hoist and slings Weight of power angling tilt blade 550 kg 1213 lb I approx I Installation To install the blade follow the ...

Page 463: ... Cover 13 Cover 14 Hoses 15 Hoses 16 Block 17 Pin 18 Pin 19 Tilt cylinder 20 Plates 21 Bracket 22 Plate 23 Plate 24 Bar 25 Pin 26 Bracket 27 Cap 28 Blade 29 End bit 30 Cutting edge 31 C frame Power angling tilt blade Disassembled view Remove the parts in the order numbered for disassembly Reassembly To reassemble the blade follow the reverse of disassembling procedure 602289 15 ...

Page 464: ...following parts 1 Lock plate 2 Pin 3 Lift cylinder and lever 4 Rubber hoses for tilt cylinder 2 pcs 2 Remove cap 5 separate the blade arm from the trunnion and reinstall the cap on each side 3 Lift off the blade and arms Weight of power tilt blade 400 kg 882 lb approx 4 The blade may be removed by moving the machine backward leaving the blade on the ground Installation To install the blade follow ...

Page 465: ...8 17 20 14 f rV 11 rf 12 Ultra super swamp model SSS 21 I 22 f 9 10 11 12 13 14 15 16 Power the parts oJ 23 Pin Tilt braces Pin Braces Cap Pin Arm Blade e 22 ff 21 17 18 19 20 21 22 23 End bit Cutting edge Trunnion Blade End bit Bit Cutting edge tilt blade Disassembled view in the order numbered for disassembly 602292 602305 17 ...

Page 466: ... the following parts at four bucket mounts 1 Bolt 2 Pin 3 Seal 4 Bucket Weight of bucket 240 kg 529 Ib approx 2 Attach slings to the lift arms 3 Remove the following parts 5 Rubber hoses for dump cylinders 4 pcs 6 Rubber hoses for lift cylinders 4 pcs 7 Lock plates 4 pcs 8 Pin 4 pcs 9 Pin 2 pcs 10 Seals 11 Bushing 12 Bucket linkage Weight of bucket linkage 400 kg 882 Ib approx 4 Remove the followi...

Page 467: ...eassembly 12 1 Pin 2 Lift cylinder 3 Pin 4 Dump cylinder 8 5 Pin 6 Arms 7 Pin 8 Arms 9 c c c c 8 7 9 Pipe 10 Frame 11 Tooth 12 Bucket 10 Bucket and linkage Disassembled view Remove the parts in the order numbered for disassembly 602296 19 ...

Page 468: ...nder of power tilt blade 2 Remove the following parts 3 Piston rod side pins of cylinders 4 Piston rod side cap of cylinder tilt cylinder of power tilt blade 5 Rubber hoses 6 Head side pins of cylinders 20 NOTEl Before disconnecting the rubber hoses be sure to stop the engine and move the control levers to all operating positions to relieve the pressure in the hydraulic circuits Power angling tilt...

Page 469: ...ers follow the reverse of removing procedure 2 Insert the head side pin and connect the rubber hoses to the cylinder While extending the piston rod insert the rod side pin Disassembly NOTE Two types of hydraulic cylinders ring nut type and gland screw type are used These types differ from each other in disassembling and reassembling procedures Lift cylinders Power anglingl Angling cylinders Ring t...

Page 470: ... Nut to be removed as an assembly including 4 thru 11 4 Piston to be removed as an assembly including 5 5 Piston seal 6 Guide bushing to be removed as an assembly including 7 thru 11 7 Dust seal 8 Rod packing 9 Buffer ring 10 Bushing 11 Piston rod 12 Bushing 13 Cylinder tube Remove the parts in the order numbered for disassem bly 602300 ...

Page 471: ...mbly including 4 thru 12 4 Piston to be removed as an assembly including 5 5 Piston seal 6 Guide bushing to be removed as an assembly including 7 thru 10 6 0 7 Backup ring 8 Dust seal 9 Rod packing 10 Buffer ring 11 Piston rod 12 Cap 13 Cylinder tube HYDRAULIC CYLINDERS 602301 Remove the parts in the order numbered for disassembly 23 ...

Page 472: ...linder 05312 10500 angling Angling cylinder BD2G tilt blade Tilt cylinder 05312 10600 Power Lift cylinder 05312 10500 tilt blade Tilt cylinder 05312 10600 Lift cylinder 05312 10800 BS3G Bucket Dump cylinder 05312 10600 3 On the ring nut type cylinder slightly push in guide bushing 6 and remove ring 2 with a screwdriver NOTE Do not use a sharp edged tool to remove ring 2 When removing the ring be c...

Page 473: ... nut type cylinder 11 10 8 2 7 6 7 6 9 r r 13 Ll ill 2 1 Tighten 10 1 5 4 3 Gland screw type cylinder 12 8 9 11 2 8 9 10 7 6 7 6 10 I I 13 I r L r r 11 Tlohten 1 12 2 5 4 3 b HYDRAULIC CYLINDERS 5 4 3 13 12 6022571 4 5 3 00 13 602258 25 ...

Page 474: ...diameter of the piston mm the Unit mm in Piston 1 0 Cylinder 24 27 30 0 94 1 06 1 18 Lift 0 cylinder Power Angling angling 0 tilt blade cylinder BD2G Tilt 0 cylinder Lift 0 Power cylinder tilt blade Tilt cylinder 0 Lift 0 cylinder BS3G Bucket Dump 0 cylinder 2 Squeeze the seal in the palm of the hand three or four times to soften it 26 Unit mm in v Cl JH 1 1 Co 0 D i Cl 250 9 84 CI Chamfer I 0 04 ...

Page 475: ...as much as it will go in and insert the tool into the piston 5 Hold down the seal by left hand and turn the arm of the tool by right hand while pushing it down After about 3 4 of the seal has been forced onto the piston hold down the seal by right hand 6 Turn the arm by left hand to force the remaining 1 4 onto the piston HYDRAULIC CYLINDERS 600151 600153 27 ...

Page 476: ...HYDRAULIC CYLINDERS 7 Install the backup ring to the piston 600154 28 ...

Page 477: ...3 24 5 95 5 Lift cylinder 687 1 36 2 BS3G Bucket 931 6 49 0 IDump cylinder I 50 0 2 5 361 7 18 1 490 3 24 5 3 Ring installation If the guide bushing is pushed in the cylinder more than is necessary the O ring would be damaged by the sharp edge of the port when the bushing is pulled out Do not push in the bushing more than L dimension Unit mm in Cylinder Dimension L Power Lift cylinder 16 0 63 angl...

Page 478: ...nch reading T 0 1 T Unit kgf m lbf ft N m Cylinder Tightening torque T Lift cylinder IS O I S Power Angling cylinder 108 S 10 8 147 1 14 7 anglingl 24 0 2 4 tilt blade Tilt cylinder p 73 6 17 4 23S 4 23 S IS O I S BD2G Lift cylinder 108 5 10 8 Power 147 1 14 7 tilt blade 4S 0 4 S Tilt cylinder 32S 5 32 S 441 3 44 1 7S 0 8 Lift cylinder S42 5 S7 9 BS3G Bucket 73S 5 78 S 4S 0 4 5 Dump cylinder 325 5...

Page 479: ...nstall a locking ring to prevent the screw from loosening The diameter and depth of this hole are as shown below Unit mm in Locking ring hole Cylinder Diameter Depth d L BD2G Power Tilt 3 5 0 14 10 5 0 41 tilt blade cylinder Lift 4 5 0 18 12 5 0 49 BS3G Bucket cylinder Dump 3 5 0 14 10 5 0 41 cylinder HYDRAULIC CYLINDERS 31 ...

Page 480: ...removal and installation BD2G Power angling tilt blade Lift cylinders Angling cylinders BD2G Power tilt blade Lift cylinders 05312 10600 BD2G Power angling tilt blade Tilt cylinder IJ 600328 BD2G Power tilt blade Tilt cylinder BS3G Bucket Dump cylinders 05312 10800 BS3G Bucket Lift cylinders 32 ...

Page 481: ...I j I I I I ...

Page 482: ...DEC 86 Printed in Japan Pub No 99879 00120 8 ...

Page 483: ...of the revised edition in the blank of Revised Edition Check Column of the updating list in the next page When you receive any supplement enter its title in Title of Separate Volume column of the updating list The updating list if properly filled will help check to see if the updated volumes are filed in this binder by referring to the Publication List For some models the binder will be divided in...

Page 484: ...tment Direct Powershlft Transmission 5 Operating Principle Testing and Adjustment Maintenance Standards Disassembly and Reassembly Hydraulic System 6 Operati g Principle Testing and Adjustment Power Train 7 Disassembly and Reassembly Hydraulic System 8 Disassembly and Reassembly 9 Wiring Dlagl 1lm for BD2G and BS3G 10 II 12 Binder Pub No 98AAB 00360 PubJication to be issued in future Pub No 99879 ...

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