Mitsubishi Heavy Industries BD2G Manual Download

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Summary of Contents for BD2G

Page 1: ...8000001 UP 28500001 UP 38000001 UP 281 00001 UP 28600001 UP 381 00001 UP v 28200001 UP 28700001 UP 38500001 UP 28300001 UP 38600001 UP MITSUBISHI TRACTOR BD2G TRACTOR SHOVEL BS3G MITSUBISHI I HEAVY INDUSTRIES LTD ...

Page 2: ...ts or asking your local Mitsubishi dealer to repair your machine be sure to give these serial numbers and service meter reading BD2G Engine serial number right side of machine MODEL I 1 MACHINE No c J ENGINE No c J MIT UBISHI HEAVY INDuSTRIES LTD rCK t1I JAf AH Nameplate left side of machine ___ L Chassis serial number left side of machine 502615 ...

Page 3: ...Engine serial number right side of machine J MODEL I I MACHINE No c J ENGINE No c J MIT UBIBWI HEAVY INDUSTRIES LTD TOKYO JAn No Nameplate left side of machine Chassis serial number left side of machine 502616 ...

Page 4: ...BD2G Major Components BD2G Radiator Blade Cutting edge Engine Front idler bit Fuel tank Final drive Track shoe Recoil spring ...

Page 5: ...2655 Accelerator lever 502656 Transmission control lever DPS 502657 Transmission control lock unlock lever DPS Unlock rtf li 1 Lock I 502658 33 502654 Inching pedal DPS Clutch II OFF j Clutch ON F 11 502659 Brake pedal lock unlock lever 502662 Brake pedal Brake ON At Brake OFF 0 0 502661 Clutch pedal DO 1 h Clutch ON ke 0 I Clutch OFF 502660 ...

Page 6: ...Blade Controls BD2G Power angling tilt control lever and safety lock lever Float 502663 Power tilt control lever and safety lock lever Float 502664 ...

Page 7: ...01959 502666 Position Head lamps Working lamp Instrument panel lamp rop Water temperature gauge Overheat ______ red Normal TEMP green 50 1889 Service meter Every 6 minutes dial advances 1 hour one number 501887 00 502665 OK monitor When any lamp glows during operation stop machine soon and check for cause See page 16 I Fuel gauge Empty red Full green 501888 1st 2nd l Starter switch Twist Twist Glo...

Page 8: ...OFF during operation When glows stop engine and check charging system 7 L 1 Working lamp indicator Glows when working lamp is turned on Engine oil pressure warning lamp Okay if this lamp is OFF during operation When glows stop engine and check for low oil level or oil leaks Battery electrolyte level warning lamp Okay if this lamp is OFF during operation When glows stop engine and add distilled wat...

Page 9: ...Others BD2G Horn switch Operator s seat fore aft adjustment 502669 502670 Operator s seat turning over 1 1 lL iJF 1 l I Seat support A WARNING Be sure to support seat after turn ing it over ...

Page 10: ...BS3G Major Components BS3G Engine Tilt cylinder Fuel tank Bucket Final drive Track shoe Tooth 502672 ...

Page 11: ...trol lever DPS 502657 Clutch OFF Clutch ON t it 0 Brake ON Ij Transmission control lock unlock lever DPS r unIOc Lock l j 502658 502674 Inching pedal DPS Clutch 11 O F I N 502659 Brake pedal lock unlock lever Lock 502662 Brake pedal II 8rnk OFF Brake ON 0 o 502661 Elmch pedal DD Clutch ON Brake 0 I ON 0 lIt Clutc h OFF 502660 ...

Page 12: ...Bucket Controls BS3G Bucket control lever and safety lock lever Float 502675 ...

Page 13: ...g lamp Instrument 1st 2nd panel lamp position position lOP 501959 6 Water temperature gauge Overheat Norma TEMP green 501889 Service meter Every 6 minutes dial advances 1 hour one number 501881 502665 OK monitor III When any lamp glows during operation stop machine soon and check for cause See page 16 i Fuel gauge Empty red Full green 501888 1st 2nd j Starter switch Twist Twist j O j O j j j O j O...

Page 14: ...FF during operation When glows stop engine and check charging system I Working lamp indicator II Glows when working lamp is turned on Engine oil pressure warning lamp Okay if this lamp is OFF during operation When glows stop engine and check for low oil level or oil leaks Battery electrolyte level warning lamp Okay if this lamp is OFF during operation II When glows stop engine and add distilled wa...

Page 15: ... BS3G Horn switch I I 1 Operator s seat fore aft adjustment Operator s seat turning over 502669 WARNING Be sure to support seat after turn 502670 ing it over L ____________________ L ________________________ ...

Page 16: ...l Use the same brand of oils 500020 Clean all grease fittings and filler ports before servicing Maintain correct oil levels at all times Before checking oil levels stop engine and wait for 5 minutes Before draining oil start engine and move machine for a while Avoid accidents 50270 I Lower blade or bucket to ground If necessary to raise blade or bucket for ac cess to certain parts securely support...

Page 17: ...rials in a safe place 500022 Before removing radia tor cap or hydraulic tank cap after opera tion wait until machine cools down to avoid having scalding hot coolant or oil blown out Before removing filler cap loosen it slowly to relieve pressure 500024 Disconnect battery ca bles before servicing electrical system Battery electrolyte is very corrosive If you drip it on your skin or clothing flush i...

Page 18: ... in battery Check for loose terminals Make sure gauges and lamps operate properly Hydraulic system Check oil level in hydraulic tank Check for leaks from hoses and cylinders L I I 502676 CAUTION Break in your machine during initiallOO hours of operation After starting a cold engine be sure to warm it up Do not rev up engine unless abso lutely necessary After initialI00 hours of operation of a new ...

Page 19: ...d starter switch in HEAT CAUTION Do not heat engine for more than 20 seconds Do not tl n starter switch to START for more than 30 seconds at a time or during operation If engine fails to start within 30 seconds wait 2 minutes before crank After starting Idle engine for 5 min utes and 1 Check water tempera ture gauge fuel gauge and warning lamps for indication 2 Check for abnormal ex haust noise an...

Page 20: ...ee of personnel and obstructions and use horn Test brakes right and left at slow speed 502679 2 Depress clutch pedal and move transmission control lever to desired speed position 502682 2 Unlock transmission control lever 3 Depress brake pedal to unlock it j I i V 502739 3 Depress brake pedal to unlock it 502681 4 Replease clutch pedal slowly If 502683 4 Move transmission con trol lever to desired...

Page 21: ...i t1 fi fi j h ii Loft tom Righttum j j_ Moderate Sharp 502684 turns turns 502685 L __________________________ 1 To make moderate turns pull steer ing clutch lever slowly and accord ingly 2 To make sharp turns pull steering clutch lever quickly all the way LtJCAUTION When shifting is difficult depress clutch pedal all the way to apply clutch brake and try again DD JCAUTION Do not drive your machin...

Page 22: ...orward change direction backward 502686 502687 Changing Speed or Direction DPS Move transmission con trollever to desired postion It is not necessary to depress inching pedal When changing direc tion be sure to come to a complete stop to avoid damage to trans mission Lt CAUTION When changing speed or direction be sure to come to a complete stop by depressing brake pedal to avoid damage to transmis...

Page 23: ...er on machine equipped with power angling tilt control 2 Make sure transmission control lever is in NEUTRAL On DPS machine lock transmission control with lock unlock lever 3 Lock brake pedal 4 Shut off engine and remove key from starter switch 5 Turn OFF battery switch 3 Depress brake pedal gently to stop your machine 3 Depress brake pedal gently to stop your machine 4 Move transmission control le...

Page 24: ...n slopes 502689 In steep downhill operation do not allow engine to overspeed Select proper speed before starting ma chine downgrade Steering controls sometimes reverse when machine is coasting downhill or being pushed by a load If left steering clutch lever is pulled half way for instance machine would make a right turn WARNING Never free wheel downgrade in NEU TRAL Always stay in gear Going over ...

Page 25: ...ack parts are subject to excessive stress and strain When operating in such a terrain loosen track adjustment to obtain 4 to 6 em 1 1 2 to 2 3 8 in sag Refer to page 54 of this manual for track adjustment Operating on snow Use snow and ice shoes whenever possible These shoes are designed for good penetration and traction on ice or hard packed snow At end of operating period clean snow or mud from ...

Page 26: ...n stripping or leveling by driving machine forward do not dump bucket fully otherwise bucket bucket linkage and frame would suffer costly damage When moving one job site to an other be sure to lock bucket control lever to avoid accidents ...

Page 27: ...d down by machine 3 Platform or ramps must have a gradient of 10 to 15 deg 4 Drive up machine forward when loading Drive it backward when unloading 5 Be sure to block truck wheels CAUTION Drive up and down without steering If machine starts slipping sideways drive it down to ground immediately and try again 6 Upon loading block tracks on both front and rear sides and secure machine with tie downs ...

Page 28: ...to ISoC SOF When using Long Life Coolant at temperatures below ISOC SOF rely on the following chart for correct percentage Starting 20 30 40 temperature 4 22 40 c OF Percentage of Long Life 35 45 55 Coolant Change Long Life Coolant every 2 years When changing flush cool ing system thoroughly Use Long Life Coolant with soft water WARNING Long Life Coolant is poisonous be careful not to drink it If ...

Page 29: ...in RED range slow down or stop machine and let engine cool Check radiator for low coolant level leaks or trash buildup After operating in hot weather Before stopping engine let it idle just longer than in cold weather for cooling Check coolant level in radiator and electrolyte level in batteries Operating in extremely dusty conditions Check air cleaner element and change it more often Clean air br...

Page 30: ...ssion case Gear oil GL 4 9 5 2 5 SAE80 SAE90 DD I Transmission case SAE5W Engine oil CD 11 2 9 SAE lOW r DPS I Transfer bevel gear Gear oil GL 4 7 l S SAE 80 J SAE 90 case DPS I Each side I I I t Final drive gear Gear oil GL 4 6 S 1 7 SAE80 J SAE 90 cases 1 9 5 2 5 2 13 3 4 I I i Hydraulic tank Engine oil CD 33 S 7 SAE5Wf SAE lOW fi t Grease fittings on Grease NLGINo O NLGINo l NLGINo 2 various po...

Page 31: ...ansmission case DPS SAE lOW Diamond HD S 3 lOW Transfer bevel gear case SAE 90 Apolloi Gear HE90 DPS Final drive gear cases SAE 90 Apolloi Gear HE90 Hydraulic tank SAE lOW Diamond HDIOWspecial NOTE These brands are subject to change without notice Avoid mixing lubricants In some cases different brands of lubricants are not compatible with each other and deteriorate when mixed It is best to stick w...

Page 32: ...hat is being charged 500029 Don t touch battery ter minals immediately after operation Removal and installation Removal Installation Disconnect cables from negative and positive ter minals in that order when removing battery Connect cables to positive and negative terminals in that order when installing it Never place a metal object across terminals Jump starting Good battery Dead battery o Connec...

Page 33: ... place Lubricate all grease fittings and change oils in all compartments Apply a thick coat of rust preventive oil to exposed sliding surfaces of hydraulic cylinder piston rods and control1inkages Disconnect battery cables and cover battery or dismount battery and store it in a dry cool place Lock all control levers in NEU TRAL and place accelerator lever in IDLING position Block tracks instead of...

Page 34: ...itch L circuit defective r RepaIr or replace Check and adjust alternator belt tension Battery dead Consult your Mitsubishi dealer Recharge or replace Measure Battery starter switch circuit defective Starter starter relay defective electrolyte specific gravity Repair or replace Consult your Mltsubishi dealer 1 For causes indicated by an asterisk or any cause other than those cited here consult your...

Page 35: ...m 9 Prime Wrong type of Q Change fuel Air cleaner dirty Clean element Low compression pressure Engine not heated Cylinders pistons and piston rings worn Heat engine properly Check and adjust Low battery voltage 5 alternator belt tension and recharge battery Defective circuit Repair or replace Consult your Mitsubishi dealer Restriction in fuel line Dirty filter Clean Clean clogged pipe or repair le...

Page 36: ...low due to worn cylinders piston rings r Too much oil in crankcase r Low viscosity grade of oil f Overcooling f Fuel injection mistimed Compression pressure too low Change oil and follow lubrication recommenda tions Change fuel Clean or replace element Cover up radiator or replace parts Flush cooling system or replace parts Replace thermostat Replace clogged fuel filter Readjust Readjust or replac...

Page 37: ...p defective Poor fuel spray from injection nozzles Compression pressure too low Too much oil in crankcase f Low viscosity grade of oil f Oil leaks Cylinders and or piston rings worn Change fuel Readjust Clean or change element Readjust or replace Repair or replace Clean or change element Retighten or replace Readjust or replace Readjust or replace Repair or replace Fill only to correct level Chang...

Page 38: ...level Low viscosity grade of oil Oil filter clogged Oil pump defective Oil pressure reguiating valVe defective Fill only to correct level Change oil and follow lubrication recommenda tions 7 Change element 7 Readjust or replace 7 Readjust or replace ...

Page 39: ... dirt f Clutch facing burnt resulting in reduced friction Clutch springs weak Clutch pedal stroke too small t Clutch pedal free play too iarge _ I Clearance unequal in clutch Clutch shifter or clutch disc binding on drive shaft Friction surfaces dirty Oil level too high Readjust Replace Wash or replace Replace Replace Readjust Readjust Readjust Disassemble and repair or replace Wash Lower oil leve...

Page 40: ...y lubricated High viscosity grade of oil Clutch brake maladjusted or worn Clutch drags Shift fork and shift rail worn or damaged Gears worn or damaged 7 Lubricate or replace 7 Change oil and follow lubrication recommenda tions 7 Readjust 7 Readjust clutch control 7 Repair or replace 7 Replace ...

Page 41: ...t splines worn Detent springs weak Bearings or bushings worn r Gear teeth worn or improperly meshing I Bearings or bushings worn Oil level too low or low viscosity grade of oil Repair or replace Replace Replace Replace Replace Repair or replace Replace Change oil and follow lubrication recommenda tions ...

Page 42: ...taneously Clutch seized Clutch oil passage restricted Shaft splines worn Oil level too low or low viscosity grade of oil Gears damaged Bearings worn or seized Clutch seized Shaft splines worn Lower oil level Replace Wash or replace Readjust or repair Replace clutch plates Repair or replace Retighten or replace gasket Change oil Repair or replace Add oil Repair or replace oil pump Readjust Repair o...

Page 43: ... Clutch springs weak or broken r Clearance unequal in clutch I l Control linkage maladjusted Booster pressure too low t Control linkage maladjusted Readjust Replace Replace Readjust Readjust Repair or replace main clutch pump Repair or replace DPS transmission pump Repair oil leaks from lines or steering cylinder Readjust ...

Page 44: ...f Implement Blade or bucket will not rise or rise too slowly 501416 501417 502753 r Tracks too loose Tracks too loose r Low oil level in hydraulic tank I f Hydraulic pump internally worn Oil lines bent 7 Readjust 7 Readjust 7 Add oil 7 Replace 7 Repair or replace ...

Page 45: ...l inspection whether or not they have expired in safe service life This is the reason for the need of such periodical change Change these parts whenever suspected of deterioration or aging even if change periods have not come yet Periodical change of these parts are not covered by Warranty Ref Change Every No 1 Fuel hoses 2 years 2 High pressure hydraulic hoses 2 years For parts to be replaced see...

Page 46: ...BD2G BS3G 2 2 pes on left side 2 pes on right side _ _ 2 2 pes on left side 2 2 pes on left side 2 pes on right side 2 pes on right side ___ r 502745 ...

Page 47: ...45 fer case DPS and add Check oil level Fuel tank and add drain 45 moisture and Clrl i n on Ref No Q Jji C Item Service Remarks Page Free play 0 5 to Cheek free 0 5 to 1 cm Brake pedal play stroke 3 16 to 3 8 in 45 and adjust Stroke 8 cm 3 1 8 in Check free Free play Clutch pedal play stroke 1 5 cm 9 16 in 45 Stroke and adjust 16 cm 6 5 16 in Inching pedal Check stroke Stroke 14 5 cm 45 DPS and ad...

Page 48: ...nge oil filter 52 DPS wash strainer Steering clutch cases Drain moisture 49 33 liters Hydraulic tank Change oiL 8 7 U S gal 52 2j Engine oil pan Change oil 7 liters 49 1 8 U S gal Change oil Hydraulic tank filter element 52 EVERY 1000 SERVICE HOURS OR 6 MONTHS Standard 6 5 liters 1 7 U S gal i2j Engine oil filter Change 50 Final drive gear Super swamp 9 5 Change oil liters 2 5 U S gal 52 cases Ult...

Page 49: ...50 Main clutch case Change oil 5 5 liters 51 DD 1 5 U S gal I Bevel gear case trans Change oil 9 5 liters 51 mission case DD 2 5 U S gal Transmission case Change oil 11 liters 51 DPS 2 9 U S gal 3 Transmission case Change oil filter 52 DPS wash strainer Hydraulic tank Change oil 33 liters 52 8 7 U S gal Hydraulic tank Change oil filter 52 element Clutch brake DD Adjust 57 ...

Page 50: ...buildup Engine compartment Check for oil or fuel leaks Hydraulic system Check for leaks worn hoses or damaged lines OGear cases Check for oil leaks a 0 ir f Implement Check for wear or damage Sprockets Check for wear or damage Engine operation Check for abnormal exhaust color sound or vibration Electrical system Check for loose wire connections or broken wires 502688 Make sure defects found during...

Page 51: ...Check oil level and add Radiator Check coolant level and add _ 502705 Main clutch case DD Check oil level and add Transmission case DPS Check oil level and add Bevel gear case transmission case DD Check oil level and add OJ Hydraulic tank Check oil level and add 502709 ...

Page 52: ... 11 I I j __I I r k l t J il W 502711 Brake pedal Check free play stroke and adjust Free play 0 5 to 1 em 3 16 to 3 8 in Clutch pedal DD Check free play stroke and adjust I I I I 0 Free play 1 5 ern 9 16 in Stroke 16 em 6 5 16 in 502713 Inching pedal DPS Check stroke and adjust Transmission control lever DPS Check clearance in guide Clearance 0 5 to 2 mm 0 02 to 0 08 in 502715 ...

Page 53: ...urs or daily N before operation Tracks Check adjustment sag Sag 2 to 3 em 3 4 to 1 3 16 in 502716 Implement Check for damage or wear 502717 Steering clutch levers Check stroke Stroke 20 to 22 em 7 7 8 to 8 11 16 in 502718 ...

Page 54: ...ry 250 service hours or monthly I Fan belt Check tension 502359 Battery Check electrolyte level battery electrolyte level warning lamp of OK monitor Upper limit c t U l O 1I111111111r Lower limit 502720 I ...

Page 55: ...Every 250 service hours or monthly IT Implement Lubricate 3 strokes from grease gun BS3G 18 fittings Straight blade 5 fittings 502725 ...

Page 56: ...uel tank Wash strainer Strainer 502721 Final drive gear cases Check oil level and add Fuel feed pump Wash filter 500318 Air cleaner Clean element 1 2 Steering clutch cases Drain moisture Engine oil pan Change oil cQ LU 502724 1 l r 502726 ...

Page 57: ...Every 1000 service hours or 6 months Engine oil filter Change Universal joint Lubricate Filter wrench EJ 2 fittings Installation 502361 502727 rtf Fuel filter Change element Element 500320 ...

Page 58: ...D Change oil Damper case DPS Change oil 502728 Main clutch case DD Wash strainer l Strainer 502729 g W 502730 Bevel gear case transmission case DD Change oil 502731 Bevel gear case transfer case DPS J Change oil 502732 Transmission case DPS Change oil 502733 ...

Page 59: ...DPS Change oil filter wash strainer Strainer 502734 C 6J Hydraulic tank Change oil 502735 iJ Hydraulic tank Change oil filter element 502736 Final drive gear cases Change oil 502737 Radiator Flush change coolant tJ L J 502738 Air cleaner Change element 502723 ...

Page 60: ...lements on hand to use while cleaning used element Dry element in breeze or current from an electric fan Do not clean elements by bumping or tapping WARNING Wear safety goggles and protective clothing when using pressure air Priming fuel system 1 Unlock priming pump 1 by turn ing it counterclockwise 2 Loosen air vent plug 2 of fuel fIlter Operate priming pump until fuel flows from vent without bub...

Page 61: ...pply grease with a grease gun into fill valve 1 until dimension A between flange and rigid bar is within 45 em 17 3 4 in 2 Operate machine backward and for ward to equalize adjustment III If it is difficult to set dimension A within 45 em 17 3 4 in consult your Mitsubishi dealer To loosen Turn fill valve 1 counterclockwise and allow grease to escape from vent hole 2 WARNING Keep your face away fro...

Page 62: ... Equalize right and left lever positions 2 To adjust released position of lever 3 loosen lock nut 4 and turn lever 3 in either direction It should be 6 5 to 7 5 em 2 9 16 to 8 11 16 in as measured from end face of instrument panel B Clearance between brake band and drum Run in adjusting nut 5 all the way and back it off 2 2 3 rotations from that position I C Stroke steering clutch levers Adjust le...

Page 63: ...n stopper bolt 1 so that pedal is 20 cm 7 7 8 in as measured from dashboard wall 2 Adjust length of rod 2 so that free play of pedal is 0 5 to 1 em 3 16 to 3 8 in II Make sure right and left brakes move simultaneously when you start depressing pedal Adjusting inching pedal DPS 20 em 7 7 8 in 502744 1 Reposition stopper bolt 1 so that inching pedal is 20 em 7 7 8 in as measured from dashboard wall ...

Page 64: ...ssed all the way with engine running at maximum speed_ 1 Adjust as installed length of spring 1 to 4 cm 1 5 8 in 2 Loosen lock nuts 2 3 and run in adjusting bolt 4 until brake band 5 comes in full face contact with drum 6 3 Back off adjusting bolt 4 2 5 to 3 rotations from that position to obtain correct clearance between band and drum Adjusting transmission control lever DPS Clearance a between g...

Page 65: ...e tration into ground or for giving dirt a rolling action ahead of blade proceed as follows 1 Set blade at large angle by turning left brace 1 counterclockwise with handle 2 2 Set blade at smaller angle by turn ing left brace 1 clockwise with handle 2 C AU T IO N Do not increase exposed length A of eye bolt 3 more than 10 5 em 4 in c o ...

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