Mitsubishi Mahindra GX3600 Service Manual Download

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MITSUBISHI TRACTOR

SERVICE MANUAL

Summary of Contents for Mahindra GX3600

Page 1: ...MITSUBISHI TRACTOR SERVICE MANUAL ...

Page 2: ......

Page 3: ...PECIFICATIONS 1 GENERAL SPECIFICATIONS 27 2 GEAR RATIO 30 3 NAME OF EACH PART 31 4 LUBRICATION 33 SECTION 3 MECHANICAL STRUCTURE 1 ENGINE 45 2 ENGINE COMPONENT RELATED DEVICE 50 3 POWER TRANSMITTING 54 4 TRANSMISSION 57 5 REAR AXLE BRAKE DIFFERENTIAL LOCK 65 6 FRONT AXLE 4WD 69 7 HYDRAULIC SYSTEM 76 8 ELECTRIC EQUIPMENT 97 9 DIMENSION FOR IMPLEMENT FIT 99 ...

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Page 5: ...1 SECTION 1 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 6: ...2 ...

Page 7: ...of controls before operating It is your responsibility to understand and follow manufacturer s instructions on machine operation service and to observe pertinent laws and regulations WARNING If you wear clothing that is too loose or do not use the correct safety equipment for your job you can be injured Always wear clothing that will not catch on objects Extra safety equipment that can be required...

Page 8: ...ved goggles or other approved eye protection CAUTION Use suitable floor service lacks or chain hoists to raise wheels off the floor Always block machine in place with suitable safety stands CAUTION When servicing or repairing the machine Keep the shop floor and operator s compartment and steps free of oil water grease tools etc Use the oil absorbing material and or shop cloths as required Use safe...

Page 9: ...5 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 10: ...6 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 11: ...7 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 12: ...8 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 13: ...9 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 14: ...10 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 15: ...11 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 16: ...12 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 17: ...13 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 18: ...14 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 19: ...15 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 20: ...16 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 21: ...17 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS GENERAL INFORMATION ...

Page 22: ...18 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 23: ...19 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 24: ...20 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 25: ...21 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS STANDARD BOLT TORQUES ...

Page 26: ...22 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 27: ...23 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 28: ...24 SAFETY GENERAL INFORMATION AND STANDARD TORQUE SPECIFICATIONS ...

Page 29: ...SECTION 2 SPECIFICATIONS ...

Page 30: ......

Page 31: ...h min tread 55 5 1410 56 1 1425 Height to Top of Frame Height to Top of Steering 55 5 1410 Wheelbase 65 0 1650 Min Ground Clearance 15 0 380 Tread Front 43 9 1115 Tread Rear 42 9 1090 Turning Radius W Brake Weight Total 2425 5 1100 at full fuel Front lbs kgf lbs kgf lbs kgf Rear DRIVE TRAIN Gear Transmission Constant main Number of Speeds F8 R8 Shuttle Forward Revers Synchro Speed 䚷Forward speed k...

Page 32: ... Cooling System gal L 1 43 5 4 Coolant bottle gal L 0 079 0 3 Crankcase gal L 1 19 4 5 Transmission Hyd gal L 7 4 28 Front Axle gal L 1 06 4 Fuel tank gal L 7 94 30 Operation Deck type Semi Flat Deck Pedal type Floor Moun Std Size at Japan 7 50 16 12 4 24 t Seat Suspention N A Steering System Hyd P S Tilt Steering wheel N A Foldable ROPS N A TIRE SIZE AG 䚷䚷䚷䚷AG Tires Front Rear 䚷䚷䚷Turf Tires Front...

Page 33: ...p std Tail lamp std Turn signal lamp std Stop lamp std manual Engine glow system 7 pin connector OTHERS Engine hand throttle std Engine foot throttle std Muffler Inner side cover Rops w seat belt Tool Tool box N A SMV emblem N A N A N A N A Bumper GRAND SPEED 12 4 24 F 1 R 1 1 66 1 39 2 2 km h 2 36 1 98 3 3 4 04 3 39 4 4 5 40 4 52 5 5 5 94 4 97 6 6 8 45 7 07 7 7 14 47 12 11 8 8 19 34 16 19 max max...

Page 34: ...30 SPECIFICATIONS 2 GEAR RATIO ...

Page 35: ...n Control Lever Parking Brake Lever Accelerator Pedal Flow Control Grip Brake Pedal Left Right Turn Signal Indicator Right 1944_0006 MFD Control Lever Step Clutch Pedal Fuel Tank Muffler Fuel Cap Shuttle Shift Lever Steering Wheel Hood Radiator Air Cleaner Battery Turn Signal Indicator Left Alternator ...

Page 36: ...attery Charge Indicator Engine Coolant Temperature Gauge Fuel Gauge Hourmeter Starter Key Switch Tachometer Combination Switch 䞉 Headlight Switch 䞉 Horn Switch 䞉 Turn Signal Switch 4 7 9 3 1 5 8 6 2 1944_0007 Meter Panel Engine Control Lever Throttle Lever Brake Pedal Left Right Clutch Pedal Shuttle Shift Lever ...

Page 37: ...ts Perform the inspection and maintenance as required 1944_0054 Fuel Tank Diesel Fuel Radiator Coolant Water Transmission Case Gear Oil Brake Link Left and Right Grease Engine Crank Case Engine Oil Rod End Grease Front Axle Case Gear Oil 3 5 7 1 6 4 2 ...

Page 38: ...place after 50 hrs after 1st inspection Inspect before work Refuel as necessary Inspect before work Refuel as necessary Cycle of Replacement Amount L Replace after 100 hrs for the 1st inspection and every 200 hrs afterwards Replace after 100 hrs for the 1st inspection and every 200 hrs afterwards Inspection before work and lubrication every 50 hrs Inspection before work and lubrication every 50 hr...

Page 39: ...f the oil level gauge and the engine oil pan and drain the drain oil 2 Close the drain oil plugs and supply new engine oil to the upper limit of the oil level gauge When inspecting or replacing the engine oil park the tractor on flat place and stop the engine The oil level gauge and the tail pipe are provided nearby Do not touch the tail pipe Also do not touch the oil level gauge until it cools do...

Page 40: ...mit of the oil level gauge if insufficient NOTE When attaching the engine oil filter apply oil to the packing side tighten the engine oil filter manually and tighten 2 3 rotation approximately after the packing makes contact with the sealing face 1944 0058 Oil Level Gauge Oil Level Gauge Oil Filter Oil Filter Tractor Right Side Tractor Right Side 5 Refueling Check the remaining amount in the fuel ...

Page 41: ... the fuel shut off valve and vent the fuel system See Air Vent Procedure in this manual 1944_0089 Fuel Filter Oil Filter Fuel Shut off Valve 7 Air Vent Procedure 1 Open the Fuel Shut off Valve 2 Starter Key Switch is turned to the䚾䚿 position Engine not running 3 Loosen the air vent screw on the fuel filter Keep it until the fuel flowing from the fuel filter becomes free of air bubbles Tighten the...

Page 42: ...ant Water If the coolant water of the radiator is handled incorrectly it shortens the service life of the engine Inspection of Coolant Water 1 A reserve tank is provided in the radiator and adjusts the amount of coolant water in the radiator Perform inspection before operation and supply coolant water if insufficient 2 Open the side cover on left and make sure that the coolant water is within the ...

Page 43: ...Cap Radiator Cap 1944_0063 Coolant Water Cock Coolant Water Hose Engine Left Side Engine Right Side 5 Supply the coolant water to the MAX upper limit of the reserve tank When the coolant water is cooled the coolant water in the reserve tank is sucked in and the water level is reduced in the reserve tank thus supply the coolant water to the MAX upper limit of the reserve tank Use antifreeze long li...

Page 44: ...il to the upper limit of the oil level gauge when sufficient Oil Replacement 1 Remove the drain oil plug located in the bottom part of the center of transmission housing and drain the oil 1944_0064 Oil Filler Plug with Oil Level Gauge Oil Filler Plug with Oil Level Gauge Upper Limit Lower Limit Specified Amount For injury prevention Place the tractor on flat place and stop the engine when inspecti...

Page 45: ... the oil level at the oil level gauge Supply oil to the upper limit of the oil level gauge if insufficient NOTE When attaching the hydraulic oil filter apply oil to the packing side tighten the hydraulic oil filter manually and tighten 2 3 rotation approximately after the packing makes contact with the sealing face 1944_0066 Hydraulic Oil Filter Hydraulic Oil Filter Cover 12 Inspection and Replace...

Page 46: ...e Nipple 1944_0069 Grease Nipple Grease Nipple 1944_0068 Drain Oil Plug Drain Oil Plug Oil Replacement 1 Remove the drain oil plugs 3 places and drain the oil 2 Close the drain oil plugs 3 Remove the air vent plug located on both gear cases 4 Supply oil through the fill hole Supply gear lube GL 4 or better gear lube until the oil flows out of the air vent plug hole and install air vent plug 5 Unti...

Page 47: ...SECTION 3 MECHANICAL STRUCTURE ...

Page 48: ......

Page 49: ...at right side of the engine and lower side of the injection pump 2 Engine serial No 1 A sticker stating the engine serial No is put at the upper surface of the engine and cylinder head cover 2 The engine serial No is stamped at the injection pump installed face Engine Model S3L3L Model Seal Engine Serial NO ...

Page 50: ... RPM Max Rated rpm 3737 3458 Dia mm 340 Pulley ratio crank shaft fan 1 33 Factory name Oil pressure switch Oil main gallery Oil lter Relief valve Oil pump Oil drain plug Oil strainer 3 Cylinder engine L3 Series Standard Speci cation For Agriculture Usage S 3 L 3 L 11 TA 1 2 Oil system 1 Specification Model S3L3L Item Lubrication Percolation type Full Àow spin on cartridge lter Oil API classi catio...

Page 51: ...pe Type Begins to Open S3L3L Forced circulation by water pump Suction type ĳ340 Belt Centrifugal pump Belt 2 8 Wax pellet type 71 1 5 C Full open 82 C Drive Water Pump Thermostat Water Capacity L Fan 1 3 Cooling system 1 Specification Water bypass hose Thermostat Water pump Radiator Cooling fan ...

Page 52: ... Diameter of Planger ĳ6 0mm Injection Nozzle Type Throttle type Injection Pressure 14 7 MPa Fuel Filter Type Paper element cartridge separate type Fuel Pump Type Electric diaphragm Fuel leak off pipe To fual tank Fuel injection nozzle Fuel pump From fuel tank Fuel lter Fuel injection pump Fuel injection pipe ...

Page 53: ...49 MECHANICAL STRUCTURE 1 5 Performance Curves ...

Page 54: ...p Injection Pump Hose 2 ENGINE COMPONENT RELATED DEVICE 2 1 Fuel System Tank Cap Rear View Fuel Tank Fuel Tank Fuel Pump Injection Pump Fuel Pump Injection Pump Tank Return hose Fuel Filter Tank Fuel Filter Hose Fuel Filter Fuel Filter Fuel Pump Hose ...

Page 55: ...51 MECHANICAL STRUCTURE 2 2 Cooling System Upper Hose Radiator Ass y Lower Hose Reserve Tank Hose Cap Radiator Net Radiator Ass y Hose ...

Page 56: ...52 MECHANICAL STRUCTURE 2 3 Air Cleaner 2 4 Mufﬂer Air Hose MufÀer Tail Pipe Air Cleaner ...

Page 57: ... between governor lever and wire ball to be 0mm 0in 3 Step on the foot pedal Adjust by the adjuster B for the wire to have the clearance between governor lever and wire ball to be 0mm 4 When returning the both accelerator lever and foot pedal to the lower idle side make sure the governor lever makes a contact with the low idle stopper 5 Engine rpm at Low idle and High idle Low Idle 995 25 rpm High...

Page 58: ... STRUCTURE 3 POWER TRANSMITTING 3 1 Power Transmitting Diagram 3 2 Clutch Structure Engine Disc Ass y Clutch Housing Cover Ass y Drive Shaft Engine Rear Plate Release Hub Release Lever Release Shaft Release Bearing ...

Page 59: ...509 mm 301 mm 3 3 Clutch Control Brake Control 1 Structure Brake Pedal RH Brake Pedak LH Brake Rod Brake Rod Brake Rod Clutch Rod Release Shaft Clutch Pedal Release Shaft Clutch Pedal Clutch Rod Parking Brake Lever Brake Pedal ...

Page 60: ...justment 1 Amount of brake pedal play A should be adjusted 35 45mm by joint B Then tighten nut C rmly Both side of brake should be adjusted same manner and height of pedal must be equal 2 After proceed 1 try actual running test to make sure both side of brake perform same level And if not adjust again A A One Side Braking Normal Clutch Rod Lock Nut Brake Rod Nut C Joint B ...

Page 61: ... the endplay of PTO shaft to be within 0 05 to 0 2mm 0 002 to 0 008 in with the liner D Main Shift PTO Shaft Pinion Shaft Pinion Shaft Shaft Shaft Shaft A B C D Main Shaft Drive Shaft 4WD Shaft Forward Reverse Forward Reverse Forward Reverse 4WD 2WD Forward Reverse 4step 3step Forward Reverse 2step 1step Forward Reverse Low High Forward Reverse 2 step 1 step 19T 29T 28T 28T 28T 28T 14T 14T 10T 44T...

Page 62: ...de by wire type with shift fork and rail 4WD shifter is shift arm type with shift piece Rear PTO Shift Lever Shuttle Shift Lever Rod Main 3 4 Rod Rod Main 3 4 Rod Main 3 4 Rod Main 3 4 Link Rear PTO Link Rear PTO Rod Shuttle Y X Rod Shuttle Rod Sub Rod Sub Rod Main 1 2 Rod Main 1 2 Rod Main 1 2 Rod Main 1 2 Main Shift Lever Sub Shift Lever Main Shift lever Sub Shift Lever 4WD Shift Lever Shuttle S...

Page 63: ...ork Shuttle Fork Rail Shuttle Rail Main Rail PTO Rail Sub Spring Main Fork 3 4 Main Fork 3 4 Main Fork 3 4 Main Fork 1 2 Main Fork 1 2 Main Fork 1 2 Spring Spring Pin Shifter PTO Fork PTO Fork PTO Fork Sub Fork Sub Fork PTO Fork Sub Fork Shuttle Fork Main Fork 3 4 4WD Shifter 4WD Shifter 4WD Shifter Sub Fork Main Fork 1 2 59 ...

Page 64: ...60 ...

Page 65: ... 0730 0006 206 1 0 0 039 0730 0006 210 2 Adjust the endplay shown in the drawing to be within 0 05 to 0 20mm 0 002 to 0 008in with liner B Unit mm in Item Thickness Parts No Liner B 0 2 0 008 0730 0005 202 0 6 0 024 0730 0005 206 Pinion Shaft Shaft 4WD Shaft Pinion Shaft Shaft Grease Liner A Liner B Grease 22T 16T 13T 33T 30T 34T 26T 20T 16T 25T 28T 14T 34T 19T 33T 35T 28T 33T 29T 22T 19T 34T 19T ...

Page 66: ... 0 2 0 008 0731 0003 002 0 4 0 016 0731 0003 004 0 8 0 031 0731 0003 008 1 0 0 039 0731 0003 010 3 Adjust the endplay shown in the drawing to be within 0 05 to 0 20mm 0 002 to 0 008in with liner C 4 Adjust the endplay shown in the drawing to be within 0 05 to 0 20mm 0 002 to 0 008in with liner D PTO Drive Shaft Oil Grease 13T 10T 44T 40T PTO Shaft Liner C Liner D Liner C Liner C PTO Shaft PTO Driv...

Page 67: ... View Hole Hole Hole Spring 1 Spring 2 Hook part Hook part Note to assembling the HUB Note to tightening lock nut Pinion shaft Lock nut 1 Tightening lock nut so that the start torque of the pinion gear may become 0 98 to 1 27Nm and pressurizing is given to taper bearings 2 In order that a lock nut may not loosen it crushes so that it may get into the slot of the pinion shaft Pinion gear Tapered ro...

Page 68: ...64 ...

Page 69: ...e Match mark VIEW FROM AROW Y Liner D Z to Z Differential lock pedal Plate A Bolt A Plate B 16 to 23 mm 0 63 to 0 91 in Bolt B Differential Shaft Differential Case Rear Axle Axle Cover Final Gear Brake Ass y Brake Arm Pinion Shaft Adjustment of Differential Lock Pedal 1 Step on the pedal and touch the pedal to the plate A Tighten the bolt A 2 Release the pedal and touch to the plate B Tighten the ...

Page 70: ...66 ...

Page 71: ...3 0 0020in 2 Adjusting method that uses special tool Unit mm in Item Thickness Parts No Liner A 0 15 0 06 0731 0002 501 0 2 0 008 0731 0002 502 0 4 0 016 0731 0002 504 0 8 0 032 0731 0002 508 1 As shown in the following figure assemble a special tools to a differential gear case 2 Measuring dimension A 3 Inserting the liner of the same thickness of dimension A to B Differential gear case A B Pinio...

Page 72: ...he lateral free play of differential case assembly to be within 0 to 0 10mm 0 to 0 004in with the liner C Unit mm in Item Thickness Parts No Liner B and C 0 4 0 016 1007 0618 200 0 2 0 008 1007 0618 100 0 1 0 004 1007 0618 000 1 6 0 063 1025 1535 000 5 Liner Adjustment of Rear Axle Shaft and Differential Lock Shifter 1 Adjust the clearance between the axle case and shifter to be within 0 20 to 0 6...

Page 73: ...ive into Surface Level Oil Seal Drive Procedure A Rear Bracket Knuckle Arm Left Knuckle Arm Right Rod End Rod End Front Bracket Axle Case Pinion Shaft Knuckle Arm Final Case Kingpin Case Axle Case B Filler Port Axle Case Pinion Shaft Front Axle Bracket Differential Shaft Right Differential Ass y Differential Shaft Left Axle Case A Wheel Shaft F F C C 23mm Final Case SECTIONAL VIEW F F SECTIONAL VI...

Page 74: ...70 ...

Page 75: ...Grease Grease Rear bracket Bond Pinish shaft Grease Grease Grease Liner B Bond 6010 Liner A Grease Grease Liner F Packing Liner 6304UU 6206 G 14T 18T Liner C Liner G Liner E Liner D mm in 12T Packing Grease 32T TMB304 6306 6305 51106 Grease GZ3W26 020 11 0 05 0 433 0 002 3 0 05 0 12 0 002 25 0 05 0 98 0 002 17 9 0 05 0 705 0 002 A D B C 6 2 ASSEMBLY AND INSTALLATION OF FRONT AXLE ...

Page 76: ...UCTURE A A B B D 11 0 05mm 0 433 0 002 in 0 05 to 0 2mm 0 002 to 0 008 in 17 9 0 05mm 0 705 0 002in C 25 0 05mm 0 98 0 002in 3 0 05mm 0 12 0 002in 0 to 0 2mm 0 to 0 008 in Liner G Liner D Liner E Liner G Liner F Liner C ...

Page 77: ... in the figure Spring stays inside Unit mm in 5 Assembly of Differential Case Assembly 1 Make sure the backlash for the pinion gear and side gear is within 0 10 to 0 30mm 0 004 to 0 012in 2 Apply the adhesives equivalent to Threebond 1374 th to to e locking bolt for the ring gear and tighten with WRUTXH DW WR 1 P WR NJI FP OEI IW 3 Place the spring pin with the slit toward as shown in the figure V...

Page 78: ...n 8 Assembly of Axle Shaft Unit mm in 2 Adjust the lateral clearance E for axle shaft to be within 0 to 0 20mm 0 to 0 008in with the liner E 3 Apply the liquid packing Threebond 1208D to the holder and cover Wrap the mounting bolt with seal tape and tighten Item Thickness Usable Limit Liner A and B 0 10 0 004 1007 0618 000 0 20 0 008 1007 0618 100 0 40 0 016 1007 0618 200 Item Thickness Usable Lim...

Page 79: ...19 400 1 40 0 055 1438 1319 300 Toe in functions as an important role to control the stability of the vehicle Tendency for control loss of vehicle while running may be caused by misalignment of toe in In such case inspect and adjust Unit mm in 1 Loosen the locknut for tie rod end 2 Remove the nut for tie rod end from the knuckle arm 3 Adjust the length of tie rod end by turning only the tie rod en...

Page 80: ...control system and mechanical auto depth control system are provided as a lift control system for 3 point link 2 Image of hydraulic system Power Steering Cylinder Pump Power Steering Pump Hydraulic Orbit Roll Transmission Control Valve Flow Control Valve Lift Arm Cylinder Filter Hydraulic Pressure Outlet ...

Page 81: ... Lowering speed adjusting valve Hydraulic lift Control valve C T2 EF N P T P1 P T3 15 2 0 MPa at 29 0 L min 0 5 51 cc rev 6 0 cc rev 13 2 cc rev 60 2 5 T1 Upper Lower EF N P T P1 External hydraulic circuit 7 2 Hydraulic Circuit ...

Page 82: ...78 ...

Page 83: ...Suction Pipe Oil Filter Oil Filter Suction Pipe Pressure Pipe Hose C Hose C Hose A Hose A Pump 1 For Lift Suction Pipe Suction Pipe Suction Pipe Suction Pipe Pump 2 For Power Steering Pressure Pipe Pressure Pipe Block Ass y Block Ass y Return Pipe Return Pipe Block Block 79 ...

Page 84: ...80 ...

Page 85: ... the inlet The oil forced out at the outlet port and sent through the system Pump Actuation View Drive Gear Driven Gear Drive Shaft Inlet Outlet Bush Pump Sectional View Cover Gear B Side Plate O Ring 3 Shape of Seal 2 Sub Pump For Power Steering Pump Model Gear Type Model KAYABA INDUSTRY KPN05 60 ARMS Discharge Amount 6 0cc rev 0 366in3 rev Relief Pressure 15 2MPa 155kgf cm2 2205pis Rotaing Direc...

Page 86: ...stment of lowering speed for the lift arm 3RVLWLRQ RI WKH OLIW DUP LV FRQWUROOHG E 3 OHYHU 1 Specifications Hydraulic Cylinder Cylinder Diameter Stroke 75 100 7mm 2 95 3 965in Maximum Dynamic Lift 1200kgf 2646lbf Preset Maximum Pressure 15 03D NJI FP2 2205psi 92mm 3 62in Oil MOS2 P MOS2 P Bush slit R L 45 Lock screw Lock screw f 7 5 m m f 2 9 5 i n R 9 5 m m R 3 7 4 i n R230 4 7 1 7 Match the punc...

Page 87: ...15 Pin 16 Screw 17 Power Arm 18 Piston Rod 19 Bush 20 Piston 21 O rin 23 Lift Shaft g 22 Ring 7 7 7 7 7 7 Flow control valve Lift arm Adjuster Stopper A PC lever Stopper B Punch mark 5 10mm 0 197 0 591in Upper limit Lower limit GZ3W31 011 Parts Parts PC lever Stopper A Stopper B Flow control valve Punch mark Lift arm Adjuster Upper limit Lower limit 2 P C System Position Control 5 10m m ...

Page 88: ...ted by movement of the spool valve It opens only when lifting Maximum Discharge PLQ JDO PLQ Maximum Usable Pressure 03D NJI FP2 2205psi Pressure Loss P T neutral pressure loss PLQ ZKHQ EHORZ 03D NJI FP2 114psi P C lifting pressure loss PLQ JDO PLQ ZKHQ EHORZ 03D NJI FP2 199psi Operating Oil Multi STOU Oil Temperature 40 C to 50 C Hydraulic pressure signal T2 T1 P C T3 4 3 2 1 Neutral oil return Va...

Page 89: ...40 2 ULQJ Part No 0830 0100 150 Size P15 Hs70 JIS B2401 2 Check Valve KHFN YDOYH Part No 1003 2416 180 2 ULQJ Part No 0830 1100 090 Size P9 Hs90 JIS B240 1 Plug Plate Sheet plug Poppet Check valve Sheet Plate Spool Unload valve PR8W4 047 Unload valve spring PR8W4 048 O ring Check valve PR8W4 049 3 Disassembly of Control Valve ...

Page 90: ...ing Procedure 1 Remove the plug and the spring of unload valve 2 The position which changes the sound when moving the spool while blowing in the air from the plug is the neutral position for the spool 3 Set the clearance T with the nut connecting the plate and poppet within 0 3 to 0 6mm 0 012 to 0 024in in this position and lock Hydraulic pressure signal T2 T1 P C T3 4 3 2 1 Neutral oil return Val...

Page 91: ...ant MoS2 P to the bush inner diameter pin oscillating part and oscillating part of the piston and piston rod 2 Toward the slit of the bush left and right for lift shaft as shown in the figure for mounting 1 Toward the slit of the bush as shown in the figure for mounting 2 The depth of press fit for bush shall be 13 5mm 0 531in on both lift and right Reference Apply some lubricant MoS2 P to the spl...

Page 92: ...ome liquid packing ThreeBond 1208D to the mounting face of the lift case for assembly 7 Refer to the table for torque for each part Standard torque unless specified MOS2 P MOS2 P Bush slit R L 45 Lock screw Lock screw Bush slit Match the punch marks of the power arm and lift shaft for assembly A A Packing GZ3W31 026C Breather 45 Lock screw Bush sift R L MoS2 P Packing MoS2 P Match the punch marks ...

Page 93: ...89 MECHANICAL STRUCTURE 7 7 7 7 7 7 7 7 7 7 9 10 11 1 5 l 40 l 130 l 40 l 40 l 110 l 110 l 110 4 places 2 8 7 3 6 4 3 3 2 2 7 Torque for Each Parts ...

Page 94: ...t and Bush 0 09 to 0 2 0 0035 to 0 0079 0 30 0 012 Clearance bet Piston Rod and Bush 0 075 to 0 216 0 003 to 0 0085 0 30 0 012 2 Adjustment of Position Control Lever Adjust the nut for adjuster to stop the lift arm at 5 to 15mm 0 197 to 0 591in before at the tip of the lift arm from the upper limit position 7 Adjuster Nut 5 to 10mm 0 197 to 0 591in GZ3W31 031 8 Inspection and Adjustment ...

Page 95: ...in Hydraulic Chart Releaf Valve Hydraulic Power Take off out G3 8 M16 x 1 5 G3 8 G3 8 G3 8 Housing Plug Plug Rc1 4 When installing a Hydraulic take off block install a plug Rc1 4 It is not provided at shipment 15 2 MPa 155 kgf cm2 0 5 0 5 0 7 7 Releaf Valve 1 Releaf Valve ...

Page 96: ...ER 3TEERING 1 Structure Hose L Steering Wheel Steering Unit Steering Mast Hose R Hose L Hose R Front Axle Cylinder Ass y Ring Steering Shaft Nut Washer Liner Bush Cylinder Ass y O Ring Ring Liner Spring Ring Bearing Steering Mast ...

Page 97: ...in which is fixing the Y and Z nuts should bend a tip on both sides 3 4 Bleeding Procedure for Power Steering After inspecting and adjusting the assembly of each part Take the following procedure for air bleeding 1 Set the engine speed to 1500 to 2000rpm Hydraulic cylinder Rod end B Hose L Nipple Rod end B Nipple Nut Y Tie rod end C Hose R E 132 5 197 43 5 1 713 43 5 1 713 116 5 4 587 116 5 4 587 ...

Page 98: ...tary valve as handle wheel turn Front Wheel Power Steering Hydraulic Circuit Arrow mark is suggest the operation of steering wheel Cylinder Pump Hydraulic Pump for Power Steering Steering Wheel Left Turn Filter Oil Feed Pipe Power Steering Unit of All Hydraulic Type Hydraulic Hose Valve System Open Center Load Effect Non load reaction Model RU051B105F6A EATON FLUID POWER Max T emperature 95 oil te...

Page 99: ...earing Race 12 Oil Seal 13 Dust Seal 14 Retainer Screw Assembly 15 Retainer Pin 16 Ball 17 Relief Poppet 18 Spring 19 O ring 20 Relief Adjust Plug 21 Drive 22 O ring 23 End Cap 24 Spacer Plate 25 Gerotor 26 Spacer 27 Plate 28 O ring 29 Cap Screw 30 Nameplate 31 Rivet 32 Damper Collar GS7W3 176 Left port L Right port R Tank port T Pump port P A A C C A A Section C C Section 2 Structure ...

Page 100: ...96 ...

Page 101: ...䠰䠡䠩䠬䠣䠝䠱䠣䠡䠟䠨䠱䠰䠟䠤䚷䡏䡓䠊 12A 26 E13 3 E12 27 26 E10 0A 41 E3 42 20 E20 9 10 E19 29 E11 31 E34 䚷䚷䠡䠰䠮䚷䡏䡋䡈䠊䠄䠬䠱䠨䠨䈈䠏䠊䠓䠑䠝䠅䠄䠤䠫䠨䠠䈈䠌䠊䠑䠓䠝䠅 10A 12 E32 B3 䠯䠰䠝䠮䠰䠡䠮䚷䠩䠫䠰䠫䠮䚷䚷䚷䠄䠍䠊䠓䡇䡓䠅 10 E14 1 E15 䠤䠡䠝䠠䚷䠨䠝䠩䠬䚷䠄䠎䠑䠳䡔䠎䠅 38 0B E1 METER䚷䠝䠯䠯䠵 indicator lamp 1 7W 31 27 44A 43A 37A 29 0C 32 12B E22 䠟䠫䠩䠞䠥䠪䠝䠰䠥䠫䠪䚷䚷䚷䚷䡏䡓䠊 41 13A 44 42 43...

Page 102: ...Harness B Turn Lamp L H Rear Combi Lamp L H Fuel Gauge Turn Lamp R H Rear Combi Lamp R H Meter Ass y Combination Switch Rear Combi Lamp Turn Lamp Battery Battery Cord ETR sol Terminal L S Alternator Alternator Horn Terminal B Terminal ST Terminal B Starter Motor Starter Motor Terminal M Safety Switch Safety Switch Brake Switch Brake Switch Fuel Pump ...

Page 103: ...99 MECHANICAL STRUCTURE 9 DIMENSION FOR IMPLEMENT FIT 6 6752 326 7 21 ȭ ȭ s 0 7 36 ȭ 2 ȭ ȭ 㸦㸧 5 5 㹼 r r r 5 9 520 52 ȭ 2 6 0 7 36 37 0 7 36 37 ȭ 2 6 ...

Page 104: ...100 MECHANICAL STRUCTURE 0 7 36 5 8 3725 5 5 372 17 5 0 7 36 37 0 7 36 37 9 520 52 ȭ s ȭ 2 5 1 266 3257 0 7 36 37 0 7 36 37 ȭ ȭ 5 833 5 1 3 1 0 2 5 7 32 17 0 ȭ 5 7 833 5 7 32 17 0 ȭ ࠉ 5 7 7 ȭ ࠉ 5 ȭ ...

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