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Mitsubishi Heavy Industries BD2G Service Manual

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SERVICE MANUAL

·.MITSUBISHI

. DIESEL ENGINE

for BD2G/BS3G

CONTENTS

• CONSTRUCTION AND FUNCTION

• SPECIAL TOOLS

• MAINTENANCE STANDARDS

• DISASSEMBLY AND REASSEMBLY

Table of Contents

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Table of Contents

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Dave

April 23, 2025

need size of oil seal in final drive

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Mr. Anderson

May 12, 2025

The size of the oil seal for the Mitsubishi Heavy Industries BD2G final drive is not provided in the given context.

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Summary of Contents for Mitsubishi Heavy Industries BD2G

Page 1 SERVICE MANUAL ·.MITSUBISHI . DIESEL ENGINE for BD2G/BS3G CONTENTS • CONSTRUCTION AND FUNCTION • SPECIAL TOOLS • MAINTENANCE STANDARDS • DISASSEMBLY AND REASSEMBLY...
Page 3 DEFINITION OF TERMS In this manual, the following terms are used in the dimensional and other specifications: NOMINAL VALUE Indicates standard dimension part. ASSEMBLY STANDARD ..Indicates dimension part, dimension attained at the time of reassembly or the standard performance. value rounded nearest...
Page 5 TABLE OF CONTENTS Group Contents Group No. External views, Sectional views, Engine serial number location, General Engine model and application codes, Specifications, Tips on disassembly and reassembly • Maintenance standards Maintenance standards, Tightening torque, Sealants • Special tools Special tool list •...
Page 7: Table Of Contents
GENERAL I. GENERAL ............. 1.1 S4E2 diesel engine - External views ........1.2 S4E2 diesel engine - Sectional views ........1.3 Engine serial number location ..........1.4 Engine model and application codes ........2. SPECIFICATIONS ............3.
Page 8: S4E2 Diesel Engine - External Views
GENERAL 1. GENERAL 1.1 S4E2 diesel engine - External views 402884 Fuel filter Intake manifold <V ® Stop solenoid ® ® Water pump Governor ® (j]) Fuel injection pump Flyw heel ® (j]) Fuel feed pump Starter ® Fan belt Left-hand side view...
Page 9 GENERAL ® 402885 ® Exhaust manifold Alternator ® ® P.T.O. Gear Oil filter Right-hand side view...
Page 10: S4E2 Diesel Engine - Sectional Views
GENERAL 1.2 S4E2 diesel engine - Sectional views 402886 ® Rocker arm Camshaft ® Piston Oil pump ® Compression ring @G!ow plug ® @Oil ring Fuel injection nozzle ® Connecting rod Transverse view...
Page 11 GENERAL 402887 ® @ Rocker shaft bracket Camshaft Thermostat ® ® @ Cylinder head Connecting rod Water pump (j]) Crankshaft gear @ Valve push rod @Piston ® ® @ Crankshaft Compression ring Crankcase ® @ Intake valve Valve pushrod Oil ring ®...
Page 12: Engine Serial Number Location
GENERAL 1.3 Engine serial number location The engine serial number is stamped on the side face of crankcase. s~erial II Engine number .9/J1 O ... """"'+t_ 1.4 Engine model and application codes SO 0 E2: Swirl combustion chamber type Series codes Piston displacement per cylinder: 739 cc (45.1 cu in.)
Page 13: Specifications
GENERAL 2. SPECIFICATIONS Model designation S4E2 Type Water-cooled, 4-stroke cycle, diesel No. of cylinders - arrangement . 4-in line Type of combustion chamber Swirl chamber Valve mechanism Overhead mm (in.) Bore x stroke 98 x 98 (3.86 x 3.86) 2.956 Piston displacement liter (cu in.) (180.3)
Page 14 GENERAL Model designation S4E2 Type Trochoid Speed ratio to crankshaft Oil pump Delivery capacity 14 (3.7) liter (U.S. ga1)/min (at 1800 engine rpm) Type Piston valve " Relief valve Opening pressure kgf/cm 2 (psi) [MPa] 3 ± 0.3 (43 ± 4.3) [0.3 ± 0.03] ·3 Type Oil filter...
Page 15 GENERAL S4E2 Model designation Type of nozzle holder Bosch, throttle Type of nozzle tip Bosch ND-DNOSD Manufacturer NIPPONDENSO No_ of spray holes Injection nozzles Diameter of spray hole mm (in.) 1.0 (0.D4) '" 0° Sprayangle " Valve 0fening pressure 120 +~o (1706 +~42) [11.8 +~.o] kgf/cm (psi) [MPa] Type Cartridge, paper element...
Page 16: Tips On Disassembly And Reassembly
GENERAL When lifting or carrying a pa'rt too 3. TIPS ON DISASSEMBLY AND heavy or too awkward for one person REASSEMBLY to handle, get another person's help This Service manual deals with and, if necessary, use a jack or chain Mitsubishi'srecommended procedures to block.
Page 17 MAINTENANCE STANDARDS 1. MAINTENANCE STANDARDS ..........12 2. TIGHTENING TORQUE ..........19 2.1 Important bolts and nuts ..........19 2.2 General bolts and nuts ..........20 3. SEALANTS .............. 21...
Page 18: Maintenance Standards
MAINTENANCE STANDARDS MAINTENANCE STANDARDS Unit· mm (in ) Repair Service Nominal Assembly standard Inspection point limit limit Group Remarks value [standard clarance} [clearance} [clearance} Maximum rpm (no·load) 2620 ± 20 Adjust governor setting. Minimum rpm (no·load) 870± 10 Nominal value: 24 kgf/cm Oil and water temp.
Page 19 MAINTENANCE STANDARDS Unit: mm (in.) Repair Service Nominal Assembly standard Group Inspection point limit limit Remarks value [standard clarance] [clearance] [clearance] .,:, Warpage of gasketed 0.05 (0.0020), 0.20 Regrind if warpage " maximum (0.0079) surface is minor. Refinish sleeves to 98.200 Inside 99.200...
Page 20 MAIN"I:ENANCE STANDARDS Unit: mm (in.) Repair Service Nominal Assembly standard Group Inspection point limit limit Remarks value [standard clarance] [clearance] [clearance] Angle 30° ~~~~ ±0.2 (±0.008) Valve sinkage (0.051) (0.028) " ~alve " margin Valve seat Valve Width angle ±0.14 (±0.0055) sinkage (0.047) (0.063)
Page 21 MAINTENANCE STANDARDS Unit: mm (in.) Repair Service Nominal Assembly standard Inspection points limit limit Remarks Group -value [standard clarance] [clearance] [clearance] Rounout measured .goo 0.4 (0.016), with pushrod sup· ".", Runout (bend) " k maximum ported at centerlines "'''' "':> :>0.
Page 22 MAINTENANCE STANDARDS Unit: mm (in.) Repair Service Assembly standard Nominal Inspection point limit Remarks Group limit value [standard c1arance J [clearance J [clearance J Protrusion Check bearing 0.35 - 0.75 above clearance. (0.0138 - 0.0295) crankcase £ Variance in weight ±3 g (±O.I oz) per engine 0.030-0.070...
Page 23 MAINTENANCE STANDARDS Unit: nun (in.) Repair Service Nominal Assembly standard Inspection point limit limit Remarks Group value [standard clarance [clearance J [clearanceJ .§ [ 0.50 J Replace connecting 0.15-0.35 End play (0.0197) . rod. (1.57) (0.0059-0.0138) " " " tS g (to.2 oz), Variance in weight """...
Page 24 MAINTENANCE STANDARDS (in~ Unit: mm Service Repair Nominal Assembly standard Group Inspection point limit Remarks Hmit value [standard clarance [clearance [clearance Outer rotor to inner 0.013-0.150 0.250 1(0.00984)1 rotor clearance [(0.00051-0.00591 Rotor to cover 0.04-0.09 1 O.IS 1 (0.00S9) clearance (0.0016-0.0035) Outer rotor to case 0.20-0.28...
Page 25: Tightening Torque
MAINTENANCE STANDARDS 2. TIGHTENING TORQUE 2.1 Important bolts and nuts Width Tightening torque Thread across Secured part or component Remarks dia.-pitch flats kgf·m lbf·ft N·m 12-1.75 ±05 Cylinder head bolts 87 ±4 118 ±5 [Wet] 8 - 1.25 1.5 ± 0.5 11 ±4 Rocker shaft brackets 15 ±...
Page 26: General Bolts And Nuts
MAINTENANCE STANDARDS 2.2 General bolts and nuts Screw thread Tightening torque washei With spring Wiihoul spring ivasher Diameter Pitch kgf.m kgr·m Ibf·ft Ibf·ft N·m 1.25 1.25 1.25 1.75 10.4 12.2 11.5 15.8 18.6 15.0 17.6 22.9 26.9 20.7 24.4...
Page 27: Sealants
MAINTENANCE STANDARDS 3. SEALANTS Mating parts Sealant Application point How to use Apply to front and Front and rear bearing Oil pan gasket ThreeBond 1104 rear lower sicjes cap seats of crankcase (bearing cap seats). (No.4) Plugs for water and oil •...
Page 29: Special Tool List
SPECIAL TOOLS SPECIAL TOOL LIST ............24...
Page 30 SPECIAL TOOLS SPECIAL TOOL LIST Part No. Shape Tool name 34491·00400 Valve guide Valve guide installation installer 670228. Valve guide 31391·10500 Valve guide removal remover 670230 Valve spring 30691·04500 Valve spring removal/installa· pusher tion 401793 31391·13010 Insert caulking Valve seat (For Intake) installation tool...
Page 31 SPECIAL· TOOLS Part No. Shape Tool name Idler shaft puller 34491·02300 Idler shaft removal 670237 Idler bushing 30091·07300 Idler bushing puller removal/installa. tion 670242 Socket 34491·00300 Camshaft thrust plate removal/ installation 670235 Oil filter wrench 30691·53301 Cartridge type oil filter removal 401822 Universal 30091·01101...
Page 32 SPECIAL TOOLS Tool name Part No. Shape Adaptor 30691·21100 Engine compres- sion pressure measurement 670233 64309-12900 Puller assembly Crankshaft gear, camshaft gear, crankshaft pulley and water pump pulley removal 670241. 33391·02100 Compression Compression gauge pressure measurement Oil seal sleeve Crankshaft 30691·13010 sleeve in·...
Page 33 OVERHAUL INSTRUCTIONS I. DETERMINING WHEN TO OVERHAUL THE ENGINE ......28 2. TESTING THE COMPRESSION PRESSURE ........29...
Page 34 OVERHAUL INSTRUCTIONS DETERMINING WHEN TO OVERHA.UL injection pump plungers, faulty injection! THE ENGINE nozzles, or poor care of the battery, starter and alternator. Generally, when to overhaul the engine The trouble to considered as the to be . determined by taking into most valid reason for overhauling the consideration drop...
Page 35 .OVERHAUL·INSTRUCTIONS 2. TESTING THE COMPRESSION PRESSURE (1) Remove the glow plug from a cylinder on which the compression pressure is to be measured. (2) Attach the adaptor (30691-21100) to threaded glow plug hole, and connect compression gauge (33391- 02100) to the adaptor. 401296 (3) Crank the engine by means of the starter,...
Page 36 OVERHAUL INSTRUCTIONS .------.&.1 1----, CAUTION is important to measure the compression pressure at periodical intervals to obtain the da.ta on the gradual change of the pressure. (b) The compression pressure would slightly higher than Assembly standard in a new or overhauled engine owing...
Page 37 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1. ADJUSTMENTS ............1.1 Valve clearance ............1.2 Fuel system priming ........... 1.3 Fuel injection timing inspection and adjustment ......1.4 No-load minimum (idling) speed and maximum speed setting inspection and adjustment ..........
Page 38 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS ADJUSTMENTS 1.1 Valve clearance Inspect and . adjust the valve .clearance when the engine is cold or when it is warm in whole. Unit: mm (in.) Assembly standard Item Intake Valve clearance 0.25 (0.0098) (cold) Exhaust (1) Inspecting valve clearance (a) Inspect the valve clearance by the...
Page 39 ADJUSTMENTS. BENCH. TEST, PERFORMANCE TESTS (2) Adjusting valve clearance (a) Loosen the lock nut for adjusting screw, and adjust the clearance by turning screw either direction to the 'extent that the gauge is slightly gripped between the rocker arm and valve cap. After adjusting clearance,...
Page 40 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1----------, . . - - - - - ( NOTE all vent plugs are tightened before the priming pump handle is locked, fuel pressure acts on feed pump, making impossible to restore the handle. (b) Wipe off fuel spilt from the vent holes with cloth •...
Page 41 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS (2) Inspecting fuel injection timing (a) Remove the delivery valve holder from No. 1 pumping element of injection pump. Take delivery valve and spring out of the holder, and restore the holder to the pump. (b) Turn the crankshaft to bring No.
Page 42 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS (b) One graduation of the scale on the injection pump coupling changes the timing by 6° in terms of crank angle. 1.4 No-load minim urn (idling)· speed and maximum speed setting inspection and adjustment . - - - - - [ N O T E ] - - - - - , For details of adjustment, refer to Fuel System in the separate volume •...
Page 43 ADJUSTMENTS. BENCH TEST. PERFORMANCE TESTS W hen the engine is noted to running with a steady speed, move speed control lever back to low idling speed position. Idling set (The setting for keeping the no-load minimum engine speed) (a) Hold speed control lever at the position for permitting the engine to run at the specified low idling speed, and set the low idling set...
Page 44 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS (3) Rack set (The setting for limiting the maximum engine output) Hold speed control lever at the posi tion for the indicated output and speed (specified for purpose of governor adjustment). Under this condition, check to sure that the engine is running in a steady state.
Page 45 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS Run in governor set bolt (maximum speed set bolt) slowly until its forward end comes in contact with speed con trol lever held as above. Secure bolt right there by tightening its lock nut. Determination of the speed regulation Speed regulation upon removing load (speed droop) Speed regulation upon removing load...
Page 46 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS [3] Computing the speed regulation From the values obtained in and [2], above; . compute the speed regulation for each load change. A total of four percent values of speed regulation are to be determined by using the indicated formulas.
Page 47 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS (e) Tightening adjusting screw, mentioned above, will increase the maximum speed, and vice versa . J------, .------.&,[ CAUTION The adjustable range is 20-notch (5 rotations) long. Never loosen the screw by more than 20 notches from the fully tightened position or the control action of the governor will become hazardous.
Page 48 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 1.5 Fan drive belt inspection adjustment Apply thumb pressure belt midway· between the pulleys to inspect belt tension. tension is incorrect, make an adjustment by means of bolt (1). Unit: mm (in.) , Item Assembly standard Fan drive belt tension 10 -15 (3/8 - 518)
Page 49 ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS 2. BENCH TEST (5) Knocking: should die away as the coolant temperature rises. No other An overhauled engine should be tested defects should be noted. performance dynamometer. This test is also for "breaking-in" of Exhaust color and abnormal smell the major running parts of the engine.
Page 50 .ADJUSTMENTS, B.ENCH TEST, PEHFDRMANCE TESTS 3.3 Test methods Fuel consumption test Engine speed (rpm) Fuel injec tion quan tity Engine output No-load maximum speed test For this test, the governor should be set for no-load maximum speed. No-load minimum speed test (a) The control lever should be set to the stable minimum speed position.
Page 51 ENGINE ACCESSORY REMOVAL AND INSTALLATION PREPARATORY STEPS ........... 46 2. ENGINE ACCESSORY REMOVAL ........... 46 3. ENGINE ACCESSORY INSTALLATION ........50...
Page 52 ENGINE ACCESSORY REMOVAL AND INSTALLATION This section explains the procedures and tips for removal' and. installation of the accessories - the preliminary process to go through for overhauling the engine. PREPARATORY STEPS (a) Shut off fuel supply, and disconnect starting system from engine.
Page 53 ENGINE ACCESSORY REMOVAL AND INSTALLATION (2) Removing glow plugs Disconnect wire (2) by loosening nut (1), and remove glow plug (3) • .------,&[ CAUTION] - - - - - - - , After removing each glow plug, cover the opening by taping to prevent dust from getting inside.
Page 54 ENGINE ACCESSORY REMOVAL AND INSTALLATION (5) Removing fuel. filter and intake and exhaust manifolds (a) Disconnect fuel hose from fuel filter (1). Remove filter (2) by unscrewing its mounting bolts. (b) Remove intake manifold (3) and exhaust manifold (4) by unscrewing mounting bolts.
Page 55 ENGINE ACCESSORY REMOVAL AND INSTALLATION Removing alternator Disconnect harness and unscrew belt adjusting plate bolt (2). Remove alternator (4) by unscrewing munting bolts (3). 401317 (10) Removing starter Disconnect harness remove (1), starter (3) by unscrewing mounting bolts (2). 401318 (11) Removing oil filter·...
Page 56 ENGINE ACCESSORY REMOVAL AND INSTALLATION ENGINE ACCESSORY INSTALLATION To install the engine accessories, use reverse removal procedures. After installing them, take - following steps: (a) Installing fuel injection pump When installing the pump, make sure that matching marks on pump drive gear and other gears are aligned with those on idler gear respectively, as...
Page 57 ENGINE PROPER l. CYLINDER HEAD AND VALVE MECHANISM ....... 52 l.1 Disassembly ............52 1.2 Inspection and repair ........... 54 1.3 Reassembly ............62 2. FLYWHEEL, TIMING GEARS AND CAMSHAFT ....... 66 2.1 Disassem bly ............66 2.2 Inspection and repair ........... 69 2.3 Reassembly ............
Page 58 ENGINE PROPER 1. CYLINDER HEAD AND VALVE MECHANISM 1.1 Disassembly Cracks, oil leaks Damaged threads, worn pushrod contact face - , . @o,l@.J---,-"----' - --=---' - ----' Worn valve cap contact face, clogged Qil hole Worn ends, distortion Wear Cracks. damage, carbon and scale deposits Worn stem or face, damage.
Page 59 ENGINE PROPER Removing rocker shaft assem blies (a) Loosen the adjusting screw of each rocker about one rotation. (b) Loosen the rocker bracket short bolt and long bolt in tha t order, remove rocker shaft assem bly from the cylinder head. ~---&J l---~ CAUTION...
Page 60 ENG I NE PRDPE R (4) Removing valves and valve springs spring pusher Using valve compress valve (30691-04500), . valve spring squarely, and remove the ® cotters. r-----[ )----~ NOTE If the valves are reused, mark them their locations 401326 installation time reassem bly.
Page 61 ENGINE PROPER (2) Replacing rocker bushings When installing a replacement bushing, align the oil holes in the bushing and rocker arm. 401327 Replacing rocker bushing Valves, valve guides and valve seats (1) Measuring valve stem diameter If the Service limit is exceeded, or if stem abnormally worn...
Page 62 ENGINE PROPER Unit· mm (in) Nominal Assembly Service Item value standard limit 0.055 - 0.085 0.150 Intake Valve (0.00217 (0.00591) stem- - 0.00335) to·guide (0.31 ) 0.070 clear- - 0.105 0.200 ance Exhaust (0.00276 (0.00787) - 0.00413) ±0.3 As·installed depth (0.67) (±0.012) of valve guide...
Page 63 ENGINE PROPER )----~ r·---'-----[ NOTE Check valve face after inspecting or replacing the valve guide. (b) ;ress the valve in to the seat ~ithout rotating it. Unit· mm (in ) Assembly Repair Item standard limit Angle 0.7 ± 0.2 Valve (0.028 ±...
Page 64 ENGINE PROPER Refacing valve seats (a) Using a valve seat cutter or valve seat grinder, cut the valve seat. After cutting, grind seat lightly by using a sandpaper of 400 grade or so, inserted between the cutter and seat. (b) Lap the valve in the seat. 401332 1--------.
Page 65 ENGINE PROPER Chill valve seat liquid nitrogen [about -170°C (-274°P)] for more than minutes with cylinder head kept normal temperature, or heat the cylinder head to 80°C to 100°C (176°P to 212°P) with the valve seat chilled in ether or alcohol con taining dry ice.
Page 66 ENGINE PROPER (b) Using a valve lapper, lap the valve in the seat. To lap, raise the valve off the seat, rotate it only a part of turn to a position and strike it against the valve seat. (c) Wash off the compound with diesel fuel.
Page 67 ENGINE PROPER Cylinder head Measuring gasketed surface warpage Measure warpage with a straightedge and a feeler gauge. If the warpage exceeds Repair limit, reface gasketed surface with a surface grinder. Unit· mm (in) Assembly Repair Item 670067 standard nmit Measuring cylinder head gasketed surface warpage 0.05 Cylinder head gasketed 0.20...
Page 68 ENGINE PROPER 1.3 Reassembly 401336 Reassembling sequence ~ ~ICrankcase <D I' I I I I @@@@(@CV '~"III ® ® ® ® ®<-® ®...
Page 69 ENGINE PROPER Installing valve stem seals Stem seal After installing the stem seal to the valve guide, make sure that the seal is properly fitted in the groove of the guide. Valve guide ,--------.&.1 CAUTION ] - - - - - - - , Do not apply any oil or sealant to the mating face of stem seal that 670080...
Page 70 ENGINE PROPER r - - - - - - - - - - - - - - - - - - , ( (3) Installing cylinder head (a) Screw tW{) guide bolts into the crankcase to hold the gasket in place.
Page 71 ENGINE PROPER (4) Reassembling rocker shafts 24.5 (0.965 in.) 22.5. (0.886 in.) The rocker arms for intake valves are different in dimension from those for exhaust valves. After installing arms, make sure that they move freely. Intake Exhaust ~~~~~~~_~~~~_~~~670364 (5) Installing rocker shaft assemblies ±...
Page 72 ENGINE PROPER 2. FLYWHEEL, TIMING GEARS AND CAMSHAFT 2.1 Disassembly 402891 402897 ® Flyw heel Oil seal @ Camshaft gear ® ® Flywheel housing Baffle plate @ Thrust plate ® Oil seal :@ P.T.O. gear @ Camshaft @Oil pan @ Idler gear (P.T.O.) Tappet ®...
Page 73 ENGINE PROPER (1) Removing flywheel (a) Unscrew flywheel mounting bolts. (b) Screw the jacking bolts into the holes provided flywheel uniformlY, and remove the flywheel. (2) Removing flywheel housing bolts, Unscrew the housing mounting and remove the housing. 401344 (3) Removing oil pan and oil pump Unscrew the oil pan mounting bolts, and remove the oil pan.
Page 74 ENGINE PROPER (5) Measuring backlash and end play Measure the backlash and end play on each -gear to obtain the data for parts replacement. (Refer to 2.2, .Group No. 402899 (6) Removing timing gears Be sure to align the timing marks for each pair of gears before removing or installing the gears.
Page 75 ENGINE PROPER 2.2 Inspection and repair Camshaft and camshaft bushings Measuring camshaft end play If the end play exceeds the Repair limit, replace the thrust plate. Unit· mm (in) Assembly Repair Item standard limit Measuring camshaft end play 0.050 0.112 0.300 Camshaft end play (0.00197 - 0.00441) (0.01181)
Page 76 ENGINE PROPER (4) Measuring camshaft journal diameter If the journals exceed the Service limit, replace the camshaft bushings. Unit· mm (in) Service Assembly Item limit standard No. I, 53.96 - 53.94 53.90 Camshaft (2.1 244 - 2.1 236) (2.1220) journal 52.96 - 52.94 52.90 diameter...
Page 77 ENGINE PROPER (2) Measuring tappet-to-guide clearance the clearance exceeds the Assembly standard, replace the tappet. Unit: mm (in ) Assembly Repair Service Item standard limit limit 22.000 - 22.021 22.100 Tappet guide (0.86614 (0.87008) inside diameter 401200 401532 . - 0.86697) Measuring tappet and guide 0.Q35 - 0.086...
Page 78 ENGINE PROPER Measuring idler bushing inside diameter and idler shaft diameter If the idler shaft-to-bushing clearance exceeds the Standard clearance, -replace- the bushing. - Unit· mm (in) Nominal Standard Repair Item clearance value limit 0.Q25 401521 401756 Idler shaft·to· - 0.D75 0.100 (1.42) Measuring idler shaft and bushing...
Page 79 ENGINE PROPER · (2) Measuring flywheel face runout With flywheel installed engine, measure its face runout. If the face runout exceeds Assembly standard, check im proper installation or foreign matter lodged in the mounting face. Unit· mm (in) Assembly Repair Item standard limit...
Page 80 ENGINE PROPER If the top surface of the belt is uniformly above the top of the pulley all the way around, it is not necessary to replace the pulley. the top surface of the belt sinks into the groove more than 1.6 mm (1/16 in.), replace the pulley.
Page 81 ENGINE PROPER 2.3 Reassembly Section A-A 402892 402906 Section B-B 402903 402887 Reassembling sequence , I , I I I 1 I I I Crankcase ® ® ® @®CV®®®@CD@ ® ®...
Page 82 ENGINE PROPER (1) Installing camshaft -gear and thrust plate Heat the gear for installation. Have the thrust plate installed in advance. Camshaft gear Installing camshaft Carefully insert the camshaft into the crankcase. Installing idler the idler while aligning Install timing marks each pair of gears, the thrust plate with bolt.
Page 83 ENGINE .PROPER g~ars (5) Inspecting and adjusting timing after installation. After installing the timing gears, be sure to inspect and adjust them as follows: (Inspecting timing gear backlash and end . play) After installing timing gears, inspect the backlash between the gears 402899 in mesh and the end play of each gear.
Page 84 ENGINE PROPER PISTONS, CONNECTING RODS, CRANKSHAFT AND CRANKCASE 3.1 Disassembly Scratches, cracks, wear, carbon deposit on outside WeaJ., scratches, rust Scale deposit, corrosion, damage Wear --:::;<D~ ® r -_ _ _ Wear clogged oil hole ® .---,~ Scratches, cracks, pitting, clogged oil hole, wear Scratches>...
Page 85 ENGINE PROPER (1) Removing connecting rod caps (a) Unscrew the nuts securing the cap. Give hammer blows to the bolts squarely and evenly· and, after the cap comes off the reamer bolt, take off the cap. (b) Mark the removed connecting. rod bearings identification cylinder numbers and kinds, upper...
Page 86 ENGINE PROPER , - - - - - - - - - - - - - - - - , ( (5) Removing piston pin (a) Using snap ring pliers, remove the snap rings .. (b) Remove the piston pin, and separate .. the piston from the connecting rod.
Page 87 ENGINE PROPER (2) Measuring cylinder sleeve insiqe 11 mm (0.43 in.) diameter (2.36 in.) 105 mm (4.13 in.) (a) Measure sleeve directions, paraliel and transverse crankshaft, three . positions, top (ridged area), middle and bottom as shown. Unit· mm (in ) Assembly Repair Service...
Page 88 ENGINE PROPER 1-------. . - - - - - - [ NOTE (a) Refinish all sleeves to the same oversize. the . sleeve is found in good condition, with the wear far less than the Repair limit, replace the piston rings, and ream off "ridge"...
Page 89 ENGINE PROPER Pistons and piston rings Measuring piston diameter (a) Using a micrQmeter, measure each piston the direction transverse to the piston pin. the diameter exceeds the Service limit, replace the piston. any pistons have to be replaced, select new pistons so that the variance in weight among pistons per engine is within the 401774...
Page 90 ENGINE PROPER Measuring piston ring end gap Place the ring in a new or master sleeve, .and measure. the gap. If the gap exceeds the Service limit, replace all rings ·a se t. (0~O'"°9~~~~~ Inside diameter master cylinder sleeve: in.) 981.035 (3.861.00138 401776...
Page 91 ENGINE· PROPER (4) Measuring piston hole diameters If the Repair limit is reached, replace piston pin. exceeded, replace the piston. Unit: mm (in.) Repair Assembly Item standard limit Piston pin 28.000 - 27.994 401206 (1.10236 - 1.10212) diameter Measuring piston pin and hole Piston pin·to·hole 0-0.016 0.050...
Page 92 ENGINE PROPER ~---&.I ]---~ CAUTION Keeping the piston protrusion within the Assembly standard is important not only for engine performance but also for prevention of interference of the valve with the piston. Connecting rods, connecting rod bearings and small-end bushings Measuring connecting rod bearing-to- crank pin clearance Measure...
Page 93 ENGINE PROPER (2) Measuring connecting rod bushing-to- piston pin clearance Measure the piston pin diameter and bushing inside diameter to determine the clearance between the two. If the clearance exceeds Repair limit, replace the pin or bushing whichever is badly worn. Unit·...
Page 94 ENGINE PROPER r - - - - - - - - - - - - - - - - . ( (b) For inspecting connecting rod for bend and twist, the connecting rod aligner is generally used. ~---~INOTE1----~ inspect bend, install .
Page 95 ENGINE PROPER (6) Measuring connecting rod end paly Install the connecting rod to the mating crankpin, and tighten its cap to the specified torque. Then, using a feeler gauge, measure the end play. the end play exceeds the Service limit, replace the connecting rod.
Page 96 ENGINE PROPER (2) Measuring crankpin diameter Using micrometer, measure crank pin ·in two positions, 1 and 2, and directions, determine the war, out of round and taper. If any of the Repair limits is exceeded, regrind the crank pin to the undersize or replace the crankshaft.
Page 97 ENGINE PROPER W hen grinding journals crank pins, be sure to produce the same fillet radius as the original one. They should have a hardness of 620 or more in terms of Vickers Hardness Number. If necessary, reharden the journals and crank pins, and inspect them foor cracks by conducting a magnaflux (magnetic particle) test.
Page 98 · ENGINE PROPER .-----1 NOTE ] - - - - - - - , Do not remove tile gear by driving with a hammer. (b) To install, heat the gear up to about 100°C (212°F) with heater. Place the new gear on the Key and notch crankshaft by aligning the key with to be aligned...
Page 99 ENGINE PROPER (2) Measuring main bearing clearance Fit the bearing shells to the crankcase and bearing cap, and tighten the cap bolts to the specified torque. Measure the inside diameter of the bearing in two positions, front and back along the longitudinal axis of crankshaft, in the criss-cross directions...
Page 100 ENGINE PROPER 3.3 Reassembly Reassembling sequence <P ® ----------~ll'----------~l,1 ~----~l (@@®(u pp er)(@@@)------>l®III®<-®(Iower) r r r ®@® ® @Oower) ®(upper) Installing main bearings (a) Install each upper shell in crankcase by fitting its locking lip in the recess. Tlie oil holes in the shell and crankcase will aligned when the shell is so installed.
Page 101 ENGINE PROPER (2) Installing crankshaft (a) Wash the crankshaft with cleaning solvent, and dry it by directing pressure air. (b) Hold the crankshaft in horizontal position, and carefully put it on the crankcase. (c) Apply a thin coat of engine oil to the journals of crankshaft.
Page 102 ENGINE PROPER , - - - - - - - - - - - - - - - - - - - , ( (4) Installing bearing cap bolts Apply engine oil to the bolts, and tighten them to the specified torque. 1O.4±O.S kgf·m (75.2±3.6Ibf·ft) N.m)
Page 103 ENGINE P.ROPER (b) Install the oil ring with its end gap positioned at 180· to that of spring --~, ,~ing expander. Attach teflon tube to the expander close to the oil ring expander '" end gap. r, . Spring expander ' ( Teflon tube ...
Page 104 ENGINE PROpER (10) Installing pistons . Camshaft side .End gap of No. 1 canpression ring (a) Apply engine oil to the piston rings, and reposition the rings by keeping their gaps away from direction of piston pin and thrust side. ?fN~.
Page 105 INTAKE & EXHAUST SYSTEMS I. DESCRIPTION ............100 2. EXHAUST MANIFOLD ............. 100 Inspection ...." ......" ....100...
Page 106 INTAKE & EXHAUST SYSTEMS DESCRIPTION Muffler Air cleaner Cylinder 401800 EXHAUST MANIFOLD Inspection (a) Inspect flanges for cracks. (b) Inspect flanges for warpage. the warpage exceeds the Assembly standard, repair the flanges. Unit· mm !fl. Assembly standard Item Inspecting exhaust manifold flanges for warpage Warpage of exhaust 0.2 (0.008), maximum...
Page 107 LUBRICATION SYSTEM 1. DESCRIPTION ............102 2. OIL PUMP ............... 103 2.1 Disassembly ............103 2.2 Inspection and repair ........... 104 2.3 Reassembly ............106 3. OIL FILTER ............. 107 Disassembly and inspection ..........107 4. RELIEF VALVE ............107 Inspection ...............
Page 108 LUBRICATION SYSTEM DESCRIPTION Valve mechanism Fuel injection pump- Piston Oil filter Water pump Relief valve Crankshaft- Oil pump Oil strainer 402910...
Page 109 LUBRICATION SYSTEM OIL PUMP 2.1 Qisassembly ,--_-----, ® Worn or broken ..gear teeth (21r-'----(8 401803 <D @) Pump drive gear Oil pump case cover Main shaft ® ® @Pin Outer rotor Oil pump case ® ® Inner rotor Taper pin...
Page 110 LUBRICATION SYSTEM Removing main shaft Take off the taper pin, and remove the drive gear from the main shaft. Then, pull the main shaft complete with the inner rotor from the pump case. 670144 (2) Removing inner rotor Take off the pin, and separate the inner rotor from the main shaft.
Page 111 LL!BRICATION SYSTEM (2) Measuring rotor-to-cover clearance (end play of rotors) If the clearance exceeds the Repair limit, replace the rotors or grind the mating faces of the case and cover. Unit: mm (in.) Assembly Repair Item standard limit 0.04 Rotor·to-cover 670147 0.15 .
Page 112 LUBRICATION SYSTEM 2.3 Reassembly 402907 Reassembling sequence <PI r t II® ® @+(l) @@ .-----1 1---------, NOTE When using replacement (new) main shaft and drive gear at the time of reassem bling the pump, drill dowel hole through the shaft and gear. (b) W hen tightening the cover bolts, be sure to make sure that the rna tching marks on the cover and...
Page 113 LUBRICATION SYSTEM OIL FILTER Disassembly and inspection • •• ••• •• • Dogged torn element Replace element every 500 hours. Apply engine oil- to O-ring when installing element. Cracks. distortion 670379 670476 ® Filter case Filter element ® ® Relief valve Center screw RELIEF VALVE Inspection...
Page 115 COOLING SYSTEM 1. DESCRIPTION ........; ..... 110 2. WATER PUMP ............110 2.1 Disassembly ............110 2.2 Inspection ............111 2.3 Reassembly ............112 THERMOSTAT .., ..•..........Inspection ............... 113 ........... 114 4. FAN AND FAN BELT Inspection ...............
Page 116 COOLING SYSTEM 1. . DESCRIPITION Thennostat Radiator Bypass pipe Water pump Cooling fan 402911 WATER PUMP 2.1 Disassembly ® ® Corrosion. feathering due to rubbing contact. damaged threads Rotation 670196 ® Oil seal @ Oil seal Cover ® Snap ring @ Unit seal Impeller ®...
Page 117 COOLING SYSTEM (1) Removing impeller The impeller is right hand-threaded. remove impeller, turn counterclockwise (in the direction of arrow). 400136 Removing shaft Remove the oil seal and snap ring, and pull shaft complete with bearings to the pulley side. 400139 2.2 Inspection (a) Inspect pump...
Page 118 COOLING SYSTEM 2.3 Reassembly ® 3.5 kgf-m (25.3 Ibf.ft) [34.3 N-m] ® ® 670197 Reassembling sequence ® 'rrrrrr@ ® CD ® ® ® CD @ @Floating seat (g:l<-@(seal ring) r------I l----~ NOTE After reassembling the pump, operate by means of the pulley and belt, making sure that it runs smoothly wi thout any sign of rubbing contact with the pump case or cover.
Page 119 WORKSHOP THEORY I. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY ....... 1.1 Oil seals ............. 1.2 O-rings ............... 117 1.3 Bearings ............. 117 1.4 Lockplates ............1.5 Split pins and spring pins ..........118...
Page 120 WORKSHOP THEORY PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 1.1 Oil seals W hen installing seals, carefully observe the following points: Driving oil seals into housings (a) Make sure that seal lip is not damaged, and position it correctly with respect to oil compartment. (b) Apply a small amount of grease to the surface of oil seal to be fitted in to housing bore.
Page 121 WORKSHOP THEORY 1.2 O-rings Use an O-ring guide of the type shown when installing O-ring over stepped portion, splines, threads or keyway to prevent damage to the ring. Apply a thin coat of grease to O-ring. 400249 O-ring guide 1.3 Bearings When installing a rolling bearing, be sure to give a push to the race, inner...
Page 122 WORKSHOP THEORY 1.4 Lock plates Bend lock plate against one of the flats of nut or bolt head as shown. rrp-, fIlS • Right Right Wrong Bending lock plates 1.5 Split pins and spring pins Generally, split pins are to be replaced at the time of disassembly.
Page 123 COOLING SYlnEM THERMOSTAT Inspection (in.) 9(O.35)~ Immerse thermostat in a water ba th, test thermostatic action by heating the bath to raise the 76.5 ±2 90 ±2 US9.7 :!:3.6)(194 :!:3.6) water temperature. the valve fails to ('To) Tempefalutt °c operate properly, replace thermosta t.
Page 124 COOLING SYSTEM FAN AND FAN BELT Inspection Distorted or cracked blade Ch~e in length, detenoration, cracks 401811...
Page 126 DEC .. '86 99879-00120- Pub. No. Printed in Japan...
Page 127 SERVICE MANUAL MITSUBISHI DIESEL ENGINE for BD2G/BS3G CONTENTS • FUEL SYSTEM • ELECTRICAL SYSTEM...
Page 129 Service Manual of Mitsubishi S4E2 Diesel Engine (Pub. No. 99159-01110-1/). For groups other than those in this Manual, refer to that Service Manual. Major equipment specifications Equipment S4E2(BD2G,BS3G) Injection nozzle Type of nozzle holder ND-DNOSD Type of nozzle tip...
Page 131 FUEL SYSTEM DESCRIPTION ............2. FUEL FILLER ............Disassembly and inspection 3. FUEL INJECTION NOZZLES 3.1 Disassembly 3.2 Inspection and adjustment ..........3.3 Reassembly ............4. FUEL FEED PUMP 4.1 Disassembly 4.2 Inspection and adjustment 5. FUEL INJECTION PUMP 5.1 Disassembly 5.2 Inspection .
Page 132 FUEL SYSTEM DESCRIPTION Fuel filter Fuel injection nozzle Fuel leak-off pipe To fuel tank From fuel tank Fuel injection pump Fuel feed pump 401812 FUEL FILTER Disassembly and inspection Cartridge type paper-element filter ~\;f'------Air vent plug Clacks, damaged threads Apply engine oil when installing.
Page 133 FUEL SYSTEM FUEL INJECTION NOZZLES 3.1 Disassembly ====1--~1 Wear-. dam---'age Carbon deposit, clogged spray hole 401816 ® Q) Retaining nut Spring ® ® Washer Nozzle tip ® Nozzle holder Distance piece ® Pressure pin 3.2 lnspection and adjustment (1) Injection pressure (a) Set up the nozzle on the tester.
Page 134 FUEL SYSTEM .----& WARNING Never expose the hand or other part of the body to fuel spray nor touch the spray hole during the test. (d) If pressure specification, make shim adjustment. . - - - - - - - ( NOTE) - - - - - - - , Increasing decreasing shim...
Page 135 FUEL SYSTEM Wash nozzle clean gasoline. After washing, assemble the needle valve and body in clean diesel fuel. r--~~-.&.[ ~~----, CAUTION ~O:j The needle valve and body are finely finished. change Needle valve Body combination or set of the valve and body.
Page 136 FUEL SYSTEM 3.3 Reassembly 5 ± 0.5 kgf.m ± 4 lbf·ft) - ! - - - - ( 2 [49 ± 5 N·m] 670038 fR~~ssembling sequence...
Page 137 FUEL SYSTEM FUEL FEED PUMP 4.1 Disassembly ", ® © • ® ® 6 ) ' 401543 @ Pushrod (j) Check valve (outlet) Priming pump ® ® ® Hollow screw Check valve spring Piston chamber plug ® ® @ Filter gauze Piston spring Check valve (inlet) ®...
Page 138 FUEL SYSTEM 4.2 Inspection and adjustment Airtightness ~=='~ Immerse the feed pump in a pool of fuel, Air pressure, with its discharge side plugged up. Apply 2 kgf/cm' • an air pressure of 2' kgf/ cm 2 (28 psi) • (28 psi) [0.2 MPa] to its suction to see if any t------i 6l----i...
Page 139 FUEL SYSTEM FUEL INJECTION PUMP 5.1 Disassembly 670191 @ Roller bushing Screw plug @ Delivery valve spring ® @ Shim @ Delivery valve Bearing cover ® @ Lower spring seat Camshaft @ Pump cylinder ® ® ® Plunger Bearing Rack guide screw ®...
Page 140 FUEL SYSTEM (1) To remove camshaft (3), turn the camshaft hand raise each tappet to its top dead center, and insert tappet insert (a) into tappet hole to make each tappet free of cam. To remove tappet insert (a), insert roller clamp (b) through the screw plug hole to pinch the tappet roller give a push to tappet...
Page 141 FUEL SYSTEM 5.2 Inspection Measure the width of plunger flange. If this flange is worn down to exceed the assembly standard, replace the pump element assembly (plunger and . bat'reI). Unit: mOl (in.) Assembly standard lIem 7 -0.05 Widih of pump element plunger flange (0.2756 ;:.0020) Measure...
Page 142 FUEL SYSTEM , - - - - - - - - - - - - - - - Using a spring balance, check the force necessary to set the control rack in sliding motion. Repair or replace the control rack if it offers a resistance requiring a greater force overcome than...
Page 143 FUEL SYSTEM 5.3 Reassembly Tightening torque: 0.5 kgf·m ± (21.7 3.61bf·ft) ± [29.4 4.9 N·m] ± Tightening torque: 6.5 ± 1.0 kgf·m (47.0 ± 7.21bf·ft) [63.7 9.8 N·m] ± 670194 IReassembling sequence...
Page 144 FUEL SYSTEM When installing plunger (14), position it with the stamped figure on its driving face coming on top (cover plate side). reversed, its lead and feed hole are not aligned and it cannot control fuel injection quantity. (2) To install tappet (7), pick up the tappet with tappet clamp (c), feed tappet in to...
Page 145 FUEL SYSTEM (5) Install governor housing temporarily and check the axial play of camshaft by using camshaft clearance gauge (e). Unit: mm (in.) 1 Assembly standard 1 0.Q3 - 0.05 (0.0012 - 0.0020)1 If the play noted is off the assembly standard indicated above, reduce or increase it by shimming: shim stock...
Page 146 FUEL SYSTEM (1) Preparation (a) Attach the rack position measure. Remove from the governor these parts: maximum speed stopper, stop adjusting screw, idling spring, torque spring and adaptor spring. Push in the control rack toward the governor side as far as it will rack position measure at the starting position...
Page 147 FUEL SYSTEM (3) Injection timing adjustment (a) Pre-stroke adjustment Loosen the nozzle holder overflow valve; move the selector lever of tester "injection timing" position; start running high-pressure pump of the tester by engaging the clutch; and, with the tappet clearance measuring device securely installed, turn...
Page 148 FUEL SYSTEM Take the position of No. 1 plunger at its beginning of injection as the reference angular position deg.), and check the angular position at which each of the rest of the plunger begins to inject. Make sure that beginning injection comes within the...
Page 149 FUEL SYSTEM Measurement of injection quantity The injection quantity varies according to the position of the control rack and the pump rpm. The injection quantity should be measured under the condi tions where the pump is set to a certain rpm.
Page 150 FUEL SYSTEM RSV GOVERNOR 6.1 Disassembly 402914 @ Screw plug @ Tension lever Bolt ® @ Lever supporting shaft @ Shackle Adjusting set assembly ® ® Start spring Adjusting lever @ Stop lever ® ® @ Snap ring Round nut Spring cover ®...
Page 151 FUEL SYSTEM Detach the cover by pulling it a little backward. Insert screwdriver, move shackle clasp downward with the tip of screwdriver and undo pinned connection between control rack and shackle (2). 402915 Unhook the start spring (3). Remove the governor cover complete with the lever mechanism.
Page 152 FUEL SYSTEM 6.2 Reassembly 402917 Governor - Sectional view (For the parts not numbered, refer to the disassembled view.) Reassembling sequence...
Page 153 FUEL SYSTEM After positioning the flyweights (5) on (J \ camshaft, secure it by tightening the round nut to the specified torque wi thround nut wrench (A). 5- 6 kgf.m (36 - 43 Ibf·ft) Tightening torque [49-59N·ml (2) Install the control spring with its Install with its opening facing the shackle.
Page 154 FUEL SYSTEM (2) Governor adjustments After checking the governor for the " Medium-speed control range various linkage sliding part 12-7 ~ Anglej~h i?ne~ conditions, make following .spring setting ,1.2 "- adjustments in that order. Angleich o\Jter spring '" ~ting "' "...
Page 155 FUEL SYSTEM Angleich control adjustment For the governor with the adaptor spring, adjust it as follows: (1) Move the adjusting lever to make it bear against maximum-speed stopper, and secure it there, and install the adaptor complete to the lower portion of the tension lever. (2) Raise the pump speed from "Na"...
Page 156 FUEL SYSTEM (2) Lower the speed, and make sure that the control rack is at above "Rg" when pump speed is at "Ng." After completing foregoing adjustments, stop running the pump and turn the adjusting lever all the way in the stopping direction and turn tlie stop adjusting screw until the control rack comes to in.) "position.
Page 157 FUEL SYSTEM FulFload ma·ximum speed same position of the adjusting lever example, where full-load maximum speed is 1300 rpm and no- load maximum speed is 1360 rpm, Speed t'egulation 1360 - 1300 x 100 1300 Generally speaking, the smaller the speed regulation, the better is the engine control;...
Page 158 FUEL SYSTEM .-----.&,.! CAUTION ] - - - - - , Never back away the screw by more than 24 notches (6 rotations), or the threaded engagement of the screw will so small as to invite a hazardous condition. Re-adjustment maximum-speed stopper setting Changing...
Page 159 FUEL SYSTEM MAINTENANCE STANDARDS 7.1 Maintenance standards Repair Service Nominal Assembly standard limit limit Remarks Inspection point Group value [standard clearance] [clearance] [clearance] Make shim adjust- ment. Pressure varies 0-+10 Valve opening by 10 kgf/cm' (142 (0 -+142) (1706) pressure psi) [1.0 MPa] per [0 - +1.0] kgf/cm' (psi) [MPa]...
Page 160 FUEL SYSTEM Repair Service Nominal Assembly standard Group Inspection point limit limit Remarks value [standard clearance] [clearance] [clearance] 150 - 200 Plunger oU· (2133 - 2844) (2133) Pump speed: tightness 200 rpm kgf/cm' (psi) [MPa] 114.7 - 19.6]. 114.7]. 10 kgf/cm' (142 Delivery valve psi) [1.0 MPa] pressure drop should...
Page 161 FUEL SYSTEM Repair Service Assembly standard Nominal limit limit Remarks Group Inspection point [standard clearance value [clearance [clearance Governor: Speed regulation", 5.0 Speed control range: 325 - 1200 rpm Total injection quantity Adjusting Pump speed Control rack position em' (eu in.)/I 000 Item mm (in.) lever angle...
Page 163 ELECTRICAL SYSTEM STARTER .............. 34 1.1 Disassembly ............34 1.2 Inspection and repair ..
Page 164 ELECTRICAL SYSTEM STARTER 1.1 Disassembly Roughness, burning, grooved wear, worn or damaged gear Brush dust buildup, Pole and field coil uneven wear, brush installation movement in holder 670248 (J) Ball bearing Pinion set Switch ® ® ® Pinion shaft Rear bracket Cover set ®...
Page 165 ELECTRICAL SYSTEM 1.2 Inspection and repair (1) Armature (a) Testing armature for short circuits Place the armature on a growler, and slowly revolve it with a hacksaw blade held above the armature core. The hacksaw blade vibrates against the core when it is above a slot containing a shorted winding.
Page 166 ELECTRICAL SYSTEM ,------------------------------, 3) Measure the depth of each mica between segments with a depth gauge. the depth exceeds the Repair limit, recondition the mica. ~ent Unit: nun (in.) Reapir limit Mica depth Good Item 0.2 (0.008), maximum Commutator mica depth 401828 (2) Field coil (a) Testing for open circuits...
Page 167 ELECTRICAL SYSTEM (b) Brush spring tension Test the spring tension (test force) using a new brush. In this test, read the load at the moment that the spring moves off the brush. If the tension is below the Service limit, replace the spring.
Page 168 ELECTRICAL SYSTEM (5) Pinion thrust gap Center bracket The pinion shaft thrust gap is the play exhibited by the pinion shaft when it is moved in the thrust direction. Measure Thrust gap the thrust gap in the following manner. it is out of specification, select the Stop ring adjusting washer and adjust the gap.
Page 169 ELECTRICAL SYSTEM 1.3 Reassembly ,-------------------~----------------------------------------~-. Apply grease to sliding surface of lever. Apply grease. Replace packing. .670044 Reassembling sequence...
Page 170 ELECTRICAL SYSTEM Inspection and testing after reassembly Pinion gap adjustment (a) If the assembled starter is wired as shown, the pinion will shift and ~<"'le!f!!'l--' S terminal turn slowly. Remove the connector from the M terminal to stop the Battery pinion.
Page 171 ELECTRICAL SYSTEM (3) Magnetic switch (a) Testing coil for open circuits B leonina! there is no continuity between S M terminals between terminal and body (ground), replace the switch. (b) lnspecting contactors for fusion there is continuity between Band 401837 - - - - - - - - - ' M terminals, replace the switch.
Page 172 ELECTRICAL SYSTEM ALTERNATOR 2.1 Disassembly .® rotation Bearing Bearing rotation ® Dirty or burned slip rings, worn oil seal contact surface of shaft. Brush movement 670213 ® (jJ) Brush holder set Bearing Screw @ Rectifier assembly Screw ®Nut ® ® @ Plate Pulley (wi th fan) Bearing...
Page 173 ELECTRICAL SYSTEM Field coil Measure the resistance between the slip rings. resistance specification, replace the rotor. (3) Stator coil Inspect for continuity between the lead wires. If no continuity is noted, the coil is open-circuited. Also check for l<~ad continuity between the wire and coil.
Page 174 ELECTRICAL SYSTEM 2.3 Reassembly 670054 Reassembling sequence rrnt: j:'® ® @-+@ Brush I I I I III® lli~~ Wire CD®®@ @(l)@ @l Push the brush into the holder, and hold l-... it there by inserting a 2 mm (0.08 in.) Rotor ,...- diameter wire into the hole in the brush.
Page 175 ELECTRICAL SYSTEM MAINTENANCE STANDARDS 4.1 Maintenance standards Repair Service Nominal Assembly standard Group Inspection point limit limit Remarks value [standard clearance] [clearance] [clearance] Diameter of (1.26) (1.22) commutator Length (0.43) (0.71) -" " Spring pressure (7.7) (5.1) " ' " kgf(lbf) [N] [34.3] [22.6]...
Page 177 BD2G, BS3G WilliNG DIAGRAM Stater switch connection Fuse Combination meter {OK monitor} G, 8 GJA S mer element warning Engine oil pressure warning lamp lamp OK monitor Glow plug HEAT Lighting switch II III test switch ,Alternator not charging Battery electrolyte level "...
Page 178 DEC. '86 99879-00120- Pub. No. Printed in Japan...
Page 179 SERVICE MANUAL MITSUBISHI . TRACTOR·· ··BD2Gi········ . . · · · · · · · · · · · · · · · · · · · · SHOVEL TRACTOR HSaG CONTENTS POWER TRAIN/HYDRAULIC SYSTEM MAINTENANCE STANDARDS...
Page 181 Cylinders ........" ..'" Lift cylinders (BD2G with power angling/tilt blade and power tilt blade) ......... .. 25 Angling cylinders (BD2G with power angling/tilt blade) ..
Page 183 FLYWHEEL CLUTCH Unit· mm (in ) Group Ref. Item Assembly standard Service limit Remarks One side: -0.4 (-0.016) 5.7 - 6.3 tbickness~ Facing ..(0.224::=- 0.248) Botb sides:-O.& Clutch discs . (-0.031) ,':: 0.7(O.028~,.max. Run;;tit 0.7 (0.028), min . :."::. 26·.6i-26.70 .
Page 184 FLYWHEEL CLUTCH 602165 602279...
Page 185 DIRECT DRIVE TRANSMISSION Unit: mm (in) Group Ref. Item Assembly standard Service limit Remarks Bacl>liish ,\lith 0.12 - 0.28 0.60 st·revers~ gear (0,004? - 0.0110) (0.0236) 0..J2~ 0.28 0.60 - (0.0047 - 0.0110) (0-0236) _ . 0.12 -0.28 0.60 2nd-reverse gear ' .
Page 186 DIRECT DRIVE TRANSMISSION 60Z242 602167 602243...
Page 187 BRAKE Unit: mm (in.) Ref. Item Assembly standard Group Remarks Service limit Outside diameter 252 (9.92) 250 (9.84) Drum Clearance in linings 0.8 (0.031) "" Thickness 6.5 (0.256) 4.5 (0.177) Linings 602244...
Page 188 STEERING CLUTCHES AND FINAL DRIVES Unit· mm (in ) Ref. Item Assembly standard Remarks Group Service limit No .. 0.50 0.15 - 0.20 Backlash with pinion' Bevel gear (0.0197) (0.0059 - 0.0079) Tapered roller Preload (bevel gear) 0.7-0.9 (5.1-6.5) beariilgs kgf·m (Ibf·ft) [N·m) [6.9 - 8.8) Free length...
Page 189 STEERING CLUTCHES AND FINAL DRIVES 602177...
Page 190 STEERING VALVE Unit· mm (in ) Ref. Item Assembly standard Group Service limit Remarks Free length 66 (2.60) Test force/length under 9.8 ±l (21.6 ±2.2) Valve springs test force [96.1 ± 9.8J/56 (2.20) . kgf (Ibl) [Nl/mni (in.) Free length 36.5 (1:44) "...
Page 191 FRAME ..---_ I)lt: ml)1 ..__ . Ref. Item Assembly standard Service limit Remarks Group Steering clutch 26 ±2 case/frame/rigid Tightening torque (188 ± 14) bar mounting kgf·m (lbf.ft) [N·m) [255 ± 20) bolts Upper: 1.2 - 2.2 Engine front (0.047 - 0.087) mount/flywheel Bracket-to-stopper...
Page 192 FRONT IDLERS Unit· mm (in ) Ref. Assembly standard Service limit Group Item Remarks 448 (17.64) Diameter Repair limit: 420 (16.54) . Diameter 411 (16.18) 413 (l6.26) Idlers 42 (1.65) Width 35 (1.38) 0.20 -0.25 1.40 Axial play (0.0079 - 0.0098) (0.0551) 0.155 - 0.235 1.000...
Page 193 HYDRAULIC ADJUSTER CYLINDERS AND RECOIL SPRINGS Unit· mm (in.) Group Ref. Item Assembly standard Remarks Service limit 381.5 (15.020) Free length 2610 ± 210 2300 (5072) Test force/length under Recoil springs (5755 ± 463) test force [22.6) / '" [25.6 ±2.I)/ '"...
Page 194 TRACK CARRIER ROLlERS Unit: mm (in.) Ref. Item Assembly standard Remarks Group No. Service limit 140 (5.51) 118 (4.65) Diameter r----- Repair limit: 120 (4.72) 98 (3.86) Diameter . . 104 (4.Q9) Rollers Width 30 (1.18) 35 (1.38) ::ll Axial play (0.039) .
Page 195 TRACK ROLLER'S ·Unit: mm (in.) Ref. Assembly standard Remarks Group Item Service limit Diameter 164 (6.46) 152 (5.98) Repair limit: Diameter 128 (5.04) 140 (5.51) 132 (5.20) r-;- Rollers Flange width 9 (0.35) 4 (0.16) 0.30 - 0.90 1.40 Axial play (0.0118 - 0.0354) (0.0551) 0.20...
Page 196 540 (21.3) (for 4 links) ing: 552 (2U3) 0.450 - 0.734 Track pins Fit in bushings (0.01772 - 0.02890) (0.098) Standard models 38.5 (1.516)(BD2G) II (0.43) Standard models 30 (1.18) (BS3G) 10 (0.39) Repair limit: Grouser Swamp models , 67.5 (2.657) 55.5 (2.185)
Page 197 TRACKS 602253 Standard model track Swamp model/super-swamp model/ultra super-swamp model track...
Page 198 HYDRALJLlC PUMP Unit· mm Group Ref. Item Assembly standard Remarks Service limit 2400 Delivery pressure Pump 180 (2560) [17.7) '" kg/eI11'(psi) .IMPa) § performance '" Capacity 54 (3295) " liter (eu in.)/min 4.7 - 5.0 Tightening torque &' Through bolts 36.2~ (34.0 - .kgf·m (lbFft) [N·m)
Page 199 CPNTROL VALVE Unit: mm (in.) Ref. Item Group Assembly standard Service limit Remarks Pressure tha~ ~~kes 180±3 relief valve Ilpen (2560 ± 43) " kgf/cm' (psi) [MPaJ [17.7 ± 0:3]' Main relief Flow rate 50± 2 valve liter (cu in.)/min. (3051 122) IO±...
Page 200 CONTROL VALVE Unit· mm (in) Group Ref. Item Assembly standard Service limit Remarks Plunger plug & 2.0 ±0.2 Tigbtening torque (14.5 ±1.4~ plunger detent " kgf·m (lbf.ft) [N.m] [19.6 ± 2.0 plug Seal cover 1.1 ± Tigbtening torque '" plates & cap (8.0 ±...
Page 201 CONTROL VALVE Unit· mm {in ) Ref. Group Item Assembly standard Service limit Remarks Pressure that makes 180 + 3 relief valve open (2560 ± kgf/cm (psi)[MPa] [17.6 ± 0.3] ± Flow rate Main relief (3051 + 122) liter (cu in.)/min valve 010+ I Valve tightening torque...
Page 202 CONTROL VALVE Unit· mm (in.) Ref. Group Item Assembly standard Service limit Remarks 3.5 + 0.4 2.9i Check valve Tightening torque (25.3 ± kgf·m (lbf.ft)[N·mJ plugs [34.3 + 3.9 5.0 + 0.5 Tightening torque Makeup valve (36.2 ± 3.6) kgf·m (lbf·ft)[N·m] [49.0 + 4.9] '4i' 2.0+ 0.2...
Page 203 CONTROL VAlVE ·602206 602208 602207...
Page 204 CONTROL VALVE Unit: (in.) Ref. Item Assembly standard Remarks Service limit Group Pressure that makes (2275 ± 43) relief valve open [15.7 0.3] kgf/cm' (psi)[MPa] 50 ±2 Main relief Flow rate. (3051 122) liter (cu in.)/min valve 10 ± I Valve tightening torque ~72 ±...
Page 205 cCONTROL VALVE Unit: mm (in.) Ref. Group Item Assembly standard Service limit Remarks Free length 39.5 (1.56) 20.8 Safety valve Test force/length under ± (45.9 3.3) springs test force ± [204.0 14.7J/ kgf (lbf)[N]/mm (in.) 34 (1.34) ± Check valve Tightening torque ±...
Page 206 CONTROL VALVE ' 1 ' 602214 602215 602199...
Page 207 CYLINDERS Unit· mm (in ) ..Ref. Item Group Assembly standard , Service limit Remarks. Fit of cylinder on Cylinder and 0.350 piston piston (0.01378) -;;- -'" Fit of guide bushing on 0.Q75.- 0.139 0.350 Guide bushing piston rod . _ (0.00295 - 0.00547) (0.01378) ".0...
Page 208 CYLINDERS Unit: mm (in.) Group Ref. Item Assembly standard Service limit Remarks Cylinder and Fit of cylinder on 0.350 " piston (0.01378) piston "" om5 - Fit of guide bushing 0.139 0.350 Guide bushing on piston rod (0.00295 - 0.00547) (0.01378) 50.0 ±...
Page 209 CYLINDERS Unit: (in.) Ref. Item Assembly standard Service limit Remarks Group Cylinder and Fit of cylinder on 0.350 -;;- piston piston (0.01378) Fit of gUide bushing 0.075 - .0.139 0.350 Guide bushing on piston rod (0.00295 - 0.00547) (0.01378) '" 70.0 ±...
Page 210 CYLINDERS Unit" mm (in) Ref, Assembly standard Remarks Group Item Service limit 0.350 Cylinder and Fit of cylinder on (0.01378) piston piston 0.075 ...: 0.1 39 " Fit of guide bushing 0.350 Guide bushing on piston rod (0.00295 - 0.00547) (0.01378) 50.0.±...
Page 211 CYLlNQERS Unit: mm (in) Ref. Assembly standard Service limit Group Item Remarks Cylinder and Fit of guide busbing 0.350 on piston (0.01378) piston Fit of guide bushing 0.075 - 0.139 0.350 Guide busbing (0.00295 - 0.00547) (0.01378) on piston rod (,!) '"...
Page 212 CYLINDERS Unit: mm (in) Group Ref. Assembly standard Item Service limit Remarks Cylinder and Fit of cylinder on 0.350 (0.01378) piston piston 0.075 - 0.139 0.350 Fit of guide bushing Guide bushing (0.00295 - 0.00547) (0.01378) on piston rod " '"...
Page 213 POWER ANGLINGITILT BLADE (BD2G) Unit: mm (in.) Ref. Item Remarks Assembly standard Service limit Group Distance from center " Cutting edges/ of bolt hole to edge 75 (2.95) 45 (1.77) end bits tip/bit tip 6.5 ± 0.7 Cutting edge Tightening torque mounting plow (47.0 ±...
Page 214 POWER TILT BLADE (BD2G) Unit: mm (in.) Ref. -item Assembly standard Remarks Group Service limit Distance from center Cutting edges/ of bolt hole to edge 75 (2.95) 45 (1.77) end bits tip/bit tip " 6.5 ± 0.7 Cutting edge Tightening torque ""...
Page 215 BUCKET AND LINKAGE (BS3G) Unit: mm (in.) Ref. Assembly standard Service limit Remarks Item Group 160 (6.30) 100 (3.94) Length 29 -32 Tightening torque for Tooth securing bolts (210 - 2311 [284 - 314 kgf·m {lbf.ft)[N·m] '" 120 (4.72) 159 (6.26) Cutting edges Width "...
Page 216 TIGHTENING TORQUE FOR STANDARD BOLTS TIGiUEf.UNG TORQUE FOR STANDARD BOLTS Unit: kgt·m . With spring washer Without spring washer Nominal Remarks: Pitch size @IDW @lw @JOOil @Iw. (mm) I.· This chart gives the (mm) torques for standard . bolts and nuts. 0.75 0.98 0.88...
Page 218 DEC. 86 99879-00120- Pub. No. Printed in Japan...
Page 219 SERVICE MANUAL MITSUBISHI TRACTOR·· TRACTOR SHOVEL BS3G (DIRECT DRIVE MODEL) CONTENTS POWER TRAIN • OPERATING PRINCIPLE • TESTING AND ADJUSTMENTS...
Page 221 FOREWORD This service manual has instructions and procedures for the subject on the front cover. The information, specifications, and illustrations used in this manual are based on information that was current at the time this issue was written. Correct servICing will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.
Page 222 ;;',...
Page 223 TABLE OF CONTENTS OPERATING PRINCIPLE General description Flywheel clutch Clutch oil line Direct-drive (DD) transmission Transmission control ........Steering clutches, brakes and final drives .
Page 225 OPERATING PRINCIPLE.
Page 226 OPERATING PRINCIPLE GENERAL DESCRIPTION Direct-drive (DO) model 602163 <I I> 602164 5 Bevel gear dri ve 1 Engine 2 Flywheel clutch 6 Steering clutch 3 Universal joint 7 Final drive 4 Transmission Major components of this power train are, by a total of four mounts fitted with from engine "I"...
Page 227 '" "0. " " '. .1' '" " «...
Page 229 OPERATING PRINCIPLE FLYWHEEL CLUTCH 602165 1 Flywheel Release lever Oil pump 2 Clutch disc 7 Release hub 12 Oil strainer Ma ting plate Release spring 13 Clutch brake 4 Pressure plate 9 Fork 10 Main shaft 5 Clutch cover This flywheel clutch grabbing...
Page 230 OPERATING PRINCIPLE CLUTCH OIL LINE 602166 1 Oil strainer 4 Oil eooler 2 Gear pump 5 Clutch main shaft 3 Relief valve 6 To and from steering valve This oil Jineis for actuating the steering valve and for cooling and lubricating the clutch discs and related parts.
Page 231 OPERATING PRINCIPLE DIRECT-DRIVE (DO) TRANSMISSION. 602167 602168 1 Input shaft 7 1st-speed drive gear 21st-speed reverse gear 8 1st-speed sliding gear 3 2nd-speed reverse gear 9 2nd-speed sliding gear 4 Input gear 10 Counter gear 11 3rd-speed sliding gear 5 2nd-speed drive gear 6 Coun tershaft 12 Bevel pinion shaft This...
Page 232 OPERATING PRINCIPLE Power flow transmission Reverse 1st-speed position Forward 1st-speed position Counlershaft 6 lIt. .:0·- 1 sl -speed drive gear 7 lsi-speed slidinXf Bevel pinion gearS shaft 12 £ L -_ _ _ - - ' 602169 602172 Forward 2nd-speed position Rev",,rse 2nd-speed, posi tion ..
Page 233 OPERATING PRINCIPLE TRANSMISSION CONTROL 602174 • 602175 602176 5 2nd-speed sliding gear 9 3rd-speed shift rail 1 1st-speed shift fork 10 Steel (detent) ball 6 3rd-speed sliding gear 2 2nd-speed shift fork 7 1st-speed shift rail 3 3rd-speed shift fork 8 2nd-speed shift rail 41st-speed sliding gear When the gearshift lever is moved into...
Page 234 OPERATING PRINCIPLE STEERING CLUTCHES, BRAKES AND FINAL DRIVES 602177 7 Disc plate 13 Shaft 1 Bevel pinion 2 Bevel gear 8 Friction plate 14 Floating seal 3 Dri ve shaft 9 Outer drum 15 Sprocket 4 Bearing cage 10 Pressure plate 16 Track 5 Steering clutch cylinder 11 Final drive pinion...
Page 235 OPERATING"PRINCIPLE STEERING CLUTCH AND BRAKE CONTROLS 602178 Steering clutch in Steering clutch in disengaged position engaged position 602179 602180 1 Steering clutch lever Friction plate 2 Steering valve Brake band 3 Steering clutch" cylinder Outer drum Pressure plate Brake pedal Disc plate 10 Ratchet (brake lock) "I"...
Page 236 OPERATING PRINCIPLE Steering clutch control hydraulic circuit 602181 602182 4 Oil cooler hose 6 Oil pump 1 Relief valve 5 Steering clutch lever 7 Steering clutch 2 Steering valve 3 Steering clutch cylinder...
Page 237 OPERATING PRINCIPLE UNDERCARRIAGE Tracks Wear strips "7" welded bearings; they can be replaced when they The track consists of shoes, pins, links are worn down to the limit. and bushings. Each link "8" overlaps the preceding link, thus forming a continuous The whole idler assembly is capable of or endless chain.
Page 239 OPERATING PRINCIPLE Tracks Carrier roller Standard type n - - - l l 0·...--.--11 6021 1 Cover 5 Shaft 1 Master 5 Seal washer Standard shoe Washer 6' Floating seal 2 Spacer 6 Pin 10 Master seal ..Roller 7 Seal support 3 Master pushing 7 Bushing 11 Seal...
Page 241 TESTING ADJUSTMENT...
Page 242 TESTING AND ADJUSTMENT ADJUSTING THE STEERING CLUTCHES AND BRAKES (B) Adjusting the clearance between brake 20 to 22 6.5 to 7.5 band and outer drum (2-9/16 2-15/i6) (7-7/8 to Screw adjusting nut "6" all the way. 8-11/1J 2, Flack off the nut 2-2/3 rotations. Unit: em (in.) (C) Adjusting stroke...
Page 243 TESTING AND ADJUSTMENT ADJUSTING THE BRAKE PEDAL ADJUSTING THE CLUTCH PEDAL Unit: em (in.) Unit: em (in.) 20 (7-7/8) 1.5(9/16) 5---1 602194 602193 [NOTE] "1." 1. Loosen lock nut Set the released position of the pedal There is no need of adjusting the "2"...
Page 244 TESTING AND ADJUSTMENT ADJUSTING THE CLUTCH BRAKE • To loosen: 1. Remove the cover, and gradually turn fill valve counterclockwise "1" allow grease to escape from vent hole tl2.1f 2. If grease does not appear at the vent hole, loosen the fill .valve until it is limited by the stopper.
Page 245 TESTING AND ADJUSTMENT TROUBLESHOOTING GUIDE Flywheel clutch Complaint Possible cause Remedy Remarks (I) No pedal free play • Clutch slips Adjust. (2) Worn down clutch facings • Replace. • (3) Clutch facings burnt, resulting Replace. in reduced coefficient of friction (4) Dirty friction surfaces of •...
Page 246 TESTING AND ADJUSTMENT Transmission Possible cause Remedy Complaint Remarks • Incomplete meshing action Disassemble and Gears slip out of mesh due to improperly assembled repair or replace. shift control mechanism • Inner end of shift lever worn Repair or replace. down or loose •...
Page 247 TESTING AND ADJUSTMENT Bevel gear Remedy Remarks Possible cause Complaint • Add or change. Excessive gea"r noise Gear oil wanting or dirty • • Noise on turning to (2) Too much backlash Adjust. one side means some rattling condition due to worn splines, loose bearings or excessive backlash.
Page 248 TESTING AND ADJUSTMENT Steering clutches and brakes Complillnt Possible cause Remedy Rem~rks (I) Control linkage out of adjust- • Clutch slips (overheats) Adjust. • Check 'ever free play. ment • (2) Dnings dirty • Wash with gasoline, Investigate to locate or replace the disc a point through which plates.
Page 249 TESTING AND ADJUSTMENT Complaint Possible cause Remedy Remarks Not enough braking force Brake out of adjustment • Adjust. • Brake lining dirty • Clean by washing. Be aware of possi- bility of oil leaking in from final drive case and bevel gear case.
Page 250 TESTING AND ADJUSTMEN'T Steering clutch cylinder Complaint Possible cause Remedy Remarks (1) Oil leaks inside cylinder • Repair or replace. Clutch drags or grabs • (2) Valve (plunger) and bore worn Repair or replace. (3) Relief valve out of adjustment •...
Page 251 TESTING AND ADJUSTMENT Remarks Remedy Possible cause Complaint • • Damaged bearings (I) Worn or damaged bearings Replace. Sprocket rattles escape notice because their effects usually show up when mao chine is running. If the sprocket is suspected to rattle, check its bearings immediately.
Page 252 TESTING AND ADJUSTMENT Undercarriage Possible cause Remedy Remarks Complaint (I) Improper installation or mis- • Check position of • Front idlers, track rollers So that track chain will alignment each and set it and carrier rollers wear move straight, correctly. front idler and other abnormally rollers must be lined...
Page 253 TESTING AND ADJUSTMENT Possible cause Complaint Remedy Remarks (3) Interference between track • Adjust axial play of • Interference is likely roller and track frame, or to occur when bushing shaft, or remove foreign matter lodged foreign matter. end faces are worn, . between the two resulting in excessive axial play of shaft.
Page 254 TESTING AND--ADJUSTMENT Possible cause Remedy Remarks Complaint (I) Track tension not enough • Adjust. Track chain tends to get off idler and rollers (2) Froni idler mispositioned • Relocate idler to correct position. (3) Recoil spring insufficiently • Adjust or replace. preloaded or broken (4) Roller flanges worn •...
Page 256 DEC.a6 99879-00120- Pub. No. Printed in Japan...
Page 257 SERVICE MANUAL MITSUBISHI TRACTOR·· BD20·· . TRACTOR SHOVEL BS3G CONTENTS DIRECT POWERSHIFTTRANSMISSION • OPERATING PRINCIPLE • TESTING AND ADJUSTMENTS • MAINTENANCE STANDARDS • DISASSEMBLY AND REASEMBLY...
Page 259 FOREWORD This service manual has instructions and procedures for the subject on the front cover. The information, specifications, and illustrations used in this manual are based on information that was current at the time this issue was written. Correct servicing will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.
Page 261 TABLE OF CONTENTS OPERATING PRINCIPLE General description Power train Damper DPS transmission Description Hydraulic control circuit ........Transmission control valve .
Page 263 OPERATING PRINCIPLE...
Page 264 OPERATI NG. PR iNCIPLE GENERAL DESCRIPTION POWER TRAIN 602306 602307 1 Engine 7 Steering clutch 8 Final drive gear 2 Damper 3 Universal joint 9 Track 10 Hydraulic pump 4 Transmission 11 Transmission oil pump 5 Transfer 6 Bevel gear Power train...
Page 265 OPERATING PRINCIPLE power train of direct powershift model consists of, from engine "I" to track "9," damper "2," universal joint "3," transmission "4," transfer "5," bevel gear "6," steering clutch "7" and final drive "8." gear Power developed engine transmitted through damper and universal joint to the transmission.
Page 267 OPERATING PRINCIPLE POWER TRAIN Universaljolnt 3 Engine 1 Transmission 4 Damper 2 clutch 7 Transmission oil pump 1] Final drive 8 602308 j)\";~d' T"'O"'\4".f'~1\,...
Page 269 OPERATING PRINCIPLE DAMPER - - - 3 '002309 1 Coil spring 3 Flywheel 2 Friction plate Damper The damper consists essentially of six coil springs "1" and two friction plates "2." Its hub is splined to the shaft and one of friction plates bolted...
Page 270 OPERATING PRINCIPLE DPS TRANSMISSION Description ~'---17 602310 1 Reverse clutch 8 Sun gear 15 Friction plate 9 Planet gear 2 Forward clutch 16 Return spring 3 3rd-speed clutch 10 Ring gear 17 Bevel pinion 11 Carrier 4 2nd-speed clutch 18 Gear pump 51st-speed clutch 12 Piston housing 19 Oil filter...
Page 271 OPERATING PRINCIPLE 602311 8 Sun gear 1 Reverse clutch 15 Friction plate Planet gear 16 Return spring 2 Forward clutch 10 Ring gear 17 Bevel pinion 3 3rd-speed clutch Carrier 4 2nd-speed clutch 18 Gear pump 12 Piston housing 19 Oil filter 51st-speed clutch 13 Piston 6 Input shaft...
Page 272 OPERATING PRINCIPLE Let us see the paths of power flow in transmission forwrd 1st speed Forward 2nd position and in reverse position. speed position Friction plates "15" are engaged with the external splines of ring gear "10" and mating plates "14"...
Page 273 OPERATING PRINCIPLE Hydraulic control circuit 602318 1 Suction strainer (with magnet) 10 Main relief pressure test port ("M") 2 Oil pump 11 Speed clutch pressure test port (liS 12 Directional clutch pressure test 139.3 liters (10.4 U.S. gaO/min at 2400 rpm! port (liD 3 Main relief valve 13 Oil cooler...
Page 274 OPERATING PRINCIPLE hydraulic control circuit consists The oil in the oil sump is lifted by oil essentially of suction strainer "I," oil pump "2" through suction strainer "1." Oil pump "2," main relief valve "3," oil cooler from the pump flows into two circuits, one leading to the steering valve for "13,"...
Page 275 OPERATING PRINCIPLE Transmission control valve o Description 602320 5 Inching valve 1 Main relief valve .6 Differential valve 2 Accumulator valve 7 Neutral switch 3 Speed selector valve 4 Directional selector valve piston chamber reverse clutch This control valve comprises accumulator piston chamber.
Page 276 OPERATING PRINCIPLE o Operation Speed selector valve "3" is neutral position, covering the port leading to the control valve operation will 1st-speed clutch piston chamber. As the described the assumption that the pressure rises cham ber "4," transmission control lever is moved from accumulator valve "1"...
Page 277 OPERATING PRINCIPLE [FORWARD 1ST SPEED position] The moment the oil in accumulator valve pressure cham ber "4" enters the 1st-speed Pre filling of 1st-speed clutch piston clutch piston chamber prefilling, chamber accumulator valve "1" returns to the right end to. uncover main port "2." Now, a When the transmission control lever is circuit bypassing...
Page 278 OPERATING PRINCIPLE 2. Pre filling of forward clutch piston chamber Upon completion prefilling 1st-speed clutch piston chamber, speed clutch pressure rises beyond kgf/cm 2 (28.4 psi) [0.20 MPa]. This pressure moves differential valve "7" to the left end, allowing the speed clutch pressure enter forward...
Page 279 OPERATING PRINCIPLE 3. Modulation action Since the speed clutch pressure is always higher than directional clutch Upon prefiJIing the forward clutch piston pressure, 1st-speed clutch forward clutch engaged in· that chamber, differential valve "7" is returned to its pressure regulating position for sequence.
Page 280 OPERATING PRINCIPLE 4. Completion of shifting In the operation for shifting into other speeds, too, differential valve "7" is returned to the right end of its stroke When accumulator valve "I" comes to the draining directional . clutch left end of its stroke, bypass orifice "9" pressure, because speed...
Page 281 OPERATING PRINCIPLE 5. Inching action inching valve regulates directional clutch pressure for driving the machine inching manner extremely slowly. Inching valve plunger "I" is connected to the inching pedal (left pedal) through rod. long inching pedal released position, plunger "I" is kept pushed to the left end of its stroke by return spring "2."...
Page 282 OPERATING PRINCIPLE draining oil from passage "4" to the oil As the inching pedal is depressed, plunger "1" is moved to the right. When it is sump through passage "8" to reduce the moved 4 mm (0.16 in.), valve "5" meters directional clutch secondary...
Page 283 OPERATING PRINCIPLE When· the inching pedal is depressed all In summary, the inching pedal may be the way and plunger "1" is moved 16.5 used like the clutch pedal of a direct- (0.65 in.) of its stroke, pressure drive model. The machine can be started regulating spring "6"...
Page 285 TESTING ADJUSTMENT...
Page 286 TESTING AND ADJUSTMENT DPS TRANSMISSION Inspection the engine stalls as soon as the transmission control lever is shifted, A good program of diagnosing and testing all clutches are not slipping. has three basic steps. does stall more than seconds, or if it does not stall at all, Asking the operator ;any: clutches...
Page 287 TESTING AND ADJUSTMENT Trouble diagnosis by oil pressure readings If transmission shifts hard: Remedy Complaint Possible cause (I) Clutch piston sealing ruptured • Disassemble and replace. No shift to some speeds. • (2) Control valve gasket ruptured Disassemble and replace. "M"...
Page 288 TESTING AND ADJUSTMENT 2. If shock is felt when shifted: Complaint Possible cause Remedy Indicating hand of pressure gauge - Accumulator valve sticking Wash valve body, check bore for .' jumps momentarily from 0 to 21 damage and, as necessary, replace kgf/cm' (299 psi) [2.06 MPa] valve and bore, if valve does not on shifting"...
Page 289 TESTING AND ADJUSTMENT inching pedal malfunctions: Complaint Possible cause Remedy Clutch grabs even if inching Clutch plates in forward or reverse Disassemble and replace. pedal is depressed. clutch seized "M," US" and uDI> port pressures: Nonnal (l) Control linkage maladjusted •...
Page 290 TESTING AND ADJUSTMENT transmission overheats: Complaint Possible cause Remedy "M,I) "D" and uS"'port pressures (I) Oil level too high • Lower oilleve!. are normal or slightly lower. (2) Oil level too low • Raise oilleve!. • "M," "D" and port pressures (1) Clutch plates seized Disassemble and replace.
Page 291 TESTING AND ADJUSTMeNT Testing the control valve Connect an oil pressure gauge to each of "JIll," "S" and "D" ports in testing the hydraulic pressures with the control valve mounted transmission. When running the transmission and control valve on the bench in order to break them in, be sure to form an oil cooler bypassing circuit by connecting two rubber hoses, one leading to the cooler inlet and the...
Page 292 TESTING AND ADJUSTMENT Port and gauge connection Pressure requirement Pressure designation M port; PF 1/8" connection with Main pressure With engine running at high idling speed and O·ring contro11ever kept in neutral, this pressure is required to take the following value: 21 kgf/cm (299 psi)[2.06 MPa] If not, adjust setting of main relief valve by...
Page 293 TESTING AND ADJUSTMENT ADJUSTING THE TRANSMISSION ADJUSTING THE INCHING PEDAL CONTROL LEVER 6 .7 602331 1. Loosen lock nut "1." 2. Reposition stopper bolt "2" so that the inching pedal is 20 cm (7-7/8 in.) as measured from the dashboard wall. 3.
Page 294 TESTING AND ADJUSTMENT TROUBLESHOOTING GUIDE Transmission Complaint Possible cause Remedy Machine does not move in one or A. Low oil pressure more speeds or all clutches slip. • Not enough oil RefIll. • Loose, broken or maladjusted Repair or readjust. control linkage •...
Page 295 TESTING AND ADJUSTMENT Complaint Possible cause Remedy • Not enough output. Engine not delivering enough power Re-tune engine. Not enough oil • Refill. • Air being sucked into oil pump Check jOint and replace pack- ing as necessary. • Sticking or bound spool in main Disassemble and repair or relief valve replace.
Page 296 TESTING AND ADJUSTMENT Possible cause Remedy Complaint • Main pressure is too high. Main relief valve maladjusted Overhaul and adjust. • Internal oil passage in main relief Overhaul and clean. (Tltis is not a symptom; it is valve clogged a finding obtained by checking with pressure gauge.) •...
Page 297 TESTING AND ADJUSTMENT Transfer Complaint Possible cause Remedy Remarks Machine does not move Machanieal trouble inside transfer Repair or replace. in any speed Machine does not move One or more gears damaged Replace. in one or more speeds, forward or backward. (1) Not enough oil Noisy operation Add oil.
Page 299 MAINTENANCE STANDARDS...
Page 300 MAINTENANCE STANDARDS DPS TRANSMISSION Unit: mm (in) Ref. Assembly standard Service Item Remarks (Standard clearance) limit ~~---------r~~.~~---~~~ Total thickness (new parts) Reverse Friction plates (4 pcs) 27.70 ± 0.80 26.10 Mating plates (4 pcs) (1.0905 ± 0.0315) (1.0276) clutch Pressure plate (I pc) Total thickness (neiv parts)- Forward and Friction plates (3 pes)
Page 301 MAINTENANCE STANDARDS 602311 602333...
Page 302 MAINTENANCE STANDARDS TRANSMISSION CONTROL VALVE Unit: mm (in. Ref. Assembly standard Servke Item Remarks (Standard clearance) limit Free length 82.5 (3.248) Diameter: Main relief valve Test force/length under 7.6 ± 0.5 13.3 (0.524) spring (inner) test force (16.8 ± 1.1)/(2 1(5) kgf (Ibf) [N] /mm (in.) [74.5 + 4.9] Free length...
Page 303 MAINTENANCE STANDARDS 602320...
Page 305 DISASSEMBLY REASSEMBLY...
Page 306 DISASSEMBLY AND REASSEMBLY DPS TRANSMISSION REMOVAL AND INSTALLATION Removal Preparatory steps Remove the under guard. (2) Drain the oil from the transmission. [11 liters (2.9 U.S. gal), approx.] (3) Drain the oil from the transfer arid bevel ger cases. [7 liters (1.8 U.S. gal), approx.] 1.
Page 307 DISASSEMBLY AND REASSEMBLY 4 Opera tor's seat and sea t plate 5 Rear cover 31 kg (68Ib), Weight of operator's seat and approx. seat plate 602336 6 Steering clutch levers 7 Steering control rods 8 Brake control rods 9 Steering clutch oil pipes (2 pcs) 10 Oil cooler pipe 11 Oil cooler hose 12 Springs (2 pcs)
Page 308 DISASSEMBLY AND REASSEMBl 2. Disconnect the following parts: 15 Inching valve link 16 Speed selector valve and directional selector valve links 602339 3. Remove the following parts: 17 Universal joint 18 Transmission 182 kg (400 Ib). Weight of transmission approx. and transfer [NOTE) Before lifting off the transmission,...
Page 309 DISASSEMBLY AND REASSEMBLY DISASSEMBLY AND REASSEMBLY Disassembly Preparatory steps (1) Remove the transfer assembly. (2) Remove the oil filter. (3) Remove the transmission control valve and main relief valve. (4) Remove the oil pump and oil pipe. (5) Remove the suction strainer. (6) Remove the air breather, oil filler and oil level gauge.
Page 310 DISASSEMBLY AND REASSEMBLY A Transmission case and flange group t--4. Remove the following parts: Lock washer (to be straightened for removal) Washer 3 Bolt (1 pc) 4 Oil filter screw 5 Oil pipe (4 pes) 6 Transmission case 602343 [NOTEl remove transmission case...
Page 311 DISASSEMBLY AND REASSEMBLY B Reverse clutch group 602346 16 Ball bearing Pump drive gear 17 Ring gear 2 Lubrication relief valve 3 Bolt (8 pes) 18 Reverse planet carrier 4 Snap ring (to be ·removed as an assembly including 5 Snap ring "19"...
Page 312 DISASSEMBLY AND REASSEMBLY C Forward clutch group and 3rd-speed clutch group 31 33 602347 1· Needle roller bearing 20 Thrust plates (6 pes) 2 Mating plates (3 pes) 21 Needle roller bearing (3 pes) 3 Friction plates (3 pes) 22 Forward &...
Page 313 DISASSEMBLY AND REASSEMBLY D 2nd-speed clutch group 602348 1 2nd-speed clutch piston housing (to be removed as an assembly including "2" thru "4") 2 Piston 3 Piston seal 4 Piston seal 5 Pressure plate 6 Return spring (5 pcs) 7 Friction plates (2 pcs) 8 Mating plates (2 pcs) 9 Snap ring 10 Snap ring...
Page 314 DISASSEMBLY AND REASSEMBLY E 1st-speed clutch group and cover group • 602349 lIst-speed clutch piston housing 15 Retaining ring 16 1st-speed planet carrier (to be removed as an assembly (to be removed as an assembly including "2" thru "4") including "17" thru "23") 2 Piston 3 Piston seal 17 Ring gear...
Page 315 DISASSEMBLY AND REASSEMBLY Inspection Friction, mating and pressure plates Measure the assembled (total) thickness of the plates. Replace the plates if the measurement exceeds the service limit. Unit: mm (in.) Assembly Service Item standard limit Assembled (total) thickness of reverse clutch plates: 27.70±0.80 26.10...
Page 316 DISASSEMBLY AND REASSEMBLY Reassembly To reassemble the transmission, install the groups in the reverse order E" thru "A"), E 1st-speed clutch group and cover group 19 1B 15 14 602352 Reassembling order 10--+9 L L 2 rrLrrrrrL. 1'25 .---. .---. -->...
Page 317 DISASSEMBLY AND REASSEMBLY D 2nd-speed clutch group 602353 Reassem bling order r r r r r r r r Transmission case r r r r 15r14 13 1 2 ·...
Page 318 DISASSEMBLY AND REASSEMBLY C Forward clutch group and 3rd-speed clutch group 5 4 3 2 8 7 6 2 3 9 14 24===~~.J1 602354 Reassem bling order 2625 LL24 21 ->19 16->14 rrr rrrrrr' rLrrrrr rrrr I!:gsmission rrrrrLrrrLrr22389 137363534 30 87611105234 2332333120 181715 1312 rr27 2829...
Page 319 DISASSEMBLY AND REASSEMBLY B Reverse clutch group 602333 Reassem bling order 'rrrrrrrrrrrrrrrrr Transmission case 18 16 24 11 17 9 8 10 2 25 4 19 -+ 7 20-+22 14 13...
Page 320 DISASSEMBLY AND REASSEMBLY A Transmission case and flange· group 602333 602368 602356 Reassembling order r r r r r r r Transmission case rrrrrrr 9 10 8 14 15 16 13 11 ->12 Tips for reassembly Apply a coat of engine oil to the 0- ring of oil filter screw.
Page 321 DISASSEMBLY AND REASSEMBLY 3. Planet carrier spring pin installation Drive the spring pin with its gap positioned the direction of carrier rotation. Drive in the planet pin with its mark "A" outside. (~JI 4. Clutch piston installation Apply a coat of hydraulic oil (SAE lOW) to the sliding surface of each piston seal before installing the seal to the clutch piston.
Page 322 DISASSEMBLY AND REASSEMBLY 7. Testing after reassem bly Apply dirt-free pressure air to the oil holes in the transmission case' to make sure that clutch pistons move smoothly in the housings A Oil hole for reverse clutch B Oil hole for forward clutch C Oil hole for 1st-speed clutch D oii hole for 2nd-speed clutch E Oil hole for 3rd-speed clutch...
Page 323 DISASSEMBLY AND REASSEMBLY TRANSMISSION CONTROL VALVE Removal and installation Dismount transmission assembly including the control valve from the machine, and remove the valve from the transmission. (Refer to the topics, Removal, DPS TRANSMISSION.) 2. To install the control valve, follow the reverse of removing procedure.
Page 324 DISASSEMBLY AND REASSEMBLY Reassembly (Clean all control valve parts except for seals by alkali washing before installing them for reassembly.) 602320 1'35-+19 Reassembling order r r r r r ,. ,. r ' r r r i 1011121314 ,---' c - - - - - - ..
Page 325 DISASSEMBLY AND REASSEMBLY TRANSFER Removal and installation Refer to the topics, DPS TRANSMISSION. Disassembly • 602364 1 Lock washer 9 Driven gear 10 Bevel pinion 2 Washer 11 Roller bearing 3 Cover 12 Dri ve gear 4 Bearing cage 5 Shims (1 set) 13 Ball bearing 6 Shim set)
Page 326 DISASSEMBLY AND REASSEMBLY Reassembly ~1---14 13--t---'IC 602369 Reassem bling order r,qrrrTfTTT" 10-+11...
Page 327 DISASSEMBLY AND REASSEMBLY. Tips for reassem bly Pinion adjustment The distance from the end face of bevel pinion and the outer face of transfer case specified each transfer because selective assembly. The specification is formed by a certain value (represented by the letter "m"...
Page 328 OISASSEMBL Y AND REASSEMBLY DAMPER· Removal The damper resembles a conventional disc clutch and is to be removed together with the engine. For removal of the damper, refer to the topics, FLYWHEEL CLUTCH, DISASSEMBLY and REASSEMBLY volume, except following items: (1) Clutch control rod Rubber hose for steering clutch oil Rubber hose for oil .cooler (flywheel...
Page 329 DISASSEMBLY AND REASSEMBLY Reassembly 602309 Reassem bling order "J--PTf Engine rr r -->...
Page 332 DEC.a6 99879-00120- Pub. No. Printed in Japan...
Page 333 SERVICE MANUAL MITSUBISHI ··TRACTOR· ····.····D··············· . . ··--··· ···G·· •••••••••• -" .,-. TRACTOR SHOVEL CONTENTS HYDRAULIC SYSTEM • OPERATING PRINCIPLE • TESTING AND ADJUSTMENTS...
Page 335 FOREWORD This service manual has instructions and procedures for the subject on the front cover. The information, specifications, and illustrations used in this manual are based on information that was current at the time this issue was written. Correct servlcmg will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.
Page 337 Makeup valve ........... 20 TESTING AND ADJUSTMENT BD2G Tractor ......-....24 Testing cylinder rods for drift ......" Testing lift cylinders for blade holding ability (BD2G-PAT, PT) ..
Page 339 OPERATING PRINCIPLE...
Page 340 OPERimNGPRINCIPLE GENERAL DESCRIPTION Angling cylinder Lift cylinder Angling valve plunger B2· Check valve Tilt cylinder Tilt valve plunger Makeup valve Angling cylinder Check valve Lift cylinder Lift valve plunger Main relief valve 180 kif/cm' (2560 psi) {l7.7 MPaJ Lll--- Hydraulic Hlter Hydraulic pump 602195 hydraulic circuit diagram...
Page 341 OPERATING PRINCIPLE Safety valve Dump valve plunger 200 kgf/cm' (2844 psi) [19.6 MPa] Makeup valve r ;;:B2lf::;;;:~Ii!!!!~~::~~~::: Safety valve ] 4'1IIIDi--I-.f-_160 kgf/cm' Lift cylinder (2275 psi) [15.7 MPa] Dump cylinder Check valve ,-;:::::::\:::tJ Makeup valve Check valve . Lift valve plunger Main relief valve 180 kgf/cm' (2560 psi) [17.7 MPa] A..-U-_--Hydraulic ftiter...
Page 342 OPERATING PRINCIPLE CONTROL VALVE 3-SECTION CONTROL VALVE (BD2G-PAT) -1--4 602198 1 Inlet & lift valve plunger section T Tank port 2 Tilt valve plunger section P Pump port 3 Angling valve plunger section A 1 Lift cylinder (rod side) 4 End plate...
Page 343 OPERATING PRINCIPLE Control valve sections 602199 Lift valve plunger section A2,A3 602200 Tilt/angling valve plunger section 1 Plunger 3 Makeup valve 2 Main relief valve...
Page 344 OPERATING PRINCIPLE Lift valve plunger in pulled-out [RAISE] position 602201 Lift valve plunger in pushed-in [LOWER] position 602202...
Page 345 OPERATING PRINCIPLE Lift valve plunger in pushed-in [FLOAT] position 602203...
Page 346 OPERATING PRINCIPLE plung~r Tilt valve in pushed-in [RIGHT TILT] position Angling valve plunger in pushed-in [LEFT ANGLING] position 602204 Tilt valve plunger in pulled-out [LEFT TILT] position Angling valve plunger in pulled-out [RIGHT ANGLING] position 82 {) 83 602205...
Page 347 OPERATING PRINCIPLE 2-SECTION CONTROL VALVE (BD2G-PT) ----1--3 602206 1 Inlet & lift valve plunger section T Tank port 2 Tilt valve plunger section P Pump port 3 End plate A 1 Lift cylinder (rod side) 4 Main relief valve B1 Lift cylinder (head side) 1180 kgf/cm' (2560 psi) [17.7 MPaJ/...
Page 348 OPERATING PRINCIPLE Control valve sections 602207 Lift valve plunger section 602208 Tilt valve plunger section 1 Plunger 3 Safety valve 2 Main relief valve 4 Makeup valve...
Page 349 OPERATING PRINCIPLE Lift valve plunger in pulled-out [RAISE] position 602209 J..;f Lift valve plunger in pushed-in [LOWER] position 602210...
Page 350 OPERATING PRINCIPLE Lift valve plunger in pushed-in [FLOAT] position ", t""----..602211 ':-'-...,.. ~."...-~-:.
Page 351 OPERATING PRINCIPLE Tilt valve plunger in pushed-in [RIGHT TILT] position 602212 Tilt valve plunger in pulled-out [LEFT TILT] position 602213...
Page 352 OI'ERATING PRINCIPLE 2-SECTlON CONTROL VALVE (BS3G) 602214 1 Inlet & lift valve plunger section T Tank port 2 Dump valve plunger section P Pump port 3 End plate A1 Lift cylinder (head side) 4 Main relief valve B1 Lift cylinder (rod side) \180 kgf!cm (2560 psi) [17.7 MPa]j A2 Dump cylinder (rod side)
Page 353 OPERATING PRINCIPLE Control valve sections 602199 Lift valve plunger section . 602215 Dump valve plunger section 1 Plunger 3 Safety valve 2 Main relief valve 4 Makeup valve...
Page 354 OPERATING PRINCIPLE Lift valve plunger in pulled-out [RAISE] position 602201 Lift valve plunger in pushed-in [LOWER] position 602202...
Page 355 OPERATING PRINCIPLE ~ Lift valve plunger in pushed-in [FLOAT] position --..-..602203...
Page 356 OPERATING PRINCIPLE - , Dump valve plunger in pulled-out [ROLLBACK] position 602216 " Dump valve plunger in pushed-in [DUMP] position 602217...
Page 357 OPERATING PRINCIPLE Relieving action MAIN RELIEF VALVE This va.lve protects. hydraulic components by limiting ·the line pressure to a preset value. is a sort of safety valve, and limits the. line pressure _ by relieving t\vo~stage through action • on~relievin{tstatll. T B A D 600057 Because of the pressure difference·...
Page 358 OPERATING PRIN81PLE Making-up action The pressure in the circuit leading to the cylinder acts on piston "3" through orifice "B." the normal state, this pressure is lower than the force of spring "4," and valve "2" is kept closed by the force of this spring.
Page 359 OPERATING PRINCIPLE Making-up action 602219 Function of safety valve and makeup valve When control valve plunger is in neutral position 602272 1 Safety valve A Port A 2 Makeup valve B Port B T Tank port W hen cylinder is loaded because the piston will move slightly, the pressure in port "A"...
Page 361 TESTING ADJUSTMENT...
Page 362 BD2G TRACTOR TESTING CYLINDEIt:RODS FOR DRIFT B. Blade tilt cylinder (BD2G-PTA, PT) Test 1 A. Blade lift cylinders (BD2G-PAT, PT) Test 1 NEUTRAL o--oe-o Raise the front end of the machine with 602220 the blade tilted left, move the control...
Page 363 5 minutes at oil temperature 40°C (86'lb 104°F) TESTING CYLINDERS FOR ACTUATING SPEED Run the engine at idling (about 800 rpm) speed. A. Blade lift cylinders (BD2G-P AT, PT) ~~~) ~6022761 Test 1 RAISE ()-O-()+e Raise the front end of the machine with...
Page 364 TESTING AND ADJUSTMENT B. Blade tilt cylinder (BD2G-PA T) Test 2 FLOAT Tilt circuit actuating speed test Specification eo-o-o Time required for altering raised RH>LH 2.0 sec. blade from right (or left) tilt to left LH>RH 1.6 sec. (or right) tilt C.
Page 365 TESTING AND ADJUSTMENT BS3G TRACTOR SHOVEL TESTING CYLINDER RODS FOR DRIFT Test 3 A. Bucket lift cylinders l'i':~ Test 602228 Fill up the bucket with material, raise the bucket to maximum height, stop the engine, move the control lever back to NEUTRAL, and observe the retraction of Raise the front end of the machine by lift cylinder rod.
Page 366 TESTING AND ADJUSTMENT B. Bucket dump cylinders Test 3· Test <!G~~Zt:~R~e~traction Retraction 602232 Fill up the bucket with material, raise the bucket until the arms become nearly Raise the front end of the machine by parallel to the ground, move the control pushing on the ground with the bucket lever to NEUTRAL, stop the engine, and being fully dumped, move the control...
Page 367 TESTING AND ADJUSTMENT B. Bucket dump cylinders Test results Possible cause In Test I alone, dump I. Safety valve in head-side cylinders yield to load circuit is leaky or and retract. damaged. 2. Makeup valve in rod·side circuit is leaky. In Test 3 alone, dump 1.
Page 368 TESTING AND ADJUSTMENT B. Bucket dump cylinders Lift circuit actuating speed test - I Specification Time required for raising empty Run the engine at minimum speed (low bucket to maximum height from IS.7 sec. idling speed). ground ® Test 2 602277 -<D Dump circuit actuating speed test...
Page 369 TESTING AND ADJUSTMENT ADJUSTING SAFETY VALVE ADJUSTING MAIN RELIEF VALVE Safety valve location Setting 180 kgf/cm' (2560 psi) Relief pressure 200 kgf/cm' BI;>2G·PT AI port in lift [17.7 MPa] (2844 psi) cyJinder rod-side circuit [19.6 MPa] 160 kgf/cm' B2 port in dump BS3G (2275 psi) cylinder head-side circuit...
Page 370 TESTING AND ADJUSTMENT TROUBLESHOOTING GUIDE HYDRAULIC SYSTEM Remedy Complaint Possible cause • Prime. (I) Air in hydraulic system I. Pump noisy, cylinder action jerky and • Prime. (2) Air leaks at pump inlet abnormal oil foaming • Replace. (3) Pump parts worn •...
Page 371 TESTING AND ADJUSTMENT BLADE (BD2G) Complaint Possible cause Remedy I. Blade (PAT) Cracks, distortion, dents or broken • Repair or replace. welds (2) Pin holes • Repair or replace bushings. WOrn (3) Blade surface worn • Repair (reinforce by welding steel plate of about 3.2 mm (0.13 in.)
Page 374 DEC. 86 99879-00120- Pub. No. Printed in Japan...
Page 375 SERVICE MANUAL MITSUBISHI TRACTOR B 2 8 TRACTOR SHOV'EL BS3G· CONTENTS POWER TRAIN . DISASSEMBLY AND REASSEMBLY...
Page 377 FOREWORD This service manual has instructions and procedures for the subject on the front cover. The information, specifications, and illustrations used in this manual are based on information that was current at the time this issue was written. Correct servicing will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.
Page 379 TABLE OF CONTENTS Engine dismounting and mounting ....... Flywheel clutch .
Page 380 ·,·1...
Page 381 ( BS3 (4) Disconnect the hoses and pipes from the blade tilt cylinder (BD2G-PT). 1 Fron t guard 2 Rubber hoses (2 pcs) 3 Shield rubber 4 Clamp...
Page 382 5 Radiator and radiator guard 6 Floor plate (platform) 7 Under guard [NOTEl W hen unscrewing the bolts securing radiator guard "5" BD2G-PAT, raise lower C-frame access to the bolts. 602371 2. Remove the following electrical wires and parts on and around the engine:...
Page 383 ENGINE DISMOUNTING AND MOUNTING 3. Remove the following parts: 19 Muffler 20 Air cleaner 21 Clutch control rod 4. Remove the following parts: 22 Steering clutch oil rubber hoses (2 pes) 23 Oil cooler rubber hoses (2 pes) 24 Electrical wire (by loosening clamps)
Page 384 ENGINE DISMOUNTING AND MOUNTING 5. Remove the following parts: 602376 25 Disconnect the universal joint. 26 Attach lifting slings to the engine hitching bolts. 27 Remove the castle nuts, washers and bolts. 28 Lift off the engine and flywheel clutch. [NOTE] To leave the engine proper alone, Weight of engine and flywheel...
Page 385 ENGINE DISMOUNTING AND MOUNTING Mounting To mount the engine and flywheel clutch, follow reverse dismounting procedure. Tips for mounting 1. Insert bolt "5" into its hole in each mount bracket, locate brackets relative to the frame. 602377 2 Washer 5 Bolt 1 Shim 2.
Page 386 ENGINE DISMOUNTING AND MOUNTING (5) After tightening brackets, check to make sure that the engine cl utch are level. Use the following replacement parts as necessary. Washers: 58611-11200, 4-mm (O.16-in.) thickness 58611-02400, 6-mm (O.24-in.) thickness Shims: 58611-02500 64361,..74611 , I-mm (O.04-in.) thickness 64361-74612, 0.5-mm (O.02-in.) thickness 64361-17516,...
Page 387 FLYWHEEL CLUTCH The flywheel clutch can be disassembled after it is dismounted from the machine together with engine, or on machine. For dismounting of the clutch from the machine, refer to the topic, ENGINE DISMOUNTING AND MOUNTING. Disassembly of the clutch on the machine Preparatory steps Remove the under guard.
Page 388 FLYWHEEL CLUTCH 6 Rubber hoses for steering clutches (2 pcs) 7 Rubber hoses for oil cooler (2 pcs) 8 Electrical wire (by loosening clamps) 2. After removing the universal joint, [NOTEj remove the following parts from the Remove the universal joint together clutch case: with the flange attached to the front end of input shaft.
Page 389 FLYWHEEL CLUTCH 5. Tilt clutch case "9" with its rear (transmission) side lower than its front side, as shown, and take the case down. 6. For removal of the parts from the clutch case removal pressure pIa te assem bly from engine flywheel, refer to the topic, Disassembly.
Page 390 FLYWHEEL CLUTCH Disassembly (The following procedure assumes that the clutch is dismounted with the engine but it may be followed in disassembling the clutch on the machine.) 602380 (Remove the parts in the order numbered for disassembly.) 1 Drain plug 21 Bolt 43 Snap ring 2 Oil level gauge...
Page 391 FL YWHEELCLUTCH Tips for disassem bly Clutch case removal Remove oil filler "3" from the threaded hole (MIO x 1.25) at the top of clutch case ·"4." Attach hook that threaded hole, and lift off the case. 2. Pressure plate assembly removal Before removing pressure plate assembly, mark pressure plate "56"...
Page 392 FLYWHEEL CLUTCH 2. Pressure springs Measure the free length, test force and squareness. Replace the spring if any of these measurements exceeds the service limi t. Unit: mm (in.) Assembly Item Service limit standard Free length 70.6 (2.780) 68.5 (2.697) Test force/length 43.5 ±...
Page 393 . FLYWHEEL CLUTCH 5. Pump drive gear Measure the pump drive gear backlash. Replace the gear if the measurement exceeds the service limit. Unit: nun (in.) Item Assembly standard Service limit 0.35 -0.42 0.70 (0.0276), Backlash (0.0138 - 0.0165) min. 602384 6.
Page 394 FLYWHEEL CLUTCH Reassembly 47 T ·gh temng torque: 1.7 kgf.m (12.3lbf.ft) [16.7 N·m] 602386 Reassembling order r ' r r r r r 56 1'1'1524950554847 515453 r ' r r r ' , r l l l r - r - r ' r r ' r ' r 1'1' r ' r - r r ' l Flywheel 595857 765321918121011141320211716151 r'r'r42 4143...
Page 395 FLYWHEEL CLUTCH Tips for reassembly Clutch disc installation Use clutch disc arbor "A" (special tool) to install pressure plate assembly including parts "46" thru "56," mating plate "58" and clutch discs "57" and "59." When installing them, note that the clutch discs are "dished."...
Page 396 FLYWHEEL CLUTCH (4) Install lock plate "47" to lever nut "48," holding the nut so it does not rotate, and secure the release lever to clutch cover "55" with bolt. 3. Split pin installation _.' . . ,I Insert the split pin into release lever "30" parallel with the shaft and spread its r--, ends properly to avoid interference with...
Page 397 DIRECT-DRIVE TRANSMISSION (DO) Removal Preparatory steps Remove the under guard. Drain the oil from the transmission case and bevel gear case. [9.5 liters (2.5 U.S. gaD, approx.] 1. Remove the following parts: 1 Floor plate (platform) (center, 1 pc) '-..(' 2 Electrical wir.e between battery switch and battery 3 Clamp for electrical wire between...
Page 398 DIRECT·DRIVE (DD) TRANSMISSION 6 Steering clutch levers 7 Steering control rods 8 Brake control rods 602337 Disconnect the following parts: 9 Steering clutch oil hoses (2 pes) 602389 Remove the following parts: 10 Universal joint 11 Transmission 2 kg (41b), Weight of universal joint approx.
Page 399 DIRECT·DRIVE (DD) TRANSMISSION Installation To install the transmission, follow reverse removing procedure, proceed as follows: Make sure that the electrical wires, pipes hoses connected properly. (2) Fill the transmission case and bevel gear case with recommended oil. Disassembly Remove the groups in the order listed below for disassembly: A Gearshift lever (transmission control lever) group B Main drive shaft (input shaft) group...
Page 400 DIRECT·DRIVE (DO) TRANSMISSION A Gearshift lever (transmission control lever) group and B Main drive shaft (input shaft) group 602391 /"-- ;> 89 88 815 86 602392 (Remove the parts in the order numbered for disassembly.) B1 Flange AI, A2 Hose clamps· BS Input gear (to be removed as an (to be loosened;...
Page 401 DIRECT-DRIVE (DO) TRANSMISSION C Shift fork group. 0 Countershaft group and E Bevel gear shaft group 602394 parts in the order numbered for disassembly.) (Remove Cl Expansion plug C19 1st-speed shift fork 013 Snap ring C2 Spring (to be removed as an 014 Ball bearing C3 Steel (detent) ball assem bly incl uding...
Page 402 DIRECT-DRIVE (DO) TRANSMISSION Tips for disassembly L Detent group (interlock mechanism) removal To remove the detent group, place the gearshift lever in NEUTRAL. NOTE] Carefully handle steel (detent) balls "C3," ·"ClO" and "CIS" to prevent them from getting lost. 602243 2.
Page 403 DIRECT·DRIVE (DO) TRANSMISSION Inspection Shift forks Measure the clearance of each shift fork its groove in sliding gear. Replace the fork if the measurement exceeds the service limit. • i Unit· mm (in) Item· Assembly standard Service limit Clearance of OJ -03 shift fork in 0.5 (0.020)
Page 404 DIRECT·DRIVE (DO) TRANSMISSION Reassembly 602167 Reassembling order r--+ r--+ r--+ r--+ r--+ r--+ r--+ r--+ r--+ r--+ r--+ r-> r--' ,.,... r - ' ' ' E3E5 E8 E7 E6 E2 E4 El 01009 08 07 06 0504 014 013 03 01 II',EI2 1'1' 0 12...
Page 405 DIRECT·DRIVE (DO) TRANSMISSION Tips for reassembly 1. Detent group (interlock mechanism) installa tion (1) Install 1st-speed shift rail "CI8" and steel balls "CI5" in that order. 602397 (2) Insert interlock pin "C14" into the hole of 2nd-speed shift rail "C12", steel balls "CI0"...
Page 406 STEERING CLUTCHES AND BRAKES Removal Preparatory steps Drain the oil from the bevel gear case and transmission case. [9.5 liters (2.5 U.S. gal), approx.] (2) Remove the, tracks (on both sides). is not necessary to remove the tracks unless they engage the sprockets.
Page 407 STEERING CLUTCHES AND BRAKES 4 Steering clutch oil pipes (4 pcs) Levers pcs) Bracket 7 Steering valve 8 Cover 602401 9 Cover 10 Shaft 11 Spring 12 Steering brake mounting bolts (4 pcs) 13 Bracket 602402...
Page 408 STEERING CLUTCHES AND BRAKES Lift the rear end of' the machine by positioning a jack under the steering clutch case so that the sprockets can be rotated, and block the final drive cases, using wood blocks, as shown. 602403 5. Hold the clutch pedal in depressed position, and place the gearshift lever in forward 1st position.
Page 409 STEERING CLUTCHES AND BRAKES 16 Washer ,,-1 Hose Steering clutch brake assembly & 602406 Installation To install the steering clutch & brake assembly, follow the reverse of removal procedure, and proceed as follows: Make sure that the oil pipes are connected properly.
Page 410 STEERING CLUTCHES AND BRAKES Diassembly A Steering clutch brake assembly & 602407 (Remove the parts in the order numbered for disassembly.) Al Pin Al3 Plate A4 Pin (to be removed as an A5 Roller Al4 Spring assembly including A6 Anchor Al5 Spacer A7 Clevis Al6 Pressure plate...
Page 411 STEERING CLUTCHES AND BRAKES B SteerIng clutch cy In I , der assembly <® 602408 L______ B1 Flange B4 Piston Shift~r B5 Backup rmg B3 BearIng B6 Cylinder C~B~e_v_e_l_g_e_a_r assem~b~IY~_-=~ -:~_-:~ _ _ _ _ _ _ _ •• - - - - @.,)I0m.
Page 412 STEERING CLUTCHES AND BRAKES Inspection Friction plates Measure the thickness and fit of its teeth outer drum splines. Replace the plate if any of these measurements exceeds the service limit. Unit: mm (in.) Assembly standard Service limit Item 8.7 (0.342) 6.0 (0.236) Thickness in Quter...
Page 413 STEERING CLUTCHES AND BRAKES Reassembly (25.3 ± 2.2IbHt) [34.3 ± 2.9 N·m] Tightening {Orallle:, ± (25.3 ± [34.3 ± Tightening torque 16 - 19 kgf·m (116 - 137Ibf.ft) [157 - 186 N·m] 602412 A3,A4 A6~~~=m= 602244...
Page 414 STEERING CLUTCHES AND BRAKES Reassembling order C Bevel gear assembly Steering clutch case C9 C7 (Outer race) C4 C5 Cl C6 C8 C2 C7 (Inner race) . '1 A Steering clutch & brake assembly I' I' I' I' I'r Flange (Bl) A13 A15 A14 A19 A17 A16 IA10 A2 A8 A6 A 1...
Page 415 STEERING CLUTCHES AND BRAKES 2. Tapered roller bearing preload adjustment (1) Tighten two adjusting nuts "C2," right and left, to settle them in place. Lock one of the nuts with its lock plate "C1," and tighten or loosen the other adjust preload.
Page 416 STEERING CLUTCHES AND BRAKES 4; Tooth contact adjustment (1) To move the bevel pinion "G" toward or .away from the bevel gear "CS" tooth contact adjustment, decrease increase shims "F" between bearing cage transmission case. (2) To determine tooth contact pa ttern, brush red lead sparingly on the bevel gear teeth, and rotate the pinion backward and forward until a...
Page 417 STEERING CLUTCHES AND BRAKES • Pinion too close to bevel gear (1) Contact extends toward the heel-end of concave faces and toward the toe-end of convex faces. (2) To correct this contact, increase the thickness of shims "P," and turn adjusting nuts "C2"...
Page 418 STEERING VALVE Removal and installation removal installation steering valve, refer topic, Removal, STEERING CLUTCHES BRAKES. Disassembly 602419 (Remove the parts in the order numbered for disassembly.) 11 Plunger valve 1 Cover 6 Return spring 12 Return spring 2 Oil seal 7 Cover 13 Valve housing 3 Pison...
Page 419 STEERING VALVE Reassembly 602278 Reassembling order...
Page 420 FINAL DRIVES Removal (disassembly) Preparatory steps Separate the tracks. (Refer to the topic, Removal, TRACKS.) Drain the oil from the final drive gear cases. When it is necessary to remove pinion "18," remove the steering. clutch & brake assembly. (Refer to -the topic, Removal.) 602420 (Remove the parts in the order numbered...
Page 421 FINAL DRIVES Tips for removal Gear case removal Using jig, remove gear case "9" together with shaft subassembly comprising parts "10" thru "14." Unit· kg (Ib) 60 (132), Standard and swamp models approx. Weight of gear 70 (154), case and shaft Super·swamp model approx.
Page 422 FINAL DRIVES Inspection Pinion and gear backlash 2. Sprockets Measure the backlash, and replace the Measure the tooth width, and replace the pinion gear measurement sprocket if the measurement exceeds the .exceeds the service limit. service limit. Unit: mm (in ) Unit: mm (in) Item Service limit...
Page 423 FINAL DRIVES Tips for reassembly Tapered roller bearing preload adjustment To adjust preload of tapered roller bearing, decrease or increase the thickness of shims "7" between the gear case and oil seal cover. Decreasing the thickness of the shims increases the preload of the bearing. Unit: kgf.m (lbf·ft) [Nom] Item Assembly standard...
Page 424 UNDERCARRIAGE Removal Preparatory steps (1) Separate the tracks. (Refer to the topic, Removal, TRACKS.) the PT model, disconnect the hydraulic hoses from the tilt cylinder, and remove the blade and blade arms. Remove the following parts: 1 Bolts securing rigid bar 2 Bolts securing rear support 2.
Page 425 FRONT IDLERS Removal and installation Preparatory steps Separate the tracks. (2) Drain the oil from the idler. Unscrews the bolts (4 pes). Hitch a wire to the idler, and pull the idler assembly off the track frame. 2. After installing the idler, center it in the track frame.
Page 426 FRONT IDLERS Reassembly Tightening torque: 6.5 ± 0.7 kgf·m (47.0 ± 5.1 Ibf·ft) [63.7 ± 6.9 N·m] Tightening torque: 7.6 ± 0.8 kgf·m _ - - - t ' (55.0 5.81bf·ft) ± [74.5 7.8 N·m] ± 602187 Reassembling order Tips for reassembly Lubrication Fill the idler with recommended oil through the plug hole in the shaft.
Page 427 RECOIL SPRINGS AND HYDRAULIC ADJUSTER CYLINDERS Removal and installation Preparatory step in the . Release pressure hydraulic adjuster cylinder completely. 1. Remove hydraulic adjuster cylinder assem bly "1." Weight of hydraulic adjuster· IS kg (33Ib). cylinder assembly approx. 2. Remove carrier roller bracket assembly (recoil spring assembly) "2."...
Page 428 RECOIL SPRINGS AND HYDRAULIC ADJUSTER CYLINDERS Disassembly , , I 602426 (Remove the parts in the order numbered for disassembly.) 1 Cover 6 Dust seal 14 Bracket 2 Stopper 7 Rod packing (for ultra-super-swamp Fill valve 8 Plate model) 4 Washer 9 Shaft 15 Carrier roller bracket 5 Cylinder...
Page 429 RECOIL SPRINGS AND HYDRAULIC ADJUSTER CYLINDERS Tips for disassembly To remove recoil spring "12," hold plate "8" with the arbor of a press having a capacity of 3 tons (6615 lb) as shown, unscrew four bolts, and gradually back off the press arbor to let the spring expand.
Page 430 RECOIL SPRINGS AND HYDRAULIC ADJUSTER CYLINDERS Reassembly Tightening torque: · 1 3.5 ± 0.5 kgf·m (25.3 ± 3.61bf·ft) [34.3 ± 4.9 N·m] Tightening torque: 26 ± 2 kgf·m ± 141bf·ft) ± 20 N·m] 602249 Reassembling order 1 2 11 r-'l' 10-8 '1'1 , .
Page 431 TRACK ROLLERS Removal Preparatory steps (1) Loosen the tracks. (2) Drain the oil from the track rollers. Place two wood blocks "A" of 300-mm (12-in.) square section behind sprockets in a chocking manner, and move the machine to ride onto these blocks until the track rollers "1"...
Page 432 TRACK ROLLERS Disassembly - "1 602431 (Remove the parts in the order numbered -for disassem bly.) 1 Collar 3 Thrust washer 5 Bushing 2 Floating seal 4 Shaft 6 Flanged roller...
Page 433 TRACK ROLLERS Reassembly Tightening torque: ± 0.8 kgf·m (5.5 ± 5.8Ibf·ft) N·m] [74.5 ± 602188 Reassembling order Tips for reassembly 2. Lubrication (1) After reassembling the roller, fill it 1. Floating seal installation with recommended oil through plug When fitting the floating seals, use a hole in the shaft.
Page 434 602432 models). Track weigh Unit: kg (Ib) 5. Insert a bar into the link and, while 280 (620), BD2G (P) holding the bar, move the machine approx. Standard model slowly forward to layout the track. 310 (680), BS3G (F) approx.
Page 435 TRACKS Disassembly 3 : - - - - - - - ' 5-----~~1 10---;7" 602434 (Remove the parts in the order numbered for disassembly.) Ia Standard shoe 4a Seal washer Ib Swamp shoe (curved apex shoe) 4b Seal 2 Pin 5 Link 3 Bushing...
Page 436 TRACKS Reassembly 602184 Tightening torque: 17 - 20 kgf-m (123 - 145Ibf-ft) (167 - 196 N-m] 602185 Reassembling order Tips for reassembly Seal washer Install the seal washers and seals as (standard and shown. swamp models) Seal (super-swamp and ultra-super-swamp models) 602435 \...
Page 437 TRACK CARRIER ROLLERS Removal Preparatory steps Loosen the tracks. (2) Drain the oil from the track carrier rollers. Push up track above carrier roller to produce some clearance between track "1" and carrier roller "2," and remove the following parts: 3 Bolts (2 pcs) 2 Track carrier roller 602436...
Page 438 TRACK CARRIER ROLLERS Disassembly 602438 numbered for disassembly.) (Remove the parts in the order 1 Cover 4 Bushing 2 Washer 5 Roller 3 Floating seal 6 Snap ring (to be removed as an 7 Seal support assembly including 8 Shaft "4"...
Page 439 TRACK CARRIER ROLLERS Reassembly :ri1:ht<miIlg torque: .2kgf·m ± 8.7Ibf.ft) 19.6 11.8 N·m] ± Tightening torque: 4.2 ± 0.4 kgf·m (30.4 ± 2.9 Ibf.ft) N·m] [41.2 ± 3.9 602186 Reassem bling order rrrrrr r Carrier roller bracket 7 3 4 5 2 1 Tips for reassembly Lubrication After reassembling the roller, fill it...
Page 440 SPECIAL TOOLS Part number Part name Shape Wrench 58809·10200 Bevel gear adjustment Adaptor Carrier roller lubrication 58609-00300 602441 Front idler and track roller Adaptor 58809·15100 lubrication Carrier roller) front idler 58309-03100 Volume pump . and track roller lubrication Flywheel clutch installation Clutch disc arbor 58809·15600 (clutch disc assembly aligning)
Page 442 DEC. 136 99879-00120- Pub. No. Printed in Japan...
Page 443 SERVICE MANUAL MITSUBISHI TRACTOR······ ·2G····· TRACTOR SHOVEL BS3Gi CONTENTS HYDRAULIC SYSTEM DISASSEMBLY AND REASSEMBLY...
Page 445 FOREWORD This service manual has instructions and procedures for the subject on the front cover. The infonnation, specifications, and illustrations used in this manual are based on infonnation that was current at the time this issue was written. Correct sefVIcmg will give these machines a long productive life. Before attempting to start a test, repair or rebuild job, be sure that you have studied the respective sections of this manual, and know all the components you will work on.
Page 446 <~ ..
Page 447 TABLE OF CONTENTS Hydraulic pump Control valve ..........Power angling/tiit blade .
Page 449 HYDRAULIC PUMP Removal Preparatory step Remove the side cover (RH) from the engine room • .&.1"4i;@@D Raise the bucket all the way, and securely support external means. (BS30) Remove the following parts: Rubber hose (suction side) Pipe 3 Rubber hose (discharge side) Pipe and connector 5 Hydraulic pump 602280...
Page 450 HYDRAULIC PUMP Disassembly 602281 Drive gear 1 Cover Bushing (2 pcs) 7 Body seal (2 pes) 2 Packing ring 12 Oil seal 3 Bushing seal (2 pcs) Body 13 Dust seal Bushing (2 pcs) Packing ring 14 Mounting flange 10 Bushing seal (2 pcs) Driven gear (Remove the parts in the order numbered for disassembly.) (NOTE)
Page 451 HYDRAULIC PUMP Reassembly Tightening torque: 4.7 - 5.0 kgf.m Ibf·ft) (34.0 - 36.2 [46.1 - 49.0 N·m] 601398 Reassembling order NOTE) 11711 1) When inserting a pair of bushings "4" and "11," hold them squarely I I I , to the bore to avoid scuffing. 4 11 outside surface bushing...
Page 452 602282 hydraulic tank. Weight of control valves Control valve for 13.5 kg (30 lb), power angling/tilt approx. blade BD2G Control valve for 10.0 kg (22 lb), power tilt blade approx. 10.0 kg (22 lb), Control valve for BS3G approx. Installation To install the control valve, follow the reverse of removing procedure.
Page 453 CONTROL VALVE 3-section control valve (BD2G with power angling/tilt blade) Disassembly and reassembly .G Tightening torque: 5.0 ± 0.5 kgf·m (36.2 ± 3.6 Ibf·ft) Tightening torque: F . [49.0 ± 4.9 N·m] I kgf.m ± (72.3 ± 7.2 Ibf·ft) [98.1 ± 9.8 N·m] A Tightening torque: 2.7 ±...
Page 454 CONTROL VALVE Disassembly C9-@ D8----'~ B15~ B17---@) DI~~ 1?,. <1;7/.1> <' f "' f CllB18 C13 C12 " Jill ,''V C14, D14 l... D7--l D6-(§lC7~ D5~C6~ C5-f§l D3----e D2~C3~ (§If'--... P C:~ ° <:l>--B12 c'Ifj ~Bll ° ~.~~~*BI9 ©> 602284 B14 Oil seal Dl Cap Bl Cap (to be removed as...
Page 455 CONTROL VALVE Reassembly 602199 Tightening torque: Tightening torque: ± 0.2kgf·m ± 0.2 kgf·m (l4.5 ± 1.4 "Jbf.ft) (l4.5 ± 1.4 Ibf·ft) [19.6 ± 2.0 N·m] [19.6 ± 2.0 N·m] 602200 Reassembling order B Inlet and lift valve plunger section ~..r- 819 r r r r r r r r r r r r r r r r...
Page 456 CONTROL VALVE 2-section control valve (BD2G with power blade) tilt Disassembly and reassembly Tightening torque:. 5.0 ± 0.5 kgf·m (36.2 ± 3.6 Ibf·ft) [49.0 ± 4.9 N·m) ~o-rq-u-e-: ----.;-F~t?r~~~~I;f~~ Tightening 1 kgf·m ± A Tightening torque: (72.3 ± 7.2 Ibf.ft) ±...
Page 457 CONTROL VALVE Disassembly .J. ,' " :::~ ~ <3 • " 'J'-. ( ) ,,-,' C13 B18 o e o / {> "- ' ,// Clef' C7-----l@!;l!OO.O 00° C12~ C6---I@ ' / B21 Cl---~ 602285 B15 Plate Cl Cap Bl Cap (to be removed as C2 Plunger plug B16 Spacer an assembly including...
Page 458 CONTROL VALVE Reassembly ~§'ldJL~~=-t~--B19 Tightening torque: ± 0.4 kgf·m (25.3 ± 2.9Ibf·ft) ~~I-'l~rh'nr'i'l'i~RTIh!-.!r'-,~-'1":=~[34.3 ± 3.9 N·m] 602207 Tightening torque: 0.4 kgf·m ± (25.3 ± 2.9 Ibf·ft) Tightening torque:" [34.3 ± 3.9 N·m] ± I kgf·m (72.3 7.21bf·ft) ± [98.1 9.8 N·m] ±...
Page 459 CONTROL VALVE 2-section control valve (BS30) Disassembly and reassembly F Tightening torque: ± 0.5 kgf·m Tightening torque: E (36.2 ±3.61bf·ft) 10 ± I kgf·m [49.0 ± 4.9 N·m] (72.3 ± 7.21bf·ft) [98.1 ± 9.8 N·m] Tightening torque: ± 0.3 kgf.m (19.5 ±...
Page 460 CONTROL VALVE Disassembly B15~ ~E B17~ B16~~ ">;~ .e'? ' d 1 2 '" .Yll 'V~ ~ "'~ , / / C15@()() /G""l" r::,Jpi • !!§J. 'B22 B14~~ B13~~~ C l - @ f~ r~~~o Bl~ ~:~0IrB19 B6_~B5 B7---<> B4-tl B3--o 602286 B1 Cap (to...
Page 461 CONTROL VALVE Reassembly Tightening torque: 3.5 ± 0.4 kgf·m (25.3 ± 2.91bf·ft) (34.3 ± 3.9 N·m] 602199 Tightening torque: ± 0.3 kgf·m _2._2_1b_f_'ft~):-[2_6_.5_±_2_.9_N_._m~] ~ Tightening torque: 1-.:(_19_.5_± 3.5 ± 0.4 kgf·m rt==~"';"----v-? (25.3 ± 2.9 Ibf· ft) [34.3 ± 3.9 N·m] Tightening torque: ---~ 2.0 ±...
Page 462 POWER ANGLING/TILT BLADE Removal Preparatory steps Place wood blocks llilder the blade frame. (2) Lower the blade to the ground, stop the engine, and move the control levers to all operating positions to relieve the pressure in the hydraulic circuits. Remove the following parts: Rubber hoses (for lift cylinders, 4 pcs) 2 Rubber hoses...
Page 463 POWER ANGLING/TIL T BLADE Disassembly and reassembly • • ---:.!..o @J:D 602289 12 Cover 1 Pin 23 Plate 2 Lift cylinder 13 Cover 24 Bar 3 Cover 14 Hoses 25 Pin 15 Hoses 26 Bracket 4 Plate 16 Block 27 Cap 5 Plate 17 Pin 28 Blade...
Page 464 POWER TILT BLADE Removal Preparatory steps (1) Lower the blade to the ground, stop the engine, and move the control lever to all operating positions to relieve the pressure in the hydraulic circuits. (2) Place wood blocks under the blade arms.
Page 465 POWER TILT BLADE Disassembly and reassembly ['.. ~:;f '---=:rV~ ~11 602292 Ultra-super-swamp model (SSS) .."'%'" ". " • . ' " • f'-' e '. "%~" ;>--:ff 602305 End bit Lift cylinder Tilt braces Cutting edge Trunnion· Braces Blade Lever End bit Cover...
Page 466 BUCKET AND LINKAGE Removal Preparatory steps (1) Lower the bucket to the ground, stop the engine, and move the control lever to all operating positions to relieve the pressure in the hydraulic circuits. Fasten the lift cylinders to the lift arms with wires.
Page 467 BUCKET AND LINKAGE Disassembly and reassembly .> 602296 5 Pin 9 Pipe 1 Pin 6 Arms 2 Lift cylinder 10 Frame 7 Pin 3 Pin 11 Tooth 4 Dump cylinder 8 Arms 12 Bucket Bucket and linkage - Disassembled view (Remove the parts in the order numbered for disassembly.)
Page 468 HYDRAULIC CYLINDERS Removal Preparatory steps Lower the blade or bucket to the ground. (2) Lift the cylinders with slings. Remove the following parts 1 Covers for angling cylinders of power angling/tilt blade 2 Cover for tilt cylinder of power tilt blade Power angling/tilt blade 2.
Page 469 8 Cylinders Weight of cylinders (approx.) Unit: kg (Ib) 13.5 Lift cylinder (30) Power angling! 12.5 Angling cylinder tilt blade (28) 13.8 . BD2G Tilt cylinder (30) 13.5 Lift cylinder Bucket (30) Power tilt blade 15.0 Tilt cylinder (33) 29.0...
Page 470 HYDRAULIC CYLINDERS Ring nut type (Example: Lift cylinder for power angling/tilt blade and power tilt blade for BD2G) 602300 1 Ring nut 7 Dust seal 2 Ring 8 Rod packing 3 Nut (to be removed as an assembly 9 Buffer ring including "4"...
Page 471 HYDRAULIC CYLINDERS Gland screw type (Example: Tilt cylinder for power tilt blade for BD2G) ·0 L--/C) 602301 7 Backup ring 1 Ring 8 Dust seal 2 Gland screw 3 Nut (to be removed as an assembly 9 Rod packing 10 Buffer ring including "4"...
Page 472 Hook wrench Cylinder part number Lift cylinder Power 05312-10500 angling/ Angling cylinder tilt blade 05312-10600 Tilt cylinder BD2G 05312-10500 Lift cylinder Power tilt blade 05312- 10600 Tilt cylinder 602303 05312- 10800 Lift cylinder Bucket BS3G...
Page 473 HYDRAULIC CYLINDERS. Reassembly Reassembling order Ring nut type cylinder 6022571 r-->" r--- 6 +- 9 -> " " L l ' i l l (Tighten) -> Gland screw type cylinder 10 7 602258 ',./ ' , 1 3 7->6+-10 (Tlohten) 5-+4...
Page 474 600149 Piston 1.0. Cylinder (0.94) (1.06) (1.18) Lift cylinder Power Angling angling/ cylinder tilt blade Tilt BD2G cylinder Lift cylinder Power tilt blade Tilt cylinder Lift cylinder BS3G Bucket Dump cylinder (2) Squeeze the seal in the palm of the hand three or four times to soften it.
Page 475 HYDRAULIC CYLINDERS piston vise, with (3) Hold (copper) caps fitted to the protective vise jaws. (4) Apply a thin coat of hydraulic oil to the seal. Fit the seal into the groove as much as it will go in, and insert the tool in to the piston.
Page 476 HYDRAULIC CYLINDERS (7) Install the backup ring to the piston. 600154...
Page 477 50.0 ± 2.5 Lift cylinder (361.7 ± 18.1) Power Angling cylinder [490.3 ± 24.5) angling! 70.0 ±3.5 tilt blade (506.3 ± 25.3) BD2G Tilt cylinder [686.5 ± 34.3) 50.0 ± 2.5 Lift cylinder Power ' (361.7 ± 18.1) tilt blade Tilt cylinder [490.3 ±...
Page 478 24.0 ± tilt blade Tilt cylinder 73.6 ± 17.4) ± 23S.4 23.S] IS.O± I.S Lift cylinder BD2G (108.5 ± 10.8) [147.1 ± 14.7] Power tilt blade 4S.0 ±4.S Tilt cylinder (32S.5 ± 32.S) [441.3 ±44.1] 7S.0 ± 8 Lift cylinder (S42.5 ±...
Page 479 The diameter and depth of this hole are as shown below: Unit· mm (in) Locking ring hole Cylinder Diameter Depth "L" "d" Power Tilt 3.5 (0.14) 10.5 (0.41) BD2G tilt blade cylinder Lift 4.5 (0.18) 12.5 (0.49) cylinder BS3G Bucket Dump 3.5 (0.14) 10.5 (0.41) cylinder...
Page 480 Part name Shape Part number Ring nut or gland screw removal and 05312·10500 Hook wrench installation BD2G - Power angling/tilt blade Lift cylinders Angling cylinders BD2G - Power tilt blade Lift cylinders 05312·10600 BD2G - Power angling/tilt blade Tilt cylinder...
Page 482 DEC. '86 99879-00120- Pub. No. Printed in Japan...
Page 483 UPDATING OF SERVICE MANUAL This Service Manual consists of the separate volumes listed in the nex t page. A revised edition will be issued for each volume when the system covered in it is improved or changed. Wheli you receive a revised edition, supersede the existing volume by the revised edition and enter the 9th-digit and 10th-digit figures of Pub.
Page 484 Hydraulic System 99879-00120-6/ Operati~g Principle/Testing and Adjustment Power Train 99879·00120-7/ Disassembly and Reassembly " Hydraulic System 99879-00120-8/ Disassembly and Reassembly " 99879-00120:9/ Wiring Dlagl'1lm for BD2G and BS3G " Dec. 1986 Binder Pub. No. 98AAB-00360 *PubJication to be issued in future.

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