Mahindra 2810 Service Manual
  1. Manuals
  2. Brands
  3. Mahindra Manuals
  4. Tractor
  5. 2810
  6. Service manual

Mahindra 2810 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

TRACTORS
2810/T290/T300/T330
SERVICE MANUAL
Chapter 1. Introduction
------------------------------------01
Chapter 2. Disassembly and reassembly of major point ------02
Chapter 3. Engine accessories ------------------------------------03
Chapter 4. Clutch system ------------------------------------------- 04
Chapter 5. Transmission
------------------------------------ 05
Chapter 6. Front axle (4WD)
-----------------------------------06
Chapter 7. Rear axle and Brakes ----------------------------------07
Chapter 8. Power steering system--------------------------------- 08
Chapter 9. Hydraulic system --------------------------------------09
Chapter 10. Electric accessories and instruments -----------10
Chapter 11. Service standard and other information ---------11

Advertisement

Table of Contents
loading

Related Manuals for Mahindra 2810

Summary of Contents for Mahindra 2810

  • Page 1 TRACTORS 2810/T290/T300/T330 SERVICE MANUAL Chapter 1. Introduction ------------------------------------01 Chapter 2. Disassembly and reassembly of major point ------02 Chapter 3. Engine accessories ------------------------------------03 Chapter 4. Clutch system ------------------------------------------- 04 Chapter 5. Transmission ------------------------------------ 05 Chapter 6. Front axle (4WD) -----------------------------------06 Chapter 7. Rear axle and Brakes ----------------------------------07 Chapter 8.

  • Page 2: Chapter 1. Introduction

    Chapter 1 Introduction INTRODUCTION--------------------------------------------------------------1-1 SAFETY INTRODUCTION-------------------------------------------------1-2 WARNING SIGNS IN THIS MANUAL ----------------------------------1-5 SAFETY SIGNS ---------------------------------------------------------------1-6 SAFETY DECALS -----------------------------------------------------------1-11 UNIVERSAL SYMBOLS --------------------------------------------------1-14 SECTION 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS -------------------------1-15 SECTION 2. SPECIFICATIONS------------------------------------------1-17 SECTION 3. GEAR TRAIN DIAGRAMS-------------------------------1-20 SECTION 4. PRECAUTIONS FOR TRACTOR OPERATIONS---1-21 1.
  • Page 3 Chapter 1 .Introduction This tractor service manual is for qualified service personnel engaged in servicing and overhauling 2810/T290/T300/T330 tractor.Use of this publication is not recommended for field operators since they usually do not have access to special tools and shop equipment essential for most servicing.
  • Page 4 SAFETY INSTRUCTION ALWAYS PRACTICE SAFETY BY THINKING BEFORE ACTION AVOID FIRE HAZARDS. -Keep fire extinguishers easily available and in good operating condition. All relevant personnel should know how to operate fire fighting equipment. -Keep a first aid kit in an easily accessible location. -Do not smoke while handling fuel,or other highly flammable material.
  • Page 5 STAY CLEAR OF PTO 1) Entanglement in rotating drive line can cause serious injury or death. 2) Keep tractor master shield and drive line shield in place at all times except for special applications as directed in the implement operator's manual. 3) Wear fairly tight tight fitting clothing.Stop the engine and be sure PTO driveline is stopped before making adjustment,connections,or cleaning out PTO drive equipment.
  • Page 6 WARNING SIGNS IN THIS MANUAL The following warning symbols in this manual draw additional attention to items of importance for the safe and correct operation of the tractor. SIGN MEANING OF SIGN Serious hazard with a very high level of risk of either serious injury or death DANGER Hazard or unsafe practice that can lead to severe...

  • Page 7: Safety Signs

    SAFETY SIGNS RECOGNIZE SAFETY INFORMATION This symbol, Safety-Alert Symbol, means ATTENTION! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message SIGNAL WORDS. A signal word—DANGER, WARNING OR CAUTION—is used with DANGER safety alert symbol.
  • Page 8 USE OF ROPS AND SEAT BELT The Roll Over Protective Structure(ROPS) has been certified to industry and/or government standards. Any damage or alternation to the ROPS, mounting hard-ware, or seat belt voids the certification and will reduce or eliminate protection for the operator in the event of a roll-over.
  • Page 9 HANDLE FUEL SAFELY-AVOID FIRES Handle fuel with care; it is highly flammable. Do not refuel the Tractor while smoking or near open flame or sparks. Always stop engine before refueling Tractors. Always keep your tractor clean of accumulated grease, and debris.
  • Page 10 AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes and nozzles, which eject fluids under high pressure. If ANY fluid is injected into the skin. Consult your doctor immediately. PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and open flame away from the top of battery.
  • Page 11 TRACTOR RUNAWAY 1. The tractor can start even if the transmission is engaged position causing Tractor to runaway and serious injury to the people standing nearby the tractor. For additional safety keep the pull to stop knob (fuel shut off control) in fully pulled out position. Transmission in neutral position, Foot brake engaged and PTO lever in disengaged position while attending to Safety Starter Switch or any other work on Tractor.
  • Page 12 SAFETY DECALS The following safety decals ARE INSTALLED ON THE MACHINE. If a decal become damaged,illegible or is on the machine,replace it.The decal part number is listed in the parts lists. WARNING ● Do not permit anyone but the operator to ●...
  • Page 13 CAUTION WARNING TO PROTECT ENGINE AND KEEP HANDS AND HYDRAULIC COMPONENTS. CLOTHING ● Idle Engine for 1 minute before shut down or full load AWAY FROM ROTATING operation. FAN AND ● Do not exceed 1/2 throttle for BELTS TO first 5 minutes of operation PREVENT SERIOUS INJURY Location: On Dash cover side RH...
  • Page 14 DANGER WARNING BLINDNESS CAN ● Pull only from drawbar. Pulling from any other RESULT FROM point can cause rear overturn. BATTERY EXPLOSION. ● Do not operate with unshielded PTO. KEEP SPARKS OR OPEN ● Disengage PTO and stop engine before FRAMES AWAY FROM servicing tractor or attaching and detaching BATTERY.

  • Page 15: Universal Symbols

    UNIVERSAL SYMBOLS Some of the universal Symbols have been shown below with an indication of their meaning. Engine speed Pressured- Corrosive (rev/minX100) open slowly substance ”Tortoise” Hours, recorded Continuous slow or Variable minimum setting ”Hare” fast or Engine coolant Warning maximum temperature setting...
  • Page 16 SECTION 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS The tractor serial number is shown on the left hand side of the tractor as shown in the picture. The engine number is stamped on the top of the engine block. Tractor Serial Number Engine Serial Number Tractor Serial Number 1.MODEL NAME PLATE...
  • Page 17 3.Engine model and engine serial number plate on the head cover. 1-16...
  • Page 18 SECTION 2. SPECIFICATIONS MODEL 2810 T290/T300/T330 Engine Maker DAEDONG KUBOTA Model 3A139A-DY1 D1503 Type Vertical,water cooled 4 cycle Diesel Out put(ps/rpm) Rated Speed 2,700rpm 2800rpm Number of Cylinder Displacement 1,393 1,499 Bore and Stroke 3.14inX3.64in 3.26inX3.64in (80mmX92.4mm) (83mmX92.4mm) Compression ratio...
  • Page 19 MODEL 2810 T290/T300/T330 Clutch Main Dry single disc,mechanic Multiple wet disk Dimensions Overall length 3150(124”) 3290(129”) Overall width 1315(51.8”) Overall Height 2,366(93.1”) Wheel base 1640(64.6) Min. Ground Clearance 325(12.8”) 294(11.6”) Tire size Front 7-16 4PLY Rear 11.2-24 4PLY Axle type...
  • Page 20 Traveling speeds:Km/h (Mile/h) Speed Main shift Range shift T290/T300/T330 2810NEW Forward Reverse Forward Reverse 0.55 0.53 0.55 0.51 0.75 0.73 0.72 0.70 0.96 0.94 0.93 0.90 1.33 1.30 1.28 1.25 1.72 1.68 1.67 1.61 2.37 2.30 2.28 2.22 3.04 2.96 2.93 2.86 4.20...
  • Page 21 SECTION 3. GEAR TRAIN DIAGRAMS FIG.1-3 GEAR TRAIN DIAGRAM 1-20...
  • Page 22 SECTION 4. PRECAUTION FOR TRACTOR OPERATION 1. INSTRUMENTS ①key switch ②temperature gauge ③tachometer ④Hour meter ⑤Fuel gauge ⑥Light switch,indicators and horn ⑦hazard warning light switch ⑧ PTO Mode switch Note; - Oil pressure warning light and charge light on the monitor array will light when the main switch is turned from OFF to ON - All lights on the panel go out automatically when the engine is started and its speed is increased to a specific level.
  • Page 23 MONITOR LIGHT ARRAY ①High Beam Lamp ②Low Beam Lamp ③PTO Monitor Lamp ④Cruise Control Lamp ⑥Fuel Empty Warning Lamp ⑦Oil pressure lamp ⑧Charge lamp ⑨Glow signal Lamp ⑩Turn Signal Lamp 1-22...
  • Page 24 2. CONTROLS 1-23...
  • Page 25 3. FILLING DIAGRAM & CAPACITY TABLE TABLE 1-7 Filling point Fillings Quantity Liter (gal.) MODEL T290/T300/T330 2810NEW RADIATOR Fresh clean 7ℓ 7ℓ Water(L.L.C) ENGINE Engine oil 5.7ℓ (1.51 gal) 5.7ℓ (1.51 gal) TRANSMISSION CASE Gear oil #80 32ℓ(8.453 US gal) 32ℓ(8.453 US gal) FRONT AXLE Gear oil #80 or #90...

  • Page 26: Maintenance Chart

    4. MAINTENANCE CHART ○ inspection,replenish,and adjustment ● Replacement △ Cleaning and/or washing ★ Consult your Dealer □ ENGINE Inspection and servicing intervals Hour of operation Judgment Inspection (X10 on hour meter) Intervals after that criteria items mm(in) ○ ● ● ●...
  • Page 27 ○ inspection,replenish,and adjustment ● Replacement △ Cleaning and/or washing ★ Consult your Dealer □ TRANSMISSION Inspection and servicing intervals Hour of operation Judgment Inspection (X10 on hour meter) Intervals after that criteria items mm(in) ○ ● ● Transmission Replace after initial 50 Clean hydraulic hrs,then after every 300 suction filter at the...
  • Page 28 Inspection and servicing intervals Hour of operation Judgment Inspection (X10 on hour meter) Intervals after that criteria items mm(in) Electric All should work Parentheses properly Adjusting Check after 300 accelerator ★ hours ★ pedal and throttle lever Oil leaks in Check every year by clutch removing the plug...

  • Page 29: Table Of Contents

    Chapter 2 Disassembly and reassembly of major components SECTION 1. GENERAL PRECAUTIONS AND SEPARATION AND REINSTALLATION------------------------------------2-1 1. Before operation----------------------------------------------------------- 2. Precautions to be followed when installing standardized parts. -----------------------------2-1 SECTION 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCKS------------2-4 SECTION 3.

  • Page 30: Before Operation

    Chapter 2 Disassembly and reassembly of major components SECTION 1. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION 2. PRECAUTIONS TO BE FOLLOWED 1.BEFORE OPERATION WHEN INSTALLING STANDARDIZED PARTS. 1) Always be safety-conscious in selecting (1) Roller or Ball bearings clothes to wear and suitable tools to use. 1) When a bearing is fitted in by the outer race,use an installer which 2) Before disassembly, be sure that you...
  • Page 31 2) During installation,be careful not to (5) Spring(roll) pins damage the lips,and assure that it is pushed in parallel to the shaft or hole. 1) Spring pins should be driven in properly as tightly. 3) When oil seals are installed,there 2) Spring pins should be installed so that should be no turnover of the lips nor their seams should face the direction...
  • Page 32 ,Be sure to wind the wire paying 4) Each contact surface should be sufficient attention to its winding coated with an adhesive(THREE BOND TB 1215) direction and bend the lock washer for and tightened evenly with bolts. secure looking. Adhesive coated surfaces should be installed within 30 minutes after application of the adhesive.
  • Page 33 SECTION 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCKS...
  • Page 34 SECTION 3. SEPARATION OF MAJOR COMPONENTS 1.SEPARATION OF THE FRONT Note: AXLE AND AXLE BRACKET When working on the 4WD version,the drive shaft should be removed ahead of time. Parts which can be inspected during This operation -Center pivot -Final case -Differential gear (1) Removal 1) Hold the front hitch or the front bracket...

  • Page 35: Separation Of The Engine And Front Axle Bracket

    1.SEPARATION OF THE ENGINE AND THE FRONT AXLE BRACKET 5) Open the front grille. Parts which can be inspected during This 6) Detach the head light wiring. operation 7) Remove the other wiring -Air cleaner 8) Remove the inlet pipe from the air cleaner. -Radiator 9) Remove the air cleaner.
  • Page 36 13) Remove the battery and battery bracket. 14) Remove the two hoses for the power steering system. 15) Remove the mounting bolts of the right hand pivot metal(support) ahead of time. 16) At this stage,the power steering unit can be removed by disconnecting both right-hand and left hand tie-rods and removing the unit mounting bolts.
  • Page 37 5) Disconnect the battery cables. 8) Disconnect the hydraulic hose from the power steering (orbitrol) FIG.2-14 6) Disconnect the panel instrument set removing bolts(4 nos.) FIG.2-17 Note: - Disconnect the linear shift control cable - Disconnect the cable from both the steering lever side and transmission.
  • Page 38 (2) Engine separation from the chassis. When separating the engine from the chassis,the following steps are required as well as the ones mentioned above. 1)Lift the engine with the hoist and hold the front axle bracket with a stands or the like.

  • Page 39: Separation Of The Front Transmission And Spacer Transmission

    4.SEPARATION OF THE FRONT TRANSMISSION AND SPACER TRANSMISSION 7) Remove the slow-return check valve knob Parts which can be inspected during This operation -PTO clutch -Linear shift gears and related parts -Main change gears 1) Removal A:Removal of the whole floor. 1) Remove the side covers(LH and RH).
  • Page 40 9) Remove the parking brake. 10) Remove the main shift and transmission range shift levers.The levers can be separated in the middle. 11) Remove the control rods of the PTO shift and 4WD shift levers from the transmission. 12) Remove the position control levers. FIG.2-28 Rubber mounting 16) Lift up the floor slightly with a hoist.
  • Page 41 18) Lift the floor gradually taking care not to allow the shaft of the slow return check valve and its hole in the floor to interfere with each other. Slow return check valve FIG.2-33 Front wheel drive FIG.2-31 Slow return check valve 3) Disconnect the brake rods.
  • Page 42 5) Remove the suction and delivery pipes. 6) Remove the delivery pipe for the PTO clutch. 7) Remove the reverse shift metal(support) FIG.2-37 Transmission (5) Install the front wheel drive shaft. FIG.2-36 Reverse shift metal (6) Position the floor taking care not to allow wiring or other parts to be pinched under it 8) Hold the clutch housing and space (7) With the floor lifted up a little, install the fuel...

  • Page 43: Separation Of The Spacer Transmission And Rear Transmission

    5.SEPARATION OF THE SPACER TRANSMISSION AND REAR TRANSMISSION (8) Remove the operator’s seat Parts which can be inspected during This operation (9) remove the position control lever - Drive pinion gear (10) Remove the lever guide. - Speed range gear(Transmission range shift) (11) When the tractor is equipped with an optional - Main change gear.
  • Page 44 (20) Remove two rubber mounts. Rubber mounting bolts FIG.2-46 sub change metal (29) Remove all the spacer-rear transmission FIG.2-44 Frame rubber mounts. case tightening bolts and nuts except the (21) Lift up the rear end of the floor/fender bottom bolt. assembly by about 10 mm,and place wood between the spacer transmission case and floor (30) Install the rear wheels(LH and RH) and the...

  • Page 45: Separation Of The Rear Transmission And Rear Axle Housing

    6.SEPARATION OF THE REAR (31) Install the rear wheels(LH and RH) and the TRANSMISSION AND REAR AXLE remained bolts.Then turn the rear wheels by HOUSING hand to move the rear transmission case away from the spacer transmission case. Parts which can be inspected during This operation - Diff Lock 2) Installation - Brakes...
  • Page 46 (4) Remove the brake rods. (5) Remove the 3-point linkage and related parts. FIG.2-55 Rear axle housing 2) Installation FIG.2-53 3-point linkage Reassemble in reverse order of disassembly. (6) Support the floor panel with a trestle or the (1) join the rear axle and rear transmission like.

  • Page 47: Separation Of The Rear Transmission And Cylinder Case

    7.SEPARATION OF THE REAR TRANSMISSION AND CYLINDER CASE (10) Detach the delivery pipe from the cylinder Parts which can be inspected during This case. operation (12) Remove the slow-return check valve along - Control valve with the shaft. - Control linkage (13) Remove the 3-point lift link and related - Piston and lift crank linkage parts from the lift arm.
  • Page 48 Chapter 3 ENGINE ACCESSORIES SECTION 1. RADIATOR ---------------------------------------------------3-1 1. General description ------------------------------------------------------3-1 2. Radiator -------------------------------------------------------------------------------------------- 3. Specifications ---------------------------- -------------------------------------------------------- 4. Removal of the radiator ------------------------------------------------------------------- 5. Inspection of each part -------------------------------------------------------------------- 6. Radiator reassembly ------------------------------------------------------3-5 7. Daily inspection -----------------------------------------------------------3-5 8. Trouble shooting ----------------------------------------------------------3-6 SECTION 2.

  • Page 49: Chapter 3. Engine Accessories

    Chapter 3.Engine accessories SECTION 1. RADIATOR 1.General description The pressure cooling system includes mainly the radiator,water pump,multi-blade fan, and the thermostat.During the warm-up period,the thermostat remains closed and coolant is directed through by-pass to the suction side of the water pump.

  • Page 50: Section 1. Radiator

    2. Radiator The radiator consists of radiator cores, a tank to Flow coolant,side plates to install the radiator, and a fan guide. Fin-tube type cores are used and the cores and tank is made of anti corrosive copper and Copper alloy. FIG.3-3 ①...

  • Page 51: Radiator

    3. SPECIFICATIONS Description T290/T300/T330/2810NEW Radiator core type Flat water tube with corrugate fins Core train number 4 trains Radiator fin pitch 4.2 mm Thermal radiator area 8.185㎡ 0.9±0.15Kgf/ ㎠ Pressure valve opening pressure 7 ℓ(contains in cylinder block) Coolant capacity Test pressure 1.8 Kgf/㎠...
  • Page 52 -Clean with a detergent When cleaning the radiator with a detergent, follow the instructions given by its manufacturer. Different detergents have different characteristics. b. Cleaning the radiator exterior Cleaning the net (wire mesh) After the tractor has been operated in dusty FIG.3-5 conditions,check the net daily and clean it if necessary.

  • Page 53: Radiator Reassembly

    6. RADIATOR REASSEMBLY 1.05 Kgf/ ㎠ Pressure valve Reassemble the radiator in the reverse order of Opening pressure (14.93 psi) disassembly. 0.04-0.05 Kgf/ ㎠ Vacuum valve Note: Opening pressure (0.57-0.71psi) - The rubber hoses should be clamped securely and must not interfere with the cooling fan. -Function test: - The radiator cores must not interfere with the The pressure type radiator cap has a pressure valve...

  • Page 54: Trouble Shooting

    8. TROUBLE SHOOTING TABLE 3-1 Problems Causes Countermeasures 1) Overheating (1) Low coolant level (1)Replenish coolant and inspect water leaks. (2) Fatigued pressure valve spring (2)Replace radiator cap. (3) Loose or broken fan belt (3)Adjust belt tension or replace. (4) Oily fan belt (4)Replace.

  • Page 55: Section 2. Air Cleaner System

    SECTION 2. AIR CLEANING SYSTEM 1.GENERAL DESCRIPTION Unfiltered air contains many particles harmful to the engine such as dust ,sand,or other foreign matter. When such foreign matter have entered in to the engine,They have mixed into the lubricant and promote wear of lubrication parts in addition to damaging the piston cylinders.To eliminate these harmful particles,an air cleaner has been installed.The air cleaner Which is installed on the T series tractor is a dry,cyclone type and is constructed as shown in the figure.
  • Page 56 2.ELEMENT AIR CLEANER (1) SPECIFICATIONS. Model 2810NEW/T290/T300/ T330 Type Dry,paper element filtering type Rated intake air volume ( ㎡ /min. (cu. ft/ min) 2.6(91. 8) air venting resistance ( ㎜ Ag) 120 or less Cyclone efficiency (%) 45 or over Total filtering efficiency (% ) 99.9 or over Dust holding capacity(gr)

  • Page 57: Inspection Of Each Part

    Note: 3. INSPECTION OF EACH PART Especially note the glue portions of the paper and 1) Inspection of the cleaner body metal parts. (1) Check the cleaner exterior for cracks, deformation,or damage and repair or replace 4. CLEANING THE AIR CLEANER if necessary.

  • Page 58: Element Installation

    -After soaking,rise it in fresh water. -Let it in a shaded and well ventilated place. Forced drying by heat or compressed air is prohibited. Note: Water applied to rinse the element should not have a pressure of more than 2.8kgf/㎠ (39.8psi).

  • Page 59: Chapter 4. Clutch System

    CHAPTER 4 Clutch system SECTION 1. GENERAL DESCRIPTION ----------------------------- 4-1 SECTION 2. SPECIFICATIONS ----------------------------------------- 4-2 SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY---4-3 1. Main clutch -------------------------------------------------------------------4-3 2. Clutch shaft and related parts----------------------------------------------4-6 3.Final adjustment of the clutch pedal---------------------------------------4-7 SECTION 4. TROUBLESHOOTING-----------------------------------------4-8...

  • Page 60: Section 1. General Description

    Chapter 4. clutch system GENERAL DESCRIPTION. The clutch is a device to engage and disengage the power of the engine.The construction of the clutch is as shown in the figure. It is composed of the flywheel which holds the clutch disc,the pressure plate,diaphragm springs,the clutch cover,and input gear.

  • Page 61: Section 2. Specifications

    SECTION 2. SPECIFICATIONS Table 4-1 Parts Items Description and assembly standard values Clutch disc. Type Dry single Facing material Y-02, Y-07 Outer dia. ×inner dia. (㎜) Ø225±1.0×Ø150±0.8 spline hub Large dia. (㎜) (in) Ø25.0 (0.984) Small dia. (㎜) (in) Ø21.7 (0.854) No.of splines Disc thickness (free) ㎜...

  • Page 62: Section 3. Disassembly,Inspection,And Reassembly

    SECTION 3. DISASSEMBLY, INSPECTION, AND REASSEMBLY 4.bolt(S) 6.Main clutch 7.Clutch disc 8.Clutch cover 9.Pin(B) 12.Input metal 13.Seal bolt 14.Nut 15.Washer spring 18.Metal sleeve 19.Seal bolt 20.O-ring 21.Sleeve 22.Clutch release bearing 23.Tension spring FIG. 4-3 Clutch assembly 1.MAIN CLUTCH Note: 1-1.Disassembly When removing the bolts,loosen them gradually Note: in diagonal sequence.
  • Page 63 1-3. Inspection of pressure plate and flywheel. 1-5.Inspection of guide ball bearing (flywheel) 1) Inspect the diaphragm spring surface for up-and-down,scratches,stepped wear,or oil 1. If the bearing does not turn smoothly due stains. to damage or seizure,replace the bearing. 2) Check the height differences of diaphragm 1-6.Reassembly of main clutch springs.

  • Page 64: Clutch Shaft And Related Parts

    (2)Inspection of sleeve 2.CLUTCH SHAFT AND RELATED PARTS. Ensure smooth movement of the sleeve.If it 1) disassembly does not move smoothly,clean and grease it. (1) Remove the tension spring and extract the Use heat-proof grease. sleeve (2) Remove the wire which is retaining the (3) Inspection of tension springs.

  • Page 65: Final Adjustment Of The Clutch Pedal

    3.FINAL ADJUSTMENT OF THE CLUTCH PEDAL 2) Adjust the clearance between the safety Clutch pedal play switch and the bolt head to 38 ±1㎜(1.496 1) Loosen the lock nuts on the clutch rod and adjust the in.) so that the switch will turn on only clutch rod length to achieve 20～30㎜...

  • Page 66: Section 4. Troubleshooting

    SECTION 4. TROUBLESHOOTING 1.PROBLEM :Clutch slippage. The initial stage of clutch slippage is very hard to notice,but the following symptoms 1) The tractor is not generating adequate power when performing heavy duty operations. 2) Output is not commensurate to increate in engine speed when the engine is accelerated suddenly during operation.
  • Page 67 4. PROBLEM: Abnormal noises There are abnormal noises emanating from the clutch. Probable causes Countermeasures -Broken or insufficiently lubricated release bearing Replace -Seized or worn pilot bearing Replace -Cracked disc plate Replace 5. PROBLEM: Dashing or shifting The tractor does not starting moving smoothly but dashes or is likely to stop when the clutch is operated during a operation.
  • Page 68 CHAPTER 5 Transmission SECTION 1.GENERAL DESCRIPTION------------------------------------5-1 1.Wheel driving system----------------------------------------------------------5-1 2.PTO drive system--------------------------------------------------------------5-1 3.Power train diagrams---------------------------------------------------------5-2 4.Construction and function of synchromesh mechanism------------- 5-2 SECTION 2. SPECIFICATIONS---------------------------------------------5-2 1. Wheel drive system----------------------------------------------------------5-2 2. PTO drive system------------------------------------------------------------5-2 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY--5-3 1. input shaft and reverse change gear(Front transmission) ------ 5-5 2.

  • Page 69: Section 1.General Description

    Chapter 5 .Transmission SECTION 1.GENERAL DESCRIPTION 1. WHEEL DRIVE SYSTEM The wheel driving system is composed of the following major components: Reverse change gears Front transmission (Linear shift mechanism) Transmission Main Change gears Space transmission Sub-change gears (speed range) Front drive change gears Ring gear Rear transmission Differentials...

  • Page 70: Power Train Diagrams

    3.POWER TRAIN DIAGRAMS Refer to page 5-49 and 50 at the end of this chapter. 4.CONSTRUCTION AND FUNCTION OF THE SYNCHROMESH MECHANISM ①Shifter ②Hub ③Block pin ④Synchro-ring ⑤Synchro-cup ⑥Thrust piece ⑦spring ⑧spline of hub(2) ⑨spline of synchro-cup(2) ⑩constant mesh gear ⑪spline of gear(10) ⑫constant mesh gear ⑬Spline of gear(12)
  • Page 71 3rd stage: 1st stage: When force(F) is applied to shifter(1) When hub(2)is pushed further,the tapered surface in through the gear shift lever,hub(2) is pushed the hole of the hub and the tapered surface on the in the direction of the arrow.Following block pin are pressed tightly against each other,this movement of the hub,other parts such as pushes synchro-ring(4) against synchro-...

  • Page 72: Section 2. Specifications

    SECTION 2. SPECIFICATIONS 1. WHEEL DRIVE SYSTEM Speed shift range Engine rated rpm: 2800 RPM Reduction Speed shift range forward 0.4524 (19/42) ratios. 0.4398 (19/30 ×25/36) reverse Main speed shift 0.4250 (17/40) 0.5833 (21/36) 0.7500 (24/32) 1.0357 (29/28) Speed range shift 0.2619 (11/42) 0.8276 (24/29) High...

  • Page 73: Input Shaft And Reverse Change Gear(Front Transmission)

    DISASSEMBLY SECTION 3. ,INSPECTION,AND REASSEMBLY 1. INPUT SHAFT AND REVERSE CHANGE GEARS (FRONT TRANSMISSION) 1.clutch release bearing 2.Sleeve 3.Spring,tension 4.Bolt(seal) 5.Metal sleeve 6.O-ring(G) 7.Bolt(seal) 8.Nut 9.Washer spring 10.Input metal 11.Ball bearing 12.Gear (helical/30) 13.Gear (helical/30) 14.Gear (helical/25) 15.Ball bearing 16.Ball bearing(HL1) 17.Washer(20X34X03) 18.Gear (helical/42) 19.Snap ring...
  • Page 74 c. Pull out input gear(19T) rearwards. 1.1 DISASSEMBLY d. Remove the sleeve metal tightening bolts and take off sleeve metal. (1)Removal of input shaft and related parts e. Draw PTO drive gear forwards. separate the engine from the front transmission f.
  • Page 75 1.2 INSPECTION Before and after disassembly,inspect each part for points mentioned below,and replace if necessary. Inspection items Standard values Usable limits 0.1 - 0.2 ㎜ 0.5 ㎜ Backlash of each gear (measured in meshed condition) (0.004-0.008 in) (0.020 in) 0 ㎜(0 in) 0.3 ㎜...
  • Page 76 1.3 REASSEMLBY (1) Sub Assembly of reverse shaft and related parts. Fig.5-12 a.Install Synchro-cups(34) on gear(16) and gear(21) respectively and retain them securely with snap rings C b.Install synchro-hub comp(35) and above sub- assemblies on reverse shaft(18) Note: As each synchromesh assembly maintains a specified installed width,be sure not to mix different pairs of the synchro-hub comp,and the synchro-cup c.
  • Page 77 (2) installation of each sub-assembled shaft. Install each sub- assembled shift into the reverse metal(Support). Note: When installing the PTO clutch assembly,apply a thin coat of grease to the seal rings and install it taking care not to damage these rings. Fig.5-13...
  • Page 78 (3) installation of input metal and related parts. Fig.5-14 Reassemble in reverse order of disassembly,following the next instructions. a.Install the idle shaft(120 so that the end with the tapped hole faces rearwards,that is ,on the snap ring installed side. b.Apply adhesive to the threads of the bolts (M8 ×20) which tighten the bearing retaining plate. c.Oil seals should be installed in their correct direction.As an oil seal is a special eccentric seal,be careful not interchange these seals.
  • Page 79 (4) installation of PTO shaft ① Pay attention to the direction of installation and check to see all the parts turns smoothly. ② When pushing the RBB's(6205 and 6005)into the gear,be careful only to push their outer races. ④ When installing the PTO clutch assembly,Apply a thin coat of grease to the seal rings and install it taking care not to damage these rings.

  • Page 80: Pto Clutch

    2. PTO CLUTCH 2-1. DISASSEMBLY Fig.5-16 (38)RBB (40)RBB (44) Snap ring (45)Back-up plate (46) Disc assembly (47)Driven plate (48) Piston (51) Seal ring (52) Seal ring (53) Cover assembly (54)Seal ring Note: Disassembly of the PTO clutch assembly should be done in a clean,dust-free place.Exercise special attention to avoid damage of the seal rings,etc a.
  • Page 81 -Inspection for disc thickness and serration wear. Inspection Items Specified values Usable limit Disc thickness 2.2±0.1mm 1.9mm (0.087 in) (0.075 in) Surface flatness 0.2mm (0.008 in) Fig.5-19 e. If the combined thickness of the return plate and brake disc deviates from the specified value, replace both parts.
  • Page 82 2.3 REASSEMBLY Reassemble the parts in reverse order of disassembly,following these instructions. Note: -Each parts should be washed clean before reassembly. -Apply multi-purpose,quality grease to needle bearings in advance. -Each bolt and nut should be tightened to Fig.5-22 the respective specified torque table. -Every time a gear is installed,its smooth 4.Bearing ball (6205) 5.Gear,helical 35T rotation should be checked.
  • Page 83 3.MAIN CHANGE,SUB-CHANGE,AND 4WD CHANGE GEARS. (1)Synchromesh transmission version. Fig.5-24 Synchromesh transmission version 5-15...
  • Page 84 Fig.5-25 Main change gear and related parts. 5-16...
  • Page 85 3.1 DISASSEMBLY Fig.5-26 Separation the spacer transmission case and rear transmission case from each other referring paragraph 5.(1) in SECTION 4.SEPARATION OF MAJOR COMPONENTS in chapter 2. With this operation,the transmission is divided into parts A and B part A includes main speed shift and mechanism and part B includes speed shifting and 4WD shifting mechanisms.(fig.5-26) Note: The separation of the gears mentioned in the figure is possible without dividing the front transmission...
  • Page 86 (1) Disassembly of main change gears(main speed shift),part of sub-change gears(speed range shift) and shifters. Fig.5-27 a. Remove the tightening bolts and pull out the b.Pull out assembly of the reverse shifter assembly of the space metal(18) metal,main speed shift gears,and shifters rearwards by tapping it with a plastic hammer.
  • Page 87 Fig.5-29. Fig.5-31 Fig.5-30 2.Disassembly of the sub-change gears (Speed range shift) a.Remove the sub-shifter and shifter stay. b.Remove the space transmission case c. Pull out the PTO shaft ,4WD shaft and gear d. Remove the snap ring from the end of the pinion gear shaft e.
  • Page 88 3.2 INSPECTION Before and after disassembly,inspect each part for points mentioned below,and replace if necessary. Inspection Item Standard Value Usable limits Backlash of each gear(measured in meshed condition) 0.1-0.2mm(0.004-0.008in) 0.5mm (0.020 in) Stepped wear of teeth 0.3 mm (0.012 in) +0.18 Assembled width of synchromesh 51.17...
  • Page 89 3.3 REASSEMBLY Reassemble the parts in reverse order of disassembly,following these instructions. Note: -Each part should be washed clean before reassembly. -Apply multi-purpose,quality grease to needle bearings in advance. -Each bolt and nuts should be tightened to the respective specified torque in accordance with the tightening torque table.
  • Page 90 a.While holding the gear in the position shown in the drawing,install the assembly of the main change gears and related parts in position by tapping it slightly on the front of a plastic hammer and then the gears by tapping it on the rear. b.
  • Page 91 b. Pay attention to the installed direction of gear Fig.5-36 5-23...
  • Page 92 4. Rear transmission case Fig.5-38 5-24...
  • Page 93 3-1. DISASSEMBLY Separate the spacer transmission and the rear transmission from each other and then remove the hydraulic cylinder case.referring to paragraph 7.(1) of SECTION 4. SEPARATION OF MAJOR COMPONENTS in Chapter 2. (1) Ring gear,Drive pinion,and related parts. Fig.5-39 1.Diff case (L) 2.Diff case(R) 4.Bolt...
  • Page 94 a.Dismount diff-case (RH) and diff-case f. Remove the pinion metal(support) tightening metal(LH) by installing push bolt as shown in bolts and take put drive pinion(19) and related Fig.5-40 parts as an assembly.The number of installed shims should be written down or memorized for later reference.
  • Page 95 (2) PTO shaft and related parts. Fig.5-29 1.O-ring 2.Plug(PTO) 3.Bolt 4.Ball bearing(HL1) 5.Collar 6.Gear spur/37 7.Snap ring 8.Collar(35X50X2) 9.Ball bearing 10.Shim(B) 11.Shim(0.5) 12.Snap ring 13.Seal oil 14. Cover(plate) 15. PTO shaft 16.Seal a.Remove the rear hitch and the trailer hitch b.Remove bolt (3) and Extract PTO plug(2) rearwards c.Extract PTO shaft(15) rearwards and remove the change gears and related parts.
  • Page 96 3-2. INSPECTION Before and after disassembly,inspect each part for the items mentioned below.Parts which deviate from the specified values should be replaced. -Wash clean all disassembled parts and check them for wear,damage,deformation,Burning ,etc. Defective parts should be corrected or replaced. Fig.5-30 -As the drive pinion and the ring gear make a pair,they (1) Drive pinion...
  • Page 97 When the drive pinion or the ring gear has been Ring gear tightening 9.0-11 Kgf.m replaced, the proper number of shims to be installed should be determined based upon the torque (39.8-69 ft.lbs) following procedure: Note: Drive pinion metal 5.5-7 Kgf.m - As shown in Fig5-34,there are two kinds of tightening torque (39.8-69 ft.lbs)
  • Page 98 Note: When reassembling the used pinion and ring gear,reinstall the same thickness of shims as was installed before disassembly in each shimming position. h.Backlash adjustment between the drive pinion and the ring pair(Fig5-35) i.As the drive pinion and the ring gear make a pair,be sure not to mate them with other parts from differential tractors.
  • Page 99 Note: Strike the circumference of the ring gear both sides with a copper hammer by turning the ring gear manually,and check to see that the backlash remains unchanged.The backlash should be checked at four points 90 degrees apart to each other. ⅲ.inspection of the tooth bearing Apply an even coat of oil-dissolved minimum on the drive pinion teeth and turn the drive pinion on the ring gear to check the tooth bearing by observing the bearing traces on the ring gear.
  • Page 100 (2) PTO shaft and related parts. a.Pushing the PTO counter gear end into the bearing until the stop on the gear is securely seated against the bearing.The seal should be coated with an adhesive (THREE BOND TB1215) on the circumference before installing. b.Install the oil seal on the PTO shaft,paying attention to its installed direction.

  • Page 101: Shifters And Related Parts

    5. SHIFTERS AND RELATED PARTS. 5.1. CONSTRUCTION (1)Forward and reverse control linkage mechanism(Linear speed shifter) (synchromesh transmission version) Fig.5-39 1.Metal(shifter,reverse) 2.Bolt(S) 3.Nut 4.Washer spring 5.Washer plain 6. Stay shifter reverse 7.Reamer bolt 8.Washer spring 9.Washer plain 10. Fork(shift/shuttle) 11. Shifter spring 12.Steel ball 13.Arm(reverse) 14.
  • Page 102 Fig.5-40 (2) Main change mechanism(Main speed shift) (Synchromesh transmission version) 1.Fork (1-2 speed) 2.Fork( Main shift/Synchro) 3.Bolt 4.Pin(A) 5.Bolt 6.Washer 7.Metal(Main shift) 8.Shift Arm 9.Rod 10.Coupling(40) 11.Set bolt 12.Main shift bracket 13.Rod change speed Fig.5-41 Fig.5-43 Fig.5-42 5-34...
  • Page 103 (3) Range shifter (Speed range shift) mechanism 1.Arm(sub shift) 2.Pin taper 3.Fork(Sub shift) 4.Shift stay(Sub shift) 5.Hook 6.Shifter spring 7.Steel ball 8.Oil seal(D) 9.Washer 10.Bolt 13.Metal sub 15.E type stop ring 16.Shim(03X16X26) 17.Bush,chain guide 18.E type stop ring 20.Lever(Sub shift/upper) 28.Lever(Sub shift/lower) 31.Grip 32.Nut...
  • Page 104 (4) Front drive change (4 WD shaft) mechanism 1.Boss 2.Spring shifter 3.Steel ball 4.Bolt(S) 5.Packing 7.Shifter arm 8.O-ring 9.Arm(4WD) 10.Spring pin 11.Lever(4WD) 12.Bush(Chain guide) 14.Grip 18.E-type stop ring 19.Rod 20.Shim(03X16X26) 22.Split Pin 23.Washer 27.Nut(fine) 28.Pin 29.Washer 30.Washer Fig.5-46 Fig.5-47 5-36...
  • Page 105 (5) Rear PTO shift mechanism Fig.5-48 1.O-ring 2.Plug(PTO) 3.Bolt 4.Ball bearing(HL1) 5.Collar 6.Gear spur/37 7.Snap ring 8.Collar(35X50X2) 9.Ball bearing 10.Shim(B) 11.Shim(0.5) 12.Snap ring 13.Seal oil 14. Cover(plate) 15. PTO shaft 16.Seal Fig.5-49 5-37...
  • Page 106 REAR PTO counter shaft mechanism Fig.5-50 1.Gear,spur 12 2.Gear spur 14 3. Snap ring(shaft) 4. Ball bearing(6205) 5. Ball bearing(6305) Note: - When pushing the R.B.B’s(6305,6205) into the gear ,spur 12,be careful only to push their inner races. - The snap ring C should be securely seated in the groove and the press-processed side turned towards the outer side.
  • Page 107 (7) Drive pinion Sub assembly Fig.5-53 1.Metal pinion 2.Taper roller bearing 3.pinion drive 10 4.Taper roller bearing 5.Gear spur 23T 6.Nut(M30X1.5) 7.Washer(28X46X03) 8.Needle bearing 9.gear spur 40T 10.Hub(28X51X59) 11.Snap ring (shaft) 12.Gear spur 33T 13.gear helical 22T 14.needle bearing 15.Washer(20X34X03) 16.Ball bearing 17.Washer(20X30X1.8) 18.Snap ring (shaft) Note: a.Apply oil to the drive pinion and related parts ahead of time.Then install them and tighten the...
  • Page 108 (8). Sub change counter shaft 1.Gear range(13X20X29T) 2.Ball bearing(6207) 3.Needle bearing 4.Gear spur(30X35T) 5.Washer(25X46X07) 6. Ball bearing(6305) Note: 1.Apply grease when installing Needle bearing 2.pay attention to the installed direction of gear(spur/30-35) 3.After installation,be sure to slide smoothly 8.Differential gears. Fig.5-55 1.Bevel 10X51 2.Case Diff(L)
  • Page 109 5-2 PRECAUTIONS FOR DISASSEMBLY, INSPECTION,AND ASSEMBLY (1) Disassembly When drawing a shifter stay from its shifter,be careful not to lose the steel ball.It can jump out of the shifter. (2) Inspection -Shifter –disengaging load: Main change and sub change:18-22 Kgf (40-49lbs) 4WD change:25-29 kgf (55-64 lbs) -Usable limit of shifter-disengaging load: Main change &...

  • Page 110: Section 4. Troubleshooting

    SECTION 4. TROUBLESHOOTING 1. WHEEL DRIVE SYSTEM Problems Causes Countermeasures Transmission makes Insufficient or improper lubricant Replenish or replace noise in neutral Excessive splines of change shaft,spline hub,etc Replace Worn or broken bearings Replace Slide couplings interfering with the gears due to worn Replace or deformed shifters Gears make a noise...

  • Page 111: Pto Drive System

    2. PTO DRIVE SYSTEM problem Causes Counter measures PTO does not spin with PTO PTO shift lever is in neutral Shift lever positively to shifted to ON Defective PTO switch replace Clogged PTO valve Wash clean Poor Pump Replace Defective solenoid valve Replace PTO spins but does not Worn clutch disc...

  • Page 112: Power Train Diagrams

    Power Train diagram Fig.5-57 5-44...
  • Page 113 CHAPTER 6 FRONT AXLE CHAPTER 6. FRONT AXLE(4WD)-----------------------------------------6-1 SECTION 1.GENERAL DESCRIPTION-----------------------------------6-1 SECTION 2. SPECIFICATIONS---------------------------------------------6-2 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY--6-3 1. Center pivot-----------------------------------------------------------------6-3 1-1. Disassembly--------------------------------------------------------------6-4 1-2. Inspection----------------------------------------------------------------6-4 1-3. Reassembly--------------------------------------------------------------6-4 2. Front differential----------------------------------------------------------6-6 2-1. Disassembly--------------------------------------------------------------6-7 2-2. Inspection----------------------------------------------------------------6-7 2-3. Reassembly--------------------------------------------------------------6-8 3. Final case--------------------------------------------------------------------6-10 3-1. Disassembly--------------------------------------------------------------6-11 3-2.

  • Page 114: Chapter 6 Front Axle(4Wd)

    Chapter 6 Front axle(4WD) 1. GENERAL DESCRIPTION The 4WD front axle is a center pivot type.The front wheel drive mechanism is incorporated as a part of the axle. The front wheel drive power is taken off the rear transmission and transmitted to the differential in the front axle where the power is divided into right and left and to the respective final cases.

  • Page 115: Section 2. Specifications

    SECTION 2. SPECIFICATIONS 23/2810,T300/T330 Wheel alignment Toe-in (mm) Camber 3°± 1° Caster 3°± 1° Φ55 Front axle Pivot metal (F) bore (mm) Φ80 Pivot metal (R) bore (mm) Pivot metal (F) bush (mm) 50X55X20 Pivot metal (R) bush (mm) 75X80X30 Φ50...

  • Page 116: Section 3.Disassembly,Inspection,And Reassembly--6-3

    SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY 1. CENTER PIVOT Fig.6-3 1.Housing,front axle 10.Bolt (M16X40) 19.O-ring(G 55) 2.Oil cap 11.Washer,spring(M16) 20.Bolt 3.Plug 12.O-ring(P) 21.Nut 4.connector 13.O-ring 22.Seal washer 5.Hose(820) 14.Spacer (R) 23.Bolt(M12X40) 6.Clamp,(worm/14.5) 16.Metal pivot(F) 24.Washer spring 8.Metal,pivot(R) 17.Bush(50X55X20) 25.Washer 9.Bush(75X80X30) 18.Spacer (F)

  • Page 117: Disassembly

    2) FRONT AXLE BUSH BORE DIAMETER 1.1.DISASSEMBLY 1) Dismount the front wheel drive shaft, Measure the bore diameter of the roll referring to the pertinent paragraph in chapter 2. bush in the pivot metal(F).If the measured value 2) Remove the right and left tie rods. exceeds the usable limit,replace the bush.
  • Page 118 Fig.6-9 Fig.6-7 Note: Slanted or forced installation of the bush should be avoided,and the bore surface of the bush should not damaged. 3) Pay particular attention to the installed direction of thrust collar,that is,with the sharply-edged face turned towards the bevel gear case. 4) When the thrust collar has been replaced or the fore-and aft play of the front axle exceeds the usable limit,correct play by screwing in the...

  • Page 119: Front Differential

    2. FRONT DIFFERENTIAL Fig.6-10 1.Oil seal 3.Pinion bevel 8T 4.Gear bevel 35T 5.Case front Diff 6.Pinion Diff (12) 7.Thrust collar 8.Gear diff side (20) 9.Washer thrust 10.Pin spring 11.Shaft diff pinion 12. Pin spring 13.Bearing Ball(6212) 14.Snap ring 15.Snap ring( hole) 16.Shim(A) 17.Shim(B) 18.Bearing taper roller 19.collar 20.Nut(M30)

  • Page 120: Disassembly

    2.1 DISASSEMBLY 6) Remove the bearings from the Axle housing 1) As concerns operation prior to removal of And the ring gear,and then the ring gear can the front axle,refer to the paragraph covering be separated from the Axle housing. disassembly of the center pivot 7) Remove the straight pin(4) which retains the 2) Remove both wheels...

  • Page 121: Reassembly

    2-3.REASSEMBLY Specified thrust play 0.1-0.3 Reassembly the parts in reverse order of mm(in) (0.004-0.011 in) disassembly,following these instructions. Note: 1)Each friction surface should be coated with grease in advance. TRB and collar should be replaced as a pair. 2)The bevel pinion and the ring gear make a distinct pair after a mesh adjustment (1) Bevel pinion (8) performed at the factory.
  • Page 122 Fig.6-16 3) DIF CASE AND BEVEL PINION 1.shim 2.shim 3.shim 4.Parallel pin Fig.6-17 Note: Discard the removed straight pin and oil seal and install a new pin and Oil seal when reassembled,because this pin and oil 1) Each friction surface should be coated seal is apt to be damaged when removed.

  • Page 123: Final Case

    3. FINAL CASE 3-1. Front gear case 1. Fig.6-18 1.Final drive case(A) 2.Gear bevel(9) 3.RBB(6208) 4.Pin,parallel 5.Bolt(fine) 6.Washer spring 7.Gear bevel(16) 8.RBB(6207) 11.Final drive case(B)(L) 13.Final drive case(B)(R) 14. Housing seal 15.Seal 16.RBB(6014) 17.shaft 18.Gear bevel(12) 19.RBB(6308) 20.O-ring 23.Cap 90 25.Shaft RH(296) 26.

  • Page 124: Disassembly

    3-2. Front gear case 2. Fig.6-19 14.Gear bevel 38 15.Snap ring 17.Seal 18.Gear bevel 11 19.RBB(6210) 20.Cover wheel shaft 30.O-ring 31.Bolt 34.Shaft wheel 35.Washer(50X60X2) 3.1 Disassembly 1) Drain oil from the final case by removing the drain plug. 2) Remove the tie rod or the tie rod end. 3) Remove the final drive case clamping bolts and take out the assembly of the wheel shaft, 4) Remove the wheel shaft cover clamping bolts...

  • Page 125: Inspection

    Note: The removed cap(90) (black plug) should be discarded and replaced when reassembled. 3.2 INSPECTION 1) Wheel shaft cover - Inspect mechanical oil seal,O-rings, Gears, cases,etc. and replace them if worn or damaged. -Measure the diameter the part which makes contact with the wheel shaft,with a micro-meter Fig.6-21 or vernier-calipers.When the measured value...

  • Page 126: Reassembly

    Wheel shaft cover 3.3 REASSEMBLY 1) Every snap ring(5) should be seated securely Reassemble the parts in reverse order of in its groove. disassembly, following these instructions. 2) Be sure the numbers of Bevel gear is correct 1) Apply an adhesive (THREE BOND TB1215) (teeth numbers are 41) to the following parts.

  • Page 127: Steering Cylinder

    - FINAL DRIVE CASE AND HOUSING - STEERING CYLINDER Fig.6-28 1) When installing the shaft,Be sure that the gears are not damaged. 2) Be sure the differences between the LH and RH shaft. Fig.6-30 Specified length 479mm 295mm 1) When installing the steering cylinder,Be sure that the rods are not damaged.

  • Page 128: Section 4.Trouble Shooting

    SECTION 4. TROUBLE SHOOTING PROBLEMS AND PROBABLE CAUSES COUNTERMEASURES ● Steering wheel hard to turn 1)Too low tire inflation Inflate to specified value 2)Broken thrust bearing Replace 3)Stuck or broken ball joint of tire-rod end Grease or replace 4)Seizure or poor lubrication of axle end bush Grease or replace ●...

  • Page 129: Chapter 7. Rear Axle And Brakes

    CHAPTER 7 Rear axle and brakes SECTION 1.GENERAL DESCRIPTION-----------------------------------7-1 SECTION 2. SPECIFICATIONS---------------------------------------------7-2 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY--7-3 1.Rear axle housing and brake system--------------------------------------7-3 1.1. Disassembly-----------------------------------------------------------------7-4 1.2. Inspection-------------------------------------------------------------------7-4 1.3. Reassembly-----------------------------------------------------------------7-5 SECTION 4.TROUBLE SHOOTING---------------------------------------7-7...

  • Page 130: Section 1.General Description

    Chapter 7. Rear axle and brakes 1. GENERAL DESCRIPTION The rear axle system is of the central axle type,which contains the final reduction gears, differential gears with diff-lock,and brakes.The power from the engine is transmitted to the right and left wheel pinions through the differential gears,and reduced in the revolution to the rear wheels by the wheel gears.

  • Page 131: Section 2. Specifications

    SECTION 2. SPECIFICATIONS MODEL 2810NEW/T290/T300/T330 Type Helical gears Final reduction gears Reduction ratio Friction Type Wet,multi-disc,Mechanically operated Plate Φ184mm(Φ7.24 in) Outer diameter Thickness 3.4±0.1 mm(0.134 in) Lining material Paper base Brake system Number of plates 4 on each side Φ188mm(Φ7.4 in) Outer diameter Thickness 2.5±0.09 mm(0.098 in)

  • Page 132: Section 3.Disassembly,Inspection,And Reassembly--7-3

    SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY Separate the rear axle housing from the rear transmission referring to paragraph 6.(1) of SECTION 4. SEPARATION OF MAJOR BLOCKS in Chapter 2 1) REAR AXLE HOUSING AND BRAKE SYSTEM 1.Rear axle Housing(L) 2.Rear axle housing (R) 3.Bolt(S) 4.Bolt(S) 5.Bolt(S)

  • Page 133: Disassembly

    1.1 Disassembly 1) Release the bolt and nut and remove them. 2) Extract the bearing(13) with a puller and remove wheel gear(16) Fig.7-4 3) Remove the collar and pull out wheel shaft(3) Fig.7-6 Note: Removed oil seal(22) should be replaced with a new one when reassembled 1.2.

  • Page 134: Reassembly

    2) Metal brake 4) Wheel shaft Check the pressure plate,and brake rod for Check the shaft for abnormalities like wear, abnormality.Replace defective parts.Replace the damage,etc,and replace a defective one. metal brake whose thickness exceeds the usable limit. 5) Bearings Check them for abnormalities like hitching, irregularity,etc.in rotation after being washed clean.Replace defective ones.
  • Page 135 4) Replace the oil seal. Install the bearing,snap ring,and collar into the axle housing,and then press in the oil seal by applying force only to the circumference as shown in the figure( Fig.7-11) Apply force only to the shaded parts Take care not to deform these portions Fig.7-11 5) press in the wheel shaft.

  • Page 136: Section 4.Trouble Shooting

    SECTION 4. TROUBLESHOOTING Problem Causes countermeasures 1) Rear axle ・ Worn or damaged bearing Replace Noises ・ Worn gear or wheel shaft Replace 2) Brake system ・ Insufficient depressing of brake Depress pedals pedals positively (1)Insufficient braking force ・ Improper pedal free play Adjust ・...
  • Page 137 Chapter 8 Power assisted steering system SECTION 1.GENERAL DESCRIPTION-----------------------------------8-1 SECTION 2. SPECIFICATIONS---------------------------------------------8-2 2.1 Gear pump-------------------------------------------------------------- 8-2 2.2 Steering valve------------------------------------------------------------8-2 2.3 Oil tank------------------------------------------------------------------- 8-2 SECTION 3. FUNCTION---------------------------------------------------8-3 3.1 Open center non load reaction---------------------------------------8-4 3.2 major component of steering valve assembly---------------------8-5 SECTION 4.DISASSEMBLY,INSPECTION,AND REASSEMBLY 4.1 Major component-------------------------------------------------------8-6 4.2 Special tools--------------------------------------------------------------8-6 4.3 Disassembly--------------------------------------------------------------8-7...

  • Page 138: Power Assisted Steering System

    Chapter 8. Power assisted steering system. SECTION 1. GENERAL DESCRIPTION The hydraulics of this power-assisted steering system are actuated by a specially designed steering valve system. Non Load reaction valve blocks the L,R cylinder ports in neutral condition and does not transmits the reaction load of the tire to the steering wheel in neutral.Generally the system is used for the vehicles that treat heavy equipment or low speed traveling.

  • Page 139: Section 2. Specifications

    SECTION 2. SPECIFICATIONS 1) GEAR PUMP MODEL T290/T300/T330 2810NEW Delivery (cc/rev) Maximum pressure(kgf/㎤) Rated operation speed (rpm) 500~3500 500~3500 Rotation direction C.C.W as viewed from shaft 2. Power steering valve Unit( orbitrol) MODEL T290/T330/T330 2810NEW Model number UBS110B08AWD Displacement (cc/rev) Rated flow (ℓ/min) Maximum system pressure (kgf/㎤) Max.

  • Page 140: Section 3. Function

    SECTION 3. FUNCTION 1.Open Center Non Load Reaction 1.Neutral Position When the steering control valve is in the neutral position,inlet flow(P) from the priority valve moves the flow selector spool against its spring.This flow is blocked at the control valve control spool.The signal port is connected to the reservoir(T) through orifices in the control spool.The priority valve will only supply enough oil to the control valve to compensate for internal leakage and maintain low stand-by pressure.The oil at each side of the steering cylinder is connected to each side of the...
  • Page 141 2)Right Turn When the steering control valve shaft is rotated to the right,the control valve moves off center.This connects the inlet port (P) to one port of each metering pump section and also connects the other port of each metering pump section to the cylinder.The amount that the spool moves off center depends on how fast the steering wheel is rotated and also how much effort is required to turn the wheel.
  • Page 142 3)Left turn When the steering control valve shaft is rotated to the left,the control valve spool moves off center.This connects the inlet port(P) to the one port of each metering pump section and also connects the other port of each metering pump section to the cylinder.The amount that the spool shifts off center depends on how fast the steering wheel is turned and how much effort is required to turn the wheel.
  • Page 143 4) Manual steering When there is no piston pump supply pressure the flow selector is moved to the left by its spring.This connects together the inlet and outlet ports of the lower gyrotor pump and disconnects this pump from the system.When the steering is operated manually,only the upper gyrotor pump section is used to direct flow to the steering cylinder.

  • Page 144: Section 4.Disassembly,Inspection,And Reassembly

    SECTION 4. Disassembly,Inspection,And Reassembly 1. Major component of steering valve (orbitrol) Fig.8-6 1.Cover bolt(6) 2. Cover bolt(1) 3. End cap(1) 4.Gyrotor(1) 5. Spacer(1) 7.Spacer plate(1) 8.Driver shaft(1) 9.Pump body(1) 10.Sleeve(1) 11.Spool(1) 12.Pin(1) 13.Center springs(6) 15.Thrust washer(2) 16.Thrust bearing(1) 17. O-ring(1) 18.Seal ring(1) 19.Dust seal(1) 20.Retaining ring(1)

  • Page 145: Special Tools

    2.SPECIAL TOOLS STEP 4. For pumps equipped with cross over check ①Torque wrench(Torque 5㎏f·m) ------------------1 valves,mark position and remove spring, ②5/12″-12 socket ----------------------------------1 valve pins and balls. ③“- ”Driver(big) ------------------------------------- 1 ④“- ”Driver(small) -----------------------------------1 IMPORTANT: ⑤Centering spring installer ------------------------- 1 Do not use a magnet to remove balls.
  • Page 146 STEP 9. Lubricate and install new o-rings onto check valve seat.Install check ball retainer,check ball and check valve seat into the pump body.Make O-ring sure the threaded end of check valve is facing outward.Install and tighten plug to a torque of 11Nm(100 lb in).
  • Page 147 NOTE: Make sure the centering spring notches STEP 15. locate correctly into the sleeve. STEP 13 install pin into sleeve assembly and install sleeve into the pump body. Install spiral retaining ring into the the groove in the pump body.Use a screwdriver to make sure the NOTE:Heat from your hands may expand spool and spiral retaining ring is located correctly into the sleeve assembly,preventing the assembly being...
  • Page 148 STEP 17 install rotor onto drive shaft.Make sure one of the rotor teeth is aligned with the connector mounting face.Lubricate and install a new o- ring into the groove in plate.Align the marks made in STEP 2, and install stator.Make sure the o-ring groove in stator is facing outwards.
  • Page 149 Align the marks made in STEP 2,and install the end cap.Install and evenly tighten the torx hand screws in two stages to a torque of 17 Nm(12 lb ft) then to 25 to 30 Nm (19 to 22lb ft) in the sequence shown.
  • Page 150 SECTION 5. TROUBLESHOOTING Problems and probable causes Counter measures 1. Steering wheel is very heavy to turn 1) Poor assemble between steering column and unit. (1)Spline of column and unit are assembled -Replace column spline tightly. (2)Spool of unit is seized by spline of column -Check column assembly face and spline length (MAX 6.5㎜) (3)Poor rotation of column...
  • Page 151 Problems and probable causes Counter measures 3. Free play of steering wheel 1)Too low elastic of centering spring ( Remove P port pipe line and check left and right turning) -Replace spring (1)Damaged spring or poor elastic 2) Depressed control set (1) Excessive fluid and pressure -Adjust fluid level and pressure properly (2) Depressed by foreign material...
  • Page 152 Problems and probable causes Counter measures 8.Serious kick-back each side (1)Poor assemble the gyrotor lower the unit -Reassemble 9. Steering wheel is very heavy to begin turning (1)Oil density is too high or cool -Replace oil 10. External Oil leakage (1)column -Replace oil seal,slide ring (2)End cap gyrotor...

  • Page 153: Chapter 9. Hydraulic System

    Chapter 9 Hydraulic system SECTION 1. GENERAL DESCRIPTION --------------------------------9-1 SECTION 2. SPECIFICATIONS -------------------------------------------9-2 SECTION 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM ----------------------------------------------------9-3 1.Hydraulic system --------------------------------------------------------- 9-3 2.Flow-divider --------------------------------------------------------------- 9-4 3.Flow-control valve(Slow-return check valve) -----------------------9-6 4.Safety valve(main relief valve)----------------------------------------- 9-8 5.Gear pump ---------------------------------------------------------------- 9-9 6.Filter----------------------------------------------------------------------- 9-14 SECTION 4.

  • Page 154: Section 1. General Description

    Chapter 9 Hydraulic system SECTION 1. GENERAL DESCRIPTION The hydraulic system is composed of a gear pump,valves,oil filter,cylinder(actuator),piping,etc.The implement lift is operated by a control valve which is actuated by the control lever through a link mechanism. ON and OFF of the PTO is controlled by a hydraulic,wet,multi-disc clutch whose circuit is opened and closed by an electromagnetic valve in the flow-divider.

  • Page 155: Section 2.Specifications

    SECTION 2.SPECIFICATIONS T300/T330 2810NEW Lift( ㎏ f) Piston and cylinder 1,330 (At lower link top end) Cylinder port leaks ( ㏄ /min) (under a pressure of 9800kpa(100 ㎏ f/ ㎠ ) Control valve (0.305cu.in) With gear oil SAE 80W Cracking pressure ( ㎏ f/ ㎠ ) main relief valve Relief pressure( ㎏...

  • Page 156: Section 3. Major Component Of The Hydraulic System

    SECTION 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM 1.HYDRAULIC SYSTEM Fig.9-2 2.O-ring(PG6) 3.Ring-back up 4.Piston 7.Rod 8. Pin spring 9.Iron wire 10.Cylinder head 11.O-ring 12. Bolt 13.Washer spring 14.Lift crank 15.Plug 16.Bolt 17.Flow con.valve 18.Dust seal 19. O-ring(P) 20.O-ring(P) 21.Knob 22.screw 23.Washer spring 24.Nut 25.Shaft(Slow return) 26.Plug(M22) 27.O-ring(P)

  • Page 157: Flow-Divider

    2.FLOW-DIVIDER GENERAL DESCRIPTION This valve is installed to bypass working fluid of a specified pressure from the main circuit into the PTO circuit through a fixed orifice.It includes a changeover valve for engaging and disengage the PTO clutch by means of a solenoid and a sequential valve for PTO circuit's over the main circuit. (1) Flow-divider (2) Transmission case (3) Relief Valve...
  • Page 158 -When the solenoid is switched 「ON」 The fluid from the pump flows to port B through port P,the pressure-reducing valve,and the changeover valve. The pressure of the PTO clutch circuit and that of passage(2) are the same and will be set as P₂.The pressurized fluid acts on the left-hand side of the valve,passing through port ;...
  • Page 159 -When the solenoid is switched 「OFF」: The fluid in the PTO clutch is unloaded to the bank through port B.Consequently pressure P2 at passage(2) becomes zero,whereas the pressure at passage (1) is P1.Then the force imposed upon the left side of spool (P1)overcomes the force imposed upon the right side (P2+spring force),so that the spool is pushed rightwards to connect port P and part A.

  • Page 160: Flow-Control Valve(Slow-Return Check Valve)

    3.FLOW-CONTROL VALVE(SLOW-RETURN CHECK VALVE) 3.1. GENERAL DESCRIPTION This valve regulates the lowering speed of the lift by controlling the unloading flow from the lift cylinder to the tank. ①Dust seal ②Snap ring ③Collar ④Body ⑤0-ring ⑥Adjust screw ⑦Back-up ring ⑧0-ring ⑨Stop ring ⑩Poppet ⑪Spring...
  • Page 161 3.2 OPERATIONS 2) Up position 1) DOWN position The flow port A,overcoming the force of spring(11),pushes up poppet (10) and The fluid from port B pushes up stop ring (9) choke(C)is fully opened regardless of the of poppet(10) until the ring comes into position of adjust screw(6).Thus the fluid contact with adjust screw(6),as it reaches flows to port B and the cylinder,which...
  • Page 162 4. MAIN RELIEF VALVE 2) PRECAUTIONS FOR DISASSEMBLY 1)GENERAL DESCRIPTION AND REASSEMBLY This valve regulates the maximum pressure in (1)Tightening torque of lock nut (9)5.0～6.0 the whole hydraulic circuit.The regulated ㎏f·㎠(36.2～43.4 ft.lbs) pressure can be set with the adjust screw. (2)Install seat(2)and then tap ball(3)(5/16) lightly so as to provide tight seating.

  • Page 163: Gear Pump

    5.GEAR PUMP 1) GENERAL DESCRIPTION This pump induces fluid from one side and delivers it from the other side,by rotating two gears meshed with each other. The actual delivery is as mentioned below,considering the consequences of fluid temperature and volume efficiency in accordance with revolution speed. That is dual pump system.
  • Page 164 ③Remove front and rear pump. 4)DISASSEMBLY Be sure not to be damaged the o-ring or steel NOTE: ball ①Before disassembling the pump,wash the outside clean.In the course of disassembling operation,all disassembled parts should be kept aside in a clean place such as on clean paper or cloth and be handled carefully so as to prevent them from becoming dirty or damaged.
  • Page 165 3) REASSEMBLY ④Tightening sequence and torque of the pump ① Install the rear pump. cover tightening bolts. ▶Install the bushing seal to bushing. ▶Tightening torque: 2.5～2.8㎏f·m ▶Install the bushing,drive gear,gear,and bushing to the housing. ▶Install the o-ring to the cover. ▶Install the cover to the housing.
  • Page 166 4) INSPECTION AND REPAIR (3) Bushing ① With clean working fluid,surfaces are (1)Check all disassembled parts for damage rarely scratched and should be smooth. and wash undamaged or usable parts in ② If there are many scratches on the bore clean diesel fuel or kerosene except rubber parts.Inspect all parts referring to these walls,or on parts which are in contact with...
  • Page 167 (4) GEAR ①With clean working fluid,surfaces are rarely scratched and should be smooth. ②If roughness can be felt by a finger nail,they are darkened,or the shaft diameter is less than 0.03 mm replace the shaft. ③Usable shaft diameter is as below Fig.9-28 gear shaft (5) Oil seal The oil seal prevents oil leaks by its inner seal lip and...

  • Page 168: Filter

    6. FILTER Fig. 9-30 Filter 1)GENERAL DESCRIPTION The tractor is equipped with two oil filters: 4) REPLACEMENT suction filter(1) and line filter(4),for better filtration. Check the O-rings for damage or deformation and replace defective ones.When installing the 2)SPECIFICATIONS filters,be sure to install the O-rings properly -Suction filter with grease applied.

  • Page 169: Remote Hydraulic Control Valve(Optional)

    SECTION 4. REMOTE HYDRAULIC CONTROL (OPTIONAL) Maximum flow (ℓ/min) Maximum pressure(kgf/㎠) System pressure (kgf/㎠)(at 26 ℓ/min) A and B port leak(cc/min) Less than 9 ①under a load of 100kgf/㎠ ② Oil temperature:50 ºC Recommended fluid DONAX TD or RPM THF500 -30 ～130℃...

  • Page 170: Section 5.Hydraulic System

    SECTION 5. HYDRAULIC SYSTEM 1.HYDRAULIC CYLINDER 1)Hydraulic system must be washed clean,and care must be taken not to let any foreign substances. 2)The O-ring and back-up ring should be coated with grease ahead of time.Install with care so as not to damage them.
  • Page 171 Fig.9-34.Lift arm 9)Adjust the angle of the roll bush from horizontal is 30° 10)Apply grease to the roll bush. 11)Apply grease to the cylinder case and lift arm face Which touched with each other. 12) When assemble the lift crank on the lift shaft, mesh their splines using the alignment marks which were put there before disassembly.

  • Page 172: Linkage(Internal)

    2. LINKAGE (INTERNAL) 1)Before installing the linkage,apply grease to relayed drive parts. 2)Drive in the roll pin into the linkage pin through the rod and lock the pin with wire. 3)Be sure not to over operate within specified spool stroke(12mm between up and down at neutral position) Fig.9-36 Linkage (internal) 9-18...

  • Page 173: Linkage(External)

    3.LINKAGE (EXTERNAL) Fig. 9-37 Linkage(external) 9-19...

  • Page 174: Main Control Valve

    4. MAIN CONTROL VALVE 4.1 GENERAL DESCRIPTION This valve controls the lifting and lowering operation of the hydraulic cylinder.It has especially been developed to control the working height of the implement.It consists of a feed back valve;direction control valve,flow-control unloading valve,and holding check valve. 4.2 SPECIFICATIONS Maximum operating pressure 300 Kgf.cm(4267 psi)

  • Page 175: Operation

    4.3 DISASSEMBLY AND INSPECTION 4.4 OPERATION 1)Neutral position In the neutral position,convensater spool(711) in open(Unload),Main spool(311) and check valve(511,531) is closed and its pressure is enough to rest the force of lift arm.. Circuit diagram in the neutral position Fig.9-43 9-21...
  • Page 176 2) Lifting position As main spool is moved to lifting position pump pressure is increased and open the check valve(511,531).The lift arm moved to lifting position by flowing to cylinder and operate piston. Circuit diagram in the lifting position Fig.9-44 9-22...
  • Page 177 2) Lowering position If main spool moved to lower positions,pump is unloading and the lift arm moved to lower position by flowing to tank in the cylinder Fig.9-45 9-23...
  • Page 178 5. SERVICING INSTRUCTIONS. Note: The spool and stopper bolt are tightened with 1) Required tools each other with adhesive applied to their threads, -6mm set screw wrench and torque Wrench so they should not be separated unless required. -19mm spanner and torque wrench by removing the stopper bolt,the poppet and -22mm spanner and screw wrench spring can be taken out of the spool.
  • Page 179 Put the poppet into hole B as shown in the figure and make sure that the poppet slides smoothly.Then put the spring in and tighten the plug,on which the O-ring must be installed,to the specified torque. -unloading valve(1) and related parts. Install the spool into hole C(Fig.9-19) in the correct direction.Put the spring in and tighten the plug to the specified torque.

  • Page 180: Section 6. Troubleshooting

    SECTION 6. TROUBLESHOOTING Problems Causes Countermeasures 1.Lift does 1) Insufficient engine speed Raise engine speed slightly not rise 2) Insufficient transmission oil Maintain oil level by replenishing with the same kind of oil 3) Air taken in through suction Tighten securely or replace broken parts. 4) Clogged suction filter Clean.
  • Page 181 Problems Causes Countermeasures 2.Too low 1)Above causes can also be Repair according to above instructions. rising speed of possible lift 2) Too small a spool stroke in Inspect,readjust,or replace link mechanism if necessary. control valve 3)Broken compensator spring Replace spring. (unloading valve 1) in control valve 4)Stuck poppet...
  • Page 182 Problems Causes Countermeasures 8.Pump noise 1) Partially clogged suction filter or Clean. suction piping. 2) Air inhaled through suction Inspect and retighten. piping and intake pipe connections for pump 3) Loosened pump cover tightening Inspect and retighten bolts. 4) Too rich oil viscosity Replace with fluid of adequate viscosity.
  • Page 183 Problems Causes Countermeasures 14.Independent 1) Stuck pressure-reducing valve Lap after correcting flaws with oil stone PTO clutch is too spool quick in engaging 2) Fatigued or broken pressure- Replace. reducing valve spring 3) Worn or broken sealing of PTO Replace clutch 4) Worn friction plates or driven Replace...
  • Page 184 Chapter 10 Electrical accessory and instruments SECTION 1. GENERAL DESCRIPTION -----------------------------10-1 SECTION 2. SPECIFICATIONS --------------------------------------- 10-1 SECTION 3. BATTERY----------------------------------------------------10-2 1.1. Inspection----------------------------------------------------------------10-2 1.2. Inspection of electrolyte level----------------------------------------10-2 1.3. Inspection of electrolyte specific gravity--------------------------10-2 1.4. Battery testing chart--------------------------------------------------10-3 SECTION 4. Meters and switches----------------------------------------10-5 1.

  • Page 185: Chapter 10 Electrical Accessory And Instruments

    Chapter 10 Electrical accessory and instruments SECTION 1. GENERAL DESCRIPTION The basic electrical system of tractors consists of the engine cranking system ,battery charging system,lighting system,meters,switches,etc. For further information concerning the engine cranking equipment and battery charging equipment, please refer to the engine manual. The battery is a power source to activate the engine cranking system,lighting system,and other electrical equipment.The lighting system is used to activate the illumination lights,indicators,and signal lights.The meter is a device that enables the operator to be aware of the present operating...

  • Page 186: Section 3. Battery

    Note: SECTION 3. BATTERY When the distilled water is added,charge the battery to mix it well into the electrolyte before 1.INSPECTION measuring the specific gravity. 1.1 INSPECTION OF ELECTROLYTE LEVEL a.Temperature correction of the hydrometer As the battery repeats charging and reading discharging during operation.The water The specific gravity of the battery...

  • Page 187: Battery Testing Chart

    1.4 BATTERY TESTING CHARTS Step 1. VISUAL INSPECTION Check for obvious damage such as cracked or broken case that shows loss of electrolyte,thermal damage,etc. Obvious damage No obvious damage Replace battery Check electrolyte level Electrolyte level is below top of Electrolyte level is above top of plates in one or more cells plates in all cells...
  • Page 188 Step 3 Load test 1.Connect voltmeter and ampere load equal to ½ the cold cranking amperes(18℃) rating of the battery for 15 seconds. 2. Observe voltage at 15 seconds with load on.Disconnect load 3.Place thermometer in one cell to take temperature of electrolyte. 4.Refer to voltage table Voltage below table value Voltage equal to or above table...

  • Page 189: Section 4. Meters And Switches

    SECTION 4. METERS AND SWITCHES 1.METERS The generated pulses are converted into voltage 1.1 Removal output through a converter.Then the voltage is divided into three different phase coils through a a. Disconnect the cable from the negative post. IC circuit.The tachometer pointer is swung by b.

  • Page 190: Thermometer

    b.Inspection -Fuel meter Note: Connect the fuel gauge to form a circuit with the 1) Figures in parentheses are reference value resisters as shown Fig.10-6 and check to see if 2) Inspect each position in order F to E the gauge pointer swings to each position: F.1/2 3) Read values in three minutes.

  • Page 191: Combination Switch

    (2) Inspection a.The main switch circuit,switching positions, and terminals are as shown in the figures. Check the continuity across respective terminals referring to the switch circuit diagram. Replace a defective switch as an assembly Fig.10-12 (3) Release the ring nut with a conventional screw drive(-) and remove the combination switch.

  • Page 192: Stop Light Switch

    -Lighting 4. STOP LIGHT SWITCH Color code (Red) (Red/ (Red/ (Red/ Green) White) Yellow) ● ● ● ● ● ● Fig.10-15 Stop light switch :Terminals : Switching positions Capacity 10~20A (DC12V) -Flasher 3 ±0.5mm Stroke to ON Color Total stroke code (Green) (White/...
  • Page 193 Each fuse is connected as follows Fig.10-18 The circuit has 8 blade type fuses in its wiring circuit.When a fuse has blown replace it with one of the same value. Fig.10-19 Note: Using a large capacity fuse or wire burn out the wiring system. Use fuse tongs to replace fuses 10-9...
  • Page 194 8.Trailer socket A hella’s 7-pin trailer socket is equipped as a standard equipment.Lamp on a trailer can be operated through the socket. Fig.10-23 Socket No. Description Color Specification Wire Housing Earth AVSS 2.0 Small light(Tail light) AVSS 0.85 Turn signal (LH) AVSS 0.85 Stop Light AVSS 0.85...

  • Page 195: Section 5. Earthing Point

    SECTION 5. EARTHING POINT Fig.10-24 1) Front axle bracket (RH) Earthed at upper upper tapped hole in the axle bracket A. Fig.10-26 3) Right surface of the frame comp.Where the battery bracket is to be installed. Fig.10-25 2) Contact surfaces of the axle bracket and engine where they tightened together 10-11...
  • Page 196 Fig.10-27 Hood frame 10-12...

  • Page 197: Section 6. Wiring Diagram

    SECTION 6. WIRING DIAGRAM 10-13...

  • Page 198: Section 7. Troubleshooting

    SECTION 7. TROUBLESHOOTING Important: Whenever effecting a repair the reason for the cause of the problem must be investigated and corrected to avoid repeating failure. The following table lists problems and their possible causes with the recommended remedial action 1. LIGHTING SYSTEM Problems Causes Countermeasures...
  • Page 199 Problems Causes Countermeasures Individual Burnt out bulb Check and renew turn signal Corroded or loose bulb contacts Inspect,clean,and renew light does not illuminate Poor ground connection or damage Inspect,clean,and tighten connections or wiring renew wiring Turn signal Faulty bulb Check and renew pilot light is Defective flasher unit Check and renew...
  • Page 200 Problems Causes Countermeasures Inoperative Burnt out fuse Inspect and renew.Check circuit before re- horn connecting power Loose or broken wires of Inspect circuit,tighten connections,or renew connections wiring Defective horn switch Check and renew Defective horn Check and renew 3.GLOW SYSTEM Problems Causes Countermeasures...
  • Page 201 4. STARTING SYSTEM Problems Causes Countermeasures Starter motor Discharged battery Check battery and charge or renew does not spin Defective stop light switch Check and renew Defective key switch Check and renew Defective starter motor connections Check,clean and tighten connections or loose battery connections Faulty starter motor Inspect,repair,or renew...
  • Page 202 Problems Causes Countermeasures Intermittent Alternator drive belt is slipping Check and adjust belt tension or renew or low Loose connection or broken cable in Inspect system,tighten connections and alternator charge system repair or renew faulty wiring output Defective alternator Check and repair or renew Warning light Faulty external charging circuit Inspect system,clean and tighten...

  • Page 203: Chapter 11. Service Standard And Other Information

    CHAPTER 11. Service standards and other information SECTION 1. SERVICE STANDARDS ------------------- 11-1 1.Engine accessories -------------------------------------- 11-1 2.Clutch damper -------------------------------------------------- 11-2 3.Transmission -------------------------------------------- 11-2 4.Front axle ------------------------------------------------- 11-3 5.Rear Axle --------------------------------------------------------- 11-4 6.Power steering system ---------------------------------------- 11-4 7.Hydraulic system ----------------------------------------------- 11-4 8.Electrical equipment -------------------------------------------- 11-7 SECTION 2.

  • Page 204: Section 1. Service Standards

    CHAPTER 11. Service standards and other information SECTION 1. SERVICE STANDARDS. Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 1.ENGINE ACCESSORIES(CHAPTER 3) 1) RADIATOR 7 ℓ Coolant capacity Radiator alone 12.7 ℓ Whole cooling system 0.9 ±0.15㎏f·㎠...
  • Page 205 Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 2. MAIN CLUTCH (CHAPTER 4) 8.4 ±0.3㎜ 6.5 ㎜ Rivet head depression CLUTCH DISC should maintained at ASSEMBLY more than 0.2 ㎜ (Dry single plate) Facing wear 0.3 ㎜...

  • Page 206: Transmission

    Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 3. TRANSMISSION (CHAPTER 5) 1) FRONT AND SPACER TRANSMISSIONS 32 ℓ TRANSMISSION OIL CAPACITY SHIFTER DISENGAGING LOAD 4 - 7 ㎏f Measured at the Main shift shifters (both for synchromesh and...
  • Page 207 Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 2) REAR TRANSMISSION (1) DRIVE PINION & RING GEAR 0.08 - 0.11 ㎏·m Starting torque 0.1 ～ 0.2 ㎜ 0.5 ㎜ Backlash Drive pinion and Adjustment of relative positioning Available shims on drive pinion ring gear support...
  • Page 208 Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 4.FRONT AXLE (CHAPTER 6) 1) Front drive axle (4WD) Front : 2.2 ㎏f/㎠ Tire inflation Rear : 1.8 ㎏f/㎠ ①Toe-in : 2 ～ 6 ㎜ Wheel alignment ②Camber : 3 °±1 °...

  • Page 209: Rear Axle

    Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 5.REAR AXLE (CHAPTER 7) 1) DISK BRAKE 3.4 ± 0.1 ㎜ 3.4 ㎜ FRICTION PLATE THICKNESS (WEAR AND CARBONIZER ) 2)SEPARATE PLATE 2.5 ± 0.09 ㎜ 2.5 ㎜...
  • Page 210 Usable limits Service instructions inspection items dimensions for reassembly and remarks 2) Dynamic lift 2000 ㎏f·㎠ T290/T300/2810 3) Cylinder case bush 55 ×60 ×50 Ø 55 ㎜ Ø 55.2 ㎜ Wear limit: 0.2 ㎜ Left side 60 ×65 ×50 Ø 60 ㎜...
  • Page 211 Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 6) SLOW RETURN CHECK VALVE(Flow control valve) 280 ㎏f/㎠ Maximum pressure Gear oil SAE #80 ～ #90 1 ㏄/min.at a pressure of 90 ㎏f/㎠ at a temperature of 50 Cylinder port leaks ±...

  • Page 212: Electrical Equipment

    8.ELECTRICAL EQUIPMENT 1)BATTERY (1)BATTERY TERMINAL POST Terminal voltage 12 V 10.8 V Charge or replace Corrosion Repair or replace (2) BATTERY CELLS Damage Replace battery (3) ELECTROLITE Cloudy fluid Replace battery Specific gravity 1.24 - 1.26 Correct Level As specified on Replace with distilled case water.
  • Page 213 (3) Turn signal switch color coding Replace a defective ●Turn signal ● ● switch switch assembly. ● ● (4) Horn switch color Replace a defective coding ● Horn switch switch assembly. ● ● (5) PARKING AND LIGHT SWITCH Replace a defective Continuity across ●...
  • Page 214 (9) HAZARD WARNING SWITCH Replace a defective ○ ○ ○ ○ switch assembly. Continuity across each terminal ○ ○ ○ ○ ○ ○ ○ ○ 10 9 11-11...
  • Page 215 SECTION 2.TIGHTENING AND STARTING TORQUE SPECIFIED FOR MAJOR PARTS 1. T290/T300/T330/2810NEW TIGHTENING PARTS BOLT AND NUT TIGHTENING TORQUE ( ㎏ f·m) (HARDNESS) 1)Front axle housing (4WD type) ① Axle bracket ～ Engine tightening bolts 16.0 ～ 18.0 M 16 (7T) ②...
  • Page 216 SECTION 3. CONVERSION TABLES M illimeters to inches Inches to millimeters 0.0394 1.0236 2.0079 2.9921 1/64 0.3969 25/64 9.9219 13/16 20.6375 0.0787 1.0630 2.0472 3.0315 1/32 0.7938 13/32 10.3188 53/64 21.0344 0.1181 1.1024 2.0866 3.0709 3/64 1.1906 27/64 10.7156 27/32 21.4313 0.1575 1.1417...
  • Page 217 L e n gth Fe e t to M e te rs 0.0000 0.3050 0.6100 0.9150 1.2200 1.5250 1.8300 2.1350 2.4400 2.7450 8.0532 3.3550 3.6600 3.9650 4.2700 4.5750 4.8800 5.1850 5.4900 5.7950 21.1097 6.4050 6.7100 7.0150 7.3200 7.6250 7.9300 8.2350 8.5400 8.8450 34.1661...
  • Page 218 Are a S qu are i nc h e s to s qu are c e ntime te rs 0.000 6.462 12.924 19.386 25.848 32.310 38.772 45.234 51.696 58.158 64.620 71.082 77.544 84.006 90.468 96.930 103.392 109.854 116.316 122.778 129.240 135.702 142.164 148.626...
  • Page 219 V ol u me Gall ons ( U.S ) to L ite rs US gal US gal Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters 0.000 3.785 7.571 11.356 15.142 18.927 22.712 26.498 30.283 34.069 37.854 41.639 45.425 49.210 52.996 56.781...
  • Page 220 M AS S P ou nds to Ki l ograms 0.000 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 4.536 4.990 5.443 5.897 6.350 6.804 7.258 7.711 8.165 8.618 9.072 9.526 9.979 10.433 10.886 11.340 11.794 12.247 12.701 13.154 13.608 14.062 14.515...
  • Page 221 P re s s u re P ou nds pe r s qu are i nc h e s to Ki l ograms pe r s qu ar e c e nti me te rs b/in2(PSI) lb/in2(PSI) Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2...
  • Page 222 Torqu e Foot pou nds to Ki l ogram me te rs ft lbs Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m 0.138 0.276 0.414 0.552 0.690 0.828 0.966 1.104 1.242 1.380 1.518 1.656 1.794 1.932 2.070 2.208 2.346 2.484 2.622...
  • Page 223 Temperature Fahrenheit to Centigrade Centigrade to Fahrenheit ˚F ˚C ˚F ˚C ˚C ˚F ˚C ˚F -28.9 35.0 -22.0 96.8 -26.1 37.8 -18.4 100.4 -23.3 40.6 -14.8 104.0 -20.6 43.3 -11.2 107.6 -17.8 46.1 -7.6 111.2 -17.2 48.9 -4.0 114.8 -16.7 51.7 -0.4 118.4...

This manual is also suitable for:

T290T330T300

Table of Contents