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Summary of Contents for ES

Page 1: ...SERVICE MANUAL MITSUBISHI DIESEL ENGINE S4E for BD2F BS3F MITSUBISHI HEAVY INDUSTRIES LTD ...

Page 2: ...t 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 are used fo...

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Page 4: ...7 47 Cylinder head 51 Timing mechanism 61 Lubrication system 63 Fuel system 65 Cooling system 78 Electrical equipment 79 Bench tests 84 DISASSEMBLY AND REASSEMBLY Hints for facilitating disassembly reassemblY work 89 Engine dismounting and mounting 89 Rocker arnlS and rocker shaft 89 Cylinder head 91 Timing gears 95 Lubrication system 97 Cooling system water pump complete with thermostat 100 Flywh...

Page 5: ...MAINTENANCE STANDARDS Maintenance standards 137 Tightening torque 147 Application of sealers 148 TROUBLESHOOTING Troubleshooting chart I Troubleshooting chart 2 SPECIAL SERVICE TOOLS 0 150 154 157 ...

Page 6: ... SERVICE GUIDE ...

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Page 8: ... liters 0 Fuel tank sludge 16 gallons Clean by flushing 0 Check water level and replenish 0 Change coolant 16 liters 0 E Radiator 4 2 gallons I I Clean radiator fins 0 S Fan belt Check and adjust tension 12 mm 1 2 in 0 of defiection 0 0 U Thermostat Check for performance 0 Coolant circuit Clean by fluslting 0 E Clean element 0 Standard duty Air cleaner conditions Replace element 0 Bolts and nuts C...

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Page 10: ...CONSTRUCTION AND FUNCTION ...

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Page 12: ...Description Exterior views CONSTRUCTION AND FUNCTION 7 ...

Page 13: ...N AND FUNCTION Left side view 8 l Water pump 2 Fan 3 Fan belt 4 Fuel injection pump 5 Fuel feed pump 6 0il pipe 7 Fuel feed pipe 8 Fuel filter 9 Rocker cover 10 Governor 11 Fuel inlet l2 Adjusting lever l3 Starter ...

Page 14: ... head 2 Crankcase 3 Service meter 4 Flywheel housing 5 Exhaust manifold 6 R ocker cover 7 0il filler 8 Thermostat 9 0il pipe 10 Fan T IT l1ruii LL J F 13 Timing gear case 14 Mounting bracket 15 0illevel gauge 16 Drain plug ll Alter nator 12 Alternator bracket 11 0il pan 9 ...

Page 15: ... Water pump g Timing gear case 16 Rocker shaft 23 Flywheel ring gear 3 Piston 10 0il pan 17 Rocker bracket 24 Flywheel 4 Camshaft gear 11 0il strainer 18 Valve push rod 25 Camshaft 5 Fan 12 Elbow 19 Cylinder head 26 Crankshaft 6 Connecting rod 13 Rocker cover 20 Crankcase 7 Crankshaft pulley 14 Exhaust valve 21 Tappet 10 ...

Page 16: ...n 3 Valve push rod 4 Tappet 5 Camshaft 6 Connecting rod 7 0il pump 8 0il strainer 9 Rocker arm 10 0il filler 11 Glow plug 12 0il injection nozzle CONSTRUCTION AND FUNCTION tM j 13 Fuel filter 14 Fuel injection pipe 15 Fuel injection pump 16 Fuel feed pump 11 ...

Page 17: ...e mm in Exhaust mm in Starting system Model Fuel feed pump Manufacturer E Cam lift mm in Model Manufacturer 0 Plunger diameter u Fuel injection pump mm in Plunger lead Cam lift mm in 12 S4E Water cooled 4 stroke cycle in line turbulence chamber type diesel 4 94 x 94 3 701 x 3 701 2609 159 19 1 1 3 4 2 Clockwise as viewed from timing gear case side ASTM No 2 D diesel fuel API service classification...

Page 18: ...um E Type Trochoid type c Speed ratio to crankshaft 1 2 0 Oil pump Displacement liter 19 2 1172 2400 engine speed minimum cu in min rpm Oil temperature 50 C 122 F c 0 Discharge pressure 3 kg em 42 7 psi oJ Oil flIter Type Paper element type Type Piston valve type Relief valve Relief pressure kg em 3 0 3 42 7 4 3 psi Capacity exci radiator liter gal 4 6 1 2 Type Centrifugal type Water pump Speed ra...

Page 19: ... gear 11 132 No of teeth Model AP401 2B c Manufacturer Mitsubishi Electric E c Type 3 phase enclosed type 5 0 Voltage current 24 volts 12 5 amperes 3 Rated voltage gener 1100 ating speed rpm Rated output gener ill ating speed rpm 1900 Alternator Maximum permissible 7000 rpm Speed ratio to crank 1 68 shaft Model RMS4227C Manufacturer Mitsubishi Electric Type Voltage regulator Regulator unit Voltage...

Page 20: ...8 F temperature and 65 humidity1 DPS model I I I I f 37 40 30 In Q e o 20 0 DD model 14 5 I I i i V V i 35 0 1000 1300 lroo 1900 2200 2500 0 1000 1300 16CX 1900 2200 2500 Speed rpm 2400 Location of engine serial number The engine serial number is embossed on the upper left hand side directly above the starting motor as shown below Engine serial number Speed rpm 240 I I I I I 15 ...

Page 21: ...extending far below the level at which conventional design crankcases are terminated to mate with the oil pan Each main bearing cap is fitted into and held by the crankcase thus providing a more reliable support for the crankshaft at five places along its length Main thrust and big end bearings The five main bearings are of shell type each consisthig of two half shells there being no distinction b...

Page 22: ... a cast out space and an orifice piece precombustion chamber jet fitted into the cylinder head from its gasketed side The shapes of the piston crown and the communicating orifice are such as to produce good turbulence even when the engine is running slowly the glow plug sticking out into the ante chamber precombustion chamber right beside the injection nozzle is a startin g aid in cold weather Cyl...

Page 23: ...ce to wear Its bore for admitting the rocker shaft is bush ed the bushing is lead bronze in materiaL Rocker arm The rocker shaft is hollow one end of it is plugged while the other end admits lube oil for lubricating the rocker arms The external surface of this shaft is hardened by nitriding at low temperatures The four rocker brackets are alluminum aHoy castings shaped identically 18 Main moving p...

Page 24: ...e piston pin hole has its axis slightly offset toward anti thrust side in order to minimize piston noise Each piston has its weight indicated on its crown by punching All four pistons are rcquired to have the same weight within a given tolerance so that the vibration of the main moving parts during operation will be minimized CONSTRUCTION AND FUNCTION 1 Crankshaft 2 Ring gear 3 Flywheel 4 Cranksha...

Page 25: ...ithstanding the high compressive force exerted by the piston and also the complex bending stress Its mini mized mass reduces the stresses due to its own inertia A lead bronze bushing is press fitted into its small end A kelmet bearing is used in the big end to cope with the high bearing load to which the big end is subjected Timing gear train l Camshaft gear 2 ldler 3 Crankshaft gear 4 lnjection p...

Page 26: ... tappet resistant to wear and strong and thus suited to high speed operalion All tappets regardless of whether they are for intake valves or exllaust valves are identical and therefore identified by the same part number The axis of the push rod is slightly offset from the center of the cam This offset is calculated to cause the tappet to rotate during operation and thus to prevent its cam riding f...

Page 27: ...alve located in the bypass passage opens to allow the oil to bypass the element and flow directly into the oil gallery The bypass valve is an emergency means it opens to avoid any critically reduced supply of lube oil to the running parts of the engine Oil pan The oil pan is a sheetmetal vessel shaped deeper in its front part to provide an oil sump The oil sump is so located because of its positio...

Page 28: ...e The fuel feed pump mounted on the fuel injectioJ1 pump body and fanning a part of the injection pump unit draws fuel from the fuel tank and delivers it through the fuel nIter to the gallery inside the injection pump The injection pump is of individual plunger type con sisting of four plunger pump elements which are driven from a common camshaft Each pump element delivers intermittently a shot of...

Page 29: ...cm 132 sq in Filtering element mesh 2 microns I Fuel feed pump The camshaft in the bottom section of the injection pump has an eccentric cam besides the cams for aclu ating the individual pump elements By this eccentric cam the pumping plunger of Ihe feed pump is actuated to draw fuel through the inlet strainer and forward it with a discharge pressure limited to 2 kg cm 28 4 psi to the injection p...

Page 30: ...on of camshaft As the plunger rises the fuel in the barrel becomes compressed and is forced out through the delivery valve into the injection pipe The upward plunger stroke effec tive in compressing or pressurizing the fuel is variable and is varied by means of the control rack and pinion in the manner to be explained later The delivery valve through which a shot of fuel is forced out into the inj...

Page 31: ...livery chamber 2 BEGINNING OF PRESSURIZATION The cam pushes up the plunger and as it rises its top portion covers the feed hole 3 FUEL DELIVERY Fuel is compressed it forces the delivery valve against its spring to unseat the valve From this moment the fuel in the line from delivery valve to injection nozzle is pushed by the plunger 4 END OF EFFECTIVE STROKE Pressurization ceases and the delivery v...

Page 32: ...s of the plunger cylinder control pinion and rack A Delivery stroke Delivery stroke Effective str l T 1 Non injection 2 Half injection Injection quantity contiol 3 Full injection 4 Delivery valve The seat of the delivery valve takes its position right above the barrel and is held down tight by the screw in pipe connection The valve has its guide portion fitted into the bore of the seat and is capa...

Page 33: ...accelerator This governor function is in sharp contrast to that of a minimum speed maximum speed governor whose control action is to limit the lowest and highest speeds of the engine leaving the control of intermediate speeds to the operator The RSV governor too limits the lowest and highest speeds to provide a speed range over wmch it performs the governing action mentioned above These limits as ...

Page 34: ...ion For the tension lever that part of the spring rate of the control spring effective for CONSTRUCTION AND FUNCTION pulling this lever can be changed by angling the spring Swiveling lever is the meanS of angling 1 Control spring 2 Tension lever 4 swiveling lever Control spring operation Note that hook hole E is in the arm of swiveling lever and that this arm can be turned down to reduce the tensi...

Page 35: ... screw guide lever tension lever control lever idling spring adaptor spring control spring swiveling lever start spring l Adjusting screw 2 Torque spring 3 Guide lever 4 Tension lever 5 Torque control lever S PinA 7 Control lever a Idling spring g Tension lever pin 10 Adaptor spring 11 Full load stopper 12 Flyweights 13 Control spring 14 Swiveling lever 15 Shackle 1S Control rack l7 5tart spring l...

Page 36: ...topped The stop device if provided makes it possible to pull the control rack directly and independently of the adjusting lever outside and swiveling lever inside This device consists of a stop lever a supporting lever two springs and a screw all associated with the control lever connected to the control rack through the shackle 1 Start spring 2 Controllever 3 Stop lever 4 crew 5 Supporting lever ...

Page 37: ... in the idling position mentioned above the governor maintains a con stant engine speed so called idling speed by responding automatically to any tendency of the speed to rise or fall and acting to cancel off this tendency by moving the control rack Suppose now that some load is put on the engine The engine will then slow down and the flyweights contract reducing the push of control block to allow...

Page 38: ... noted is lower than the original no load speed by several percent despite the fact that the adjusting lever has been kept at the position limited by the maximum speed stopper This difference in speed between no load condition and full load condition is due to the speed droop or speed regulation characteristic inherent in the governor of this type_ Speed droop is desirable for the stability of an ...

Page 39: ...e engine rises The reason Is that air has mass and takes a definite time to flow As long as the amount of air drawn into the cylinder is sufficiently large for the amount of fuel sprayed into it there is practically no problem the fuel will burn completely and the exhaust smoke will be clean However under full load condition and consequently with a large amount of per stroke fuel injected a questi...

Page 40: ...th stop lever tilts the control lever to pull the control rack all the way out to the non injection position thereby causing the engine to stop Injection nozzle and nozzle holder Referring to the cross section of the nozzle the internal space of the nozzle and holder is filled with fuel The leakoff line for passing the fuel back to feed pump is connected to nozzle holder The leakoff passage drille...

Page 41: ... 3 0istance piece 4 Pres5ure pin Pressure spring 6 Washer 7 Nozzle holder g Gasket 9 Nut Injection nozzle Cross section Thermostat I I I I Cylinder head U o Thermostat bypass D I Crankcase I Water pump 1 I Cooling system block diagram 36 l Thermostat 2 Water temperature gauge 3 Bypass hose 4 Radiator 5 Water jacket 6 Cylinder head 7 Crankcase 8 Drain plug CD 5 7 8 Direction of coolant flow ...

Page 42: ...t a rising rate of flow with a corresponding decreases in the amount of coolant being bypassed As the tern perature reaches 90 C l94 F the valve becomes full open shutting off the bypass passage The probe for temperature gauge 2 is installed in the coolant outlet of cylinder head It is with the signal produced by this probe that the gauge located at the control station operates Water pump Pump cas...

Page 43: ...ge Output Yoke dia Rating Rotation Weight No load characteristic Locked rotor characteristic Switch on voltage 38 Starter switch l ___ ____ _ Glow plug pilot lamp Charge pilot lamp Oil press ure Indicator If f l Fuse box jh Battery 12V OAH x 2 Circuit diagram Specification Lever shift pinion type with over running clutch built on totally enclosed water proof DC motor M005T27671 compound wound 24 v...

Page 44: ... are distributed around the inner race each being pressed against the cam by a spring The splined sleeve is capable of sliding axially along the shaft and when it does slide the whole clutch moves axially As the motor shaft rotates the sleeve revolves with the shaft when the sleeve is prevented from advancing any further with the pinion meeting the stopper to drive the pinion in mesh with the ring...

Page 45: ...vances smoothly to mesh its pinion with the ring gear b As the pinion meshes into the ring gear fully the plunger is allowed to move in all the way making its contactor to close thereby permitting full current to flow throUgil terminals M B into the motor Consequently the motor runs with full force to crank the engine Under this condition the coil in series with the motofis shunted so that practic...

Page 46: ... Searing CONSTRUCTION AND FUNCTION Alternator J20091 2 Rear bracket 5 Front bracket 7 Diode a Pulley 9 Bearing 3 5tator coil 6 Fan Alternator Cross section 4 Charging system operation The first of the two circuit diagrams to follow shows how the current flows from the battery when the key switch is turned on for starting up the engine The second shows the flow of current for charging the battery I...

Page 47: ...current for starting the engine 42 Under this condition points PI p and P3 remain in the indicated state by their springs Current flows in VCI but it is too small to be of any consequence b Normal charging operation As the engine starts up the alternator unit begins to develop output voltage so that VC becomes energized by the voltage between terminal N and ground E as mentioned before to open poi...

Page 48: ... resistor Rs pass some current for the alternator field when points p are open they prevent the voltage from fluctuating so widely as to cause the lamp to flicker Glow plugs Each precombustion chamber of the engine has a glow plug The plug is a starting aid and serves to warm up the chamber by glowing red with electricity supplied from the battery It is of a sheathed type in construction The four ...

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Page 50: ...MA1NTENANCE AND ADJUSTMENT ...

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Page 52: ...iddle section of the belt between alternator pulley and water pump pulley and see how much this portion of the belt deflects by measuring with a rule The deflection should be 12 mm 1 2 in if not loosen the mounting bolts of the alternator holder to displace the holder in order to lighten orslacken the belt After obtaining the prescribed amount of deflection be sure to tighten the bolts good and ha...

Page 53: ...ons and piston rings are available for the two oversizes 3 If any sleeve bore is unevenly worn determine the oversize to which the sleeves are to be rcbored on the basis of the maximum wear noted This will ensure perfect roundness in the oversized bores NOTE If the cylinder sleeves are found in good condi tion vith the wear far less than the repair limit it is permissible rebuild the engine with r...

Page 54: ... 1 0 98 0 10 93 0 34407 00300 0 07 0 2 3 858 0 0039 0 0 0028 3 66 0 0079 Main bearing inspection I Inspect each main bearing for evidence of wiping or fatigue failure for scratches by dirt particles imbedded and for improper seating on the bore MAINTENANCE AND ADJUSTMENT bearing cap On the basis of findings determine whether the bearing should be replaced or not 2 Check each main bearing to be use...

Page 55: ... tochole 0 0014 clearance 0 0034 0 0047 0 004 Tappet hole 22 0 021 0 1 0 diameter 0 866Ij 00083 0 004 Camshaft hole inspection I Inspect the inside surface of each hole for wear and scratch 2 Mike the I D of respective holes and also the camshaft journals and from the readings taken compute the radial clearance available on each journal If the clearance exceeds the limit insert bushing or replace ...

Page 56: ...it grind smooth the seating face of each valve removing the wear groove if any and finishing it to the specified angle of 45 deg For this service use a valve refacer Unit mm in Item Standard Service limit 8 0 045 0 1 Intake 0 060 0315 0 00177 0 004 Valve stem 0 00236 diameter 8 0 060 Exhaust 0 075 0 15 0315 0 00236 0 0059 0 00295 1 2 0 0472 Valve head thickness I 5 0 059 after refacing Valve head ...

Page 57: ...ead 2 Guide A Guide length outside hole Installing valve guide 4 Valve stem seal replacement The valve stem seals should be replaced if the engine disassembled shows evidence of lube oil leaking into the combustion chambers along valve stems The seal can be readily removed When putting on a new seal make sure that it fits snugly into tlie annular groove provided in the valve guide end I If a valve...

Page 58: ...body 4 Valve guide 2 Valve seat 5 Calking ring 3 Cylinder head Installing valve seat by using calking tool Valve spring inspection Inspect each spring for cracks and check it for square ness free length and as installed length against these specifications MAINTENANCE AND ADJUSTMENT Unit mm in Item Standard Repair limit Valve spring 48 85 47 6 free length 1 92 i 1 874 Valve spring 0 4 25 max square...

Page 59: ...f the flange faces are warped by more than 0 2 mm 0 0079 in when checked as shown grind them smooth and flat If any flange is found cracked replace the manifold Checking exhaust manifold flange faces for flatness 54 Crankshaft inspection 1 Crankshaft distortion Support the crankshaft as shown and roll it to measure its deflection with a dial gauge Distor tion is one half of the deflection dial gau...

Page 60: ...h as roughing scratches pitting and burns and as necessary repair the crankpins by grinding to the next undersize or replace the crankshaft MAINTENANCE AND ADJUSTMENT Miking crankshaft crankpins Positions for miking crankpin b Mike each crankpin to take a total of four readings to determine the wear out of round and taper If any of the limits is exceeded repair by grinding to the next undersize or...

Page 61: ...erence between the width of thrust bearing and the dimension A indicated below 1 A Journal width for thrust bearing 5 Oil seal inspection Inspect each oil seal and replace it if it is badly worn damaged or thermally fatigued at the lip surface An oil seal suspected of poor sealing action evidenced by signs of leakage noted upon engine disassembly must be inspected more closely 6 Oil seal sleeve in...

Page 62: ...0S9 0 008 skirt oversize O SO mm 94 36 0 0IS 0 0197 in 3 71S0 0 000S9 oversize At piston 0 6IS o 680 crown 0 02421 0 02677 C 0 46S o S30 At No 1 land 0 01831 0 02087 At No 2 land 0 4IS o 480 Piston 0 01634 0 01890 clear Just below 0 27S 0 340 0 2 ance oil ring 0 01083 0 01339 0 008 in 17 mm bore 0 669 in O l9S o 260 below oil 0 00768 0 01024 ring 37 Smm 1 476 in 0 ISS 0 220 below oil 0 00610 0 008...

Page 63: ...16 0 0031 0 0079 c earance No 2 0 D25 0 060 0 15 in the 0 0010 0 00236 0 0059 groove 0 025 0 060 0 15 No 3 0 0010 0 00236 0 0059 5 Pin clearance in piston Replace the piston or piston pin if the pin clear ance as computed from diameter readings taken on pin hole and pin exceeds the service limit Unit mm in Item Standard Repair limit 0 Piston pin diameter 28 0 006 0 1 102 0 00024 Pin clearance in t...

Page 64: ...006 MAINTENANCE AND ADJUSTMENT J8806 Checking connecting rod fco twist b Inspect each big end bearing for evidence of wiping or fatigue failure for scratches by dirt particles imbedded in and for improper seating on the bore Determine whether the bearing should be re used or replaced on the basis of findings c Check the radial clearance between crankpin and bearing if the repair limit specified be...

Page 65: ...ch bearing shell for crush_ Shells found to be loose in the bore or have an exces sive crush must be replaced A crush of up to 0 04 mm 0_0016 in which will yield to a load of 350 kg 772 lb is prescribed As in the case of the main bearing shells some crush is needed for securing a proper fit without which the bearing might roll or jump in place resulting in localized overloading and consequ ent fla...

Page 66: ...em Standard Repair limit Flatness of friction 0 15 0 006 0 5 surface max 0 020 Face runout of 0 15 0 006 0 5 friction surface max 0 020 3 Make sure that the flywheel securing bolts are in good condition with their screw threads showing no signs of stripping The ring gear with broken or badly worn teeth must be replaced Clean the bushing for pilbt bearing if the bushing is abnor mally worn or showi...

Page 67: ... 2 087 0 0016 0 0024 Camshaft journal to 0 04 0 09 0 15 hole clearance 0 0016 0 0035 0 0059 Miking camshaft journals 62 Timing gear inspection I Be sure that the backlash in each mesh is within the repair limit If the limit is exceeded reduce the backlash by replacing the worn gear To measure backlash use a thickness gauge put the gauge squarely into between two gear teeth Checking timing gear bac...

Page 68: ...ed condition c Crankshaft gear Replace the gear if its teeth show signs of defective tooth contact or are excessively worn or otherwise defective d Idler gear Inspect the idler gear teeth and as necessary replace the gear 6 Inspect the gear case for cracks and for evidence of oil leakage at the part ahead of the crankshaft Acracked case must be replaced Inspect the crank pulley too examining the c...

Page 69: ... the pump body from the mike readings if the service limit in terms of clearance value is exceeded or if the shaft is in badly dam aged condition replacement is necessary Unit mm in Item Standard Service limit to Rotor shaft 13 0 015 diameter to 0 512 0 00059 Shaft to body 0 032 0 074 0 15 clearance 0 00126 0 00291 0 0059 Oil fIlter inspection The fIltering element is prescribed to be replaced aft...

Page 70: ...ge Inspect the housing for cracks broken screw threads and other types of damage and repair or replace it as necessary 4 Priming pump wear Inspect the piston and cylinder for scratch marks wear and rusting Check the seating faces of its valve for wear An excessively worn or damaged seating face must be corrected by replacement Fuel feed pump testing The feed pump is in satisfactory condition when ...

Page 71: ... be told from its appearance A worn plunger has nO surface luster If any of the four plungers is in defective condition to require replacement then all four pumping elements plunger and barrel should be replaced to ensure the uniform pumping perform ance for the four injection nozzles This replace ment is necessary also when any of the pumping elements rails to meet the following test require ment...

Page 72: ...142 psi If tlus duration is not less than 5 sec onds then the delivery valve is satisfactorily tight Item Service limit Seating tightness of delivery valve in terms of duration for 5 seconds minimum a drop of 10 kg cm2 142 psi from 150 kg cm2 2133 psi When the injection pump is in disassembled state check the fit of the delivery valve piston in the bore by holding the valve with fingers as shown F...

Page 73: ...8 replaced Measure the free length of each spring if the spring is found to be shorter by 0 5 mm 0 020 in plunger spring or by 1 mm 0 039 in delivery valve spring than the smallest stand ard length replace it Unit mm in Item Standard Service limit Plunger 49 1 0 0 5 Free length spring 1 929 g 039 0 020 ofspring Delivery 32 0 5 I valve 1 26 0 020 0 D4 spring Inspect each plunger spring seat if the ...

Page 74: ... these parts maximum speed stop per stop adjusting screw idling spring torque spring and adaptor spring ush in the control rack toward the governor side as far as it will go and set the rack position measure 95904 01060 at the starting position zero mm Setting rack measure at O mm position MAINTENANCE AND ADJUSTMENT c Bleed air out of the injection pump as follows First move the selector lever of ...

Page 75: ...is not within the standard range adjust the pre stroke by repositioning the tappet adjusting bolt vertically with the tappet wrench Turning this bolt by about a half rotation varies the pre stroke by about 0 5 mm 0 020 in After making this adjustment be sure to have the lock nut tightened fully Check and adjust the other plungers for the prescribed pre stroke by repeating the foregoing procedure b...

Page 76: ...antity is measured as follows Close the nozzle holder overflow valve so that the injection nozzle will spray out the fuel delivered by its pumping element Have the high pressure pump of the tester taken out of service by disen gaging its clutch Keep the selector lever in injec tion position NOTES 1 a Keep the fuel supply pressure at 2 0 kg cm 28 4 psi b Be sure to use a measuring cylinder for each...

Page 77: ... Standard Service diameter limit 0 Flyweight 16 0 11 0 25 roller O D 0 63 0 0 0098 0 0043 72 2 Inspection of parts related to control lever a If the control block is worn down at its end and chrome plating is off replace the control block or guide lever b Measure the clearance between the holes of the tension lever and guide lever and supporting lever shaft If the limit is reached replace them If ...

Page 78: ...trol adjustment low speed control adjustment and torque spring adjustment Each adjustment will be explained in reference to the characteristic curves a Preparation Install the angular c le plate protractor on the governor housing to read the angular posi tion of the adjusting lever vertical 40 Protractor on governor housing MAINTENANCE AND ADJUSTMENT b Maximum speed adjustment I Setting the full l...

Page 79: ... e is sharper and if it should be too sharp the governor would become too sensitive It is important to note that the speed regulation of an engine unit complete with its injection pump and governor is determined not solely by the governor setting but by the character istics of the engine Which were explained earlier in the discussion of the torque spring For the present engine a proper regulation ...

Page 80: ...ximum speed will rise too high in operation 3 Lower the speed to Ng 200 rpm this should cause the control rack to move in and comes to Rg 11 0 mm 0 433 in mini mum owing to the action of the idling spring MAINTENANCE AND ADJUSTMENT Setting idling spring for low speed control 4 After completing the foregoing adjustments stop running the pump and turn the adjusting lever in the stopping direction un...

Page 81: ...ng pressure 120 kg cm 1706 psi 3 fuel rpm mm in supply ptessure 2 0 kg cm 28 4 psi and 4 high 400 lOA 0 1 pressure tester pump 1 6 nun 0 0630 in dia x 6 51 0 50 0 4094 0 0039 mm 0 2362 in dia x 600 mm 23 622 in 8 8 0 1 650 0 3465 0 0039 Pump Rack Individual Permissible speed position Pumping injection difference strokes rpm mm in cc cu in cc cu in 4 Match between injection pump and engine 1000 8 5...

Page 82: ...ed to as valve opening pressure or begin ning of injection pressure but will be called here injection pressure for short The value of this pressure is specified it is checked and adjusted as follows a Install the injection nozzle in the nozzle tester and operate the manual pumping handle of the tester several strokes to prime the nozzle b MAINTENANCE AND ADJUSTMENT Move the lever up and down slowl...

Page 83: ... used in the engine provided that it passes this final test seating tightness test With the injection nozzle mounted on the nozzle tester raise the pressure slowly to 100 or 110 kg cm 1422 or 1564 psi without exceeding the set pressure of 120 kg cm 1706 psi so that the needle valve will not unseat Hold the pressure and observe the nozzle tip there should be no evidence of fuel oozing out to form a...

Page 84: ...tained in an appropriately sized pan and by heating the water with such as an electric stove Check the rising temperature with a thennorneter MAINTENANCE AND ADJUSTMENT Inspection of fan belt and fan I Inspect the belt for signs of deteri oration such as cracks and check it for permanent stretch An excessively stretched or cracked belt must be replaced 2 Inspect the fan blades for distortion and c...

Page 85: ...eld and low speed Very large cur rent and very Short circuited field coil Wgh speed The best way of testing the starter is to run it under loaded condition but that requires special testing equipment For ordinary servicing pur poses the no load test and troubleshooting guide will do 2 Inspection after disaSsembly 80 a Check the armature coils and commutator for ground open and short A circuit test...

Page 86: ...est in the manner already outlined and check the magnetic switch and its lever mechanism for pinion shifting action To check to see if the pinion plunges forward and recedes properly open and close the switch in the test circuit arranged as shown below repeatedly The pinion should move back and forth smoothly through its full stroke without any hitches If any faulty movement is noted of the pinion...

Page 87: ...rrent from the alternator itself from the DC output terminal of its rectifier whose output voltage is now high enough to buck the current from the battery Raise the speed further until the voltmeter reads 28 volts and check the speed right then This speed is the one at which the alternator unit develops the rated voltage and should be about 1100 rpm Next close switch K2 with the variable load resi...

Page 88: ...ced_ c Checking the field coils for short through layers Check the ohmic resistance of field circuit by using the circuit tester with its testing prods put to the two slip rings_ The field coils are in Cd MAINTENANCE AND ADJUSTMENT sound condition if a resistance reading of approximately 27 oluns at 20 C 68 F is obtained_ A lower reading than this calls for rotor replacement Checking field coils f...

Page 89: ...the overhauled engine is capable of 84 The test bench is an apparatus complete with a dynamo meter In the following procedures a standard type test bench is assumed 1 Breaking in Have the engine set up on the bench and aligned to the dynamometer Operate the engine for a total of2 hours according to the schedule indicated below During this operation observe the running condition carefully and if an...

Page 90: ...eter b Setting the rack injectionquantity test Set the rack so that fuel injection quantity will be between 7 6 and 7 8 liters 464 and 476 cu in per hour at 1600 engine rpm c Setting the idling stop screw no loadminimum speed test Set the stop screw so that when the adjusting lever is turned to bear against this screw the governor will allow the engine to run at 600 rpm 3 Engine output test Turn o...

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Page 92: ...DISASSEMBLY AND REASSEMBLY ...

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Page 94: ...kets and the like are concerned c Before fitting a running part be sure to oil its sliding surfaces Use clean fresh engine oil d Have the specified sealing compound on hand Use of the compound is prescribed for most of sealing parts e Torque limits are specified for some bolts and nuts Be sure to use torque wrenches and to refer to the specified values of torque limits Engine dismounting and mount...

Page 95: ...ance is prescribed to be 0 25 mm 0 0098 in cold Rocker shaft disassembly and reassembly Q 0 l Eye bol t 2 0il pipe 3 Snap ring A Washer 5 Rocker arm assembly lO Bracket 11 Short bolt 14 Long bolt 15 Spring 16 Shaft Rocker shaft assembly Exploded view Rocker shaft assembly 1 To break the rocker shaft assembly taken off the cylinder head into its component parts the first step is to remove snap ring...

Page 96: ... a Cyllnder head bolt 9 Cylinder head Removing cylinder head 3 CAUTION Cover up the open ends of injection pipes and air intake pipe to avoid entry of dirt When removing the gasket from cylinder head be careful not to nick or mar the gasketed surfaces of head and block Read the torque needed to loosen each cylinder head bolt these readings might help locating the cause of the trouble reported Inst...

Page 97: ...le holder 2 Glow plug Disassembling cylinder head 1 2 Remove nuts 3 securing exhaust manifold 4 to the block Take off manifold 4 3 Similarly remove intake manifold 5 92 3 Nut 5 lntake manifold 4 i xhaust manifold Disassembling cylinder head 2 4 Remove thennostatelbow 6 and take out ther mostat 7 6 Thermostat elbow 7 Thermostat Disassembling cylinder head 3 5 Remove exhaust and intake valves as fol...

Page 98: ...m which it w s removed in disassembly c Leave the valve guides in place unless they need replacement d Observe the carboned condition of the com bustion chamber surfaces intake and exhaust ports and valve heads before cleaning them What is observed is an important symptom for troubleshooting e To remove the valve guide be sure to use the valve guide remover CAl DISASSEMBLYAND REASSEMBLY o 2 l Valv...

Page 99: ... Rocker bracket 6 valve guide 7 ExhauSt valve 8 Valve seat g Cover lO Rocket arm l1 Rocker shaft 12 Spring retainer 13 Valve cap 14 Valve cotters 15 Spring l6 Stem seal 17 Glow plug 18 Leak off pipe 19 Nozzle 20 Cylinder head 21 Precotnbustion chamber jet J j Cylinder head Cross section 1 Assuming that the valve guides have been removed install each guide 2 as shown with the use of the guide insta...

Page 100: ... bolt 3 securing the adjusting plate to the alternator and take off fan belt 4 1 Bolt and washer 14 pes each 2 Fan Removing fan 3 Bolt 4 Fan belt 2 Remove nut 5 on water pump shaft and hut 6 on crankshaft From the pump shaft remove fan spacer and by using the fan puller A draw pump pulley 7 Draw pulley 8 from crankshaft with the puller DISASSEMBLY AND REASSEMBLY 5 Nut and washer 7 Pump pulley 6 Nu...

Page 101: ...ming gears be sure to tum over the crankshaft to bring these gears into the position at which the timing marks provided on them meet each other Removed gears if any are to be fitted to take the same angular position which is illustrated below 3 l Camshaft gear 3 Crankshaft gear 2 ldler gear 4 lnjection pump gear Timing gear match marks meeting each other Installation The procedure is generally the...

Page 102: ...cified in terms of belt defiection and is prescribed to be 12 mm 0 472 in deflection under thumb pressure Lubrication system Oil fIlter removal and installation The oil filter is bolted to the crankcase Removing the four bolts I allows the fIlter 2 to be detached from the engine for removal When installing the fIlter make DISASSEMBLY AND REASSEMBLY sure that the seating face is clean and that the ...

Page 103: ...he oil pump will not come off if oil pump drive gear is firmly meshed with camshaft skew gear While giving a pull to the oil pump turn over the crankshaft a little to ease the drive gear from the skew gear When installing the oil pump examine the gasket for the mounting bolt Replace the gasket if it is nicked or otherwise defective Oil pump disassembly 1 From the pump remove oil strainer 2 and pum...

Page 104: ... Main shaft a lnner rotor 7 lnner rotor pin Removi ng inner rotor pin Oil pump reassembly After securing inner rotor to shaft by driving in the pin insert the shaft into the pump case and mount the gear on the shaft locking the gear by driving in the tapered pin DISASSEMBLY AND REASSEMBLY 2 3 l 4 IflJll ifHl 5 d 0 1 Pump drive gear 2 Main shaft 3 Pump case 4 Outer rotor 5 lnner rotor Oil pump Cros...

Page 105: ...capable of sucking oil in Cooling system water pump complete with thennostat Water pump removal 1 Remove four bolts I and take off fan 2 Loosen bolt 3 and remove fan belt 4 l Bolt and washer 4 pes each Removing fan 3 Bolt 4 Fan I e t 2 Loosen clamp 5 and disconnect bypass hose 6 3 The oil pipe for pressure feeding lube oil to the water pump is connected to the pump by means of union nut 7 Loosen t...

Page 106: ...ening of crankcase to avoid entry of dirt Water pump disassembly 1 801t 2 Cover 3 lmpelJer 6 Snap ring 7 Bearing a Shaft 4 Unit seal 9 Bearing 5 0il seal lO Pump case Water pump Exploded view 1 Remove cover 2 which is secured to the pump case by bolts 1 DISASSEMBLY AND REASSEMBLY l Bolt and washer 2 Cover Removing pump cover 2 Hold the pump shaft rigidly and unscrew pump impeller 3 to remove it fr...

Page 107: ... the shaft into the case 3 To the pulley side of the pump case fit snap ring 5 4 Attach unit seal 7 to impeller 8 and mount the impeller on the shaft by running the impeller onto the shaft 5 Put on cover 9 and after fastening it down to the case check to be sure that the impeller does not rub the cover Flywheel and ring gear lUng gear separation from flywheel It is assumed here thalthe clutch has ...

Page 108: ... the 100 C 2IfF bath will heat it uniformly to this temper ature Upon removing the ring gear from the oil bath fit it to the flywheel making sure that the ring is seated firmly 3 Drive the pilot bushing into the flywheel DISASSEMBLY AND REASSEMBLY il lJI A ii Installing pilot bushing 4 Screw two guide bolts A into the crankshaft end Hold out the flywheel squarely against crankshaft positioning it ...

Page 109: ...l filter given here are self explanatory and will serve to explain the methods of disassembly and reassembly l Filter cover 4 Spring 7 Drain plug 2 Gasket 5 Filter case 8 Bolt 3 Element 6 80h 9 Air vent plug Fuel filter Cross section 104 1 Parts are to be taken off one another in the ascending order of reference numbers l Bolt 2 Filter cover 3 Gasket 4 Element 5 Spring seat 6 Spring 7 Filter case ...

Page 110: ... nozzle tip 2 Clamp retaining nut 1 between the jaws of a vise as shown put the wrench to the holder and loosen it to separate it from the nut 1 3 Take out of the removed holder these parts nozzle tip 3 distance piece 4 pressure pin S spring 6 and washer 7 Wash the disassembled parts clean with clean kerosine or diesel fuel oil and dry them with compressed air Using a wooden scraper remove carbon ...

Page 111: ...ver rod 1 and disconnect fuel feed pipe 4 from the pipe joint at injection pump Similarly dis connect the pipe between fuel filter and injection pump Remove fuel return pipe 3 by undoing its pipe connections 106 At each injection pipe connection on the pump unit undo connector 5 to disconnect injection pipe 6 Remove oil pipe 7 l Adjusting lever rod 2 Control wire 4 Fuel feed pipe 5 Connector 6 lnj...

Page 112: ...he following manner Setting injection timing DISASSEMBLY AND REASSEMBLY 4 Tilting the pump toward the engine advances the timing and vic e versa _ Refer to the graduation marks provided on the edge face of the mounting flange one division is equivalent to 6 deg of crank angle S Having made sure that all timing marks are matched as prescribed and that the beginning if injection is correctly timed i...

Page 113: ...ew 7 I Remove priming pump 2 and take out check valve 3 l Valve holder 3 Check valve 2 Priming pump Removing priming pump 108 NOTE Priming pump is not meant for disassembly its cylinder and valve holder are integrally com bined by using a bonding compound 2 Loosen piston chamber plug 4 pick out piston spring 6 and draw out piston 5 4 Piston chamber plug 6 Piston spring 5 Piston Removing feed pump ...

Page 114: ...es of injection pump unit and set up the pump on the bench Drain lube oil I Detach and remove the governor cover as follows a Loosen idle lock nut I remove idling sub spring 2 loosen screws securing cover piece 3 and take off this cover piece b Remove the six screws 4 securing the governor DISASSEMBLY AND REASSEMBLY cover to the housing and detach the cover by pulling it a little Insert the screwd...

Page 115: ...t snap ring 14 drive out lever bushing 15 to outer side This permits the lever 12 to come out of the cover Removing tension lever Governor reassembly Carry out the sequential steps of disassembly in reverse order adhering to the following instructions I Flyweight mounting After positioning the flyweights on camshaft secure it by tightening the round nut to 6 kg m 43 4 ft lb Be sure to place a spri...

Page 116: ...s smoothly without unduly heavy resistance After securing the governor cover to the housing check to be sure that tensioning and relaxing the start spring cause the control nick to slide outward and inward smoothly Injection pump disassembly inspection and reassembly I General rules onwork a Make a batch of washing fluid available for ready use For the washing fluid use clean kerosine or diesel fu...

Page 117: ...n the work bench by means of the holding fixture Remove the cover plate and look in to see if there are signs of rnalcondition NOTEl Removing one part after another without exam ining each part critically and heeding to the story each part wants to tell is a wasteful practice and prevents you from taking proper measures necessary for restoring the pump as close to the original condition as possibl...

Page 118: ...the tappet Remove all four tappets in this manner NOTE Removing screw plugs f Remove the bearing cover and draw out the camshaft gently CAUTION When removing the bearing cover be careful not to nick or mar the seating faces or oil leakage will develop during operation I t j i 11 t j Removing camshaft Tilt down the pump so that the plungers and springs will not fall off Removing tappets i Remove th...

Page 119: ...the cylinder barrel from top side by pushing on it s bottom Removing cylinder m Remove the rack guide screw and draw out the control rack Removing control rack 3 Inspection Layout the removed parts in the trays segregating them in groups each group for each pumping element and related parts as identified for the respective reference numbers No 1 No 2 No 3 and No 4 Do not disturb the original suits...

Page 120: ... the methods to be described SUbsequently DISASSEMBLY AND REASSEMBLY o Oe Delivery valve test Set up the pump on the tester and install a test pressure gauge on one of the delivery valve holders Prime the pump with fuel oil and drive the pump at 200 rpm with the control rack locked in idling position The pressure gauge indication under this running condition tells whether the cylinder and plunger ...

Page 121: ... on its rack teeth must be replaced After reassembling the pump check each pinion for backlash and as necessary replace the pinion or control rack or both to reduce the backlash to the specification Unit mm in Item Standard Service limit Rack to pinion backlash 0 15 0 25 0 0059 0 0098 116 e Tappets Using a dial gauge read the radial play of the roller of each tappet by moving the roller up and dow...

Page 122: ...by the locating pin and positioning groove 1CAUTIONS 1 a These cylinders are meant for thumb pres sure fit Never attempt to drive them into the bores with such as a mallet b After fitting each cylinder into the bore making it seat firmly in place check to be sure that it will not rotate when turned with a finger Installing pumping element cylinder b Fit a new valve gasket to the delivery valve and...

Page 123: ...ch stroke end rotates the pinion by an equal amount f Install upper spring seats and plunger springs Using the plunger clamp fit the lower spring seat to each plunger and insertthe plunger into the barreL 118 Inserting upper spring seat and plunger spring NOTES a Be sure to hold each plunger true and square and insert it straight into the barrel b Remember the driving face on which a number is mar...

Page 124: ...to the camshaft and install it positioning it in place with the marked end face coming on the drive side DISASSEMBLY AND REASSEMBLY k Put on the bearing cover tentatively and check the axial play of the camshaft by using the camshaft clearance gauge 95905 01080 If the play noted is off the range indicated below reduce or increase it into the specifted range by shimming shim stock for this purpose ...

Page 125: ...camshaft Engine proper Disassembly Removing tappet Inserts Drain out engine oil and coolant Wash the exterior surfaces of the engine clean arid set it up on the disassembly stand After removing the various compo nents attached to the engine proper proceed as follows I Remove a total of 24 bolts securing oil pan I to crankcase and take off the oil pan Remove oil pump 2 as outlined in OIL PUMP REMOV...

Page 126: ...flywheel 6 Remove bolts I securing the rear housing 2 to the rearplate and take off the housing JCAUTION Exercise caution not to damage the oil seal fitted to the rear housing DISASSEMBLY AND REASSEMBLy 1 Bolt 2 Rear housing Removing rear housing 7 Remove connecting rods pistons and crankshaft as follows a Remove 8 nuts fastening down the connecting rod caps two nuts on each cap Take off caps I co...

Page 127: ... restored to its original location in reassembly_ b Remember No 1 and No 5 bearings have two side seals each d Lift the crankshaft 5 off and out of crankcase as shown 5 Crankshaft Removing crankshaft 8 Remove the remaining main bearing shells 1 The idler shaft need not be removed unless to do so is absolutely necessary the puller A must be used to draw out this shaft 122 l Bearlng shell Taking off...

Page 128: ...SASSEMBLY AND REASSEMBLY 4 Pin 6 Connecting rod 5 Piston C Drift Removing piston pin d From the small end of connecting rod remove the bushing NOTE Wash the disassembled parts clean and de carbon them II Clean the crankcase by washing it in a bath of caustic soda solution or cleaning solvent removing grease and grime from all surfaces in and out Clean oil drillings and holes with a long handle bru...

Page 129: ...haft Side that is opposite to the pre chamber side Secure the pin in place by fitting the other snap ring The pin and pin hole are sized for loose fit and therefore the pin should go into the hole when given thumb pressure This J insertion wiUbe made easier by having the piston warmed up in advance Using the piston ring tool fit the piston rings two compression rings and one oil ring to the piston...

Page 130: ...n the tappets in the respective tappet holes Lightly oil the seats of main bearings and fit the upper bearing shells to the seats making sure that the tab formed of the shell fits snugly into the recess provided in the seat Fit thrust plate 3 to the rear side of the seat 3 Thrust plate Fitting upper bearing shells 6 Install the crankshaft as follows a Lower crankshaft in level position and rest it...

Page 131: ...ates Unit mm in Item Standard Repair limit Crankshaft end play 0 10 0 264 0 30 0 0039 0 0I 039 0 012 7 Apply SUPER THREE BOND No 10 to cap seals 1 and insert the seals into bearing cap grooves at No I and No 5 main bearing cap 126 l Crankcasa l Cap seal Fitting cap seal 4 1 3 Cap seal 2 Main bearing cap 4 Rounded corner of cap seal Position of cap seal in groove CAUTIONS I a Be sure to insert each...

Page 132: ... match each cap to its big end as governed by the marks DISASSEM BLY AND REASSEMBLY 3 ap 4 Nut 18 pcs Tighteningbig end cap nuts 9 Check the side play of each connecting rod big end by barring it to one side and inserting a thickness gauge into the clearance If the clearance side play measured exceeds service limit the bearing shells or connecting rod must be replaced Unit mm in Item Standard Serv...

Page 133: ...me off The lip portion is indicated by the arrOW 14 Drive dowel pin I into crank gear Drive ball bearing into flywheel 2 Secure flywheel to crankshaft through the crank gear by tightening the four mounting bolts to 8 5 0 5 kg m 61 5 3 6Ib ft with the lock washers inserted under bolt heads Lock the bolts securely by bending the washers positively_ l Dowel pin 2 Flywheel Installing flywheel Starter ...

Page 134: ...washer 2 pes each 5 Rear bracket 6 Yoke 7 Center bracket a Front bracket 9 Armature 10 Lever 11 Lever spring 12 Rubber packing 13 0verrunning clutch 14 Pole piece Starter Exploded view I Remove two bolts 1 securing the magnetic switch to front bracket 8 and take off the switch 2 l Bolt and washer 2 pcs each 2 Magnetic switch Removing magnetic switch 2 From front bracket 8 remove plunger 3 com plet...

Page 135: ...9 rubber packing 12 lever 10 spring II overrunning clutch 13 complete with pinion B Front bracket 11 Leve spring g Armature 12 Rubber packing 10 Lever 13 0verrunning clutch Separating front bracket from rotor 7 Remove overrunning clutch 13 from armature 9 13 0verrunning clutch Removing clutch from armature CAUTION l Before drawing off the center bracket tape the splined portion of the shaft so tha...

Page 136: ... piece 3 Brush 4 Armature 5 enter bracket 6 Plunger 7 Lever a Overrunning clutch 9 Field coil 10 Bearing Starter Cross section Jill DISASSEMBLY AND REASSEMBLY T l Front bracket 12 Rear bracket 13 Magnetic switch 131 ...

Page 137: ...ach 5 Alternator assembly Alternator disassembly and reassembly 132 801t 3 pes 2 Front bracket 3 Rotor 4 Stator coil S ReST bracket 6 Pulley 7 Fan 8 Diode g Brush Alternator exploded view I Pulling out through bolts I will pennit removal of rotor 3 with front bracket and pulley and stator coil 4 with rear bracket t Bol 3 pc 2 Front bracket 3 Rotor 4 5t8tor coli 5 Rear bracket 6 Pulley 2 Hold rotor...

Page 138: ...EMBLY AND REASSEMBLY Regulator unit removal and installation The regulator unit is mounted on the inboard side of the dashboard To remove the regulator unit undo the coupler I remove mounting screws 2 and detach it from the dashboard Reverse these steps to install the regulator unit l Coupler 3 Regulator unit 2 Mounting screw 2 pes Regulator unit in place Regulator unit disassembly and reassembly ...

Page 139: ... i ...

Page 140: ...MAINTENANCE STANDARDS ...

Page 141: ... j ...

Page 142: ...0 5 kg em 7 1 psi 3 0 20 0 035 0 1 20 0 047 0 0014 O 0 008 0 Q15 0 0006 max 0 35 0 75 0 0138 0 0295 0 04 0 08 J 0 0016 0 0031 0 20 J 0 0079 0 025 0 060 0 15 0 0010 0 0024 J 0 0059 Remedy Adjust governor Hone sleeve to 0 25 0 0098 or 0 50 0 0197 oversize with prescribed tolerance Oversizepistonsand piston rings should be used Check bearing clearance Use pistons by replacing piston rings up to servi...

Page 143: ...n erankpinangles Assembly standard Repair limit Standard clearance Clearance 0 30 0 50 0 0118 0 0197 J 1 5 J 0 059 0 0 016 0 0 0006 J 0 05 J 0 002 0 020 0 051 0 08 J 0 0008 0 0020 J 0 003 3g 0 1 oz 5g 0 18 oz 0 035 0 100 0 20 J 0 0014 0 0039 J 0 008 0 15 0 35 0 006 0 014 0 05 0 002 0 15 0 006 0 05 0 002 0 01 0 0004 max as runout Variance in dia 0 01 0 0004 max 0 03 0 0012 0 2 0 008 20 V Service li...

Page 144: ...0 05 0 0020 0 05 0 115 0 20 1 0 0020 0 0045 1 0 008 0 1 0 264 0 0039 0 01039 1 0 30 1 0 012 0 15 0 006 max 0 50 0 020 0 05 0 002 max 0 2 0 008 0 2 0 008 1 3 0 051 0 14 to 0055 1 6 0 063 0 3 0 012 0 05 0 002 0 055 0 085 0 0022 0 0033 1 0 070 0 100 0 0028 0 0039 1 0 2 0 008 0 Q3 0 0012 max per pendicular to valve face L _______ Straighten or replace crankshaft Replace bearings unless repair limit is...

Page 145: ...471 0 3 0 01181 01 02 6 684 0 26315 45 944 1 8088 j g gmi 01 02 7 344 0 28913 40 232 1 5839 0 02 0 0008 max 36 1 417 0 Q25 0 075 0 00098 0 00295 J 0 0 1 0 0 004 J Repair limit Service limit Clearance Clearance 47 6 1 874 44 1 732 0 12 J 0 10 0 004 0 0047 at tappet hole dia 0 07 J 0 0028 0 15 J 0 0059 0 3 J 0 0118 01 02 6 184 0 24346 01 f12 6 844 0 26945 0 05 0 0020 0 1 J 0 0039 0 35 0 0138 J Remed...

Page 146: ...9fF E Valve lift 9 90 C 0 35 194 F 1 f 0 009T 0 045T 0 00035T O OOI77TJ 0 07 0 20 0 25 0 0028 0 0079 0 0098 0 032 0 074 0 00126 0 00291 J 0 20 0 28 0 0079 0 0110 O IS 0 04 0 09 J 0 0059 0 0016 0 0035 0 013 0 15 0 0005 0 0059 0 3 kg cm 4 27 psi 0 011L 0 025t 0 0004L O OOIOT J O OOIT O OI7T 0 00004T 0 00067T J 0 010 0 025 0 00039 _0 00098 0 010 0 022 0 00039 0 00087 1 O OOIT O OI7T 0 00004T 0 00067T...

Page 147: ...bly Standard not more than 50 cc 3 cu in min 25 max 30 45 seconds max 50 seconds Unit mm in Remedy Remarks Adjust by means of Injection pressure varies shim s 10 kg em 142 2 psi per 0 1 0 004 of shim thickness Test by means of hand tester using dieseHuel at 20 C or 68 F approx Spray of fuel oil should If spray pattern is imP be uniform and consist proper even after nO zzle is of nne droplets washe...

Page 148: ...0031 J 0 3 0 0118 max 11 0 433 0 050 0 097 0 0020 0 0038 1 17 0 669 0 0 027 0 075 0 0 0011 0 00295 49 1 929 1 0 0 039 0 0 5 0 020 44 1 732 0 15 0 0059 1 0 25 1 0 0098 150 g 5 3 oz with pump at standstill SO g 1 8 az with pump funning at 1000 rpm 32 1 26 0 5 0 02 1 0 04 1 95 0 077 0 05 0 002 Pump speed Rack position Strokes Injection quantity rpm mm mm cc cu in 1000 8 5 0 335 200 7 2 7 8 0 44 0 48 ...

Page 149: ...0 0006 0 0022 J Repair limit I Service limit Clearance Clearance ND DNOSD 6 x 1 6 x 600 1 4 x 1 16 x 23 5 8 120 kg em 1706 4 psi 2 0 kg em 28 44 psi ASTM Diesel fuel No 2 0 15 0 0059 J 0 10 0 00394 0 10 0 0039 0 08 0 0031 J 0 11 0 0 25 Remedy Unit mm in Remarks Replace bushing or swivcllevcr Replace 0 ring and oil seal when replacing bushing Replace pinand leverifpinhole is worn abnormally or worn...

Page 150: ...oltage VI Current A Rpm Voltage V Current A Torque Switch IN Switch OFF 23 50 max 4500 9 700 max 4 kg m 29 16V max When circuit min ft 1b min is opened Rear Rear Intermediate metal Commutator 0 0 Brush Shaft Metal Front Front Bracket shaft service limit Height Wear Spring compression 14 2 0 050 142 0 027 206 0 02 kg IIbl 0 077 0 016 0 08 43 2 0559 0 0020 0559 0 0011 0 811 0 0008 1 701 0 0030 0 000...

Page 151: ...Clearance Clearance Voltage regulator Lamp relay Air gap 1 0 1 4 0 9 1 4 0 039 0 055 0 035 0 055 0 75 1 1 Contact point gap 0 3 0 012 min 0 030 0 043 0 75 l l Back gap 0 Q30 0 043 27 5 30 5 at 3000 No load voltage V rpm alternator speed Cut out voltage V 6 5 7 5 Cut in voltage V S max Unit mm in Remarks 1 z i m Z z m f i z rJ o f ...

Page 152: ...5 0 5 5 0 0 5 Connecting rod cap bolts 61 5 3 6 Nozzle holder retaining nuts 36 2 3 6 8 5 0 5 Injection pump delivery valve holders 3 0 0 5 Flywheel bolts 61 5 3 6 21 7 3 6 1 8 0 5 3 5 0 5 Camshaft thrust plate bolts 13 3 6 Flywheel housing bolts 25 3 3 6 Front plate bolts 1 8 0 5 13 3 6 Timing gear case bolts 3 5 0 5 25 3 3 6 Crankshaft pulley nut 40 0 5 290 3 6 Idler thrust plate bolt 3 5 0 5 25...

Page 153: ...MAINTENANCE STANDARDS APPLICATION OF SEALERS Apply to Mating part Sealer Main bearing caps Crankcase bearing caps SUPER THREE BOND No 5 Side seals Crankcase bearing caps SUPER THREE BOND No 5 148 ...

Page 154: ...TROUBLESHOOTING I i l r i i I f j I ii f I ...

Page 155: ...ection 0 0 0 quantity Excessive injection 0 quantity Improper fuel spray from 0 0 0 0 0 0 0 0 injection nozzles Excessive fuel return from 0 0 0 E injection nozz les 0 t Injection timing too advanced 0 0 0 0 0 u Injection timing too retarded 0 0 0 0 0 0 Defective auto timer 0 0 0 0 0 Defective governor control spIing Maladj lsted governor dainper spring 0 0 Engine speed too low 0 Failure of engine...

Page 156: ...sary Replace nozzle tips Check and replace spring if necessary Then adjust governor setting on bench Adjust _ Adjust idling set bolt Hold lever in STOP position Use fuel for cold weather o Use good quality oil Use proper viscosity oil Use proper viscosity oil 0 0 0 0 o 0 0 0 o 0 o o o o o o o Retighten and replace packing if necessary Change element and oil Check and replace if necessary Check and...

Page 157: ...n Battery voltage drop Open circuit in glow plugs or pilot lamp Short circuit in glow plugs Detective alternator Defective alternator relay Improper wiring Jammed moving parts Worn cylinders pistons or piston rings Sticking piston rings Excessive main bearing clearance i Loose connecting rod cap bolts E Interference between valve and piston 152 Broken valve springs Excessive valve clearance Foreig...

Page 158: ...ary Repair or replace if necessary Repair or replace Repair or replace starter if necessary Repair or replace ling gear Replace pinion Recharge or replace battery If necessary heat it Replace _ Replace copper packings and if necessary glow plUgs o Replace alternator if necessary o Adjust or replace Connect wires properly Repair or replace Repair or replace Check and replace bearing s with undersiz...

Page 159: ... quantity Worn or broken plunger springs Replace plunger springs Loose plunger pinions Reinstall properly by matching marks Defective delivery valves Replace valves Worn or broken delivery valve Replace valve spring springs Governor stop lever link is Straighten link placing binding lever in neutral position Control rack is sticky ReIubricate or repair Jammed plungers Replace plungers Jammed tappe...

Page 160: ... gear train gears Worn cams tappets or bearings Replace in fuel injection pump Poor grade of fuel Use good quality fuel Waler in fuel Use good quality fuel Lack of oil in oil pan Add oil to prescribed level Air in oil strainer Rep ce damaged pipes or packings Retighten loose connections if any Low oil pressure Defective oil pump Repair Clogged fuel lines Clean Defectiveoil pressure regulatingvalve...

Page 161: ...er leaks from unit seal of water Replace seal pump Cra ck in crankcase water jacket Replace crankcase Water leaks from other parts Check and repair Air in cooling system Bleed air by loosening air bleed plug drain plug or hose clamp Rust and scale deposited in Flush Failure of radiator to radiator dissipate heat properly Dust and dirt around radiator Flush Slippage of fan belt Adjust belt tension ...

Page 162: ...SPECIAL SERVICE TOOLS ...

Page 163: ... SPECIAL SERVICE TOOLS j MODEL 60 95 158 ...

Page 164: ...oval 8 30691 J800 Cranking handle I Engine cranking 9 34491 00300 Socket I Camshaft thrust plate removal and installation 10 34491 00100 Cylinder sleeve installer I Cylinder sleeve installation J 30091 01101 or Universal extension I Injection pump removal and commercially available installation 12 31391 12900 or Piston ring tool I Piston ring removal and commercially available installation Removal...

Page 165: ... 2 31391 10500 Valve guide 1 remover Valve seat insert 3 31391 13010 caulking tool I intake valve Valve seat insert 4 31391 13020 caulking tool I exhaust valve 5 30691 11100 Adaptor I 6 34491 00200 Piston guide I 7 MH061077 01 Idler shaft I puller 8 30691 11800 Cranking handle I 9 34491 00300 Socket I I 10 34491 00100 Cylinder sleeve I installer 30091 01101 or Universal II commercially extenSion I...

Page 166: ...tion The remover is for driving the guide out of the hole Ie 17 55 Material S53C Valve guide installer part number 34491 00400 0 5 e 1 I 11 1 J j 8 B 30 158 188 Matenal S53C Valve guide remover part number 31391 10500 How to use I o 2 A 3 V _ _ I Installer 3 Cylinder head 2 Valve guide A 17mm 0 67 in Installing valve guide Remover 3 Cylinder head 2 Valve guide Removing valve guide 161 ...

Page 167: ...lking tool intake valve part number 31391 13010 00 not chamfer 1 w ffd ffp 0 I I 0 MM N o Grind _N qq 50 16 14 qq q 00 0 T T I I r 80 70 0 N Material SK5 or SK7 150 Valve seat caulking tool exhaust valve part number 31391 13020 How to use I Ref 162 CD 33 exhaust 42 intake 5 Cylinder head b n r gasketed surface l Caulking body 2 valve 3 Cylinder head 4 valve guide 5 Caulking ring Installing and cau...

Page 168: ...5 ial SS41 60 Adaptor part number 30691 11100 Piston guide Use this tool when inserting the piston into cylinder It protects pistons and piston rings against damage and facilitates the feeding in of the piston Test pressure gauge installed with the adaptor 02 50 1 g Material STKM12A 0 r13A 04 Piston guide part number 34491 00200 163 ...

Page 169: ...haft one of the liming gear parts I Inserting piston into cylinder o 1 5e MIOX 1 25 MIOX 1 25 I I 5e 164 rT g N ro MI Detail3 Sl Material S43C ro Fo 50 44 J shhah VOA I o I J SO Details 1 2 5Z Material l STKMllA 2 SS00P 16 2 MIOX 1 25 I Idler shaft puller part number MH0610n 01 w ...

Page 170: ...ut 5 to force the shaft out by jacking action Thh tool is for turning over crankshaft as in valve elearance adjustment and others Its hexagonal hole fits l Crankcase 2 Puller 3 Stud M10 G t 4 ldler shaft 5 Nut the crank pulley securing nut Removing idler shaft I I 3 7 4 t Material SS41 Cranking handle part number 30691 11800 165 ...

Page 171: ...s to secure the camshaft thrust plate through the holes provided in camshaft gear and also the shorter ones of the bolts for securing the rocker brackets It can be used in torquing the glow plugs too 11 45 40 85 Socket part number 34491 00300 How to use Tightening shorter bolt on rocker bracket Securing the camshaft thrust plate 166 j ...

Page 172: ...eve installer 2 into sleeve 1 and push on the top end of the installer with a press arbor to force the sleeve into cylinder 3 The fuel injection pump unit is mounted on engine front plate as secured by two bolts Thi s extension tool is for bringing the wrench head to these bolts l Cylinder sleeve 2 lnstaller 3 Cylinder Pressing replacement sleeve into cylinder 14 to 3 l 1 I II II 1 I A 1 I Y II J ...

Page 173: ...use 1 Compression rings A Piston ring tool 2 0il ring Removing piston rings 168 Puller assembly For use in removing crankshaft pulley water pump i pulley crankshaft gear camshaft gear and injection pump gear Size of pulley to clamp Diam MIN X Width MAX 40mmXl10mm 150 mm X 80 mm LLI_ Puller assembly part number 64309 12900 Idler bushing puller For use i n removing and inslalling idler bushing and c...

Page 174: ... after plating 2 Quench and temper HRC 40 50 Idler bushing puller part number 30091 07300 Adaptor For use in removing and installing idler bushing and camshaft bushings when necessary Material 8S41 B part number 30891 04500 Adaptors O 5e 45 3 Material S541 B part number 30891 04600 169 ...

Page 175: ... I I I I I ...

Page 176: ...Printed in Japan ...

Page 177: ...SERVICE MANUAL MITSUBISHI TRACTOR TRACTOR SHOVEL BD2F BS3F DIRECT POWERSHIFT TRANSMISSION OPERATING PRINCIPLE TESTING AND ADJUSTMENT MAINTENANCE STANDARDS DISASSEMBLY AND REASSEMBLY ...

Page 178: ...ught 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 are used...

Page 179: ... i 1 ...

Page 180: ...ench test criteria for transmission oil pump 20 Adjustment of control linkage for steering clutches 20 Adjustment of steering clutch brakes 22 Clutch pedal adjustment 22 DPS control lever adjustment 23 MAINTENANCE STANDARDS Bolt tightening torque 26 Transmission 26 Transmission control valve 28 DISASSEMB LYAND REASSEMBLY Transmission Removal 33 Disassembly 34 Transmission case and flanged end disa...

Page 181: ...e disassembly and reassembly 53 Main relief valve disassembly and reassembly 54 Safety and pilot valve disassembly and reassembly 54 Clutch valve disassembly and reassembly 55 J Directional selector valve disassembly and reassembly 56 Speed selector valve disassembly and reassembly 57 Special service tools 58 ...

Page 182: ...OPERATING PRINCIPLE ...

Page 183: ... i I ...

Page 184: ...ansfer gear 5 bevel gear 6 and steering OPERATING PRINCIPLE clutches 7 right and left Two tracks 9 are driven by the final drive gears The engine and damper case are coupled together integrally Four rubber mounts of anti vibration sleeve type are used to support the engine at four places Specifically the engine crankcase rests on these mounts two on each side The transmissjon and transfer gear are...

Page 185: ...ular direction are located between the disc and the friction plates 2 fonning two sets and serve to absorb torsional shocks The shocks contemplated in the design of this damper come in two directions from the engine as when the engine is quickly accelerated or decelerated and from the ground through the power line By absorbing these shocks the damper protects gears bearings and shafts 1 Coil sprin...

Page 186: ...ve unit not shown in the below cutaway view an oil pump and filter and two shafts input and output _ REVERSE clutch 2 FORWARO clutch 3 SECOND high clutch 4 FIRST lQw clutch 5 lnput shaft 6 0utput shaf 7 Sun gear 8 Ring gear g Carrier lO Planet gear l1 Housing 12 Friction plate 13 Mating plate 14 Piston 15 Return spring 16 Transfer gear 17 Bevel pinion gear OPERATING PRINCIPLE 5 ...

Page 187: ...tandstill the ring gear revolves counter to the direction of sun gear rotation There are four sets of planet gears three for each set There are five ring gears of which one is a link between REVERSE planet gears and FORWARD car ier FOR WARD carrier and HIGH carrier may be regarded as constituting a single integral piece HIGH ring gear links HIGH planet gears to LOW carrier In the clutch friction p...

Page 188: ...s of power flow just explained are schematically shown in these diagrams Input Output FORWARD LOW drive OPERATING PRINCIPLE Input f I g Output FORWARD HIGH drive Let s see what happens ifREVERSE clutch is engaged with FORWARD clutch disengaged with input shaft running as before In tltis case REVERSE carrier is now scized and remains standstill Its pinions meshed with linking ring gear drive FORWAR...

Page 189: ...differential pressure across its element rises to and above 2 0 kg cm 28 4 psi a warning lamp lights up and the bypass circuit opens to pass the oil around the element thus ensuring the adequate oil supply to the control valve unit Oil pump 2 is driven from transmission input shaft it is mounted on the front end of transmission casco The control valve unit comprises main relief valve 5 directional...

Page 190: ...r valve 8 so that the oil flows through the oil hole OPERATING PRINCIPLE provided in valve 8 and direct into the piston chambers thereby expediting the pressure build up in these cham bers this may be spoken of as rapid filling up of the piston chambers with oil With the pushing back of valve 8 pilot valve 10 too yields to its spring force and moves back to block the circuit bypassing main orifice...

Page 191: ...ing position as the engine is started up Note the schematic a in which safety valve 10 is shown in blocking state the state prior to the starting up of the engine Ports E and F are not in communi cation so that the oil pump discharge pressure does not 10 reach the main orifice 12 In other words the pressure for engaging the directional and speed clutches is not available to the selector valves 6 7...

Page 192: ...TESTING AND ADJUSTMENT ...

Page 193: ... J 1 1 I ...

Page 194: ...r or failure of sealing members defective parts such as piston seals and 0 rings 6 Main relief valve is internally dirty with 6 Overhaul Correct its pressure alien matters stuck in sliding clearance setting or is out of adjustment 7 Oil is too low in viscosity 7 Use Class CD oil engine oil of API classification whose viscosity rating is SAE lOW B Mechanical failure I Broken transmission shaft 1 Di...

Page 195: ...t into neutral or 2 Burnt clutches 2 Disassemble and replace burnt remains on even when parts clutch pedal is pressed fully 3 Clutch piston friction phites or mating 3 Disassemble repair or replace plates are bound 4 Clutch valve is seized and does not move 4 Disassemble repair or replace into draining position 5 Oil level too high or too low 5 Adjust to the prescribed level Abnormal oil tempera I...

Page 196: ... replace gaskets or add oil to oil pan 6 Oil leakage from loose joint or connec 6 Inspect and repair replacing 0 tion rings and seals a s necessary Clutch oil pressure is 1 Main pressure too low 1 Refer to the procedure immediate abnormally low when lyabove clutch pedal is in released Transmission responds too slow condition to shifting This is not a symptom it 2 Sticking spool in clutch valve 2 O...

Page 197: ...lete standstill If it takes longer than 3 seconds or if the machine continues to roll it means that clutch is slipping Trouble diagnosis by oil pressure readings The following information augments the TROUBLE SHOOTING GUIDE and teaches on the basis of pressure reading more specific possible causes Three test pressure gauges are needed one for M port one for D port and one for S port of the control...

Page 198: ...omentarily from 0 to 20 orifice is clogged damage and as necessary repair kg cm 284 psi on shifting to valve and bore to make the valve any gear move smoothly 2 Indicating hand of pressure gauge a Clutch piston is sticking a Disassemble and repair or replace jumps momentarily from 0 to 20 b Accumulator valve is sticking or b Refer to I above kg cm 284 psi on shifting to orifice is clogged s me gea...

Page 199: ...rod D port pressure Rises but not is positioned the other way Be sure the 8 mm 0 31 in dia rod smoothly as the pedal moves around the clutch valve is correctly positioned in releasing direction will not function properly 3 Releasing the pedal quickly fails to make the machine pick up speed quickly the machine starts off slowly A M port pressure Normal A Foreign matter stuck on check A Disassemble ...

Page 200: ... be 20 kg em 284 psi for the three ports M D and S An abnormally high steady state pressure means 1 the main relief valve being sticky or 2 the spring of this valve being weakened Testing the control valve unit The following procedure is for determining whether the control valve unit is operating properly without regard to the transmission by checking the oil pressure at the three ports mentioned ...

Page 201: ...applies next These requirements in terms of the posi tion of the lever tip as measured from the edge of the dashboard are specified 20 Pressure requirement With engine running at high idling speed and control lever kept in neutral this pressure is required to be within this range 118 22 kg cm 256 313 psi If not adjust the setting of main relief valve by increasing or decreasing the thickness of it...

Page 202: ...he requirement on distance a for clutch releasing position is accurately satisfied U nit mm in Operating effort Adjusting method Loosen nut I turn rod 2 to I 2 kg 2 2 4 4 Ib adjust and tighten nut 1 2 Brake adjusting nut setting Refer to the part for steering brakes Pull lever till brake band begins to move Loosen lock nut 5 to bring CI C2 a2 pin to end of slot in clevis 4 and Start of 145 ISS 125...

Page 203: ...to 0 08 in between clevis pin 8 and end of slot see the magnified view Be sure that the distance between this pin and that on the other end of rod 7 is 571 mm 22 48 in 4 After making these adjustments check to be sure that lock nuts are tight 22 Checking pedal stroke and operating effort With steps 1 and 2 properly carried out the pedal should have the following pedal play and stroke and its opera...

Page 204: ...ke sure that the clearances e and I measure between 0 5 and 2 mm 0 02 and 0 08 in 3 If any of the six clearances is off the stated range loosen four lock nuts 1 and shorten or elongate rods 2 and 3 To gain access to these parts remove the control box side cover and the cover under the left hand fender in BS3F or the platform Re in BD2F 4 After adjusting tighten the lock nuts and re check the clear...

Page 205: ... ...

Page 206: ...MAINTENANCE STANDARDS ...

Page 207: ... plates and three discs 0 8492 0_0244 Total thickness of 1st speed clutch new 15044 0 44 4 three plates and two discs 0 6079 0 0173 Thickness of new disc 2 95 O IO 0 1161 0 0039 Verify items 1 thru 4 and thickness of each disc Length under test force 29 1 14 Clutch piston Test force 6 01 kg l3 25Ib 0 5 kg 5 l Ilb return spring Free length after test 33 1 30 Outside diameter 12 5 0 492 Length under...

Page 208: ...MAINTENANCE STANDARDS 27 ...

Page 209: ...2 Length under test force 62 2 44 6 5 0 6 kg 5 3 kg Clutch valve Test force 14 3 I 3lb 1I 7Ib 4 return spring Free length after test 95 3 74 Outside diameter 18 5 0 728 Length under test force 17 0 67 Test force 6 0 0 3 kg 5 0kg 5 Clutch valve 13 2 0 7Ib 1I Olb spring Free lengUI after test 31 1 22 Outside diameter 11 4 0 449 Length under test force 37 1 46 Test force 16 0 0 5 kg 13 kg 6 Pilot val...

Page 210: ...ng Item Standard Lenglhunder lesl force 8 9 0 350 Tesl force Free length after lesl 19 0 75 Oulside diameter 7 5 0 295 CD I J MAINTENANCE STANDARDS Unit mm iri Tolerance Service limit 0 23 0 02 kg 0 18 kg 0 51 0 04 Ib 0040 lb 29 ...

Page 211: ... ...

Page 212: ...DISASSEMBLY AND REASSEMBLY ...

Page 213: ... I I I ...

Page 214: ...t plungers 4 of DPS control valve unit 5 Remove pedal bracket assembly 5 6 Disconnect oil pipe 6 7 Disconnect and remove universal joint 7 8 Disconnect oil pipe 8 9 Hitch a lifting sling A to the transmission case and tension the sling to take up the weight of the transmission DISASSEMBLY AND REASSEMBLY 10 Remove eight bolts 9 fastening the transmission case to the steering clutch case 11 Detach t...

Page 215: ... pipes are indicated by arrows in the second photo 2 Bend down lock washer I and remove bolt 2 and washer 3 3 Remove bolts 4 securing the splbed flange piece 34 Disassembly Preparatory steps a Have the transfer gear assembly removed b Remove oil filter c Remove the transmission control valve unit d Remove oil pump e Remove magnet strainer l Lock washer 2 801t 3 Washer 5 Bolt 6 Bolt 7 Transmission ...

Page 216: ...ission case 6 Run jacking bolts E e into the end plate detaching the case from the plate 7 Lift transmission case 7 off leaving behind the clutch assembly A standing on the end plate DISASSEMBLY AND REASSEMBLY 8 Pick out snap ring 8 from pump driven gear 9 By driving from inside the case force out flange piece 10 Renjove seal cover 11 and take out driven gear 9 35 ...

Page 217: ...eight bolts 5 to be tightened 4 Install the input shaft ball bearing by driving it into the case 5 Fit the oil seal into seal cover 6 by driving install the cover and secure it to the case by tightening its four bolts 7 6 Install the splined flange piece 8 driving it into the bearing and put on uO ring 36 7 Fit washer 9 and lock washer 10 to the end face of input shaft run bolt 11 into the shaft a...

Page 218: ...ese nine bolts 4 in place The bolt to be left is indicated as a DISASSEMBLY AND REASSEMBLY l Pump drive gear 6 snap ring 6 Snap ring 7 Mating plate a Friction plat e 9 Return spring lO Pressure plate 11 Piston housing 12 Piston 13 Jnput shaft 14 End housing 15 Ring gear 16 Planet carrier 1i Spring pin l8 Planet pin 19 Thrust washer 20 Needle bearing 21 Planet gear 37 ...

Page 219: ...the end housing and epicyclic gear sub assembly R 8 Take out fO li mating plates 7 four friction plates 8 five return springs 9 and pressure plate 10 38 9 Pick out piston l2 complete with piston seal from piston housing II 10 Remove input shaft l3 from epicyclic gear sub assembly R by driving the shaft 11 Remove ring gear 15 and planet carrier R C from end housing 14 l2 Using a proper drift remove...

Page 220: ...h a way that its oil hole will point to the center of the carrier 2 Drive spring pin 6 into the carrier at each planet and lock the pin by punching its end DISASSEMBLY AND REASSEMBLY 3 Fit ball bearing 8 to end housing 7 by driving and install the 0 ring on the back of end housing 4 Fit the planet carrier R complete with planets to end housing 7 5 Mount the ball bearing next to the sun gear of inp...

Page 221: ...together by tightening only one bolt b 9 Install two snap rings 15 16 to retain the ball bearing between end housing and carrier Tins completes reassembly of the REVERSE section 10 Place the REVERSE section B on the FOR WARD HIGH section and secure the former to the latter by tightening eight bolts 19 1l Install lubricating valve 18 and secure it with two bolts 19 to end plate 12 Feed pump drive g...

Page 222: ...r FORWARD DISASSEMBLY AND REASSEMBLY l Needle bearing 2 Matlng plate 3 Frlctlon plate 4 Return spring 5 Pres ure plate 6 Linking ring gear 7 5nap ring a Snap ring 9 Bolt 11 8nap ring 12 0utput shaft 13 B811 bearing 14 Snap ring 15 011 seal 16 Bearlng case 17 FORWARD ring gear 19 ressure plate 20 Return spring 21 Frlction plate 22 Mating plate 23 HIGH ring gear 24 HIGH planet gear 25 Carrier seal 2...

Page 223: ...p ring 11 draw the shaft 12 off remove ball bearing 13 snap ring 14 from shaft and take off two oil seals 15 from bearing case 16 10 Lift the combination D of piston housing and FORWARD HIGH epicyclic gearings complete with ring gear 17 Remove five clutch pins 18 11 Take out pressure plate 19 five return springs 20 three friction plates 21 and three mating plates 22 These parts are for HIGH The HI...

Page 224: ...h pin the reaction due to tlus tapping facilitates easing out of the planet pin 14 Drive out of the piston housing 27 the common carrier The carrier comes off complete with the FORWARD epicyclic gearing C NOTE Give a mark to the piston housing in order to identify its FORWARD side and HIGH side DISASSEMBLY AND REASSEMBLY 15 Remove two carder seals 25 and dis lssembICthe epicyclic gearing into thre...

Page 225: ...using 4 Set the sub assembly A of planet carrier in the common piston housing The carrier is now complete with FORWARD epicyclic gearing Install three HIGH planet gears 8 on the HIGH side of the carrier 44 5 Insert five piston pins 9 into the common piston housing 6 Onto the LOW section B install ring gear 10 and place three mating plates II and three friction plates 12 alternately set up five ret...

Page 226: ...ing 22 to the case cover Feed the output shaft into the LOW and FORWARD HIGH sections and seat the bearing case D snugly on the case cover DISASSEMBLY AND REASSEMBLY 13 Fit snap ring 23 to the output shaft and mount needle bearing 24 on the shaft 14 Into the snap ring groove provided in the toothed periphery of carrier fit snap ring 25 This is FORWARD side of the carrier IS Squeeze snap ring 25 in...

Page 227: ...ut on five return springs 28 and stack three fiiction plates 29 and three mating plates 30 alternately LOW section disassembly 46 1 Piston housing 2 Piston 3 Pressure plate 4 Return spring 5 Friction plate 6 Mating plate 7 LOW ring gear 8 Snap ring g Carrier seal 1O LOW planet gear ...

Page 228: ...two friction plates 5 and two mating plates 6 3 Lift off LOW ring gear 7 4 Remove snap ring 8 retaining the ball bearing in place DISASSEMBLY AND REASSEMBLY 5 From the case cover remove the epicyclic gear sub assembly A 6 Remove carrier seal 9 and disassemble the epicyclic gearing to take out three planet gears 10 47 ...

Page 229: ... ball bearing 4 Install ring gear 5 resting it on the case cover 48 5 Insert LOW piston 7 into piston housing 6 Be sure that the piston is complete with seal 6 Place two mating plates 8 and two friction plates alternately set up five return springs 10 and pressure plate ll on the case cover Lower the piston housing onto what are on the cover case Transfer gear disassembly 1 Remove twelve bolts 1 s...

Page 230: ...and take off washer 4 3 Remove four bolts 5 run in two jacking bolts and force bearing case 6 out 4 Pick out snap ring 7 5 Remove six bolts 8 and take off transfer gear cover 9 DISASSEMBLY AND REASSEMBLY 6 Pull off transfer driven gear 11 from bevel pinion shaft 49 ...

Page 231: ...inion 4 and drive the bearing into the transfer gear case 50 3 Fit transfer driven gear 6 onto the splined shank of bevel pinion 4 Put on transfer gear cover 7 and secure it to the case by tightening six bolts 8 5 Drive ball bearing 9 into the cover and retain it by fitting snap ring 10 6 Drive ball bearing 12 into bearing case 11 and retain it by fiiting snap ring 13 7 Put on shim 14 and drive be...

Page 232: ...827 10900 and 58827 11000 each in three sizes are available for use in this adjustment 58827 10900 0 10101 0 004 in 0 4 mm 0 016 in 1 0 mm 0 039 in 58827 11000 0 1 mOl 0 004 in 0 4 mm 0 016 in 1 00101 0 039 in This specification is 46 2 mm 1 819 in m IOO 0 1 mOl 0 004 in if 01 is positive 46 2 mm 1 819 in rn 100 0 1 mrn 0 004 in if rn is negative Shim thickness lII DISASSEMBLY AND REASSEMBLY Value...

Page 233: ...he bevel pinion comes on the left side as seen in the sec tional view This is a requirement to be met in the DPS transmission For the DD transmission the bevel crown gear comes on the right side Disassembly and reassembly CONTROL VALVE UNIT Control valve unit Exploded view 52 ...

Page 234: ...sure to tighten similar bolts equally to avoid distortion of parts in which spools plungers and valves have to move back and forth by sliding Binding sticky or othenvise erratic movement of these sliding members is often due to unequal tightening of bolts and screws Valve housing disassembly 1 Remove three bolts 1 and one bolt 2 and take off upper housing 3 2 Remove gasket 4 and three plugs 5 3 Re...

Page 235: ...g lightly on the housing with such as a wooden mallet draw out bearing roller 8 and take out check seat Main relief valve reassembly 1 Insert check seat 1 into the housing and seCUIe by installing bearing rolier 2 2 Install main spring shim main valve slug and uO ring 3 Put on the cover 54 Safety and pilot valve disassembly 1 Remove two bolts I and take off cover 2 2 Remove safety valve assembly A...

Page 236: ...ve reassembly I Insert stopper 1 into the housing and secure it by installing bearing roller 2 DISASSEMBLY AND REASSEMBLY 2 Install pilot valve spring slug pilot valve 0 ring and cover 3 Build up the safety valve assembly 4 Insert safety valve spring and valve assembly into the housing and install OH ring and cover Cllltell valve disassembly I Remove two bolts and take clutch cover I and plunger 2...

Page 237: ...tch spring pin spring valve slug spacer and rod NOTE 1 When inserting the clutch rod into the clutch valve be sure to reed that part of rod having oil holes A into the valve 3 Fit two 0 rings to the clutch cover and insert the cover and plunger into the housing 56 Directional selector valve disassembly I Remove two detent sub assemblies I top and bottom and pull out selector plunger 2 2 Remove two...

Page 238: ...g I securing it with bearing roller 2 and lock the roller by punching 3 Insert plug check spring and 0 ring and put on the cover 4 Insert the plunger and install the detent sub assemblies DISASSEMBLY AND REASSEMBLY Speed selector valve disassembly I Remove two bolts I and take off cover 2 2 Remove detent sub assemblies 3 top and bottom and take out speed plunger 4 and 0 ring 57 ...

Page 239: ...valve reassembly I Install the oil seal by driving it into the housing and insert the speed plunger and fit 0 ring 2 Install detent sub assemblies and put on the cover SPECIAL SERVICE TOOLS Part number Tool name Shape Use 58609 04200 Hook For lifting clutches i 58 ...

Page 240: ...Printed in Japon ...

Page 241: ...SERVICE MANUAL MITSUBISHI TRACTOR TRACTOR SHOVEL BD2F BS3F DIRECT DRiVE TRANSMISSION TYPE POWER TRAIN HYDRAULIC SYSTEM MAINTENANCE STANDARDS ...

Page 242: ...8 Final drives 10 Frame 12 Front idlers 14 Recoil springs 15 Track carrier rollers 16 Track rollers 17 Tracks 18 Hydraulic pump 20 Hydraulic control valve BD2F 21 Hydraulic control valve BS3F 22 Hydraulic tank 25 Lift cylinders BS3F 26 Dump cylinders BS3F 27 Blade lift cylinders BD2F 28 Bucket and linkage BS3F 29 Blade BD2F 30 ...

Page 243: ... worn away FriCtion surface thickness 13 0 0 512 12 5 0 492 max 4 Mating plate 0 05 0 1 0 2 Friction surface flatness 0 0020 0 004 0 008 Free length 70 6 2 780 68 5 2 697 Pressure Load to compres spring 43 5 2 17 39 2 5 springs to initial working length 95 9 4 78 86 4 48 2 1 898 1 kg lb Squareness Up to 2 Over 3 Fit on bearing 1 9 G r 0 075 A B 6 Release levers 0 5 10 0201 Stroke 18 3 4 min 7 Stru...

Page 244: ...FLYWHEEL CLUTCH o o o 3 ...

Page 245: ...ee length 5 Poppet springs Load to compress spring to initial working length 55 2 2 kg Ib Countershaft end securing Tightening torque 6 bolts bevel kg m Ib ft pinion securing bolts 4 Assembly standard 0 12 0 30 0 0047 0 0118 0 12 0 28 0 0047 0 0110 7 1 7 2 0 280 0 283 0 020 0 062 0 00079 0 00i44 62 2 44 9 8 0 49 21 6 1 08 2 7 0 3 19 5 2 2 Service limit 0 6 0 024 0 6 0 024 7 7 0 303 0 5 0 020 60 5 ...

Page 246: ...TRANSMISSION DIRECT DRIVE 5 5 ...

Page 247: ...1 0 2 1 0 00394 0 00476 0 008 Radial fit of outer 0 200 0 275 0 5 a rotor in pump body 0 00787 0 01083 0 020 b End fit of rotors in 0 04 0 09 0 15 1 2 Outer rotor pump body 0 0016 0 0035 0 0059 and inner rotor Fit of inner rotor 0 013 0 150 0 25 c trochoid teeth in 0 00051 0 00591 0 0098 outer rotor 3 Oil pump Tightening torque 1 7 mounting bolts kg m lb f 12 3 6 ...

Page 248: ...BRAKE BRAKE Unit mm in Ref Item Assembly standard Service limit Remarks No 1 Drum Outside diameter 252 9 92 250 9 84 Clearance in linings 0 8 0 031 2 Linings Thickness 6 5 0 256 4 5 0 177 7 ...

Page 249: ... 343 6 0 24 4 Clutch facings 0 16 0 52 0 8 Backlash with outer drum 0 0063 0 0205 0 031 Thickness 2 8 0 110 2 3 0 091 Backlash wiUdnner dmm 0 14 0 30 0 6 5 Clutch plates 0 0055 0 0118 0 024 As assembled thickness of 69 66 plates 6 pcs and facings 2 72 2 60 6 pcs 6 Clutch shaft Fit in pressure plate 0 3 0 375 0 012 0 01476 7 Lever and roller Clearance 1 5 0 059 Drive shaft 8 clutch shaft Tightening...

Page 250: ...STEERING CLUTCHES I t rr L 9 ...

Page 251: ...9 2 Sprockets Tooth width 40 1 57 36 1 42 Pinion lock Tightening torque 4 2 0 4 3 plate mounting kg m lb ft 30 4 2 9 bolts 4 Tapered roller Preload 0 29 0 37 bearings kg m lb ft 2 1 2 7 Final drive Tightening torque 8 4 0 8 5 case mounting kg m lb ft 60 8 5 8 bolts 6 Sprocket Tightening torque 55 5 mounting bolts kg m Ib ft 397 8 36 2 10 ...

Page 252: ...FINAL DRIVES 11 ...

Page 253: ...lutch case clearance Lower 1 5 2 0 mount 0 059 0 079 Engine front Tightening torque 15 9 1 6 3 mount attaching kg m lb ft 115 11 6 bolts Flywheel clutch Tightening torque 15 9 1 6 4 case mounting kg m lb ft 115 11 6 bolts 5 Radiator mount As tigiltened clearance 25 5 ing bolts 1 004 Standard models 1200 47 1 4 6 Center to center Swamp models 1400 55 1 8 10 3 8 Difference be of tracks tween An and ...

Page 254: ...FRAME BD2F CD lfl I 3 4 m t ift l CD I cc f 1 r o A II I _ J LJo 8 I I 13 ...

Page 255: ...er at I b 42 1 65 35 1 38 Axial play 0 2 0 25 1 4 0 008 0 0098 0 055 2 Shafts Fit in bushing 0 1 55 0 235 1 0 0 0061 0 0 00925 0 039 3 Filler plugs Tightening torque 7 6 0 8 kg m lb ft 55 5 8 Bearing shaft Tightening torque 6 5 0 7 4 securing taper kg m lb ft 47 5 1 pin bolts Guides track a Lateral clearance I 0 04 3 0 12 5 frames b Vertic al clearance I 0 04 3 0 12 14 ...

Page 256: ... 5755 463 5072 326 12 83 I kg lb 0 075 0 164 0 8 2 Cylinders Fit on piston 0 00295 0 00646 0 031 Track carrier Tightening torque 13 5 J 4 3 roller bracket kg m lb ft 97 6 10 1 mounting bolts Roller shaft Tightening torque 7 6 0 8 4 bracket securing kg m lb ft 55 5 8 bolts Tightening torque 3 5 0 4 5 Filler valves kg m lb ft 25 3 2 9 Track adjuster 248 9 316 4 6 cylinders Adjustment 9 800 12 46 15 ...

Page 257: ...Diameter at 1 a 110 4 33 98 3 86 Repairllmit 102 4 02 1 Rollers 30 1 18 35 1 38 c Width at I c d Axial play 0 2 0 5 1 0 0 008 0 020 0 039 Roller shafts Fit in bushings 0 185 0 226 1 6 2 0 00728 0 00890 0 063 3 Filler plug Tightening torque 4 2 0 4 kg m lb ft 30 4 2 9 4 Roller shaft Tightening torque 12 2 1 2 securing bolts kg m lb ft 88 2 8 7 16 ...

Page 258: ...ameter at I b 140 5 51 128 5 04 Repair limit 132 5 20 1 Rollers 9 0 35 4 0 16 c Flangewidth d Axial play 0 30 0 90 1 4 0 0118 0 0354 0 055 2 Roller shafts Fit in bushings 0 2 0 25 1 6 0 008 0 0098 0 063 3 Fillerplugs Tightening torque 7 6 0 8 kg m Ib ft 55 5 8 4 Roller mount Tightening torque 6 0 6 ing bolts kg m Ib ft 43 4 4 3 17 ...

Page 259: ...b Link pitch 540 21 3 550 21 65 Limit for revers ing 552 21 73 3 Track pins Fit in bushings 0 45 0 734 2 5 0 0177 0 02890 0 098 Standard models 38 5 1 516 BD2F II 0 43 Standard models 30 1 18 BS3F 10 0 39 4 Shoes Grouser Swamp models Repair limit 57 5 height 67 5 2 657 55 5 2 185 2 264 Super swamp models 57 5 2 264 52 5 2 067 Repair limit not specified 5 Tracks Sag 20 30 3 4 l l 8 6 Shoes bolts Ti...

Page 260: ...TRACKS 2 b 2 a Standard model track Swamp model super swamp model track 19 ...

Page 261: ...t Remarks No Rpm 2400 Delivery pressure 160 2275 BD2F kg em psi Pump Capacity 64 3906 Uter eu in 1 perform ance Rpm 2400 Delivery pressure 160 2275 BS3F kg em psi Capacity liter eu in 64 3906 2 Pump cover Tightening torque 4 75 g 25 mounting bolts kg m Ib ft 34 36 8 CD 20 ...

Page 262: ...to initial working length 8 42 0 7 6 6 26 5 1 043 kg Ib Free length 59 2 32 3 Plunger center Load to compress spring 5 4 0 5 8 kgl45 mm spring to initial working length 11 9 1 1 17 611b11 85 in 46 6 1 83 kg Ib Plunger detent Tightening torque 75 0 5 4 plug kg m Ib ft 542 3 6 Relief valve Tightening torque 7 0 7 5 plug kg m Ib ft 51 5 Tightening torque 4 6 0 5 6 Bolts kg m Ib ft 33 3 3 6 Pressure t...

Page 263: ... psi Safety valve 53 7 2 114 kg lb 4 spring Free length 63 8 2 512 Pressure setting outer Head Load to compress spring 47 3 4 9 140 kg cm2 side to initial working length 104 3 10 8 1991 psi 56 2 2 213 kg Ib Free length 34 5 1 358 5 Check valve Load to compress spring 0 10 0 01 0 09 kg 30 mm spring to initial working length 0 22 0 02 0 20 Ib 1 l8 in 30 5 1 201 kg Ib Free length 34 5 1 358 6 Make up...

Page 264: ... 145 14 14 Bolts Tighteriing torque 4 6 0 5 kg m Ib ft 33 3 3 6 Pressure that makes relief 160 3 15 Main relief valve valve open kg em psi 2275 42 7 performance Flow rate 64 3 liter cu in min 3906 IS3 Pressure that makes ISO 2 Rod relief valve open 2560 2S 4 side kg em psi Flow rate 23 2 Safety valve liter cu in 01in 1404 122 16 perform ance Pressure that makes 140 2 Head relief valve open 1991 28...

Page 265: ...HYDRAULIC CONTROL VALVE BS3F Safety make up valve dump Check valve lift Make up valve lift 24 ...

Page 266: ... 5 6 13 2 38 1 50 kg lb I Copper washers are used they are 2 Tank cover Tightening torque 3 5 0 3 meant to be reo mounting bolts kg m Ib ft 25 3 2 2 placed each time the bolts ate loosened 3 Filter cover Tightening torque 4 8 0 5 center bolt kg m lb ft 34 7 3 6 4 Filter bleeder Tightening torque 2 5 0 2 plug drain plug kg m lb ft 1S l 1 4 5 Tank cover Tightening torque 3 5 0 3 mounting bolts kg m ...

Page 267: ...cylinder on pis ton 0 0138 0 075 0 139 0 35 2 Fit of guide bushing on piston rod 0 00295 0 00547 0 0138 Piston securing Tightening torque 95 5 3 nut kg m lb ft 687 36 Tightening torque 75 8 4 Gland screw kg m lb ft 542 58 Stroke 386 15 20 5 Piston rod Center to center of pins with cylinder fully 700 27 56 retracted 26 ...

Page 268: ...der on piston 0 0138 Fit of guide bushing on piston rod 0 D75 0 139 0 35 2 0 00295 0 00547 0 0138 Piston securing Tightening torque 50 2 5 3 nut kg m Ib ft 362 18 Gland screw Tighkning torque 45 4 5 I 4 kg m Ib ft 325 32 5 Stroke 423 5 16 67 5 Piston rod Center to center of pins with cylinder fully retracted 866 5 34 11 27 ...

Page 269: ...arks No 0 075 0 139 0 35 1 Fit of guide bushing on piston rod 0 00295 0 00547 0 0138 2 Piston securing Tightening torque 50 2 5 nut kg m lb ft 362 18 3 Cylinder head Tightening torque 45 4 5 kg m lb ft 325 32 5 Stroke 689 27 13 4 Piston rod Center to center of pins with cylinder fully 917 36 10 retracted 28 ...

Page 270: ...689 0 024 1 Fit of each pin in b 45 1 77 0 10 0 175 0 6 bushing 0 0039 0 00689 0 024 50 1 97 0 13 0 219 0 6 c 0 0051 0 00862 0 024 2 Cutting edge width 159 6 26 120 4 72 3 Tooth length 160 6 30 100 3 94 4 Tooth securing Tightening torque 29 32 bolts kg m lb ft 210 231 5 Lock plate Tightening torque 3 5 0 3 mounting bolts kg m lb f 25 3 2 2 2 3 29 ...

Page 271: ...ng edges Dimension at 1 75 2 95 45 1 77 end bits Cutting edge Tightening torque 6 5 0 7 2 mounting plolV kg m Ib ft 47 0 5 1 bolts 3 Trunnion Tightening torque JO 4 1 mounting bolts kg m Ib ft 75 2 7 2 4 Trunnion cap Tightening torque 15 8 1 6 mounting bolts kg m Ib ft J 14 3 11 6 CD r l tt 30 ...

Page 272: ... j Printed in Jit paJ i Q 1 d j nril fJ ...

Page 273: ... j SERVICE MANUAL MITSUBISHI TRACTOR TRACTOR SHOVEL BD2F BS3F DIRECT DRIVE TRANSMISSION TYPE POWER TRAIN HYDRAULIC SYSTEM DISASSEMBLY AND REASSEMBLY ...

Page 274: ...ght 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 are used ...

Page 275: ... J ...

Page 276: ... Clutch housing assembly and clutch disc assembly removal and installation 20 Clutch brake disassembly and reassembly 22 Main drive shaft disassembly and reassembly 23 Clutch filter and oil pump removal and installation 25 Clutch release shaft and release lever disassembly and reassembly 26 Clutch cover and pressure plate disassembly and reassembly 27 Release lever height adjustment 28 Steering cl...

Page 277: ...ing seal disassembly and reassembly 49 How to service the floating seal 49 Hydraulic system Hydraulic pump removal imd installation 50 Gear pump disassembly and reassembly 50 Hydraulic tank removal and installation BS3F 51 Hydraulic tank removal and installation BD2F 52 Hydraulic tank disassembly and reassembly 52 Hydraulic control valve disassembly and reassembly BS3F 53 Hydraulic control valve d...

Page 278: ...ring clutch and brake pedal 0 Re val of steering cJutch 1evcr assembly 0 0 Universal joint removal 0 Transmission oil draining 0 R moval of steering clutch brake control rods 0 0 0 0 Removarof steering c1ut h c se bra eket 0 0 0 0 Draining steering clut eh cas 0 Remoyal ofsteering clutch assembly 0 0 Final drive draining 0 0 Track br aking at master pin 0 0 0 Hydraulic tank draining 0 0 Hydraulic ...

Page 279: ... hoist to take up the weight of the guard hold the guard steady Remove eight bolts 6 four on each side 4 Raise radiator guard 5 just a little in suspended state and shift the guard forward to separate it from the frame Radiator guard mounting BS3F Mount the gl lards by reversing the removal procedure 2 Radiator guard removal BD2F Preparatory step Lower the blade and rest it on the ground I Remove ...

Page 280: ... guards by reversing the removal procedure Radiator removal Preparatory step Have the radiator guards taken down I Loosen drain cock I and make the radiator empty of water RADIATOR GUARD AND RADIATOR 2 Remove four bolts 2 and take down fan guard 3 3 Loosell hose clips 4 5 and disconnect rubber hoses 6 7 4 Remove clevis pin 9 from each rod 8 right and left 5 At each side of the radiator remove slol...

Page 281: ...ATOR Radiator mounting Reverse the removal procedure to mount the radiator After setting the radiator in place however be sure to adjust it making it trued up relative to the frame by turning two clevises 13 one oneach side 4 ...

Page 282: ...ct controlrods 2 3 from engine side 3 Disconnect electrical wire 4 from the starter 4 Disconnect glow plug wire 5 5 Remove horn 6 6 Disconnect alternator wire 7 7 Disconnect oil pressure unit wire 8 and engine grounding wire 9 8 Disconnect wire from thermo gauge unit 10 9 Remove four bolts 11 and take off universal joint 12 in the hydraulic pump drive line 10 Draw out clevis pin 13 and disconnect ...

Page 283: ...nce is gone measuring 0 mm at one or more mo nts replace all four mount brackets 2 After installing the 1 0 universal jOilits one is the joint in iiydraulic pump lrive line and the other is that which is between clutch and transmission check to be sure they are nea yhorizontal 3 With mount bolt 5 in place scejf clearance 8 is between 1 2 and 2 2 mm 0 047 and 0 087 in if not reduce or increase the ...

Page 284: ...ENGINE 7 ...

Page 285: ...T Removal Preparatory step Have floor plates Fr and Re removed to provide access to t he joint I Remove bolts I 2 four each 2 Pick out universal joint 3 Installation To install the joint reverse the two sequential steps of removal 8 ...

Page 286: ...ly into position reversing the procedure of rem jya1 Transmission control lever and cover disassembly I Set up the removed transmission a sembiyon the work stand or bench Remove plug 1 plug base 2 and gasket 3 2 Take off level gauge 4 and remove pipe 5 3 Remove bolts 6 7 to free control lever 8 Be sure to recover spdl g washers when removing these bolts 4 Pull out control lever 8 and separate or t...

Page 287: ... the inner side and bolts 13 on the outer side of the case 3 Mount spring 12 retainer 11 cover 10 and dust cover 9 on the inner end of control lever 8 4 Insert lever 8 into caSe 15 positioning the lever angularly to bring its pivoting groove to the hiner side of the case 5 Put on cover 10 and secure it by tigMening bolts 6 7 Use spring washerson these bolts 6 Install level gauge pipe 5 using the s...

Page 288: ...ive to the splined end on the steering clutch case side of the shaft Take out spacer 12 constant mesh gear 13 1st reverse gear 14 spacer IS 1st gear 16 and spacer 17 Remove bearing 18 from main drive shaft 11 and snap ring 19 and bearing 20 from the case these bearings may be left in place unless removal is necessary Main drive shaft reassembly I Drive bearing 20 into the case wall on output side ...

Page 289: ...ange I and mount this flange on shaft 11 6 Install lock washer 10 and lock nut 9 to secure the bearing and snap ring on the output end of main drive shaft Subseqnent step The control lever and cover can now be restored Shift fork disassembly I Preparatory steps a Have the contiollever and cover removed b Remove the main drive shaft Remove three expansion plugs 0 from the traris mis sian case 2 Fro...

Page 290: ...hift rail and 3rd shift rail 5 Free 2nd shift fork 10 by removing its set screw 8 and take out 2nd shift rail 9 and fork 10 TRANSMISSION 6 From 2nd shift rail 9 pick out interlock pin 11 7 Remove two steel balls 12 located between 2nd shift rail and 1st shift rail 8 Free 1st shift fork IS by removing its set screw 13 and take out 1st shift rail 14 fork 15 and collar 16 13 ...

Page 291: ... and spring in the fork Similarly install the plunger and plug in 1st sMtfork 5 14 2 Insert 1st shift rail 14 into the case mountingI thereon 1st shift fork 15 and collar 16 Secure the fork by tightening its set screw I 3 Lock the tightened screw 13 to the fork with a wirepiece 3 Insert into the ball hole between Istsl iftrail and 2nd shift rail twosteelballs 12 4 Insert interlock pin II into 2nd ...

Page 292: ... TRANSMISSION 8 Place three steel balls 3 and three springs 2 in the holes provided in the top face of the transmis sion case 9 Drive into the Case wall thiee expansion plugs I using a proper drift and hammer Subsequent step The subsequent work is in two jobs install ing the main drive shaft assembly and reassem bling the control lever and cover on the top of the transmission case Countershaft dis...

Page 293: ...shaft into the case from the universal joint side input side and while pulling the shaft 14 out through the 18 output side case wall take out 1st sliding gear 2nd sliding gear 12 and 3rd sliding gear 13 1 j 5 Pick out snap ring 15 off bevel gear shaft 14 andremove the inner race of bearing 16 from the shaft From the case wall remove the bearing outer race Bevel gear shaft reassembly I Fit bearing ...

Page 294: ...the case by tighiening four bolts I each with a spring washer thus completing the reassem bly in place of the countershaft Subsequent steps The subsequent jobs are a shift fork reassembly b main drive shaft reassembly and c reassembly of control lever and cover all in place Bevelgear shaft disassembly Preparatory step The following procedure assumes that a control lever and cover are off b main dr...

Page 295: ... I I ...

Page 296: ...ear II 4 Fit 0 ring 9 and shim 10 to bearing case 7 and position the cage s ftiaiely at the bore to force it into the case wall Be sure to keep the cage trued up by running in four guide bolts B These bolts are for aligning the bolt holes TRANSMISSION 5 Using the drift drive the cage into the case wall 6 Fit gasket 3 and put on cover 2 Secure the cover by tightening four bolts I a spring washer is...

Page 297: ...19 b its 4 securing clutch housing to flywheel housing A spring I asher is lised on each bolt 5 Remove the breather plug and run lifting eye bolt B into the plug base 6 By operating the hoist suspend the clutch housing assembly 5 and in suspended state sever it from flywheel housing Take off gasket 6 20 7 InstaU four guide bolts C by running them into clutch spring holes provided in the clutch cov...

Page 298: ...r D to the center offlywheel and pass inner disc 11 mating plate 10 and outer disc 9 onto the arbor FLYWHEEL CLUTCH 2 rUt on clutch cov r assembly 8 and secure it to the flywheel by tightening 12 bolts 7 Be sure to use a spr ng wasller on each bolt Remove four guide bolts C and pull off arbor D 3 Fit gasket 6 to flywheel housing bring in clutch housing assembly 5 in suspended state and fit the ass...

Page 299: ... From brake lever 12 remove split pin 13 slotted nut 14 seat IS spring 16 seat 17 and adjusting bolt 18 Clutch brake reassembly I Mount adjusting bolt 18 seat 17 Spring 16 seat IS and slotted nut 14 on the brake ever 12 run down slotted nut to compress the spring to 40 mm I S7 in in leJigth and lock the nut by inserting split pin O iI i J 2 Connect adjusting bolt 18 to the forked lug by means of c...

Page 300: ...1 2 hub 3 and two bushings 4 2 Remove four bolts 5 and their spring washers and draw out the main shaft assembly Remove gask i 1 FLYWHEEL CLUTCH 3 Remove three bolls 7 each complete with a spring washer and take off cover 8 4 Pick out seal ring 9 and snap ring 10 and detach cover 12 from main drive shaft I I 5 Remove beafing 13 and oil seal 14 from cover 12 Main drive shaft reassembly I Fit oil se...

Page 301: ... 24 5 Fit gasket 6 to the mating face of clutch housing position the main drive shaft assembly in place and secure the assembly by tightening four bolts 5 using a spring washer on each bolt 6 Drive the two bushings into rClease hub 3 as shown and combine bearing halves I with the hub thus building up the release bearing 7 Slide the release bearing onto main drive shaft Subsequent step The job to f...

Page 302: ...ove oil filter 5 filter case 6 and gasket 7 6 FLYWHEEL CLUTCH 4 Remove four spring washered bolts 8 fastening down the pump in place 5 From clutCh housing draw out assembly 9 and 0 ring 10 clutch pump Clutch fIlter and oil pump installation I Fit 0 ring 10 to the clutch pump assembly and fit the assembly to clutch housing 2 Tighten four spring washered bolts 8 to secure the cl ltch pump assembly i...

Page 303: ...cover key 3 2 Pull out spring pin 4 and remove lever 5 3 Pull out split pin 6 and clevis pin 7 Draw out clutch release shaft 9 while picking up clevis 8 Gutch release shaft and release lever reassembly I Into each hole right and left push needle bearing 10 by driving and nt oil seal 11 as shown 26 2 Peed clutch release shaft 9 into clutch housing while holding clev s 8 inside to receiveshaft 9 Wit...

Page 304: ... rekase lever 13 remove split pin 10 washer II and pin 12 and take out the release lever 10 Remove pin 14 and separate lever support IS from release lever 13 FLYWHEEL CLUTCH l Clutch cover 2 Pressure plate 3 Reamer bolt w spring washer 4 Washer 5 Bolt w spril 9 washer 6 Lock plate 7 Nut 8 Return spring 9 Pressure spring 10 Split pin l1 Washer 12 Pin 13 Release lever 14 Pin 15 Lever support 16 Clut...

Page 305: ...Lever Ij ight refers to the elevation of the inner tip of release lever above the friction surface of flywheel The following procedure assumes that the flywheel has been removed from the engine and is now placed on a surface plate I Rig up a dial gauge as shown making sure its supporting fixture is solid and free of any rattle Place a 74 mm 2 91 in block gauge on the flywheel and adjust the dial g...

Page 306: ...Remove a total of 8 bolts 11 to sever coupling from clutch shaft i _ II 7 Remove a total of20 bolts 12 to undo the flange conne ction between brake drum and pinion NOTE l Removal ofbolts ll 12 will be facilitated by pushing the machine to rotate the drive line just a little at a time 8 Push clutch shaft toward final drive toundo the spigot fit in the coupling and under this condition remove the st...

Page 307: ...ase 30 8 Connect the lever and anchor to the brake banI Put on the bracket bolt the anchor and put 0 the cover Subsequent steps a Installation of the steering clutch control and clutch adjustment b Installation of the brake control rods c Installation of the seat and seat bracket Steering clutch disassembly Preparatory step Have the steering clutch severed from the brake drum and have the below na...

Page 308: ...shifter 14 and yoke 15 STEERING CLUTCHES AND BRAKES Steering clutch reassembly Needed tool Qt Symbol Steering clutch tool 58609 01900 I A The reassembling procedure is the reverse of the disassembling procedure but some of the individual steps must be carried out as follows a Force guide pins I into plate 2 b f when inserting the two kinds plates into drum 5 be sure to mate the toothed faces of pl...

Page 309: ...is 17 1 7 kg m 123 123Ib ft Bevel gear and shaft disassembly Preparatory step I 32 Have the steering clutch and brake assem blies right and left rem oved in advance and have the below named tool on hand Needed tool Qt Symbol Wrench 58809 10200 I A Unbend lock washer I Remove bolt 2 and washer 3 Repeat tItis at the other end of bevel gear shaft 2 Force out bevel gear shaft 4 by driving with a soft ...

Page 310: ...RING CLUTCHES AND BRAKES c When tightening bolt 4 at each end face of bevel gear shaft torque it to anywhere between 16 and 19 kg m liS and 134Ib ft d Backlash between bevel gear 5 and pinion 6 is meant to be adjusted by repositioning nuts 7 right and left in place This backlash is prescribed to be between 0 15 and 0 20 mm 0 0059 and 0 0079 in After adjusting check to be sure that the tooth contac...

Page 311: ...nufacture Thus a set of general rules cannot be quantitatively stated for these two adjustments The procedure is the same for all cases but a trial and error method must be used to obtain the specified backlash and tooth contact pattern in the manner to be described below The pinion and gear are selectively combined during manufacture the twoform a set If either the gear or the pinion has to be re...

Page 312: ...llowing method assumes that the pinion and gear have _ been instal1e d with a proper backlash produced by the foregoing method Bear in mind that a proper backlash adjustment usually brings the pinion and gear into a properly meshed condition Using a paste ofred lead or prussian blue roll contact patterns according to the standard practice The mesh is correct and proper if the contact pattern start...

Page 313: ...ack away the pinion Example C Incorrect contact pattern due to pinion adyanced too much Repositioning the pinion in order to obtain the contact pattern approximating that of Example A neces sarily disturbs the backlash adjustment For tltis reason backlash and tooth contact must be adjusted alternately more than once untilboth become satisfactory 36 ...

Page 314: ...h lO Cap 2 Cove 11 Bolt and washer 5 each 3 Bolt 12 Bolt and washer 12 each 4 Lock washer 6 Washer l3 Roller bearing l 4 Roller bearing 6 Sprock et 1 Gear 7 Bolt and washer 6 each 16 Floating seal a Seal case 17 Shaft 9 Gear case Final drive Exploded view Pinion sub assembly Exploded view 1S Spacer i Bolt 2 pes 2 Lock plate 4 8all bearing 5 Pinion 6 80h 8 nd washer 6 each 7 QiI seal S 5eal case 9 ...

Page 315: ...se together with shaft sub assembly in suspended state rt WARNING As the final drive gear case comes off in suspended state the gear shaft parts from the clutch case Unless the lifting tool or its eqUivalent is used to hold the shaft to the gear case the shaft sub assembly might slip off and drop to the loor resulting in possible personal injury Use of the lifting tool or its equivalent is mandato...

Page 316: ... m 2 10 2 68Ib ft FINAL DRIVE l o 0 Attach an arm to the pinion and hook a spring balance to the arm as shown Read the force needed to turn the pinion and compute the_ torque on the basis of the scale reading and the length of the arm T kg m lb ft F kg lb X L m ft where L is the radial length and F is the scale reading Examples Where L 0 25 rri 0 82 ft Xl 1 16 kg 2 56Ib and X2 IA8kg 3 261b T 0 29 ...

Page 317: ... should force the track into slackened state 4 Again if the track still remains tight chock a piece of wood into between sprocket wheel and track and drive the machine backward just a little This will pull back front idler to force the grease to come out of vent hole Track removal I Drive the machine until master pin I comes to the rear part of sprocket wheel 2 40 2 Slacken the track as described ...

Page 318: ...e pair of links from another l Bolt nut and washer 4 each 2 Shoe 3 Pin 4 Bushing UNDERCARRIAGE r I I I I I I I I I 0 to I _ I I I I I I I I I I I BD2F I ____ 1 5 Link g Seal washer 6 Master pin 10 Spacer 7 Master bushing 11 Swamp shoe 8 Master link Track segment Exploded view 41 ...

Page 319: ...r guard 5 by removing 16 bolts 3 and 4 bolts 4 3 Remove four bolts 6 from underside of frame and take down the track roller assembly Repeat this process at each roBer 42 Track roIler instaIlation 1 With the machine herd in the condition illustrated above fit each track roller assembly to frame and secure it by boiting 2 After installing all track rollers bolt the guard to the frame and drive the m...

Page 320: ...ler Caution must be exercised not to damage the seals and 0 rings b Never use a screwdriver to fit the seals and washers 4 Using a lint free cloth or a brush and the washing fluid clean the surface of the steel ring which is a part of the floating seal set Make sure that this surface is free of any g ime 5 Fit the two collars and retain them in place by installing snap rings 6 Using the above name...

Page 321: ...row mark upward as shown and tighten the two bolts to clamp the shaft Carrier roller disassembly Preparatory step Have the oil inside tIle oller drained out completely l PJug 5 801t 9 Floating seal 2 801t and washer 3 each 6 Washcr lO Seal support 3 Cover 7 Roller l1 Bushing 2 pes 4 Lock washer 8 Shaft 12 Snap ring Track carrier roller Exploded view 44 ...

Page 322: ...f oil into the roller through the plug bolt hole Be sure to tighten the plug bolt good and hard Recoil spring removal Preparatory step UNDERCARRIAGE Have the grease cylinder completely depress urized the method of relieving the pressure is described under How to slacken the track chain I Remove four bolts I and dismount carrier roller bracket 2 in the cylindrical base of which is contained the rec...

Page 323: ...isassembly 46 l Plate 2 801t and washer 4 each 3 Spring 4 Spring retainer 5 Carrier roller bracket 6 Cylinder 7 Shaft 8 Rod packing 9 DU5t seal lO Plate n Seal 12 Fill valve 13 Stopper 14 Cover Recoil spring assembly Exploded view ...

Page 324: ...ssembly 1 Fit the rod packing and dust seal in the cylinder and insert the shaft 2 Insert the spring into the carrier roller bracket and lock the spring in place with the spring retainer and plate by tightening the four bolts Place the seal and guide plate on it by tightening the three bolts Subsequent step Installation of the track carrier roller Front idler removal Preparatory step Have the trac...

Page 325: ...m each bearing I to free the bearing from the haft and pull the bearing off 3 Take out floating seal 2 and thrust washer 3 48 4 Carry out the above steps on the other side and pull shaft 4 out of the idler 5 Drive bushings out of the idler bore Front idler reassembly Needed tool Qt Symbol Adaptor 58809 15100 J A I Install the two bushings ill the bore of the idler 2 Insert the shaft into the idler...

Page 326: ...ing removed in disassembly must not be re used in reassembly 3 WASHING Clean each removed floating seal by washing To be washed are the steering rings and collar and also the steel bushing seal supports by which the floating seal is held in place Use a clean washing fluid and a cloth or a brush It is permissible to use the washing fluid to clean 0 rings but do not Soak them with jhe washing fluid ...

Page 327: ...eferringto the exploded view of the gear pump remove four bolts I and take off cover 2 and mounting flange 12 2 Lay down pump body 9 PuIi out drive gear 8 by hand and remove bushings NOTE If the bushing will not come out tap onthe pump body with a plastic hammer to shake the bushings loose Be sure to place the pump body on a resilient base and tap lightly 3 Pull out driven gear 7 and remove bushin...

Page 328: ...efore drawing them out in disassembly 4 Install the other buslungs to which bushing seals and packing rings are attached Put on the cover and fasten the whole assembly together by tighten ing the four thru bolts NOTE Before inserting the drive alld driven gears into the bore liave the splirted portion of drive gear shaft wrapped with one or two layers of cellophane tape so that when the shaft pass...

Page 329: ...lve 2 Run eye bolt 3 into the top of the tank hitch a lifting sling to the bolt and operate the hoist to take up the weight of the tank 3 Remove four bolts 4 and lift the tank away Hydraulic tank installation BD2F Reverse the removal procedure to remount the tank and complete the work by installing the driver s seat and arm rest and by filling up the tank Hydraulic tank disassembly Remove filter s...

Page 330: ... cover 4 Insert the element and secure it in place by tightening its stud to tltis torque value IFilter stud tightening torque 3 5 0 3 kg m 25 3 2 2Ib ft I NOTE An arrow mark is provided on the element cover Be sure to position the element so that the arrow will point upward W ZL t i ff L il lP Hydraulic control valve disasSembly BS3F I Disassemble the make upvalve in three steps a Remove two bolt...

Page 331: ...d safety make up valve as follows 54 a Detach the two safety valve sub assemblies A B NOTE Thesc valves are set to relieve at 180 kg cm2 2560 psi in valve A and 140 kg cm2 1991 psi in valve B b Remove four bolts I and take out valves 4 and springs 3 from body 2 0 Remove safety valve body 5 and from the o removed body separate plug 6 shim 7 springs 8 9 washer 10 and valve 11 4 Disassemble the relie...

Page 332: ...lts I and take out cap 2 and operating plunger 3 b Remove two plugs 4 and draw plunger out of cap HYDRAULIC SYSTEM c Clamp the plunger steady While pushing spring retainer 5 to compress the spring pick washer 6 off the plunger 6 Disassemble the dump cylinder plunger as follows a Remove two bolts 1 and take out operating plunger 3 complete with cap 2 b Push down spring 5 with one hand just a little...

Page 333: ...safety and safety make up valve sub assem bly 6 lift cylinder check valve and 7 make up valve sub assembly_ 56 Hydraulic control valve disassembly BD2F i Disassemble the make up valve in two steps a Remove bolts 1 2 two each and take out the make up valve sub assembly b Remove spring 3 and valve 4 from the body 2 Disassemble the relief and pilot valve sub assembly as in the case of the similar sub...

Page 334: ...g its components in the following sequence I check valve 2 plunger 3 relief and pilot valve sub assembly and make up valve sub assembly Lift cylinder removal BS3F Preparatory step Have the bucket lowered to and resting on the ground I Disconnect two pipes 1 and e ach side of the machine 2 Take up the weight of the lift cylinder with a lifting sling and hoist or tie the cylinder to the arm with a r...

Page 335: ...moval BD2F Preparatory step Have the blade lowered to and resting on the round I Remove pin 1 from the rod connectiori ofeach cylinder Operate the hydraulic system to contract the two blade cylinders fully 2 Tie the two cylinders respectively with a rope in order to hold them steady iri place 3 Disconnect two pipes 2 from each cylinder and remove four bolts 3 Untie and take off the cylinders 58 Bl...

Page 336: ... Dust seal 2 pes 12 0 ring 18 _ing Hydraulic cylinder Exploded view How to fit seal to piston Preparatory step To fit the seal 8 to the piston 7 shown in the exploded view a special tool must be used This tool differs in dimension for different hydraulic cylinders as follows Unit mm in Hydraulic cylinder Piston ID Dimension 0 Lift cylinder 30 1 18 29 5 1 l61 Blade cylinder 24 0 94 23 5 0 925 f Cal...

Page 337: ...ove formed of the piston Insert the tool into the piston 4 Hold down the seal with the left hand and slowly tum the ann rod of the tool letting the rod ride on the seal A downward push must be maintained on the rod in so turning in order to f nce the seal i to the groove 1n this manner force abo ut three quarters of the seal into the groove 60 5 Change the hand and turn the aml rod in th other dir...

Page 338: ... arbor SPECIAL SERVICE TOOLS Use For lifting the clutch For turning adjusting nuts in bevel gear adjustments For disassembly and reassembly of steering clutches For charging oil into carrier rollers For charging oil into front idlers and track rollers For tightening gland screws of dUrilP and blade cylinders For tightening gland screws of lift cylinders For aligning clutch discs and plates in flyw...

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