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Mitsubishi Heavy Industries BD2GII, Service Manual, Page: 30 / 150

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Mitsubishi Heavy Industries BD2GII Service Manual Download Page 30

Summary of Contents for BD2GII

Page 1: ...w Up 2B1 02467uP3S1 00060 up 2B2 00775 UP 3S5 00098 up 2B3 00295UP3S6 00061 up 2B5 00883 up 2B6 01125 up 287 00047 up TRAcnrOR OiL BSSon POWER TRA N CONTENS SYSTEMS OPERAT ON TEST NG AND ADJ US11NG D SASSEMBLY AND REASSEMBLY t W VV TI 1 ...

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Page 3: ...ofoperations where hazards exist Warning labels have also put on the machine to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons These labels identify hazards which maynot be apparentto a trainedmechanic There are manypotential hazards during repair for an untrained mechanic and there is no way to label the machine ag...

Page 4: ...ft DPS transmission 17 Transmission hydraulic control 20 Transmission control valve 22 Operation 23 Steering clutches brakes and final drives 31 Steering clutch and brake controls 32 Steering clutch hydraulic control 33 Undercarriage 34 TESTING AND ADJUSTING DPS transmission 38 Inching pedal 45 Transmission control lever 45 Steering clutches 46 Brake pedal 47 Clutch pedal 47 Clutch brake 48 Tracks...

Page 5: ...sion and steering clutches 89 DPS transmission 91 Transmission control valve 108 Transfer 110 Bevel gear 112 Damper 113 Steering clutches and brakes 115 Steering valve 126 Final drives 128 Undercarriage 132 Front idlers 133 Recoil cylinders and recoil springs 135 Track rollers 139 Tracks 142 Track carrier rollers 145 Special tools 148 ...

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Page 7: ...SYSTEMS OPERAT O ...

Page 8: ...N GENERAL 1NFORMATION The BD2GII and BS3GII machines are either direct çlrive type or direct power shift type the difference being based on the type of a ansmission they use Direct Drive Type Direct Power Shift Type 2 ...

Page 9: ... pinion at the rear of the transmission sends the power to bevel gear5 The power is then sent through steering clutches 6 into final drives 7 to the sprockets which drive the tracks The engine and flywheel clutch are integrally coupled and are mounted on the frame at four places with cylindrical rubber mounts The transmission is housed in its own case which is bolted to the front of the steering c...

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Page 11: ...he output shaft of the transmission drives the input shaft of transfer 5 The bevel pinion in the transfer sends power to bevel gear 6 The power is then sent through steering clutches 7 into final drives 8 to the sprockets which drive the tracks The engine and damper are integrally coupled and are mounted on the frame at fourplaces with cylindrical rubber mounts The transmission planetary gears and...

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Page 13: ...ooth clutch engagement Dishing the clutch discs willpermit a gradual engagement of the clutch facings with the flywheel and pressure plate When in the engaged position the dished clutch discs are pressed flat between the flywheel and pressure plate FLYWHEEL CLUTCH 1 Flywheel 2 Clutch discs 3 Mating late 4 Pressure plate 5 Clutch cover 6 Release lever 7 Release hub 8 Pressure spring 9 Fork 11 Gear ...

Page 14: ...his relief valve the oil flows to the steering clutch valves The remainder of the oil flows through oil cooler 4 built in the lower tank of the radiator to clutch main shaft 5 from which it is sprayed on the clutch discs andpressure plate for lubrication and cooling The oil used for actuating the clutch valves is returned to the top of the clutch case for lubri cation 1 Oil strainer 4 Oil cooler 2...

Page 15: ...slid into mesh with gear on the cduntersha t 2nd shaft For the selection ofreverse speed sliding gear is slid into mesh with gear on the input shaft 1st shaft DIRECT DRWE DD TRANSMISSION 1 Input shaft 2 1st speed rev rse gear 3 2nd speed reverse gear 4 Input gear 5 2nd speed drive gear 6 Countershaft 7 1st speed drive gear 8 1st speed sliding gear 9 2nd speed sliding gear 10 Countergrear 11 3rd sp...

Page 16: ...V Input 2nd speed reverse gear 3 2nd speed sliding gear 9 3 9 12 602173 Forward 3rd speed position Input shaft 1 1st speed reverse gear 2 lst speed sliding gear 8 Input shaft 1 V I 2 8 12 Bevel pinion shaft 12 602172 1 4 10 6 5 9 12 602 l 70 Bevel pinion shaft 12 Input gear 4 Countergear 10 3rd speed sliding gear 602 171 1 4 10 11 12 14 ...

Page 17: ...h fit into notches on the shiftrails If 1st shift rail 7is moved for making a shift the shift lever is moved to forward 1st speed posi tion for example 2nd shift rail 8 and 3rd shift rail 9 are locked by the steel balls This holds the transmission gears so that they will not slide out of position TRANSMISSION CONTROL DD 1 1st shift fork 5 2nd speed sliding gear 8 2nd shift rail 2 2nd shift fo 6 3r...

Page 18: ...lates is bolted to flywheel 3 The combination of coil springs and friction plates absorbs power impulse from the engine which would otherwise be transmitteddirectly to the gears in the transmission as when the engine is quickly accelerated or decelerated and shocks from the ground through power train DAMPER 1 Coil spring 3 Flywheel 2 Friction plates 16 ...

Page 19: ...se clutch Forward clutch 3rd speed clutch 2nd speed clutch 1st speed clutch Input shaft Output shaft 8 Sun gear 9 Planet gear 10 Ring gear 11 Carrier 12 Piston housing 13 Piston 14 Mating plate 15 Friction plate 16 Return spring 17 Bevel pinion 18 Gear pump 19 Oil filter 17 ...

Page 20: ...onal 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 Each planetary gear set comprises sun gear 8 planet gears 9 carrier 11 and ring gear 10 The sun gear rotates the cat rier revolves and the planet gears rotate on their own shafts orpins and revolve with the carrier on which they are mounted 19 1 60231...

Page 21: ...es In forward 1st speed position forward clutch 2 and 1st speed clutch 5 are engaged Because forward ring gear lOis 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 7 In reverse position reverse clutch 1 is engaged In this case the reverse carrier is locked and th...

Page 22: ...alve 9 Inching valve 10 Main reliefpressure tap M 11 Speed clutch pressure tap S 12 Directional clutch pressui tap D 13 Oil cooler built in radiator lower tank 14 Oil filter 15 Lubrication relief valve 16 To steering valve 1 Suction strainer with magnet 2 Gearpump 37 7 liters 10 U S gal min at 2300 engine rpm 40 PS model 39 3 liters 10 4 U S gal min at 2400 engine rpm 20 ...

Page 23: ...1 0 kgf cm2 14 psi 0 1 MPaJ 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 to 28 psi 0 1 to 0 2 MPaJ for protection The oil in the oil sump is lifted by gear pump 2 through Suction strainer 1 Oil from the pump flows into two circuits oneleadingto the steering valve for actuating the ...

Page 24: ... 3 Directional selector valve 4 directs the oil to either forward clutch piston chamber or reverse clutch piston chamber 4 Speed selector valve 3 directs the oil to any of the 1st speed 2nd speed and 3rd speed clutch ports 5 Inching valve 5 actuated by the inching pedal reduces the pressure in the forward or reverse clutch piston chamber to control the clutch in transition from full engage ment to...

Page 25: ...hamber4 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 pressure chamber 4 for pres sure accumulation This pressure accumulation continues until the accumulator valve comes to the left end of its stroke As the engine starts main pressure is applied through main port2 to speed selectoryalve 3 and a...

Page 26: ...peed clutch port Cl and for ward clutch port CF respectively Under this condition the pressure is being ap plied to the 1st speed clutch piston chamber but it is not applied to the forward clutch chamber yet The moment the oil in accumulator valve pres sure chamber 4 enters theist speed clutchpiston chamber for prefiuing accumulator valve 1 re turns to the right end to uncover main port 2 Now a ci...

Page 27: ...s beyond 2 kgf cm2 28 psi 0 2 MPa This pres sure moves differential valve 7 to the left end allowing the speed clutóh pressure oil to enter forwardclutchpressureport CF through inching valve 8 Since accumulator valve 1 does not move yet keeping main port 2 uncovered the oil from the pump flows into the forward clutch piston cham ber without being metered 25 ...

Page 28: ...port 2 Then only the oil metered by main oii Ice 5 flows into the 1st speed clutch circuit to move accumulator valve 1 slowly and to increase both forward and 1st speed clutch pressures gradu ally This is called modulation action Since the speed clutch pressure is always higher than the directional clutch pressure the 1st speed clutch and forward clutch are engaged in that sequence This means that...

Page 29: ...ve 7 still remains in the pressure regulating position This keeps the forward clutch pressure lowe r than the 1st speed clutcif pressure by 2 kgf cm2 28 psi 0 2 MPaJ 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 pres sure decreases in advance Subsequent action...

Page 30: ...nching pedal is in released posi tion plunger 1 is kept pushed to the left end ofits stroke by return spring 2 Under this condition primary pressure in passage 3 is adiñftted into secondary pressure passage 4 thus maintaining 21 kgf cm2 299 psi 2 MPa pressure there I Plunger 2 Return spring 3 Primary pressure passage from differential valve 4 Secondary pressure passage to directional selector valv...

Page 31: ...cm2 57 to 0 psi 0 4 to 0 MPaJ within the range of 4 to 16 5mm 0 16 toO 65 in stroke of plunger 1 16 5 mm 0 65 in 0 kgf crn2 0 psi 0 MPa 602328A As the inching pedal is depressed plunger 1 is moved to theright When it is moved4mm 0 16 in valve 5 meters the oil flowing into passage 4 from passage 3 and at the same time starts draining oil from passage 4 to the oil sump throughpassage 8 toreduce the ...

Page 32: ...e tered Consequently secondarypressure falls to zero and the machine is brought into a complete stop as in neutral In summary the inching pedal may be used like the clutch pedal of a 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 t...

Page 33: ...eering clutch lever Outer driven drum 9 is bolted to the flange of final drive pinion Inner driving drum 6 to the flange of drive shaft 3 Fricdon plates 8 are engaged with the outer dtum and disc plates 7 with the inner drum The tack ofthese plates is normally kept compressed by spring loaded pressure plate 10 to transmit the power to the final drive involving pinion 11 and gear 12 When disengaged...

Page 34: ...sure pressure plate 4 is moved away from the staãk of disc plates 5 and friction plates 6 to disengage the clutch When the lever is further pulled brake band 7 is contracted to brake outer drum 8 to interrupt the flow of power to the final drive It is possible to disengage the steering clutch without braking for gradual turn or to disengage it with braking for sharp turn As brake pedal 9 is depres...

Page 35: ...ON SThERING CLUTCH HYDRAULIC CONTROL 602181A 1 Relief valve 2 Steering valve 3 Steering clutch cylinder 4 Oil cooler hose 5 Steering clutch lever 6 Gearpurnp 7 Steering clutch 602182 4 Control for DD type is shQwn 33 ...

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Page 37: ...TESTDNG AND ADJUSTDNG ...

Page 38: ...e inching pedal and transmission control lever linkages for adjustment 3 Operating the machine Get on the machine and operate it for testing During the test shift the transmission into all gears forward and reverse and operate the inch ing pedal If the machine fails to start smoothly or if inching or shifting is hard see Trouble shooting which follows Testing the clutches for slippage 1 Start the ...

Page 39: ...eading at taps M I 2 Clogged oil passage between Check and clean clogged part by and S strainer and pump between flushing or repair leaking point All low not higher than pump and line filter or between 10 kgf cm2 142 psi 1 MPa filter and control valve or leakage 3 Main relief valve sticking Disassemble and clean No shift to all gears Main orifice restricted Disassemble and clean Pressure reading a...

Page 40: ... in shifting from ito 2 and 2 to 1 Possible cause 1 Accumulator valve sticking Indicating hand takes 2 seconds or more in deflecting from 0 to 21 kgf cm2 299 psi 2 MPaI Remedy ____ 2 Accumulator valve spring weakened Wash valve body cheek bore for damage and as necessary replace valve and body if valve does not move sliding smoothly Indicating hand takes longer time than normal to deflect from 0 t...

Page 41: ...maladjusted Check and adjust is depressed 2 Clutch valve defective Disassemble wash and repair or Pressure reading at taps M and S replace Normal Pressure reading at tap D Does not drop toO kgf cm2 Releasing inching pedal after fully Clutch valve sticking Disassemble and clean by washing depressing causes machine to jerk Replace 2 piece spool as necessary in standing start Pressure reading at taps...

Page 42: ...and replace defective Normal transmission parts 6 If output power is not enough Complaint Possible cause Remedy Pressure reading at taps M D Oil level too low Add oil and S Low Pressure reading at taps M D 1 Engine lacks power Tune up engine and 2 Mechanical trouble inside Overhaul and replace defective transmission parts 7 Ifoilpressuresarehigh Complaint Possible cause I Remedy Pressure reading a...

Page 43: ...on Whenrunning the transmission and control valve on the bench in order tO break them in be sure to form an oil cooler bypassing circuit by connect ing two rubber hoses one leading to the cooler inlet and the other from the cooler outlet 1 Main relief pressure Tap M 2 Speed clutch 1st speed 2nd speed and 3rd speed pressure Tap S 3 Directional clutch forward and reverse pressure Tap D 43 ...

Page 44: ...is required to take the following value 0 kgf cm2 for both clutches with control lever in neutral Not lower than main relief pressure by 2 kgf cm2 28 psi 0 2 MPa with control lever in 1st 2nd or 3rd speed position Shifting time S G 1 8 with 0 ring Measure time required for pressure to change when control lever is shifted from neutral to any position or from one position to another Shifting Time N ...

Page 45: ... wall Loosen lock nut 3 Adjust the length ofrod so that lever 4 starts moving when the inching pedal is depressed Loosen lock nut 6 Reposition stopper bolt 7 so that the pedal stroke is 14 5 cm 5 7 in 2 Turn rods 4 and 5 to adjust c1earani e a 3 4 5 6 Clearance a between guide 2 and lever 1 should be 0 5 to 2 0 mm 0 02 to 0 08 in in any lever position 1 Loosenlocknut3 45 ...

Page 46: ...o thatitis 6 5 to 7 5cm 2 6 to 3 0 in from the end of instrument panel B Adjusting the clearance between brake band and outer drum 1 Screw adjusting nut 6 all the way 2 Back 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 is 20 to 22 cm 7 9 to 8 7 inS from release position to fully pulled position When m...

Page 47: ...n of the pedal by turning stopper bolt 2 so that it is 20 cm 7 9 in from the dashboard wall 3 Loosen lock nut 3 4 Set the free play of the pedal by turning rod 4 so that it is 1 5 cm 0 6 in Loosen lock nut 5 Set the stroke of the pedal by turning stopper bolt 6 so that it is 16 cm 6 3 in 3 Loosen lock nut 3 4 Set the free play of the pedal by turning rod 4so that it is 0 5 to i o cm 0 2 to 0 4 in ...

Page 48: ...ease does not appear at the vent hole loosen the fill valve until it touches the stop per 3 Ifgrease does not appear at the vent hole and the vent hole appears to be open and the track appears to have tension start the engine and move the machine back and forth slightly 4 If the track still appears to have tension even after such a backward and forward move ment ofthe machine insert awood block in...

Page 49: ...2 in 2 Operate the machine backward and forward to equalize the adjustment NOTE When applying grease into the fill valve be careful not to increase the dimension A betweenthe cylindershaftflange andrigid bar mounting bolt more than is specified Dimension A Unit mm in dar swamP mode1 400 15 7 er swamp model 530 21 L su1 1 swamp model 490 19 3 49 ...

Page 50: ...nd repair or shaft replace 5 Dirty friction surfaces of clutch Clean by washing discs Clutch chatters when Release bearing seized poorly Disassemble and repair lubricate or disengaged lubricated or damaged replace Incomplete disengagement Oil viscosity too high Change with oil of proper viscosity resulting in hard shifting Hard gear shifting Clutch brake maladjusted or band Adjust or replace linin...

Page 51: ...djust clutch 2 Shift lever or forks loose or worn Repair or replace 3 Foreign matter lodged between Clean by washing gears 4 Oil viscosity too high Change with oil of proper viscosity 5 End faces of gear teeth damaged Repair or replace 6 Distorted or broken forks Repair or replace Noisy 1 Not enough oil or oil dirty Add or change 2 Backlash too large Change gears 3 Worn damaged or rattling Adjust ...

Page 52: ...rating is SAB 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 Beyel gears or other gears Disassemble and replace defective C Neutral safety valve malfunctions Ov...

Page 53: ...out pf order 5 Dragging clutches 6 Clutch valve linkage maladjusted 7 Dragging brakes 8 Continuous overloading of machine o Refill Check joint and replace packing as necessary Disassemble and repair or replace o Disassemble and replace the spring Replace Clean or replace Disassemble and replace Change oil ReadjusL o Readjust Disassemble and replace Readjust Readjust Disassemble and replace burnt p...

Page 54: ...Not enough oil Add oil 6 Oil leakage from loose joint or Inspect and repair replacing 0 connection rings and seals as necessary Clutch oil pressure is abnormally 1 Main relief pressure too low Refer to the procedure immedi low when inching pedal is in atel above released condition Transmission responds too slow to shifting This is not a symptom it shows up as slow response of transmis 2 Clutch val...

Page 55: ... worn or damaged Replace 4 Shaft splines worn Replace 5 Gear tooth contact incorrect Readjust or replace or teeth worn or damaged Oil leakage 1 Oil level too high Lower oil level 2 0 rings damaged Replace 3 Oil seals damaged Replace 4 Transfer case installation loose Retighten or replace or packing defective packing Overheating 1 Oil level too low Add oil 2 Backlash too large or too small Repair o...

Page 56: ...ight too loose Adjust or replace Raceways could be in or damaged cracked spalled or otherwise damaged condition 4 Bearings out of alignment Adjust Oil leakage 1 Too much gear oil or oil Remove excess oil to Leakage of oil into viscosity too low hold oil level as steering clutch side prescribed or change incapacitates this oil by one meeting device viscosity specffica tion 2 Defective oil seal Repl...

Page 57: ...s of disc plates 5 Weakened or brokan clutch Replace a 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 Steer ing clutch cylinder Clutch drags 1 Clu...

Page 58: ...rags 1 Maladjustment Adjust as prescribed Uneven or inadequate band to drum clearan is likely to result in overheating Readjustment is necessary if pulling steering clutch lever justalitile 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 I 1 Foreign particles lodged Di...

Page 59: ... Remedy Remarks Noisy 1 Not enough gear oil or dirty Add or change After working ma gear oil chine on muddy or flooded ground check oil for contamination by examining oil sampled out of drain point 2 Backlash too large 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 1 Not enough gear o...

Page 60: ...ers and front idler or of the track frame When checking these for alignment check track frame too for misalignment particu larly at its front end Side faces of sprockets 1 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 v om strips ...

Page 61: ...in wavy fashion to rub rollers and sprocket if pins and bushings are worn down 5 Front idler and track rollers Repair or replace Track will oscillate have too much axial play 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 malcondition Secure specified link allows roller flanges to height rub link bosses...

Page 62: ...olts securing roller shaft Disassemble and bushings broken repair Abnormal noise from 1 Loose shoe bolts Retighten This reLightefling undercarriage should be carried out as early as possible otherwise the whole shoe assembly would fail beyond repair Z Bolts securing roller shaft Retighten collar loose 3 Bolts securing roller shaft Disassemble and bushing broken or missing repair 4 Track pitch too ...

Page 63: ...ate idler to correct position 3 Recoil spring insufficiently Adjust or replace preloaded or broken 4 Roller flanges worn Repair or replace Refer to Complaint Front idlers tack rollers and carrier rollers wear abnor mally 5 Abusive steering by operator Avoid backing and sharp turning on rough wound 6 Sprocket teeth worn Repair by welding 63 ...

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Page 65: ...D SASSEMBLY AND REASSEM8LY ...

Page 66: ...h the engine and flywheel clutch or damper hoisted after they are removed from the machine b drain the coolant 13 liters 3 4 U S gal approx c raise the bucket fully and support the lift cylinders with the bracket lower it to the ground rubber after removing the radiator guard and side covers BS3GI d disconnect the hoses and pipes from the blade tilt cylinder BD2GII PT 1 Radiator grille 2 Rubber ho...

Page 67: ...lower the C frame for access 2 Remove the following electric 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 Before disconnecting the wires markthem forthe components to which they are to be reconnected at the time of installq tion 12 Air cleaner indicator wire 13 Glow plug wire 14 Stop solenoid wire 15 Sta...

Page 68: ...move the following parts 19 Reserve tanic 20 Muffler 21 Air cleaner 22 Clutch control rod 4 Remove the following parts 23 Steering clutch oil rubber hoses 2 pcs 24 Oil cooler rubber hoses 2 pcs 25 Electric wire by loosening clamps 68 ...

Page 69: ...e engine hitching bolts 28 Remove the castle nuts washers and bolts 4 places 29 Lift off the engine andflywheel clutch OTE The word engine when used in the cur rent manuals does not L iclude the follow ing components a Flywheel clutch b Hydraulic pump Weight of engine and 340 kg 750 lb flywheel clutch assembly approx 69 ...

Page 70: ...f not decrease or increase the thickness of shims 3 to set the clearance within this range at each bracket 4 Tighten castle nut 6 to the specified t9rque 5 After tightening all mount bracket bolts check to make sure the engine and clutch assembly is nearly horizontal LNOTE J If the engine and clutch assembly is not horizontal increase or decrease the thick Lness of shims 1 and shims 58611 11200 t ...

Page 71: ... machine method Start by a remove the under guard b drain the oil from the clutch case 5 5 liters 1 5 U S gal approx I 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 6 Rubber hoses for steering clutches 2 pcs 7 Rubber hoses for oil cooler 2 pcs 8 Electric wire by looseni...

Page 72: ...emove the oil filler from the threaded hole Mb 1 25 at the top of clutch housing 9 Attach hook A in that threaded hole and hoist the housing o When hoisting the clutch housing cover L e dashboard for protection 4 Unscrew the bolts securing the clutch hous ing and move the housing backward until it is possible to pull the main drive shaft out of the clutch cover Have the sling off hook A and attach...

Page 73: ...ywheel follow the steps under Disassembly For disassembly and reassembly of the gear pump refer to GEAR PUMP FOR TRANSMISSION AND STEERING CLUTCHES Installation Toinstall follow thereverse ofremoval sequence Off the machine method 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 t...

Page 74: ... 17 Lever 18 Support 19 Pin 20 Bolt 21 Pin 22 Pin 23 Lever 24 Oil seal 25 Needle roller bearing 26 Shaft 27 Release lever fork 28 Oil seal 29 Needle roller bearing 30 Needle roller bearing 31 Bearing 32 Release hub 33 Bushing Remove 34 thru 39 as an assembly 34 Cover 35 Snap ring 36 Main drive shaft 37 Bearing 38 Oilseal 39 Cover 40 Snap ring 41 Gear 42 Snap ring 43 Bearings 44 Spacer 45 Clutch ho...

Page 75: ...ned hole ofclutch disc andrun guide bolt B into each clutch spring hole Tighten the guide bolts to compress the clutch springs lightly and remove the pressure plate assembly Inspection 1 Clutch discs Measure the face runout facing wear and looseness of mating 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 fo...

Page 76: ... exceeds the service limit Unit mm in I Item I Assembly standaid I Service limit 1 b icimess of I tion surface 20 2 0 795 19 7 0 776 1 O 05to0 15 Flatness 0 0020 to 0 0059 L 0 30 0 0118 4 Mating plates Measure the thickness and flatness ofthe fricrion surface Replace the plates if any of these measurements exceeds the service limit Unit mm in I Item j Assembly standard Service linñt j Thickness of...

Page 77: ...ting gear Replace the gearifthe measurement exceeds the service limit Unit mm in Assembly standard Service limit 0 35 to 0 42 070 00276 0 0138 to 0 0165 6 Brake band Measure the thickness ofthe facing band if the measurement exceeds limit 602384 Replace the the service Unit mm in 602385 77 ...

Page 78: ...MBLY AND REASSEMBLY 56 r i r_ 52 49 50 55 48 47 515453 59 58 57 46 fl18 11 I fl 29 28 25 24 27 26 21 23 22 43 44 42 41 40 12 j 38 37 36 35 34 20 19 16 15 14 3 2 5 4 1 wheel 78 Reassembly Reassembly sequence 78 ...

Page 79: ...o retain the original setting D 600355 2 Put the clutch disc mating plate clutch disc and clutch cover assembly in that order on flywheel C or thejig Then remove guide bolts B 3 Set the dial inthcator at the tip of the release lever Take an indicatorreading and tighten or loosen the lever nut until the reading is 0 mm After following this step on the other three release levers tap each release lev...

Page 80: ...n Insert the splitpin into release lever 27 in parallel with the shaft and spread its ends properly to avoid interference with the pump drive gear 4 Oil seal installation Apply acoatofThreeBond 1 lO4to theperiphery of oil seal 38 before installation 80 ...

Page 81: ...ttery and starter 4 Operator s seat and seat plate 5 Rear cover seat and seat plat DIRECT DRiVE DD TRANSMISSION Removal Start by a remove the under guard b drain the oil from the transmissiOn case and bevel gear case 9 5 liters 2 5 U S gal approxi 1 Remove the following parts 1 Floor plate platform center 1 pc 81 ...

Page 82: ...Universal joint 11 TransmisSion NOTE Before hoisting the transmission shift it forward to pull the pinion back out ofmesh with the bevel gear Installation Toinstall follow thereverse ofremoval sequence Inspection after installation 1 Make sure that the electric wires pipes and hoses are connected properly 2 Fill the transmission case and bevel gear case with recommended oil 602389 c3 S 602390 82 ...

Page 83: ...A2 Hose clamps Remove Al thru A7 as an assembly A3 Cover A4 Cover A5 Retainer A6 Spring A7 Control lever A8 Lever case A9 Transmission cover Disassembly sequence Input gar 2nd speed reverse gear Spacer 1st speed reverse gear Spacer Ball bearing Input shaft Snap ring Ball bearing A3 Al A 4 A9 602391 B16 602392 Remove Bl and B2 as an assembly Bi Flange B2 Plug Remove B3 and B4 as an assembly B3 Cove...

Page 84: ...d shift rail Remove Ci9 thni C22 as an assembly C19 1st speed shift fork C20 Spring retainer C21 Spring C22 Plunger Di Cover 1 2 Washer 1 3 Washer Remove 1 4 thru 1 12 as an assembly 1 4 Spacer D5 Countergear 1 6 Spacer 1 7 2nd speed drive gear 1 8 Spacer D9 1st speed drive gear 1 10 Spacer Dii Roller bearing 1 12 Countershaft 1 13 Snap ring 1 14 Bail bearing El cover E2 Washer Remove E3 thru ES a...

Page 85: ...in the following directions 1 Drive out input shaft main drive shaft B 14 toward the steering clutch case side 2 Drive out countershaft D12 toward the steering clutch case side 3 Drive out bevel pinion shaftEl2 toward the universal joint side 3 Bevel pinion shaft bearing cage removal Using jacking bolts rei ove bearing cage E3 together with bearing E5 and shims E4 4 Bevel pinion shaft bearing remo...

Page 86: ...Unit mm in ervjc J 0 5 0 020 2 Detent springs Measure the free length and test force of each spring Replace the spring if any of these measurements exceeds the service limit Unit mm in Item Assembly Se ice limit 7 j_ standard I Test force I kgf lbf N 9 80 0 49 7 5 I Initial working 22 1 17 I length 96 5 74 L55 2 17 3 Gear backlash Measure the backlash of the gears Replace the gears if the measurem...

Page 87: ...SSEMBLY Reassembly Reassembly sequence E3 E5 E8 El E6 E2 E4 El DlO D9 D8 Dl D6 D5 D4 D14 D13 D3 Dl E1 2 Dl 2 Eli ElO E9 Dli D2 602167 602168 Transmission case BI B8 B9 BlO 811 B12 813 B3 B4 Si B2 case Bl4 Bl6 815 85 B6 87 ...

Page 88: ...tent parts with each shift rail held in NEUTRAL 2 Bevel pinion shaft installation I 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 1mm 1 819 0 004 in 2 The standard value of this dimension is indicated on the end face ofpinion Refer ring to that value increase or decrease the thickness of shims E4 to be fitted to pini...

Page 89: ... Disassembly sequence Remove 1 and 2 as an assembly 10 ring 2 Cover 3 SideplateB Remove 4 thru 7as an assembly 4 Side plate A 5 Driven gear 6 Drive gear 7 Gear plate 8 Gasket A 9 Gasket B 10 Balance seal 11 Snap mg 12 Oil seal 13 Mounting flange 6 4 10 13 12 zj A T 605193 89 ...

Page 90: ...ASSEMBLY AND REASSEMBLY Reassembly Reassembly sequence t H H H i H 12 11 10 9 8 4 6 5 7 3 NOTEd Be sure to replace gasket A8 gasket B9 balance seal 10 and oil seal 12 when reas sembling the pump 605043 90 ...

Page 91: ...pprox c drain the oil from the transferandbevel gear cases 7 liters 1 8 U S gal approx Sequence 1 Remove the following parts 1 Floor plates platform 3 pcs 2 Electric wire between battery switch and battery 3 Clamp for electric wire between battery and starter 4 Operator s seatandseatplate 5 Rear cover Weight of operator s 31 kg 68 Ib seat and seat plate approx 5 602336 91 ...

Page 92: ...ke control rods 9 Steering clutch oil pipes 2 pcs 10 Oil cooler pipe 11 Oil cooler hose 12 Springs 2 pcs 13 Inching control rod 14 Neutral switch wire 2 Disconnect the fOllowing parts 15 Inching valve link 16 Speed selector valve and directional selector valve links 602339 602338 92 ...

Page 93: ...ion shift it forward to pull the pinion back out ofmesh the bevel gear Installation Toinstaji follow thereverse ofremoval sequence Inspection after installation 1 Make sure that the electric wires pipes and hoses are connected properly 2 Adjust the inching pedal Refer to TEST ING A D ADJUSTING 3 Fill the transmission and transfercases with recommended oil 93 ...

Page 94: ...ssembly and reassembly of the gear pump refer to GEAR PUMP FOR TRANSMISSION AND STEERING CLUTCHES Disassembly sequence Remove the following groups in the alphabetical order A Transmission case and flange group B Reverse clutch group C Forward clutch group and 3rd speed clutch group 0 2nd speed clutch group V E 1st speed clutch group and cover group When disassembling the transmission place it on a...

Page 95: ...pe 4pcs 6 Transmission case p E J To remove transmission case 6 attach the hangers to its front face and hoist the case with that face up Thread size ofhangers M1O 1 25 2 Remove the following parts from case 6 7 Flange 8 Oil seal 9 Retaining ring 10 Ball bearing 11 Snapring 12 Gear pump driven gear 13 Ball bearing 14 Retaining ring 15 Ball bearing 16 Retaining ring 602343 7 602345 95 ...

Page 96: ...cs 9 Friction plates 4 pcs 10 Return spring 5 pcs 11 Pressure plate 12 Piston 13 Piston seal 14 Pistonseal 15 Input shaft 16 Ballbearing 17 Ring gear Remove 18 thru 24 as an assembly 18 Reverse planet carrier 19 Seal ring 20 Spring pin 3 pcs 21 Pin 3 pcs 22 Planet gear 3 pcs 23 Thrust plates 6 pcs 24 Needle roller bearing 3 pcs 25 Ball bearing 26 Reverse clutch piston housing 2 4 15 16 26 10 8 18 ...

Page 97: ...move 12 thru 23 as an assetrbly 12 Spring pin 3 pcs 13 Pin 3pcs 14 Planet gear 3 pcs 15 Thrustplate 6pcs 16 Needle roller bearing 3 pcs 17 Spring pin 3 pcs 18 Pin 3 pes 19 Planet gear 3 pcs 20 Thrust plates 6 pcs 21 Needle roller bearing 3 pcs 22 Forward 3rd speed planet carrier 23 Seal rings 3 pcs 24 Piston 25 Piston seal 26 Piston seal 27 Piston 28 Piston seal 29 Piston seal 30 Pin 5 pcs 31 Ball...

Page 98: ...ston seal 4 Piston seal 5 Pressure plate 6 Return spring 5 pcs 7 Friction plates 2 pcs 8 Mating plates 2 pcs 9 Snap ring 10 Snapring Remove 11 thru 17 as an assembly 11 2nd speed planet carrier 12 Spring pin 3 pcs 13 Pin 3 pcs 14 Planet gear 3 pcs 15 Thrustplate 6pcs 16 Needle roller bearing 6 pcs 17 Ball bearing 18 Ring gear 18 7 2 4 3 9 8 602348 98 ...

Page 99: ...cs 7 Friction plates 2 fpcs 8 Mating plates 2 cs 9 Oil seal retainer 10 Oil seals 2 pcs 11 Retaining ring 12 Snap ring 13 Output shaft 14 Ballbearing 15 Retaining ring Remove 16 thru 23 as an assembly 16 1st speed planet carrier 17 Ringgear 18 Springpin 3pcs 19 Pin 3 pc 20 Planet gear 3 pcs 21 Thrust plates 6 pcs 22 Needle roller bearing 3 pcs 23 Sealring 24 Ball bearing 25 Cover Disassembly seque...

Page 100: ...te 1 pc Forward Thickness of new plates 3rd Frictionplates 21 57 0 62 20 40 speed Mating plates 3p 0 8492 0 8031 clutches Pressure plate 1 0 0244 2nd speed Thickness of new plates 15 44 0 44 1st Frictionplates 2pcs 0 6079 14 60 speed Mating plates 2pcs 0 0173 0 5748 clutches Pressure plate 1 pc Thickness of one new friction 2 95 0 10 2 45 plate 0 1 161 0 0965 0 0039 2 Thrust plates Measure the thi...

Page 101: ...ssembly To reassemble install the groups in the reverse sequence E thru A E 1st speed clutch group and cover group Reassembly sequence 13 12 14 10 9 i H i H H H 24 15 11 17 8 7 6 5 1 6 23 I 19 21 18 22 20 21 20 22 25 4 3 602352 101 ...

Page 102: ...18 I Transmission l 1 17 10 9 8 7 5 5 1 case 15r 14 13 12 4 3 18 DISASSEMBLY AND REASSEMBLY D 2nd speed clutch group Reassembly sequence ...

Page 103: ...REASSEMBLY 21 19 16 EEEEEEFE EEEFE rr EE 2 38 9 1 37 36 35 34 23 32 33 3 20 18 IT 15 13 12 28 r Transmis EFEFErm 8 7 6 II 10 5 2 3 4 C Forward clutch group and 3rd speed clutch group Reassembly sequence 26 25 LL24 103 ...

Page 104: ...DISASSEMBLY AND REASSEMBLY B Reverse clutch group Reassembly sequence irr4rir2r ir rFFrr 2rrrrrr m 5 21 28 14 13 20 22 104 ...

Page 105: ... AND REASSEMBLY Reassembly sequence r Transmission case 721354 9 10 8 14 15 18 13 I 11 12 Suggestions 1 Apply a coat of engine oil to the 0 ring of oil filter screw 2 Bend each lock washer properly against the fiat of bolt 4 602333 602368 602356 105 ...

Page 106: ... pin with its mark A outside 4 Clutch piston installation Apply a coat of hydraulic oil SAB lOW to the sliding surface of each piston seal and install the seal to the clutch piston as shown 5 Piston housing installation Install the piston housings 5 pcs with their recessed portions aligned as shown This illus tration shows the piston housings seen from the engine end 106 ...

Page 107: ...e pressure air to the oil holes in the transmission case to make sure that the clutch pistons move smoothly in the housing A Oil hole for reverse clutch B Oil hole for forward clutch C Oil hole for 1st speed clutch D Oil hole for 2nd speed clutch E Oil hole for 3rd speed clutch 2 to 3 kgfIcm Air pressure 28 to 43 psi 196to294kPa 60 2360 602361 107 ...

Page 108: ...4 as an assembly 3 Slug 4 Valve 5 Inner spring 6 Outer spring 7 Roller pin 8 Plug 0 ring 9 Valve body 10 Cover 0 ring 11 Accumulator piston 12 Seat 13 Outer spring 14 Inner spring 15 Pin 3pcs 16 Plug 2 pcs 0 ring 17 Spring 2 pcs 18 Detent ball 2 pcs 19 Cover switch 0 ring 20 Speed selector plunger 21 Spring 22 Differential valve 23 Directional plunger 24 Return spring 25 Inching valve 26 Inching s...

Page 109: ...eassembly Clean all control valve parts except for seals by alkali washing before installing them for reassembly 32 31 33 23 22 21 19 20 r 25 30 29 24 26 27 13 14 12 11 10 36 12 678 3 16 1 15 18 17 Reassembly sequence S 34 35 109 ...

Page 110: ...Disassembly TRANSFER 1 Lock washer 2 Washer 3 Transfer cover 4 Bearing cage 5 Shims 1 set 6 Shims 1 set 7 Snapring 8 Roller bearing 9 Driven gear 10 Bevel pinion 11 Roller bearing 12 Drive gear 13 Bail bearing 14 Ballbearing 15 Transfer case 12 3 13 0 5 12 7 10 11 602364 110 ...

Page 111: ...DISASSEMBLY AND REASSEMBLY Reassembly sequence Er 14 12 liE15 111 ...

Page 112: ...O olmm ocyj4in ifthe m value is plus or 46 2mm 1 819 in m 100 0 1 mm 0 004 in if the m value is minus The shims for adjusting the pinion are available in these thickness Unit mm in Part number Shim thicknesses I J 58827 10900 0 1 0 004 0 4 0 016 1 0 0 039 L58827 11000 0 1 0 004 0 4 0 016 1 0 0 03 J BEVEL GEAR Installation Install the bevel gear on the left side in case of the DPS transmission inst...

Page 113: ...WHEEL CLUTCH except for the following items 1 Clutch control rod 2 Rubber hose for ste ring clutch oil 3 Rubber hose for oil cooler flywheel clutch group Installation Toinstall follow the reverseofremoval sequence Disassembly Disassembly sequence 1 Drain plug 2 Flange 3 Air breather 4 Connector 5 Damper cover 6 Shaft 7 Ballbearing 8 Snap ring 9 Oil seal 10 Damper 113 ...

Page 114: ...DISASSEMBLY AND REASSEMBLY Reassembly Engine 10 7 8 9 6 2 Reassembly sequence 10 6 602309 114 ...

Page 115: ...kets Refer to Removal TRACKS Removal sequence 1 Disconnect the following electric wires 1 Wire between battery switch and battery 2 Clamp for wire between battery and starter 2 Remove the following parts 1 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 pcs 4 Steering clutch oil pipes 4 pcs ...

Page 116: ...at the sprockets can be freely rotated and block the final drive cases using wood blocks as shown 5 Hold the clutch pedal in depressed position and place the transmission control lever in forward 1st position 6 Unscrew bolts 14 and 15 securing the steer ing clutch brake assembly To do this turn the splined portion of traiismission input shaft S to rotate that assembly to remove the bolts one by on...

Page 117: ...verse ofremoval sequence Suggestions for steering clutch brake assem bly and cylinder assembly removal These assemblies can be removed from the steering clutch case by removing bracket 13 with the operator s seat tilted forward It is not necessary to remove the seat plate Inspection after installation 1 Make sure that the oil pipes are connected properly 2 Fill the steering clutch with recommended...

Page 118: ...oller Ad Anchor A7 Clevis A8 Adjus ng nut A9 Brake band assembly AiD Outer drum All bolt A12 Plate A13 Plate A14 Spring A15 Spacer A16 Pressure plate A17 Disc plate A18 Friction plate A19 Inner drum Number of friction plates A18 No of friction 1 Machine model plates A18 PS standar swamp models 6 each side S super ultra super Swamp I 7 each side J models I Disassembly sequence 118 ...

Page 119: ...gear assembly Cl Locking plate C2 Nut C3 Set screw to be loosened Disassembly sequence 33 Bearing B4 Piston 35 Backup ring 36 Cylinder Disassembly sequence Remove C4 CS and outer race of C7 as an assembly C7 Roller bearing C4 Bearing cage C8 Bevel gear CS Oil seal C9 Drive shaft C6 Collar 119 ...

Page 120: ...ion plates 7 2 728 2 60 pcs SOPS model 2 Friction plates Measure the thickness of each friction plate and its backlash with the outer drum splines Replace the plate if any of these measurements exceeds the service limit Unit mm in Service Item Assembly standard I sons 8 7 0 343 I model 6 0 Thickness I I 4OPS 0 236 7 5 0 295 model Backiash with outer 0 16 to 0 52 I 0 80 drum splines 0 0063 to 0 020...

Page 121: ...DISASSEMBLY AND REASSEMBLY Reassembly A3 602412 602244 Tightening torque 3 5 0 3 kgfm 25 2 lbf ft 34 3 N m Tightening torque 3 5 0 3 kgfm 25 2 1bf ft 34 3 N m 121 ...

Page 122: ...ive shaft B4 B3 B2 SI Suggestions 1 Drive shaft installatio i 1 Before installing 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 C8 in the steering clutch case fit the inner race ofright hand roller bearing C7 to the shaft 2 Friction plate and disc plate installation 1 The 50 PS model has seven friction plates ...

Page 123: ...8 kgf m Preload 5 2 to 6 4 lbf ft 7 1 to 8 6 N mJ 6 55 to 8 00 kgf Spring balancer reading 14 4 to 17 6 lbf 64 2 to 78 5 N 4 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 9O at a time and take the s...

Page 124: ...teeth No To make the tooth contact pattern more visible lightlypress the gear when rotating L e 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 coi vex and concave faces Incorrect tooth contact 0 Pinion too far away from bevel gear 1 Contact extends toward the toe end of concave face...

Page 125: ...vex faces 2 To correct this contact increase the thick ness of shims F and turn adjusting nuts C2 to move gear C8 towardpinion G Recheck the contact pattern by brushing red lead OTE The foregoing tooth contact adjustments are meaningless unless the bevel gear and pinionbacklash has been adjustedproperly Pinion too close to bevel gear 602418 125 ...

Page 126: ...ation ofthe steering valve refer to Removal STEERING CLUTCHES AND BRAKES Disassembly Disassembly sequence 1 Cover 2 Oil seal 3 Piston 4 Valve spring 5 Plunger valve 11 Plunger valve 12 Return spring 13 Valve housing 12 8 602419 6 Return spring 7 Cover 8 Oil seal 9 Piston 10 Valve spring 126 ...

Page 127: ...DISASSEMBLY AND REASSEMBLY Reassembly I H r13 12 ll 1O 9 8 T 1 2 3 6 5 4 Reassembly sequence 127 ...

Page 128: ...ting seal 7 Shims 8 Screw Remove 9 thru 14 as an assembly 9 Gear case Remove 10 thru 14 as an assembly 10 Tapered roller bearing 11 Gear 12 Spacer 13 Tapered roller bearing 14 Shaft 15 Snap ring 16 Roller bearing 17 Snap ring 18 Pinion 19 Bail bearing 20 Oil seal Start by a b c when it is necessary to remove pinion 18 remove the steering clutch brake assem bly Refer to Removal Disassembly sequence...

Page 129: ...e to remove the case to which the shaft subassembly is installed 2 Tapered roller bearing removal 1 Remove the innerrace androllers oftapered roller bearing 10 as the components of the shaft subassembly Remove the outer race ofthis bearing from the steering clutch case when required 2 Similarly remove taperedroller bearing 13 Remove its outer race from the gear case 9 3 The outer race of rOller be...

Page 130: ...he service limit Unit mm in Item Assembly standard Service limit Width of teeth 40 1 57 36 1 42 J Installation reassembly Reassembly sequence 20 19 iT 16 15 13 9 8 7 5 6 4 3 2 14 12 11 10 Inner race Steering i clutch case 3 2 11 Tightening torque 7 6 to 9 2 kgf m 55 to 67 lbf ft 75 to 90 N m 602421 10 Outer race 130 ...

Page 131: ...d of the bearing Unit kgf m lbf ft N mJ Assembly standard 0 29 to 0 37 2 to 3 3 to4J J Item I Tapered roller bearing pinion preload V Starting torque T of pinion F kgf lbf N x Lm in distance from center of pinion Example V IfLis 25cm 9 8 in the balancerreading should be 1 l6kgf 2 6 lbf hAN to 1 48kgf 3 3lbf 14 5 N as calculated below 0 29 kgf m 2 lbf ft 3 N mj O 25ni 9 8in xX1 1 16 kgf 2 6 lbf 11 ...

Page 132: ...inder and remove the blade and blade arms Removal sequence 1 Remove the following parts 1 Bolts securing rigid bar 4 pcs 2 Bolts securing rear support 4 pcs 2 Hoist orjack up the machinejust a little and securely block the rigid bars and steering clutch cases using wQod blocks 3 Remove the undercarriage Installation To install follow the reverse of removal Se quence 132 ...

Page 133: ...b drain the oil from the idler Unscrews the bolts 4 pcs Fasten a hoist to the idler and pull the idl r assembly off the track frame I Guide 2 Shim 3 Bearing 4 Floating seal 5 Thrust washer sight of front idler 38 kg 84 ib approx Remove 6 thru 8 as an assembly 6 Shaft 7 Bushing 8 Idler Disassembly Disassembly sequence 133 ...

Page 134: ...5 6 lbf ft 75 8N m Reassembly sequence 6754321 Suggestions Lubrication 602187 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 cc 3 7 cu in S 90 gear oil approx Part number Part name Adaptor pump 58809 l5 100 Volume 58309 03100 1 6 8 134 ...

Page 135: ...tops moving backward Removal sequence 1 Remove recoil cylinder guard 1 2 Remove recoil cylinder assembly 2 by un screwing mounting bolts 4 pcs I Weight of hydraulic adjuster 15 kg 33 lb inder assembly approx 3 Remove carrier roller bracket assembly re coil spring assembly 3 Weight of carrier roller brack1 42 kg 93 ib assembly with carrier roller J approx Remove the track carrier roller assembly Re...

Page 136: ... Fill valve 4 Washer ReThove 5 thru 7 as an assembly 5 Cylinder 6 Dust seal 7 Rod packing 8 Plate 9 Shaft 10 Ring 11 Spring retainer 12 Sphng 13 Carrier roller bracket 14 Bracket for ultra super swamp model 15 Carrier roller bracket for ultra super swamp model 3 1 11 2 602426A 136 ...

Page 137: ...atleast 3 tons 7000 Ib as shown unscrew four bolts and gradually back offthepress arbor to letthe spring expand Take out the plate spring retainer 11 and spring z Never attempt tto remove the recoill springs without using a press or the cover retainer and spring Will lilly out L resulting in a serious personall injury 137 ...

Page 138: ...tallation Compress spring 12 as in case of disassembly and install plate 8 to the spring Reassembly Tightening torque 13 5 1kgf rn 98 7 1bf ft 132 10 N m Tightening torque 14 7 2 2 kgf m 106 16 lbfft 144 22N mi Reassembly sequence 602249 13 1O 8 2 Suggestion 138 ...

Page 139: ...o these blocks until the trackrollers 1 and 3 float up and away from the track 2 Chock the tracks at front end with blocks B 3 Remove the following parts 1 Track rollers 3 pcs center 2 Track roller guards front and rear 3 Track rollers front and rear Weight of track roller 1 pc lb Installation To install follow the reverse of removal se quence 6 0 0 5 kgf m Tightening torque for 43 4 lbf ft track ...

Page 140: ...DISASSEMBLY AND REASSEMBLY Disassembly 5 Bushing 6 Flanged roller Disassembly sequence I Collar 2 Floating seal 3 Thrust washer 4 Shaft 140 ...

Page 141: ...loating seals 2 Using a lint free cloth or a brush and wash ing fluid clean the surfaces of metal rings of floating seals making sure that these rings are free of any grime 2 Lubrication 1 After reassembling the roller fill it with recommended oil through plug hole in the shaft 2 Use an adaptor and volume pump for this filling I Capacity 75 cc 4 6 cu in SAE9O gear oil approx Part name Part number ...

Page 142: ... and steering clutch case Installation To install follow the reverse ofremoval sequence Suggestions 1 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 2 Install the seal washers properly Drive in the master pin with its center hole outside For detail of seal washer installation refer to Reassembly 3 To dri...

Page 143: ...bly la Standard shoe lb Swamp super swamp ultra super swamp shoe curved apex shoe r 2 Pin 3 Bushing 4a Seal washer for standard and swamp models 4b Rubber seal for super swamp and ultra super swamp models 5 Link Disassembly sequence 143 ...

Page 144: ...5 lbf ft 167 to 19 6 Nm 602185 Reassembly sequence 4a 3 2 Suggestions Install the seal washers and rubber seals as shown 4b 3 2 Track pans for standard and swamp models Ia swarrp models Seal washer standardarid swamp models Rubber seal super swamp and ultra super swamp models 602435A 144 ...

Page 145: ...o produce some clearance between track 1 and carrier roller 2 and remove the following parts 1 Bolts 2 pcs 2 Track carrier roller Installation To install follow the reverse of removal se quence Suggestions 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 Adjusting after installation Adjustthetracks Referto ...

Page 146: ...DISASSEMBLY AND REASSEMBLY Disassembly Disassembly sequence 1 Cover 2 Washer Remove 3 thru 5 as an assemHy 3 F1oa ing seal 4 Bushing 7 602438 5 Roller 6 Snap ring 7 Seal support 8 Shaft 146 ...

Page 147: ...roller fill it with recommended oil through plug hole in the cover 2 Use an adaptor and volume pump for this filling Capacity I cc 2 cu in SAE9O gear oil approx Part name Part number Adaptor I 58609 00300 Volume pump 58309 03 100 Tightening torque 12 2 1 2 kgf m 88 9 lbf ft 120 12N mj Tightening torque 4 2 0 4 kgf m 30 3 lbf ft 41 4N m 602186 147 ...

Page 148: ...DISASSEMBLY AND REASSEMBLY SPECIAL TOOLS 148 ...

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