Page 1: Table Of Contents
TRACTORS T390/T400/T430/T450 SERVICE MANUAL Chapter 1. Introduction ------------------------------------01 Chapter 2. Disassembly and reassembly of major point ------02 Chapter 3. Engine accessories ------------------------------------03 Chapter 4. Clutch system ------------------------------------------- 04 Chapter 5. Transmission ------------------------------------05 Chapter 6. Front axle (4WD) ----------------------------------06 Chapter 6. Front axle (sheet metal) ---------------------------06 Chapter 7.
Page 2 Chapter 1 Introduction INTRODUCTION-------------------------------------------------------------1-1 SAFETY INTRODUCTION------------------------------------------------1-2 WARNING SIGNS IN THIS MANUAL ---------------------------------1-5 SAFETY SIGNS --------------------------------------------------------------1-6 SAFETY DECALS ----------------------------------------------------------1-11 UNIVERSAL SYMBOLS --------------------------------------------------1-14 SECTION 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS ----------------------------1-15 SECTION 2. SPECIFICATIONS------------------------------------------1-17 SECTION 3. GEAR TRAIN DIAGRAMS-------------------------------1-20 SECTION 4. PRECAUTIONS FOR TRACTOR OPERATIONS---1-21 1.
Page 3: Chapter 1. Introduction
Chapter 1 .Introduction This tractor service manual is for qualified service personnel engaged in servicing and overhauling 3510/4110/T390(T400)/T430(T450) tractor.Use of this publication is not recommended for field operators since they usually do not have access to special tools and shop equipment essential for most servicing.
Page 4 SAFETY INSTRUCTION ALWAYS PRACTICE SAFETY BY THINKING BEFORE ACTION AVOID FIRE HAZARDS. -Keep fire extinguishers easily available and in good operating condition. All relevant personnel should know how to operate fire fighting equipment. -Keep a first aid kit in an easily accessible location. -Do not smoke while handling fuel,or other highly flammable material.
Page 5 STAY CLEAR OF PTO 1) Entanglement in rotating drive line can cause serious injury or death. 2) Keep tractor master shield and drive line shield in place at all times except for special applications as directed in the implement operator's manual. 3) Wear fairly tight tight fitting clothing.Stop the engine and be sure PTO driveline is stopped before making adjustment,connections,or cleaning out PTO drive equipment.
Page 6 WARNING SIGNS IN THIS MANUAL The following warning symbols in this manual draw additional attention to items of importance for the safe and correct operation of the tractor. SIGN MEANING OF SIGN Serious hazard with a very high level of risk of either serious injury or death DANGER Hazard or unsafe practice that can lead to severe...
Page 7 SAFETY SIGNS RECOGNIZE SAFETY INFORMATION This symbol, Safety-Alert Symbol, means ATTENTION! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message SIGNAL WORDS. A signal word―DANGER, WARNING OR CAUTION―is DANGER used with safety alert symbol. DANGER identifies the most serious hazards.
Page 8 USE OF ROPS AND SEAT BELT The Roll Over Protective Structure(ROPS) has been certified to industry and/or government standards. Any damage or alternation to the ROPS, mounting hard-ware, or seat belt voids the certification and will reduce or eliminate protection for the operator in the event of a roll-over.
Page 9 HANDLE FUEL SAFELY-AVOID FIRES Handle fuel with care; it is highly flammable. Do not refuel the Tractor while smoking or near open flame or sparks. Always stop engine before refueling Tractors. Always keep your tractor clean of accumulated grease, and debris. Always clean up spilled fuel.
Page 10 AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes and nozzles, which eject fluids under high pressure. If ANY fluid is injected into the skin. Consult your doctor immediately. PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and open flame away from the top of battery.
Page 11 TRACTOR RUNAWAY 1. The tractor can start even if the transmission is engaged position causing Tractor to runaway and serious injury to the people standing nearby the tractor. For additional safety keep the pull to stop knob (fuel shut off control) in fully pulled out position.
Page 12: Safety Decals
SAFETY DECALS The following safety decals ARE INSTALLED ON THE MACHINE. If a decal become damaged,illegible or is on the machine,replace it.The decal part number is listed in the parts lists. WARNING ● Do not permit anyone but the operator to ●...
Page 13 CAUTION WARNING TO PROTECT ENGINE AND KEEP HANDS AND HYDRAULIC COMPONENTS. CLOTHING ● Idle Engine for 1 minute before shut down or full load AWAY FROM ROTATING operation. FAN AND ● Do not exceed 1/2 throttle for BELTS TO first 5 minutes of operation PREVENT SERIOUS INJURY Location: On Dash cover side RH...
Page 14 DANGER WARNING BLINDNESS CAN ● Pull only from drawbar. Pulling from any other RESULT FROM point can cause rear overturn. BATTERY EXPLOSION. ● Do not operate with unshielded PTO. KEEP SPARKS OR OPEN ● Disengage PTO and stop engine before FRAMES AWAY FROM servicing tractor or attaching and detaching BATTERY.
Page 15: Chapter 5. Transmission
UNIVERSAL SYMBOLS Some of the universal Symbols have been shown below with an indication of their meaning. Engine speed Pressured- Corrosive (rev/minX100) open slowly substance ”Tortoise” Hours, recorded Continuous slow or Variable minimum setting ”Hare” fast or Engine coolant Warning maximum temperature setting...
Page 16 SECTION 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS The tractor serial number is shown on the left hand side of the tractor as shown in the picture. The engine number is stamped on the top of the engine block. Tractor Serial Number Engine Serial Number Engine Serial Number Tractor Serial Number...
Page 17 3.Engine model and engine serial number plate on the head cover. 1-16...
Page 18 SECTION 2. SPECIFICATIONS MODEL T390/T400 T430/T450 Engine Maker KUBOTA KUBOTA Model V1903 V2203 Type Vertical,water cooled 4 cycle Diesel Out put(ps/rpm) Rated Speed 2,800rpm 2600rpm Number of Cylinder Displacement(cc) 1,857 2,197 Bore and Stroke (80mmX92.4mm) (87mmX92.4mm) Compression ratio 22:1 22:1...
Page 19 MODEL T390/T400 T430/T450 Clutch Main Dry single disc,mechanic Multiple wet disk Dimensions Overall length 3531(139”) 3531 (139”) Overall width 1475(58.1”) 1490(58.7”) Overall Height 2228(87.7”) 2288(90.1”) Wheel base 1800 (70.8”) (Distance between shafts) Min. Ground Clearance 308(12.1”) 330(13”) Tire size Front...
Page 20 Traveling speeds:Km/h (Mile/h) Traveling Speed : km/hour MODEL T390/T400 T430/T450 Range Main shift Forward Reverse Forward Reverse shift 0.39 0.36 0.55 0.50 0.75 0.68 0.98 0.89 1.14 1.09 1.02 0.93 1.60 1.53 1.43 1.30 2.17 2.07 1.93 1.77 2.85 2.71 2.54...
Page 21 SECTION 3. GEAR TRAIN DIAGRAMS (T390/T400) Fig.1-3 GEAR TRAIN DIAGRAM 1-20...
Page 22 SECTION 3. GEAR TRAIN DIAGRAMS (T430/T450) Fig.1-3 GEAR TRAIN DIAGRAM 1-21...
Page 23 SECTION 4. PRECAUTION FOR TRACTOR OPERATION 1. INSTRUMENTS ①key switch ②temperature gauge ③tachometer ④Hour meter ⑤Fuel gauge ⑥Light switch,indicators and horn ⑦hazard warning light switch ⑧ PTO Mode switch ⑨ PTO ON OFF switch Note: - Oil pressure warning light and charge light on the monitor array will light when the main switch is turned from OFF to ON - All lights on the panel go out automatically when the engine is started and its speed is increased to a specific level.
Page 24 MONITOR LIGHT ARRAY ①High Beam Lamp ②Low Beam Lamp ③PTO Monitor Lamp ⑥Fuel Empty Warning Lamp ⑦Oil pressure lamp ⑧Charge lamp ⑨Glow signal Lamp ⑩Turn Signal Lamp 1-23...
Page 25 2. CONTROLS 1.Steering wheel 2.parking brake pedal 3.Lear shift lever(Linear shifting between forward and reverse traveling) 4. Clutch pedal 5.PTO shift lever 6. Speed range shift lever 7.Throttle lever 8. Tilting pedal 9.Brake pedals 10.Accelerator pedal 11. Dif-lock pedal 12. Main shift lever 13.
Page 26: Chapter 6. Front Axle (4Wd)
3. FILLING DIAGRAM & CAPACITY TABLE TABLE 1-7 MODEL T390/T400 T430/T450 Filling point Fillings Quantity Liter (gal.) RADIATOR Fresh clean 9ℓ 9ℓ Water(L.L.C) ENGINE Engine oil 5.8ℓ (1.58 gal) 7.0ℓ (1.90 gal) TRANSMISSION CASE THF500 34ℓ(9 US gal) 34ℓ(9 US gal)
Page 27: Maintenance Chart
4. MAINTENANCE CHART ○ inspection,replenish,and adjustment ● Replacement △ Cleaning and/or washing ∊ ENGINE ★ Consult your Dealer Inspection and servicing intervals Hour of operation Judgment Inspection (X10 on hour meter) Intervals after that items criteria mm(in) Engine oil Replace after every Level is ○...
Page 28 ○ inspection,replenish,and adjustment ● Replacement △ Cleaning and/or washing ∊ TRANSMISSION ★ Consult your Dealer Inspection and servicing intervals Hour of operation Judgment Inspection (X10 on hour meter) Intervals after that items criteria mm(in) Transmission Replace after initial 50 Clean hydraulic ○...
Page 29 Inspection and servicing intervals Hour of operation Judgment Inspection (X10 on hour meter) Intervals after that items criteria mm(in) Electric All should work properly apparatuses Adjusting Check after 300 accelerator hours ★ ★ pedal and throttle lever Oil leaks in Check every year by clutch removing the plug...
Page 30 Chapter 2 Disassembly and reassembly of major components SECTION 1. GENERAL PRECAUTIONS AND SEPARATION AND REINSTALLATION------------------------------------2-1 1. Before operation---------------------------------------------------------- 2. Precautions to be followed when installing standardized parts. ----------------------------2-1 SECTION 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCKS -----------2-4 SECTION 3.
Page 31: Before Operation
(2) Oil seals 1) Oil seals installer should be designed so as 9) When replacing parts,use authorized, genuine not to deform the oil seals. TYM parts only.TYM assumes no responsibility for accidents,operating problems or damage caused by the use of imitation parts.
Page 32 2) During installation,be careful not to (5) Spring(roll) pins damage the lips,and assure that it is pushed in parallel to the shaft or hole. 1) Spring pins should be driven in properly as tightly. 3) When oil seals are installed,there should 2) Spring pins should be installed so that their be no turnover of the lips nor dislocation of seams should face the direction from which the...
Page 33 ,Be sure to wind the wire paying sufficient 4) Each contact surface should be coated with an attention to its winding direction and bend adhesive(THREE BOND TB 1215) and tightened the lock washer for secure looking. evenly with bolts. Adhesive coated surfaces should be installed within 4) When locking bolts and nuts with an 30 minutes after application of the adhesive.
Page 34 SECTION 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCKS...
Page 35 SECTION 3. SEPARATION OF MAJOR COMPONENTS 1.SEPARATION OF THE FRONT (2) Installation AXLE AND AXLE BRACKET 1) Install the front axle assembly. 2) Install both pivot metals(supports) Parts which can be inspected during This operation -Center pivot -Final case -Differential gear (1) Removal 1) Hold the front hitch or the front bracket securely with a crane or stands.
Page 36: Chapter 8. Power Steering System
1.SEPARATION OF THE ENGINE AND THE FRONT AXLE BRACKET 5) Open the front grille. Parts which can be inspected during This 6) Detach the head light wiring. operation 7) Remove the other wiring -Air cleaner 8) Remove the inlet pipe from the air cleaner. -Radiator 9) Remove the air cleaner.
Page 37 13) Remove the battery and battery bracket. 14) Remove the two hoses for the power steering system. 15) Remove the mounting bolts of the right hand pivot metal(support) ahead of time. 16) At this stage,the power steering unit can be removed by disconnecting both right-hand and left hand tie-rods and removing the unit mounting bolts.
Page 38 5) Disconnect the battery cables. 8) Disconnect the hydraulic hose from the power steering (orbitrol) Fig.2-14 6) Disconnect the panel instrument set removing bolts(4 nos.) Fig.2-17 Note: - Disconnect the linear shift control cable - Disconnect the cable from both the steering lever side and transmission.
Page 39 (2) Engine separation from the chassis. When separating the engine from the chassis,the following steps are required as well as the ones mentioned above. 1)Lift the engine with the hoist and hold the front axle bracket with a stands or the like.
Page 40: Separation Of The Front Transmission And Spacer Transmission
4.SEPARATION OF THE FRONT TRANSMISSION AND SPACER TRANSMISSION 5) Remove the frames(LH and RH) Parts which can be inspected during This operation -PTO clutch -Linear shift gears and related parts -Main change gears 1) Removal A:Removal of the whole floor. 1) Remove the side covers(LH and RH).
Page 41 8)Remove the dif-Lock pedal 13) When the tractor is equipped with an optional remote control valve,remove the remote control valve link. 14) Drain the fuel system of fuel. 15) Remove four rubber mounts. Fig.2-26 Diff-lock pedal 9) Remove the main shift and transmission range shift levers.The levers can be separated in the middle.
Page 42 18) Lift the floor gradually taking care not to allow the shaft of the slow return check valve and its hole in the floor to interfere with each other. FIG.2-31 Slow return check valve FIG.2-33 Front wheel drive 3) Disconnect the brake rods. Note: Lift up the floor gradually making sure that all relevant wiring.
Page 43 (1) Assemble the front and spacer transmission. (10) Connect the power steering wheels. (11) Connect the accelerator wires. (12) Install wiring (13) Connect the negative battery cable. (14) Install the side covers(RH and LH) (15) Fill the transmission case with oil 3510/4110/T390(T400)/T430(T450):34(9 us gal) 2-13...
Page 44: Separation Of The Spacer Transmission And Rear Transmission
5.SEPARATION OF THE SPACER TRANSMISSION AND REAR TRANSMISSION 8) remove the position control lever and draft Parts which can be inspected during This operation control lever - Drive pinion gear - Speed range gear(Transmission range shift) - Main change gear. - 4WD drive gear 1) Removal (1) remove side cover(LH and RH)
Page 45 (19) Remove two rubber mounts. FIG.2-46 sub change metal FIG.2-44 Frame rubber mounts. (29) Remove all the spacer-rear transmission (20) Lift up the rear end of the floor/fender case tightening bolts and nuts except the assembly by about 100 mm,and place wood bottom bolt.
Page 46: Separation Of The Rear Transmission And Rear Axle Housing
(4) Install the hydraulic piping. (5) Install two rear rubber mounts. (6) Install exterior parts. (7) Fill the transmission case with oil 3510/4110/T390(T400)/T430(T450):34(9 us gal) 6.SEPARATION OF THE REAR TRANSMISSION AND REAR AXLE HOUSING Parts which can be inspected during This operation - Diff Lock FIG.2-53 Brake rod...
Page 47 (6) Support the floor panel with a trestle or the 2) Installation like. Reassemble in reverse order of disassembly. (7) Remove the rubber mount along with the (1) join the rear axle and rear transmission bracket. Note: Make sure that the diff-lock shifter is fitted into the groove in the dif-lock metal Rubber mounting bolts FIG.2-55 Frame rubber mounts.
Page 48: Separation Of The Rear Transmission And Cylinder Case
7.SEPARATION OF THE REAR TRANSMISSION AND CYLINDER CASE (10) Detach the delivery pipe from the cylinder Parts which can be inspected during This case. operation (12) Remove the slow-return check valve along - Control valve with the shaft. - Control linkage (13) Remove the 3-point lift link and related - Piston and lift crank linkage parts from the lift arm.
Page 49 Chapter 3 ENGINE ACCESSORIES SECTION 1. RADIATOR ---------------------------------------------------3-1 1. General description ------------------------------------------------------3-1 2. Radiator -------------------------------------------------------------------------------------------- 3. Specifications ---------------------------- -------------------------------------------------------- 4. Removal of the radiator ------------------------------------------------------------------- 5. Inspection of each part -------------------------------------------------------------------- 6. Radiator reassembly ------------------------------------------------------3-5 7. Daily inspection -----------------------------------------------------------3-5 8. Trouble shooting ----------------------------------------------------------3-6 SECTION 2.
Page 50 Chapter 3.Engine accessories SECTION 1. RADIATOR 1.General description The pressure cooling system includes mainly the radiator,water pump,multi-blade fan, and the thermostat.During the warm-up period,the thermostat remains closed and coolant is directed through by-pass to the suction side of the water pump.
Page 51: Section 1. Radiator
2. Radiator The radiator consists of radiator cores, a tank to Flow coolant,side plates to install the radiator, and a fan guide. Fin-tube type cores are used and the cores and tank is made of anti corrosive copper and Copper alloy. FIG.3-3 1.Radiator assy 5.Bolt...
Page 52: Radiator
3. SPECIFICATIONS Description 3510/4110/T390/T430 Radiator core type Flat water tube with corrugate fins Core train number 3 trains Radiator fin pitch 3 mm Thermal radiator area 18.04㎡ Pressure valve opening pressure 1.1±0.15Kgf/ ㎠ Coolant capacity 7 ℓ(contains in cylinder block) Test pressure 1.5 Kgf/㎠...
Page 53 -Clean with a detergent When cleaning the radiator with a detergent, follow the instructions given by its manufacturer. Different detergents have different characteristics. b. Cleaning the radiator exterior Cleaning the net (wire mesh) After the tractor has been operated in dusty FIG.3-5 conditions,check the net daily and clean it if necessary.
Page 54: Radiator Reassembly
6. RADIATOR REASSEMBLY Pressure valve 1.05 Kgf/ ㎠ Reassemble the radiator in the reverse order of Opening pressure (14.93 psi) disassembly. Vacuum valve 0.04-0.05 Kgf/ ㎠ Note: Opening pressure (0.57-0.71psi) - The rubber hoses should be clamped securely and must not interfere with the cooling fan. -Function test: - The radiator cores must not interfere with the The pressure type radiator cap has a pressure valve...
Page 55: Trouble Shooting
8. TROUBLE SHOOTING TABLE 3-1 Problems Causes Countermeasures 1) Overheating (1) Low coolant level (1)Replenish coolant and inspect water leaks. (2) Fatigued pressure valve spring (2)Replace radiator cap. (3) Loose or broken fan belt (3)Adjust belt tension or replace. (4) Oily fan belt (4)Replace.
Page 56: Section 2. Air Cleaner System
SECTION 2. AIR CLEANING SYSTEM 1.GENERAL DESCRIPTION Unfiltered air contains many particles harmful to the engine such as dust ,sand,or other foreign matter. When such foreign matter have entered in to the engine,They have mixed into the lubricant and promote wear of lubrication parts in addition to damaging the piston cylinders.To eliminate these harmful particles,an air cleaner has been installed.The air cleaner Which is installed on the T series tractor is a dry,cyclone type and is constructed as shown in the figure.
Page 57 2.ELEMENT AIR CLEANER (1) SPECIFICATIONS. Model 3510/4110/T390/T430 Type Dry,paper element filtering type Rated intake air volume ( ㎡ /min.(cu.ft/min) 2.6(91.8) air venting resistance ( ㎜ Ag) 120 or less Cyclone efficiency (%) 45 or over Total filtering efficiency (%) 99.9 or over...
Page 58: Inspection Of Each Part
Note: 3. INSPECTION OF EACH PART Especially note the glue portions of the paper and 1) Inspection of the cleaner body metal parts. (1) Check the cleaner exterior for cracks, deformation,or damage and repair or replace 4. CLEANING THE AIR CLEANER if necessary.
Page 59: Element Installation
-After soaking,rise it in fresh water. -Let it in a shaded and well ventilated place. Forced drying by heat or compressed air is prohibited. Note: Water applied to rinse the element should not have a pressure of more than 2.8kgf/㎠ (39.8psi).
Page 60 CHAPTER 4 Clutch system SECTION 1. GENERAL DESCRIPTION ----------------------------- 4-1 SECTION 2. SPECIFICATIONS ----------------------------------------- 4-2 SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY-4-3 1. Main clutch -------------------------------------------------------------------4-3 2. Clutch shaft and related parts--------------------------------------------4-8 3.Final adjustment of the clutch pedal-------------------------------------4-9 SECTION 4. TROUBLESHOOTING---------------------------------------4-10...
Page 61: Section 1. General Description
Chapter 4. clutch system GENERAL DESCRIPTION. The clutch is a device to engage and disengage the power of the engine.The construction of the clutch is as shown in the figure. It is composed of the flywheel which holds the clutch disc,the pressure plate,diaphragm springs,the clutch cover,and input gear.
Page 62: Section 2. Specifications
SECTION 2. SPECIFICATIONS Table 4-1 Parts Items Description and assembly standard values Clutch cover Type Springs: shape Coil spring Quantity Free length mm (in) 87.4(3.44) Installed length/Load mm/Kgf(in/lb) 53/64.4(2.09/141.7) Lever plate height(above flywheel surface)mm (in) 65±0.7(2.5590 Lever height difference limit between levers mm(in) 0.7(0.028)or less Hub spline: large dia.
Page 63: Section 3. Disassembly,Inspection,And Reassembly-4-3
SECTION 3. DISASSEMBLY, INSPECTION, AND REASSEMBLY 1.Cover (clutch/260) 2. Pressure plate 3.Release lever 4.Spring 5.Spring Cap 6.Return Spring 7.Bolt(Lever) 8.Lever 9.Split pin 10.Disc(Clutch/260) 11.Bolt(S) 12.Metal(Input) 13.Bolt(seal) 14.Nut 15.Washer plain 16.Snap ring 17.Gasket FIG. 4-3 Clutch assembly 18.Metal(sleeve) 19.Bolt(seal) 20.O-ring 1.MAIN CLUTCH 21.Sleeve 1-1.Disassembly 22.Clutch release bearing...
Page 64 4)Install a special tool on the clutch cover assembly and screw in the screw until the release levers are freed. Note: Ensure that the claw positions are in contact and tighten the center screw gradually. Fig. 4-7 1.2. INSPECTION (1) Inspection of the clutch disk Check the clutch disk for wear or cracks on the facing,loose rivets,broken torsion springs, or wear of the hub splines.
Page 65 Note: Be sure to replace any clutch disc which has 0.2mm (0.008in) or less in rivet suppression.Use of a insufficient rivet depression disc will result in serious damage to the flywheel and the pressure plate. 2) Any oil stained clutch disc must be replace. However,a very small oil stain may simply be removed by use of a volatile solvent.
Page 66 3) Adjustment of pressure springs. 2) Measure the deviation from vertical using a square,Replace springs which are slanted When the friction surfaces of the pressure plate more than approximately 2 degrees. and the flywheel are repaired by grinding or machining the installation height of the pressure springs increase by the ground-off value both on the flywheel and the friction plate resulting in decreased spring tension.Consequently,adjusting...
Page 67 1.3. REASSEMBLY Note: Reassemble them in reverse order of After the release lever height adjustment,be disassembly in accordance with the sure to install the cotter pin. following instructions. 1)Be sure to keep oil off of the clutch disc,the pressure plate,and the flywheel. 2) Apply a thin coat of molybdenum disulfide- based grease to revolving or sliding parts prior to reassembly.
Page 68: Clutch Shaft And Related Parts
2)Inspection of sleeve 2.CLUTCH SHAFT AND RELATED PARTS. Ensure smooth movement of the sleeve.If it (1) disassembly does not move smoothly,clean and grease it. 1) Remove the tension spring and extract the Use heat-proof grease. sleeve 2) Remove the wire which is retaining the 3) Inspection of tension springs.
Page 69: Final Adjustment Of The Clutch Pedal
3.FINAL ADJUSTMENT OF THE CLUTCH 2) Adjust the clearance between the safety PEDAL switch and the bolt head to 38 ±1㎜(1.496 Clutch pedal play in.) so that the switch will turn on only 1) Loosen the lock nuts on the clutch rod and adjust the when the clutch is disengaged to allow the clutch rod length to achieve 20∼30㎜...
Page 70: Section 4. Troubleshooting
SECTION 4. TROUBLESHOOTING 1.PROBLEM :Clutch slippage. The initial stage of clutch slippage is very hard to notice,but the following symptoms 1) The tractor is not generating adequate power when performing heavy duty operations. 2) Output is not commensurate to increate in engine speed when the engine is accelerated suddenly during operation.
Page 71 4. PROBLEM: Abnormal noises There are abnormal noises emanating from the clutch. Probable causes Countermeasures -Broken or insufficiently lubricated release bearing Replace -Seized or worn pilot bearing Replace -Cracked disc plate Replace 5. PROBLEM: Dashing or shifting The tractor does not starting moving smoothly but dashes or is likely to stop when the clutch is operated during a operation.
Page 72 CHAPTER 5 Transmission SECTION 1.GENERAL DESCRIPTION------------------------------------5-1 1.Wheel driving system----------------------------------------------------------5-1 2.PTO drive system--------------------------------------------------------------5-1 3.Power train diagrams---------------------------------------------------------5-2 4.Speed shift patterns and gear train diagrams---------------------------5-2 5.Construction and function of synchromesh mechanism------------- 5-5 SECTION 2. SPECIFICATIONS---------------------------------------------5-7 1. Wheel drive system----------------------------------------------------------5-7 2. PTO drive system------------------------------------------------------------5-7 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY-5-8 1.
Page 73: Section 1.General Description
Chapter 5 .Transmission SECTION 1.GENERAL DESCRIPTION 1. WHEEL DRIVE SYSTEM The wheel driving system is composed of the following major components: Reverse change gears Front transmission (Linear shift mechanism) Transmission Main Change gears Space transmission Sub-change gears (speed range) Front drive change gears Ring gear Rear transmission Differentials...
Page 74: Speed Shift Patterns And Gear Train Diagrams
4.SPEED SHIFT PATTERNS AND GEAR TRAIN DIAGRAMS. 1)Linear shift(reverse change gears) Forward Fig.5-2 Reverse Fig.5-3 2) Main speed shift(Main change gears) Fig.5-4 Fig.5-5...
Page 75 Fig.5-6 Fig.5-7 3) Speed range shift(Sub-change gears) (Low) Fig.5-9...
Page 76 (MID) Fig.5-10 (HIGH Fig.5-11 4)PTO speed shift(PTO change gear) Fig.5-12 Fig.5-13...
Page 77: Construction And Function Of Synchromesh Mechanism
5.CONSTRUCTION AND FUNCTION OF THE SYNCHROMESH MECHANISM 1) Construction ①Shifter ②Hub ③Block pin ④Synchro-ring ⑤Synchro-cup ⑥Thrust piece ⑦spring ⑧spline of hub(2) ⑨spline of synchro-cup(2) ⑩constant mesh gear ⑪spline of gear(10) ⑫constant mesh gear ⑬Spline of gear(12) ⑭Spline hub ⑮Spline of spline hub(14) Fig.5-14 Synchromesh 16.Snap ring C(for shaft) The synchromesh mechanism includes the...
Page 78 3rd stage: 1st stage: When force(F) is applied to shifter(1) When hub(2)is pushed further,the tapered surface in through the gear shift lever,hub(2) is pushed the hole of the hub and the tapered surface on the in the direction of the arrow.Following block pin are pressed tightly against each other,this movement of the hub,other parts such as pushes synchro-ring(4) against synchro-...
Page 79: Section 2. Specifications
SECTION 2. SPECIFICATIONS 1. WHEEL DRIVE SYSTEM Model 3510/4110 T390 T430/T431 Speed shift range forward reverse Reduction Linear shift forward 1/ 1.238 ratios. reverse 1/ 1.354 Main speed shift 1/ 2.105 1/ 1.5 1/ 1.107 1/ 0.844 Speed range shift 1/24.191...
Page 80: Input Shaft And Reverse Change Gear(Front Transmission)
DISASSEMBLY SECTION 3. ,INSPECTION,AND REASSEMBLY 1. INPUT SHAFT AND REVERSE CHANGE GEARS (FRONT TRANSMISSION) 1.Gear helical(30) 2.Shaft 4. Ball bearing 5.Ball bearing 7.Reverse shaft 8.Ball bearing 9.Ball bearing 10.Gear helical(26) 11.Needle bearing 12.Washer(25X46X03) 14. Synchronizer 15.Snap ring 17.Needle bearing 18.Washer(30X46X03) 19.Gear(helical/33-29) 21.Ball bearing 22.Clutch release...
Page 81 c. Pull out Helical gear(21T) rearwards. 1.1 DISASSEMBLY d. Remove the sleeve metal tightening bolts and take off sleeve metal. (1)Removal of input shaft and related parts e. Draw Input gear forwards. separate the engine from the front transmission f. Remove snap ring C referring to the paragraph 3.(1) of SECTION 4.
Page 82 a.Draw shaft along with gear(Fig5-24) b.Draw PTO drive gear;PTO clutch assembly;PTO drive shaft;gear all together as an assembly. Note: Be careful not to damage the seal ring of the PTO clutch c.Extract the assembly of gear,reverse shaft,synchromesh assembly,and gear. Fig.5-25 Note: When the PTO clutch assembly is trouble-free,keep it aside,without disassembling it,in a Clean,dust- free place...
Page 83 (3) Disassembly of reverse shaft and related parts. (17) Needle bearing (20) Needle bearing (33) RBB(6305) (34)Synchro-cup (35)Synchro-hub comp (36)RBB(6306) (37) Snap ring Fig.5-26 a.Remove bearings(33 and 36) b.Remove washers(15 and22),needle bearings(17 and 20),synchro-hub comp,(35),etc.synchro-cup(34) can be taken off as an assembly with gears(16 and 21). c.Remove snap ring(37) and detach the synchro-cup.
Page 84 1.3 REASSEMLBY (1) Sub Assembly of reverse shaft and related parts. Fig.5-27 a.Install Synchro-cups(34) on gear(16) and gear(21) respectively and retain them securely with snap rings C b.Install synchro-hub comp(35) and above sub- assemblies on reverse shaft(18) Note: As each synchromesh assembly maintains a specified installed width,be sure not to mix different pairs of the synchro-hub comp,and the synchro-cup c.
Page 85 (2) installation of each sub-assembled shaft. Install each sub- assembled shift into the reverse metal(Support). Note: When installing the PTO clutch assembly,apply a thin coat of grease to the seal rings and install it taking care not to damage these rings. Fig.5-28 5-13...
Page 86 (3) installation of input metal and related parts. Fig.5-29 Reassemble in reverse order of disassembly,following the next instructions. a.Install the idle shaft(12) so that the end with the tapped hole faces rearwards,that is ,on the snap ring installed side. b.Apply adhesive to the threads of the bolts (M8 ×20) which tighten the bearing retaining plate. c.Oil seals should be installed in their correct direction.As an oil seal is a special eccentric seal,be careful not interchange these seals.
Page 87: Pto Clutch
2. PTO CLUTCH 2-1. DISASSEMBLY Fig.5-30 (38)RBB (40)RBB (44) Snap ring (45)Back-up plate (46) Disc assembly (47)Driven plate (48) Piston (51) Seal ring (52) Seal ring (53) Cover assembly (54)Seal ring Note: Disassembly of the PTO clutch assembly should be done in a clean,dust-free place.Exercise special attention to avoid damage of the seal rings,etc a.
Page 88 -Inspection for disc thickness and serration wear. Inspection Items Specified values Usable limit Disc thickness 2.2±0.1mm 1.9mm (0.087 in) (0.075 in) Surface flatness 0.2mm (0.008 in) Fig.5-33 e. If the combined thickness of the return plate and brake disc deviates from the specified value, replace both parts.
Page 89 2.3 REASSEMBLY Reassemble the parts in reverse order of disassembly,following these instructions. Note: -Each parts should be washed clean before reassembly. -Apply multi-purpose,quality grease to needle bearings in advance. -Each bolt and nut should be tightened to Fig.5-36 the respective specified torque table. -Every time a gear is installed,its smooth 4.Bearing ball (6205) 5.Gear,helical 35T rotation should be checked.
Page 90: Main Change,Sub-Change,And 4Wd Change Gears
3.MAIN CHANGE,SUB-CHANGE,AND 4WD CHANGE GEARS. (1)Synchromesh transmission version. Fig.5-38 Synchromesh transmission version 5-18...
Page 91 Fig.5-39 Main change gear and related parts. 5-19...
Page 92 3.1 DISASSEMBLY Fig.5-40 Separation the spacer transmission case and rear transmission case from each other referring paragraph 5.(1) in SECTION 4.SEPARATION OF MAJOR COMPONENTS in chapter 2. With this operation,the transmission is divided into parts A and B part A includes main speed shift and mechanism and part B includes speed shifting and 4WD shifting mechanisms.(fig.5-26) Note: The separation of the gears mentioned in the figure is possible without dividing the front transmission...
Page 93 (1) Disassembly of main change gears(main speed shift),part of sub-change gears(speed range shift) and shifters. Fig.5-41 a.set the cut away part of the gear so that it clears the gear as shown in fig.5-42 b.Remove the tightening bolts of the reverse metal(support) (two straight pins are installed) c.Pull out the assembly of the reverse shifter metal,main speed shift gears,and shifters...
Page 94 Fig.5-43. (2)Disassembly of the sub-change gears (Speed range shift) a.Remove the sub-shifter and shifter stay. b.Pull out the PTO shaft ,4WD shaft and gear Fig.5-45 c. Remove the snap ring from the end of the pinion gear shaft d. Remove the hub e.
Page 95 3.2 INSPECTION Before and after disassembly,inspect each part for points mentioned below,and replace if necessary. Inspection Item Standard Value Usable limits Backlash of each gear(measured in meshed condition) 0.1-0.2mm(0.004-0.008in) 0.5mm (0.020 in) Stepped wear of teeth 0.3 mm (0.012 in) +0.18 Assembled width of synchromesh 51.17...
Page 96 3.3 REASSEMBLY Reassemble the parts in reverse order of disassembly,following these instructions. Note: -Each part should be washed clean before reassembly. -Apply multi-purpose,quality grease to needle bearings in advance. -Each bolt and nuts should be tightened to the respective specified torque in accordance with the tightening torque table.
Page 97 a.While holding the gear in the position shown in the drawing,install the assembly of the main change gears and related parts in position by tapping it slightly on the front of a plastic hammer and then the gears by tapping it on the rear. b.
Page 98 (2)Reassembly of sub-change gears (speed range shift) -Reassemble the parts in reverse order of disassembly following next precautions. a.Never forget to install needle roller bearing and collar Fig.5-50 b. Pay attention to the installed direction of gear Fig.5-51 5-26...
Page 99 c. Be sure to install the sub-change shifter Fig.5-52 5-27...
Page 100: Rear Transmission
4. Rear transmission case Fig.5-53. 4 speed PTO version 5-28...
Page 101 3-1. DISASSEMBLY Separate the spacer transmission and the rear transmission from each other and then remove the hydraulic cylinder case.referring to paragraph 7.(1) of SECTION 4. SEPARATION OF MAJOR COMPONENTS in Chapter 2. (1) Ring gear,Drive pinion,and related parts. Fig.5-54 1.Diff case (L) 2.Diff case(R) 4.Bolt...
Page 102 a.Dismount diff-case (RH) and diff-case g. Remove the pinion metal(support) tightening metal(LH) by installing push bolt as shown in bolts and take put drive pinion(19) and related Fig.5-55 parts as an assembly.The number of installed shims should be written down or memorized for later reference.
Page 103 (2) PTO shaft and related parts. Fig.5-59 1.Rear transmission case 2.Change arm 3.Cam. 4. Change plate 5.PTO shifter stay 6.PTO shifter 7.Gear spur(38-33) 8.PTO shaft 9.Gear spur(12-17) a.Remove the rear hitch and the trailer hitch b.Remove change plate(4) c.Extract PTO shaft(5) rearwards and take out shifter(6) d.Be alert to the steel ball which mat spring out of the shifter.Extract PTO shaft(10) rearwards and remove the change gears and related parts.
Page 104 4.2. INSPECTION Before and after disassembly,inspect each part for the items mentioned below.Parts which deviate from the specified values should be replaced. -Wash clean all disassembled parts and check them for wear,damage,deformation,Burning ,etc. Defective parts should be corrected or replaced. Fig.5-60 -As the drive pinion and the ring gear make a pair,they (1) Drive pinion...
Page 105 When the drive pinion or the ring gear has been Ring gear tightening 9.0-11 Kgf.m replaced, the proper number of shims to be installed should be determined based upon the torque (39.8-69 ft.lbs) following procedure: Note: Drive pinion metal 5.5-7 Kgf.m - As shown in Fig5-64,there are two kinds of tightening torque (39.8-69 ft.lbs)
Page 106 Note: When reassembling the used pinion and ring gear,reinstall the same thickness of shims as was installed before disassembly in each shimming position. h.Backlash adjustment between the drive pinion and the ring pair(Fig5- i.As the drive pinion and the ring gear make a pair,be sure not to mate them with other parts from differential tractors.
Page 107 Note: Strike the circumference of the ring gear both sides with a copper hammer by turning the ring gear manually,and check to see that the backlash remains unchanged.The backlash should be checked at four points 90 degrees apart to each other. ⅲ.
Page 108 (2) PTO shaft and related parts. a.Pushing the PTO counter gear end into the bearing until the stop on the gear is securely seated against the bearing.The seal should be coated with an adhesive (THREE BOND TB1215) on the circumference before installing. b.Install the oil seal on the PTO shaft,paying attention to its installed direction.
Page 109: Shifters And Related Parts
5. SHIFTERS AND RELATED PARTS. 5.1. CONSTRUCTION (1)Forward and reverse control linkage mechanism(Linear speed shifter) (synchromesh transmission version) Fig.5-69 1.Metal(shifter,reverse) 2.Bolt(S) 3.Nut 4.Washer spring 5.Washer plain 6. Stay shifter reverse 7.Reamer bolt 8.Washer spring 9.Washer plain 10. Fork(shift/shuttle) 11. Shifter spring 12.Steel ball 13.Arm(reverse) 14.
Page 110 Fig.5-70 Fig.5-71 (2) Main change mechanism(Main speed shift) (Synchromesh transmission version) 1.Rail(shifter/1 2.Rail(shifter 3 8.Link 9.Link 13.Guide 15.Metal(Main) 21.Fork(shifter/main) 22..Fork(shifter/main) ,4th) 33.Lever(bar/16)lower 34.Lever(bar/16)upper 38.Gasket(Main metal) Fig.5-72 Note: The bolt tightening the bottom of the metal(Support) should be coated with an adhesive ahead of time Fig.5-73 5-38...
Page 111 (3) Range shifter (Speed range shift) mechanism 1.Rail(shifter,sub) 3.Fork(shifter,sub) (High-Mid) 5.Hook(Shifter,sub) (Mid-Low) 6.Shifter spring 7.Steel ball 8.Guide 9.Bolt(S) 10.Metal (SUB) 11,12.Bolt 15.lever(Bar,16) 16.Bolt 17.Snap ring 18.Seal 19.Spring 20 Pin 21.Boots 22.Wire 23.Sub shift speed grip 25.Gasket 41.Nut 42.Washer Fig.5-74 Note: The bottom two tightening bolts should be coated with an adhesive on their threads before being tightened.
Page 112 (4) Front drive change (4 WD shaft) mechanism 1.Metal(shifter) 2.Shifter spring 3.Steel ball 4.Bolt 5.Nut 6.Washer spring 7.Arm comp 8.O-ring 9.Arm(plate) 10.Spring pin 11.Lever(bar,12) 12.Bush 14.Knob 15.Bracket 16.Bolt 17.Tension arm washer 18.Snap ring 19.Rod 22.Elbow 23.Nut 24.Washer spring Fig.5-76 25.Stud 26.Packing Fig.5-77 5-40...
Page 113 (5) Rear PTO shift mechanism Fig.5-78 1.Rear transmission case 2.Change arm 3.Cam. 4. Change plate 5.PTO shifter stay 6.PTO shifter 7.Gear spur(38-33) 8.PTO shaft 9.Gear spur(12-17) Fig.5-79 5-41...
Page 114 REAR PTO counter shaft mechanism Fig.5-80 1.Gear,spur 12 2.Gear spur 14 3. Snap ring(shaft) 4. Ball bearing(6205) 5. Ball bearing(6305) Note: - When pushing the R.B.B’s(6305,6205) into the gear ,spur 12,be careful only to push their inner races. - The snap ring C should be securely seated in the groove and the press-processed side turned towards the outer side.
Page 115 (7) Drive pinion Sub assembly Fig.5-83 1.Metal pinion 2.Taper roller bearing 3.pinion drive 10 4.Taper roller bearing 5.Gear spur 23T 6.Nut(M30X1.5) 7.Washer(28X46X03) 8.Needle bearing 9.gear spur 40T 10.Hub(28X51X59) 11.Snap ring (shaft) 12.Gear spur 33T 13.gear helical 22T 14.needle bearing 15.Washer(20X34X03) 16.Ball bearing 17.Washer(20X30X1.8) 18.Snap ring (shaft) Note: a.Apply oil to the drive pinion and related parts ahead of time.Then install them and tighten the...
Page 116 (8). Sub change counter shaft 1.Gear range(13X20X29T) 2.Ball bearing(6207) 3.Needle bearing 4.Gear spur(30X35T) 5.Washer(25X46X07) 6. Ball bearing(6305) Note: 1.Apply grease when installing Needle bearing 2.pay attention to the installed direction of gear(spur/30-35) 3.After installation,be sure to slide smoothly 8.Differential gears. Fig.5-85 1.Bevel 10X51 2.Case Diff(L)
Page 117 5-2 PRECAUTIONS FOR DISASSEMBLY, INSPECTION,AND ASSEMBLY (1) Disassembly When drawing a shifter stay from its shifter,be careful not to lose the steel ball.It can jump out of the shifter. (2) Inspection -Shifter –disengaging load: Main change and sub change:18-22 Kgf (40-49lbs) 4WD change: 25-29 kgf (55-64 lbs) -Usable limit of shifter-disengaging load:...
Page 118: Section 4. Troubleshooting
SECTION 4. TROUBLESHOOTING 1. WHEEL DRIVE SYSTEM Problems Causes Countermeasures Transmission makes Insufficient or improper lubricant Replenish or replace noise in neutral Excessive splines of change shaft,spline hub,etc Replace Worn or broken bearings Replace Slide couplings interfering with the gears due to worn Replace or deformed shifters Gears make a noise...
Page 119: Pto Drive System
2. PTO DRIVE SYSTEM problem Causes Counter measures PTO does not spin with PTO PTO shift lever is in neutral Shift lever positively to shifted to ON Defective PTO switch replace Clogged PTO valve Wash clean Poor Pump Replace Defective solenoid valve Replace PTO spins but does not Worn clutch disc...
Page 120: Power Train Diagrams
Power train diagram Fig.5-87 5-48...
Page 121 CHAPTER 6 FRONT AXLE CHAPTER 6. FRONT AXLE(4WD)-----------------------------------------6-1 SECTION 1.GENERAL DESCRIPTION-----------------------------------6-1 SECTION 2. SPECIFICATIONS---------------------------------------------6-2 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY--6-3 1. Center pivot-----------------------------------------------------------------6-3 1-1. Disassembly---------------------------------------------------------------6-4 1-2. Inspection-----------------------------------------------------------------6-4 1-3. Reassembly---------------------------------------------------------------6-4 2. Front differential-----------------------------------------------------------6-6 2-1. Disassembly---------------------------------------------------------------6-7 2-2. Inspection-----------------------------------------------------------------6-7 2-3. Reassembly---------------------------------------------------------------6-8 3. Final case--------------------------------------------------------------------6-10 3-1. Disassembly--------------------------------------------------------------6-11 3-2.
Page 122 Chapter 6 Front axle(4WD) 1. GENERAL DESCRIPTION The 4WD front axle is a center pivot type.The front wheel drive mechanism is incorporated as a part of the axle. The front wheel drive power is taken off the rear transmission and transmitted to the differential in the front axle where the power is divided into right and left and to the respective final cases.
Page 123 SECTION 2. SPECIFICATIONS 3510/4110/T400/T450/T451 Wheel alignment Toe-in (mm) Camber 3°± 1° Caster 1°± 1° Front axle Pivot metal (F) bore (mm) Φ55 Pivot metal (R) bore (mm) Φ80 Pivot metal (F) bush (mm) 50X55X20 Pivot metal (R) bush (mm) 75X80X30 Housing (F) Diameter (mm) Φ50 Housing (R) Diameter (mm)
Page 124 SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY 1. CENTER PIVOT Fig.6-3 1.Housing,front axle 10.Bolt (M16X40) 19.O-ring(G 55) 2.Oil cap 11.Washer,spring(M16) 20.Bolt 3.Plug 12.O-ring(P) 21.Nut 4.connector 13.O-ring 22.Seal washer 5.Hose(820) 14.Spacer (R) 23.Bolt(M12X40) 6.Clamp,(worm/14.5) 16.Metal pivot(F) 24.Washer spring 8.Metal,pivot(R) 17.Bush(50X55X20) 9.Bush(75X80X30) 18.Spacer (F)
Page 125 2) FRONT AXLE BUSH BORE DIAMETER 1.1.DISASSEMBLY 1) Dismount the front wheel drive shaft, Measure the bore diameter of the roll referring to the pertinent paragraph in chapter 2. bush in the pivot metal(F).If the measured value 2) Remove the right and left tie rods. exceeds the usable limit,replace the bush.
Page 126 Fig.6-9 Fig.6-7 Note: Slanted or forced installation of the bush should be avoided,and the bore surface of the bush should not damaged. 3) Pay particular attention to the installed direction of thrust collar,that is,with the sharply-edged face turned towards the bevel gear case. 4) When the thrust collar has been replaced or the fore-and aft play of the front axle exceeds the usable limit,correct play by screwing in the...
Page 127 2. FRONT DIFFERENTIAL Fig.6-10 1.Oil seal 3.Pinion bevel 8T 4.Gear bevel 23T 5.Case front Diff 6.Pinion Diff (12) 7.Thrust collar 8.Gear diff side (20) 9.Washer thrust 10.Pin spring 11.Shaft diff pinion 12. Pin spring 13.Bearing Ball(6212) 14.Snap ring 15.Snap ring( hole) 16.Shim(A) 17.Shim(B) 18.Bearing taper roller 19.collar 20.Nut(M30)
Page 128 2.1 DISASSEMBLY 6) Remove the bearings from the Axle housing 1) As concerns operation prior to removal of And the ring gear,and then the ring gear can the front axle,refer to the paragraph covering be separated from the Axle housing. disassembly of the center pivot 7) Remove the straight pin(4) which retains the 2) Remove both wheels...
Page 129 2-3.REASSEMBLY Specified thrust play 0.1-0.3 Reassembly the parts in reverse order of mm(in) (0.004-0.011 in) disassembly,following these instructions. Note: 1)Each friction surface should be coated with grease in advance. TRB and collar should be replaced as a pair. 2)The bevel pinion and the ring gear make a distinct pair after a mesh adjustment (1) Bevel pinion (8) performed at the factory.
Page 130 Fig.6-16 3) DIF CASE AND BEVEL PINION 1.shim 2.shim 3.shim 4.Parallel pin Fig.6-17 Note: Discard the removed straight pin and oil seal and install a new pin and Oil seal when reassembled,because this pin and oil 1) Each friction surface should be coated seal is apt to be damaged when removed.
Page 131 3. FINAL CASE 3-1. Front gear case 1. Fig.6-18 1.Final drive case(A) 2.Gear bevel(9) 3.RBB(6208) 4.Pin,parallel 5.Bolt(fine) 6.Washer spring 7.Gear bevel(16) 8.RBB(6207) 11.Final drive case(B)(L) 13.Final drive case(B)(R) 14. Housing seal 15.Seal 16.RBB(6014) 17.shaft 18.Gear bevel(11) 19.RBB(6308) 20.O-ring 23.Cap 90 25.Shaft RH(296) 26.
Page 132 3-2. Front gear case 2. Fig.6-19 14.Gear bevel 38 15.Snap ring 17.Seal 18.Bearing 19.RBB(6210) 20.Cover wheel shaft 30.O-ring 31.Bolt 34.Shaft wheel 35.Washer(50X60X2) 3.1 Disassembly 1) Drain oil from the final case by removing the drain plug. 2) Remove the tie rod or the tie rod end. 3) Remove the final drive case clamping bolts and take out the assembly of the wheel shaft, 4) Remove the wheel shaft cover clamping bolts...
Page 133 Note: The removed cap(90) (black plug) should be discarded and replaced when reassembled. 3.2 INSPECTION 1) Wheel shaft cover - Inspect mechanical oil seal,O-rings, Gears, cases,etc. and replace them if worn or damaged. -Measure the diameter the part which makes contact with the wheel shaft,with a micro-meter Fig.6-21 or vernier-calipers.When the measured value...
Page 134 Wheel shaft cover 3.3 REASSEMBLY 1) Every snap ring(5) should be seated securely Reassemble the parts in reverse order of in its groove. disassembly, following these instructions. 2) Be sure the numbers of Bevel gear is correct 1) Apply an adhesive (THREE BOND TB1215) (teeth numbers are 41) to the following parts.
Page 135: Steering Cylinder
- FINAL DRIVE CASE AND HOUSING - STEERING CYLINDER Fig.6-28 1) When installing the shaft,Be sure that the gears are not damaged. 2) Be sure the differences between the LH and RH shaft. Fig.6-30 Specified length 526mm 342mm 1) When installing the steering cylinder,Be sure that the rods are not damaged.
Page 136 CHAPTER 6 *This chapter is applied to sheet metal FRONT AXLE CHAPTER 6. FRONT AXLE(4WD)-----------------------------------------6-1 SECTION 1.GENERAL DESCRIPTION-----------------------------------6-1 SECTION 2. SPECIFICATIONS---------------------------------------------6-2 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY--6-3 1. Center pivot-----------------------------------------------------------------6-3 1-1. Disassembly---------------------------------------------------------------6-4 1-2. Inspection-----------------------------------------------------------------6-4 1-3. Reassembly---------------------------------------------------------------6-5 2. Front differential-----------------------------------------------------------6-6 2-1. Disassembly---------------------------------------------------------------6-7 2-2. Inspection-----------------------------------------------------------------6-8 2-3.
Page 137: Chapter 6 Front Axle(4Wd)
Chapter 6 Front axle(4WD) 1. GENERAL DESCRIPTION The 4WD front axle is a center pivot type.The front wheel drive mechanism is incorporated as a part of the axle. The front wheel drive power is taken off the rear transmission and transmitted to the differential in the front axle where the power is divided into right and left and to the respective final cases.
Page 138: Section 2. Specifications
SECTION 2. SPECIFICATIONS T390//T430 Wheel alignment Toe-in (mm) Front axle Center Pivot Axle diameter front axle (mm) Φ80 Front diff holder (mm) Pivot metal (F) bush bore (mm) Φ80 Bearing cover shaft diameter (mm) Φ35 Case shaft Diameter (mm) Φ55 Case bush bore (mm) Φ55...
Page 139: Center Pivot
SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY 1.CENTER PIVOT T390,T430,T431 Fig.6-3 1.Lock bolt 9.Thrust collar 2.Pivot metal (support) 10.Bush(65X70X44) 3.Spacer 11.Rear pivot metal Support) 4.connector 12.Bolt(M18X1.5X55:7T) 5.Bush(55X60X50) 13.Oil seal 6.Axle housing 14.Cover 7.Bevel gear case 8.X-ring...
Page 140: Disassembly
1) Bevel case shaft diameter mm (in) Measure the diameter at a roll bush contact point with a micro meter or vernier calipers. If the T390 /T430 measured value is less than usable limit ,replace the case. Standard value as assembled Ø55 (2.165)
Page 141: Reassembly
Note: After correcting the pivot metal play,tighten the lock nut of the adjusting bolt to a torque of 11.7~13.7KN-cm(1200~1400 kgf-cm) 5) The reassembled front axle should rock smoothly while pivoting. 6) When the tie-rods are reinstalled,the toe-in should be adjusted.At the same time,the steering Fig.6-8 angles of the both wheels should also be adjusted.
Page 142: Front Differential
2. FRONT DIFFERENTIAL Fig.6-12 1.Bevel case 8. Tapered roller bearing 2.Diff-Metal(support) 9.Bevel pinion 3. Shim A 10.Washer (85X98X05) 4.Shim B 11.Bevel gear(20 T) 5.Nut(M28X1.5) 12. Bevel pinion(11T) 6. Sleeve 13. Front diff-case 7. Shims ( A and B)
Page 143: Disassembly
2.1 DISASSEMBLY 7) Remove the bearings from the Diff case 1) As concerns operation prior to removal of And the ring gear,and then remove the bolt. the front axle,refer to the paragraph covering The ring gear can then be separated from the disassembly of the center pivot diff-case.
Page 144: Inspection
Note: 10) When separating the TRB’s from the bevel As a general rule,a disassembled lock nut pinion,release the calking of the lock nut and should be replaced and a new one should remove the bearings. be installed.However,when there is no Note: alternative but to reuse the disassembled The lock nut should be calked at a point...
Page 145: Final Case
3. FINAL CASE Fig.6-18 1.Final drive shaft 2.bevel gear 3.Bearing cove 4.bevel gear 5.Counter shaft 6.Final case A 7.Flat seat thrust bearing 8.Roll bush 9.Final case B 10.Bevel gear 11.Seal(Blank plug) 12. Bevel gear 13. Stop ring 14.Wheel shaft cover 15.Wheel shaft 16.
Page 146 *Inspection prior to disassembly -Try to move the final case B up and down to make sure that there is no play. Standard value as 0~0.2mm assembled mm( in) (0~0.008) Usable limit: mm(in) 0.5(0.020) -When the play exceeds the usable limit,correct it by a shimming adjustment.
Page 147: Inspection
3.2 INSPECTION 8) Extract the wheel shaft bearing together with the bevel gear,using a bearing puller. 1) Bearing cover shaft diameter Measure the diameter the part which makes contact with the roll bush in the drag arm,with a micro-meter or vernier-calipers.When the measured value less than the usable limit,replace the bearing cover.
Page 148: Reassembly
3) Final case A shaft diameter 5) Inspect other bearings,oil seals,O- rings, shafts, gears,cases,etc., and replace them Measure the diameter of the shaft part which if worn or damaged makes contact with the roll bush with a micrometer or vernier calipers.When the 3.3 REASSEMBLY measured value is less than the usable limit,replace the case(Fig.6-27)
Page 149 6)The oil seal should be coated with grease in advance.Then install them carefully,assuring that their lips are not turned over. 7) The reassembled final case (B) should turn smoothly until it makes contact the stopper. 8) When the wheel(tire) is reinstalled,turn it by hand to make sure that all the mechanism turns smoothly without making any noise.
Page 150: Section 4.Trouble Shooting
SECTION 4. TROUBLE SHOOTING PROBLEMS AND PROBABLE CAUSES COUNTERMEASURES ● Steering wheel hard to turn 1)Too low tire inflation Inflate to specified value 2)Broken thrust bearing Replace 3)Stuck or broken ball joint of tire-rod end Grease or replace 4)Seizure or poor lubrication of axle end bush Grease or replace ●...
Page 151 CHAPTER 7 Rear axle and brakes SECTION 1.GENERAL DESCRIPTION-----------------------------------7-1 SECTION 2. SPECIFICATIONS---------------------------------------------7-2 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY--7-3 1.Rear axle housing and brake system--------------------------------------7-3 1.1. Disassembly-----------------------------------------------------------------7-4 1.2. Inspection-------------------------------------------------------------------7-4 1.3. Reassembly-----------------------------------------------------------------7-5 SECTION 4.TROUBLE SHOOTING---------------------------------------7-7...
Page 152 Chapter 7. Rear axle and brakes 1. GENERAL DESCRIPTION The rear axle system is of the central axle type,which contains the final reduction gears, differential gears with diff-lock,and brakes.The power from the engine is transmitted to the right and left wheel pinions through the differential gears,and reduced in the revolution to the rear wheels by the wheel gears.
Page 153 SECTION 2. SPECIFICATIONS MODEL 3510/4110/T390(T400)/T430(T450) Type Helical gears Final reduction gears Reduction ratio Friction Type Wet,multi-disc,Mechanically operated Plate Outer diameter Φ184mm(Φ7.24 in) Thickness 3.4±0.1 mm(0.134 in) Lining material Paper base Brake system Number of plates 4 on each side Outer diameter Φ188mm(Φ7.4 in)
Page 154 SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY Separate the rear axle housing from the rear transmission referring to paragraph 6.(1) of SECTION 4. SEPARATION OF MAJOR BLOCKS in Chapter 2 1) REAR AXLE HOUSING AND BRAKE SYSTEM 1.Housing(Axle,LH) 2. Housing(Axle,RH) 3.4.5.6.Bolt 7.Washer spring 8.Snap ring 9.Bolt 10.Wheel shaft 11.Gear(helical/55)
Page 155 1.1 Disassembly 1) Release the lock of Nut and remove the nut 2) Extract the bearing with a puller and remove wheel gear Fig.7-4 3) Remove the collar and pull out wheel shaft(3) Fig.7-6 Note: Removed oil seal should be replaced with a new one when reassembled 1.2.
Page 156 2) Metal brake 4) Wheel shaft Check the pressure plate,and brake rod for Check the shaft for abnormalities like wear, abnormality.Replace defective parts.Replace the damage,etc,and replace a defective one. metal brake whose thickness exceeds the usable limit. 5) Bearings Check them for abnormalities like hitching, irregularity,etc.in rotation after being washed clean.Replace defective ones.
Page 157 4) Replace the oil seal. Install the bearing,snap ring,and collar into the axle housing,and then press in the oil seal by applying force only to the circumference as shown in the figure( Fig.7-11) Apply force only to the shaded parts Take care not to deform these portions Fig.7-11 5) press in the wheel shaft.
Page 158 SECTION 4. TROUBLESHOOTING Problem Causes countermeasures 1) Rear axle · Worn or damaged bearing Replace Noises · Worn gear or wheel shaft Replace 2) Brake system · Insufficient depressing of brake Depress pedals pedals positively (1)Insufficient braking force · Improper pedal free play Adjust ·...
Page 159 Chapter 8 Power assisted steering system SECTION 1.GENERAL DESCRIPTION-----------------------------------8-1 SECTION 2. SPECIFICATIONS---------------------------------------------8-2 2.1 Gear pump-----------------------------------------------------------------8-2 2.2 Steering valve-------------------------------------------------------------8-2 2.3 Oil tank--------------------------------------------------------------------8-2 SECTION 3. FUNCTION---------------------------------------------------8-3 3.1 Open center non load reaction---------------------------------------8-3 SECTION 4.DISASSEMBLY,INSPECTION,AND REASSEMBLY 4.1 major component of steering valve assembly ---------------------8-7 4.2 Special tools--------------------------------------------------------------8-8 4.3 Disassembly--------------------------------------------------------------8-8 SECTION 5.
Page 160: Power Assisted Steering System
Chapter 8. Power assisted steering system. SECTION 1. GENERAL DESCRIPTION The hydraulics of this power-assisted steering system are actuated by a specially designed steering valve system. Non Load reaction valve blocks the L,R cylinder ports in neutral condition and does not transmits the reaction load of the tire to the steering wheel in neutral.Generally the system is used for the vehicles that treat heavy equipment or low speed traveling.
Page 161: Section 2. Specifications
SECTION 2. SPECIFICATIONS 1) GEAR PUMP MODEL 3510 4110 T390 T430/T431 Delivery (cc/rev) 4.778 4.778 Maximum pressure(kgf/㎤) Rated operation speed 600~3000 2700 rpm 3062 rpm 2843rpm (rpm) Rotation direction C.C.W as viewed from shaft 2. Power steering valve Unit( orbitrol)
Page 162: Section 3. Function
SECTION 3. FUNCTION 1.Open Center Non Load Reaction 1.Neutral Position When the steering control valve is in the neutral position,inlet flow(P) from the priority valve moves the flow selector spool against its spring.This flow is blocked at the control valve control spool.The signal port is connected to the reservoir(T) through orifices in the control spool.The priority valve Will only supply enough oil to the control valve to compensate for internal leakage and maintain low stand-by pressure.The oil at each side of the steering cylinder is connected to each side of the...
Page 163 2)Right Turn When the steering control valve shaft is rotated to the right,the control valve moves off center.This connects the inlet port (P) to one port of each metering pump section and also connects the other port of each metering pump section to the cylinder.The amount that the spool moves off center depends on how fast the steering wheel is rotated and also how much effort is required to turn the wheel.
Page 164 3)Left turn When the steering control valve shaft is rotated to the left,the control valve spool moves off center.This connects the inlet port(P) to the one port of each metering pump section and also connects the other port of each metering pump section to the cylinder.The amount that the spool shifts off center depends on how fast the steering wheel is turned and how much effort is required to turn the wheel.
Page 165 4) Manual steering When there is no piston pump supply pressure the flow selector is moved to the left by its spring.This connects together the inlet and outlet ports of the lower gyrotor pump and disconnects this pump from the system.When the steering is operated manually,only the upper gyrotor pump section is used to direct flow to the steering cylinder.
Page 166: Section 4.Disassembly,Inspection,And Reassembly
SECTION 4. Disassembly,Inspection,And Reassembly 1. Major component of steering valve (orbitrol) Fig.8-6 1.Cover bolt(6) 2. Cover bolt(1) 3. End cap(1) 4.Gyrotor(1) 5. Spacer(1) 7.Spacer plate(1) 8.Driver shaft(1) 9.Pump body(1) 10.Sleeve(1) 11.Spool(1) 12.Pin(1) 13.Center springs(6) 15.Thrust washer(2) 16.Thrust bearing(1) 17. O-ring(1) 18.Seal ring(1) 19.Dust seal(1) 20.Retaining ring(1)
Page 167: Disassembly
2.SPECIAL TOOLS STEP 4. For pumps equipped with cross over check ①Torque wrench(Torque 5㎏f·m) -----------------1 valves,mark position and remove ②5/12″-12 socket ---------------------------------1 spring,valve pins and balls. ③“- ”Driver(big) ------------------------------------ 1 ④“- ”Driver(small) ----------------------------------1 IMPORTANT:Do not use a magnet to ⑤Centering spring installer ------------------------ 1 remove balls.
Page 168 STEP 9. Lubricate and install new o-rings onto check valve seat.Install check ball retainer,check ball and check valve seat into the pump body.Make O-ring sure the threaded end of check valve is facing outward.Install and tighten plug to a torque of 11Nm(100 lb in).
Page 169 NOTE: Make sure the centering spring notches STEP 15. locate correctly into the sleeve. STEP 13 install pin into sleeve assembly and install sleeve into the pump body. Install spiral retaining ring into the the groove in the pump body.Use a screwdriver to make sure the NOTE:Heat from your hands may expand spool and spiral retaining ring is located correctly into the sleeve assembly,preventing the assembly being...
Page 170 STEP 17 install rotor onto drive shaft.Make sure one of the rotor teeth is aligned with the connector mounting face.Lubricate and install a new o- ring into the groove in plate.Align the marks made in STEP 2, and install stator.Make sure the o-ring groove in stator is facing outwards.
Page 171 Align the marks made in STEP 2,and install the end cap.Install and evenly tighten the torx hand screws in two stages to a torque of 17 Nm(12 lb ft) then to 25 to 30 Nm (19 to 22lb ft) in the sequence shown.
Page 172: Section 5. Troubleshooting
SECTION 5. TROUBLESHOOTING Problems and probable causes Counter measures 1. Steering wheel is very heavy to turn 1) Poor assemble between steering column and unit. (1)Spline of column and unit are assembled -Replace column spline tightly. (2)Spool of unit is seized by spline of column -Check column assembly face and spline length (MAX 6.5㎜) (3)Poor rotation of column...
Page 173 Problems and probable causes Counter measures 3. Free play of steering wheel 1)Too low elastic of centering spring ( Remove P port pipe line and check left and right turning) -Replace spring (1)Damaged spring or poor elastic 2) Depressed control set (1) Excessive fluid and pressure -Adjust fluid level and pressure properly (2) Depressed by foreign material...
Page 174 Problems and probable causes Counter measures 8.Serious kick-back each side (1)Poor assemble the gyrotor lower the unit -Reassemble 9. Steering wheel is very heavy to begin turning (1)Oil density is too high or cool -Replace oil 10. External Oil leakage (1)column -Replace oil seal,slide ring (2)End cap gyrotor...
Page 175 Chapter 9 Hydraulic system SECTION 1. GENERAL DESCRIPTION ---------------------------------9-1 SECTION 2. SPECIFICATIONS --------------------------------------------9-2 SECTION 3. DISASSEMBLY AND ADJUSTMENT--------------------9-3 1.Hydraulic system ------------------------------------------------------------9-3 2.Disassembly--------------------------------------------------------------------9-4 3.Reassembly--------------------------------------------------------------------9-5 3.1 General precautions---------------------------------------------------- 9-5 3.2 Reassembly steps-------------------------------------------------------- 9-7 4.Adjustment of the link mechanism-------------------------------------- 9-8 SECTION 4. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM -------------------------------------------------------9-10 1.main control valve ------------------------------------------------------- 9-10 2.Flow-divider --------------------------------------------------------------- 9-19...
Page 176: Section 1. General Description
Chapter 9 Hydraulic system SECTION 1. GENERAL DESCRIPTION The hydraulic system is composed of a gear pump,valves,oil filter,cylinder(actuator),piping,etc.The implement lift is operated by a control valve which is actuated by the control lever through a link mechanism. ON and OFF of the PTO is controlled by a hydraulic,wet,multi-disc clutch whose circuit is opened and closed by an electromagnetic valve in the flow-divider.
Page 177: Section 2.Specifications
SECTION 2.SPECIFICATIONS MODEL 3510 4110 T390/ T430/ T431/ T400 T450 T451 Piston and cylinder Lift(at lower link top end) 1300 Kgf Control valve Cylinder port leaks (under a pressure of 9800KPa[(100Kgf/㎠) 5cc(0.305 Cu in) with gear oil of SAE 80)]...
Page 178: Section 3. Disassembly And Adjustment
SECTION 3. DISASSEMBLY AND ADJUSTMENT 1.HYDRAULIC SYSTEM Fig.9-2 1.Cylinder 2. O-ring 3.O-ring 4.Ring 5.Piston,Hyd. 6.Rod piston 7. Bush 8.Pin,Hyd. 9.Lift crank 10.Plate 11.Relief valve 12. Knob 13.Shaft 14.Seal dust 15.Valve flow control 16. O-ring 17.Bolt(M12) 18. C-ring(shaft) 19.Arm,Lift 20. Bush(50X55X44) 21.Bolt(M8X50) 22.
Page 179: Disassembly
2.DISASSEMBLY 1)Remove the cylinder case assembly,referring to relevant paragraph in Chapter 2. Fig.9-4 4) Applying aligning marks on the Lift shaft(26) and right hand lift arm(19),Then remove the arm Fig.9-2 Note: Put the cylinder case on a wooden plank to prevent the surface from damage.
Page 180: Reassembly
7) Remove the set bolt for the lift crank and 10) Remove the bolt and extract the main remove the assembly of the lift shaft and lift control valve arm. Fig.9-8 8) Remove the assembly of the lift crank and piston rod. Fig.9-11 9) Unhook the each link parts and remove the cover main control valve...
Page 181 5) When assembling the lift crank on the lift 7) When installing the control valve,apply grease lift shaft,mesh their splines using the to the o-rings and avoid their dislocation or alignment marks which were put their binding during tightening the valve to the before disassembly specified torque 8) Tighten the slow return check valve to the...
Page 182 4) Install the lift crank temporarily along with the feed back link.Install the piston on the lift crank. Fig.9-19 3.2 REASSEMBLY STEPS. Fig.9-22 1) Install the main control valve 5) Install the lift shaft and lift crank together in accordance with the aligning marks on them. 2) Install the clevis comp.
Page 183: Adjustment Of The Link Mechanism
4. ADJUSTMENT OF THE LINK MECHANISM. Fig.9-25 1) Adjustment of the position control link Point 2. Fix the clearance between the body and mechanism plate on the control valve and the casing spool to be 10 mm,while the gap A Place the cylinder case assembly upside so that the should be 26mm (Fig.9-27),while the lift arm can be moved freely...
Page 184 Point 3.Set the feed back link so that there is no play by the adjusting nut. Point 4. Apply an locktite to adjusting Nut. Fig.9-28 Thus the adjustment of the position control linkage is completed. 2) Adjustment of the draft-control link mechanism Point 1.Shift the draft-control lever to the top position and the position-control lever to...
Page 185: Main Control Valve
SECTION 4. MAJOR COMPONENTS OF THE HYDRAULIC SYSTEM 1. MAIN CONTROL VALVE 1.1 GENERAL DESCRIPTION This valve controls the lifting and lowering operation of the hydraulic cylinder.It has especially been developed to control the working height of the implement.It consists of a feed back valve;direction control valve,flow-control unloading valve,and holding check valve.
Page 186 2) Unloading valve(1) (compensator) it consists of the spool and spring. While the main spool is neutral or in the lowering position,it diverts all the fluid from the pump directly to the tank.In this state,the pump delivery pressure is regulated to be 7-8Kgf/㎠(100-114 psi) To prevent engine power loss and fluid temperature rise.
Page 187 4) Holding check valve It consists of a check poppet and spring,and is installed between the cylinder port and the main spool. It blocks the flow from the cylinder to the valve in the neutral and in the lifting position,thus preventing the cylinder from releasing in the neutral or lifting position when the pump stops.
Page 188 1.4 OPERATION Port p means “pump port”,and is connected to the pump,while port C means “Cylinder port”, and is connected to the cylinder.Drain ports T1 to T4 are connected to the tank. 1) Neutral position Fig.9-34 In the NEUTRAL position,Spring chamber of unloading valve connected to TANK(T2),Therefore the force imposed upon the right hand side of the unloading valve,then the fluid from the pump flows into TANK(T1).
Page 189 2) Lifting position Fig.9-35 When the main spool is shifted to the lifting position,Passages to the Tank(T2) are closed with unloading spring and the Fluid from the pump flows into unloading valve spring.,therefore the force imposed up the left-hand side of the unloading check valve,Consequently the fluid in the T1 port becomes to close the unloading.
Page 190 3) Lowering position Fig.9-36 When Main spool is shifted to the lowering position,Unloading spring is connected to the Tank(T2),and the force imposed up the right hand side of the unloading check,therefore the fluid from the pump flows into the Tank(T1). Consequently the force imposed up the left hand side of the main check valve,which is connected with Plate-B to open the T3 port.
Page 191 1.5. SERVICING INSTRUCTIONS. Note: The spool and stopper bolt are tightened with 1) Required tools each other with adhesive applied to their threads, -6mm set screw wrench and torque Wrench so they should not be separated unless required. -19mm spanner and torque wrench by removing the stopper bolt,the poppet and -22mm spanner and screw wrench spring can be taken out of the spool.
Page 192 Put the poppet into hole B as shown in the figure and make sure that the poppet slides smoothly.Then put the spring in and tighten the plug,on which the O-ring must be installed,to the specified torque. -unloading valve(1) and related parts. Install the spool into hole C(Fig.9-19) in the correct direction.Put the spring in and tighten the plug to the specified torque.
Page 193: Flow-Divider
2.FLOW-DIVIDER( PTO solenoid valve) 2.1 GENERAL DESCRIPTION This valve is installed to bypass working fluid of a specified pressure from the main circuit into the PTO circuit through a fixed orifice.It includes a changeover valve for engaging and disengage the PTO clutch by means of a solenoid and a sequential valve for PTO circuit's over the main circuit.
Page 194 -When the solenoid is switched 「ON」 The fluid from the pump flows to port B through port P,the pressure-reducing valve,and the changeover valve. The pressure of the PTO clutch circuit and that of passage(2) are the same and will be set as P₂.The pressurized fluid acts on the left-hand side of the valve,passing through port ;...
Page 195 -When the solenoid is switched 「OFF」: The fluid in the PTO clutch is unloaded to the bank through port B.Consequently pressure P2 at passage(2) becomes zero,whereas the pressure at passage (1) is P1.Then the force imposed upon the left side of spool (P1)overcomes the force imposed upon the right side (P2+spring force),so that the spool is pushed rightwards to connect port P and part A.
Page 196: Pressure Control Valve
3. PRESSURE CONTROL VALVE (1) Flow-divider (2) Transmission case (3) Relief Valve (4) Pressure control valve Fig.9-40 3.1. GENERAL DESCRIPTION This valve is composed of the body,plunger,piston,springs,and plug.It serves to absorb shocks which are given when the PTO clutch engages. 3.2.
Page 197 2) When the clutch is in half-engaged state: When the clutch cylinder is completely activated,the pressure in circuit(1) starts rising at point P1 on the graph in Fig.9-42.When the pressure reaches point P2,the piston starts moving to the right overcoming the force of spring(6 and 7). Here the flow through chock(2) causes some difference in pressure between circuit (1) and chamber (3) .
Page 198 2) When the clutch is engaged completely When the piston(6) moves to the end,there is no flow throgh chock(2) and the pressures in chamber (3) and circuit(1) become equal,that is,the pressure which the plunger receives on both sides are the same.Consequently,plunger(7) is pushed back to the left by the force of spring(9),which closes the passage from port B to port T.With this,the pressure in circuit(1) starts rising at point P3 up to the supplied pressure.Thus the clutch engagement is maintained.
Page 199 4. FLOW-CONTROL VALVE(SLOW-RETURN CHECK VALVE) 4.1. GENERAL DESCRIPTION This valve regulates the lowering speed of the lift by controlling the unloading flow from the lift cylinder to the tank. ①Dust seal ②Snap ring ③Collar ④Body ⑤0-ring ⑥Adjust screw ⑦Back-up ring ⑧0-ring ⑨Stop ring ⑩Poppet...
Page 200 4.2 OPERATIONS 1) DOWN position 2) Up position The fluid from port B pushes up stop ring The flow port A,overcoming the force of (9) of poppet(10) until the ring comes into spring(11),pushes up poppet (10) and contact with adjust screw(6),as it reaches choke(C)is fully opened regardless of the chamber(R).
Page 201: Safety Valve
5.SAFETY VALVE( Optional) 5.2 OPERATION 5.1 GENERAL DESCRIPTION With the chock closed completely by turning the This valve is installed in the slow return check adjust screw tightly clockwise,the implement valve circuit and able to be installed in the cylinder mounted on the lift is held at a specified case instead of Bolt.When the adjust screw of the height.While the tractor is traveling on roads in the...
Page 202 3) MEASUREMENT OF THE RELIEF PRESSURE (1)3 POINT TO TEST RELIEF PRESSURE ①Remove the plug in the delivery pipe on the right-hand side of the transmission case and install a compression gauge to measure the pressure. Fig.9-48 Keep the engine speed at 2600 rpm and shift the position control lever at the highest position.
Page 203: Gear Pump
7.GEAR PUMP 7.1 GENERAL DESCRIPTION This pump induces fluid from one side and delivers it from the other side,by rotating two gears meshed with each other. The actual delivery is as mentioned below,considering the consequences of fluid temperature and volume efficiency in accordance with revolution speed. That is dual pump system.
Page 204 7.1.2 Gear pump (Model: 4110.T390(T400).T430(T450).T431(T451) Fig. 9-50 Gear pump 1.Gear pump 2.O-ring(S) 3.Bolt(S) 5.Collar 6.Drive pump(34T) 8.O-ring(S) 9.Stud 10.Nut 11.Washer spring 12.Holder pump 13.Bolt(S) 14.Bolt(S) 15.Drive pump(17T) gear 16.Angular ball bearing 17.Snap ring 7.2 OPERATIONS. This pump induces fluid from one side...
Page 205 ③Remove front and rear pump. 7.3 DISASSEMBLY Be sure not to be damaged the o-ring or steel NOTE: ball ①Before disassembling the pump,wash the outside clean.In the course of disassembling operation,all disassembled parts should be kept aside in a clean place such as on clean paper or cloth and be handled carefully so as to prevent them from becoming dirty or damaged.
Page 206 3) REASSEMBLY ④Tightening sequence and torque of the pump ① Install the rear pump. cover tightening bolts. ▶Install the bushing seal to bushing. ▶Tightening torque: 2.5∼2.8㎏f·m ▶Install the bushing,drive gear,gear,and bushing to the housing. ▶Install the o-ring to the cover. ▶Install the cover to the housing.
Page 207 4) INSPECTION AND REPAIR (3) Bushing ① With clean working fluid,surfaces are (1)Check all disassembled parts for damage rarely scratched and should be smooth. and wash undamaged or usable parts in clean diesel fuel or kerosene except rubber ② If there are many scratches on the bore parts.Inspect all parts referring to these walls,or on parts which are in contact with points,and repair or replace defective parts.
Page 208 (4) GEAR ①With clean working fluid,surfaces are rarely scratched and should be smooth. ②If roughness can be felt by a finger nail,they are darkened,or the shaft diameter is less than 0.03 mm replace the shaft. ③Usable shaft diameter is as below Fig.9-66 gear shaft (5) Oil seal The oil seal prevents oil leaks by its inner seal lip and...
Page 209: Filter
The tractor is equipped with two oil filters: suction filter(1) and line filter(4),for better filtration. 8.2 SPECIFICATIONS 1)Suction filter Model 3510 4110/T390(T400)/T430(T450)/T431(T451) Applicable oil DONAX TD or RPM THF 500 Rated flow rate(ℓ/min.) Filtration density 35 ㎛ 25 ㎛ Filtration area 6231 ㎠...
Page 210: Section 5.Remote Hydraulic Control(Optional)
SECTION 5. REMOTE HYDRAULIC CONTROL 1.GENERAL DESCRIPTION - A hydraulic operated implement can be driven and controlled with this optional remote hydraulic control valve set. - The valve is connected between the gear pump and the main control valve and is given a priority to draw hydraulic power.
Page 211: Specifications
3. SPECIFICATIONS Maximum flow (ℓ/min) 45LPM Maximum pressure(Kgf/㎠) A and B port leak Oil temperature:50℃(122℉) 9 cc/min Under a load of 100Kgf/㎠ Recommended fluid THF 500 Operating temperature range -20℃~80℃ Fig. 9-69 Remote hydraulic pump 3.1 HYDRAULIC CIRCUIT P:From pump T:To tank A:High pressure port B: Return port...
Page 212 Chapter 9 Hydraulic system *This chapter is applied to old version SECTION 1. GENERAL DESCRIPTION ---------------------------------9-1 SECTION 2. SPECIFICATIONS --------------------------------------------9-2 SECTION 3. DISASSEMBLY AND ADJUSTMENT --------------------9-3 1.Hydraulic system ------------------------------------------------------------9-4 2.Disassembly--------------------------------------------------------------------9-5 3.Reassembly --------------------------------------------------------------------9-5 3.1 General precautions ---------------------------------------------------- 9-5 3.2 Reassembly steps -------------------------------------------------------- 9-6 4.Adjustment of the link mechanism -------------------------------------- 9-8 5.Special jigs for link adjustment -------------------------------------- 9-11...
Page 213: Section 1. General Description
Chapter 9 Hydraulic system SECTION 1. GENERAL DESCRIPTION The hydraulic system is composed of a gear pump,valves,oil filter,cylinder(actuator),piping,etc.The implement lift is operated by a control valve which is actuated by the control lever through a link mechanism. ON and OFF of the PTO is controlled by a hydraulic,wet,multi-disc clutch whose circuit is opened and closed by an electromagnetic valve in the flow-divider.
Page 215: Section 2.Specifications
SECTION 2.SPECIFICATIONS MODEL 3510 4110 T390/ T430/ T431/ T400 T450 T451 Piston and cylinder Lift(at lower link top end) 1300 Kgf Control valve Cylinder port leaks (under a pressure of 9800KPa[(100Kgf/㎠) 5cc(0.305 Cu in) with gear oil of SAE 80)]...
Page 216 SECTION 3. DISASSEMBLY AND ADJUSTMENT 1.HYDRAULIC SYSTEM 15.O-ring 30.Pilot spool arm comp 1.Flow-control valve 16.Back up ring 31.Draft control arm comp (slow-return check valve) 17.Piston rod 32.Stopper 2.Safety valve or plug 18.Lift shaft 33.Spring holder 3.Cylinder valve 19.Oil seal 34.Spring 4.O-ring(G80) 20.Lift arm 35.Washer...
Page 217: Disassembly
2.DISASSEMBLY 2.REASSEMBLY 1) Remove the cylinder case assembly,referring Reassemble in reverse order of disassembly. to relevant paragraph in Chapter 2. 3.1 GENERAL PRECAUTIONS 1) Hydraulic system parts should be completely be free from dust before reassembly. 2) All removed O-rings should be replaced with new ones.which should be lubricated with grease before installation.
Page 218 Note: Before installing the linkage,set the load of the pressure spring to be 9.5-9.8Kgf(20.9-21.6 lbs)by making the installed length of the spring 21.5 mm (0.0847 in) (Fig.9-7) 4) Install the main control valve and return spring Fig.9-5 3.2.REASSEMBLY steps 1) Install the draft control linkage. Fig.9-8 5) Install the lift crank temporarily along with the feed back link.Install the piston rod on the...
Page 219 (Fig.9-10).Apply grease to the roll bush. Fig.9-10 7) Drive the oil seal onto the lift shaft and install the lift arm. Note: When installing the oil seal,take care not to allow the oil seal lips to be damaged by the splines of the lift shaft.
Page 220 4. ADJUSTMENT OF THE LINK MECHANISM Fig.9-11 1)Adjustment of the position-control link mechanism. Place the cylinder case assembly upside down so that the lift arm can be moved freely. Point 1. Set the load of the pressure spring of the pilot spool control arm to be 9.5-9.8 Kgf (20.9-21.6 Point 3 lbs):the installed length of the spring is about...
Page 221 Point 5 Link so that there is no play by the adjusting Set the clearance between the pilot spool and the screw.It is recommended to hold the draft control push rod to be 0-0.2mm(0-0.008in) with the push rod pushed against the arm for easier adjusting screw.
Page 222 Point 2. Point 6 Turn the lift crank to the bottom position Loosen the draft link boss and eliminate its fore and –aft play.Then turn the boss so that the hole Point 3 in it becomes horizontal. Insert a spool jig between the back face of the snap ring on the main spool front and the casing Thus the adjustment of the draft-control link and set the clearance to be 9 mm(0.35 in).The...
Page 223: Special Jigs For Link Adjustment
5.SPECIAL JIGS FOR LINK ADJUSTMENT Rod gauge(A) Rod gauge(B) Set gauge(A) 9-11...
Page 224: Main Control Valve
SECTION 4. MAJOR COMPONENTS OF THE HYDRAULIC SYSTEM 1. MAIN CONTROL VALVE 1.1 GENERAL DESCRIPTION This valve controls the lifting and lowering operation of the hydraulic cylinder.It has especially been developed to control the working height of the implement.It consists of a feed back valve;direction control valve,flow-control unloading valve,and holding check valve.
Page 225 2) Unloading valve(1) (compensator) it consists of the spool and spring. While the main spool is neutral or in the lowering position,it diverts all the fluid from the pump directly to the tank.In this state,the pump delivery pressure is regulated to be 7-8Kgf/㎠(100-114 psi) To prevent engine power loss and fluid temperature rise.
Page 226 4) Holding check valve It consists of a check poppet and spring,and is installed between the cylinder port and the main spool. It blocks the flow from the cylinder to the valve in the neutral and in the lifting position,thus preventing the cylinder from releasing in the neutral or lifting position when the pump stops.
Page 227 1-4 OPERATION The valve operation is explained here referring to Fig.9-16 to 18. Port P means”pump port” and is concerned to the pump,while port C means “Cylinder port”,and is connected to the cylinder.Drain port T1 to T4 are connected to the tank. 1) Neutral position Fig.9-24 In the neutral position,orifice (7) is closed,orifice(16) is open,and chamber(1) is connected to port T4...
Page 228 The pressure in chamber(32)(pilot pressure)becomes equal to the tank pressure[ 0 Kgf/㎠(0 psi)] because chamber(32) is connected with chamber(5). The pilot spool is then shifted rightward and passages(29 and 30) are connected with each other.Consequently the pressure in check valve spring chamber(26) becomes high enough to hold the piston steady and the check valve poppet (D) completely closes the cylinder circuit.In this state,fluid leaks through port C are prevented by the check valve poppet seat and also by friction surfaces of the pilot spool and the spool (H)(unloading...
Page 229 When spool (A) is shifted to the lifting position,orifice(6) is closed,and orifice(7) is opened and chamber(1) is connected with chamber(3) through passages(37 and 38):passages to the tank are closed.As orifice (11) is opened and orifice(10) closed,chamber(5) is connected to the tank. Chambers(3 and 4) are connected with each other through orifice(9).
Page 230 In the same manner as in the neutral position,unloading pilot pressure becomes 0 Kgf/㎠(0 psi) And almost all fluid delivered by the pump flows out into the tank through chamber(15), orifice(35), and chamber(14).Pump delivery pressure becomes7-8 Kgf/㎠(100-114psi).Orifice (10) is opened, allowing part of the fluid delivered by the pump to flow into chamber(5) and through passage(31) into chamber(32).
Page 231 4) Lifting to neutral shifting(unloading process) While the piston is rising,the configuration of the control valve is the same as in the lifting position. But when the piston stops rising at a required position,spool(A) returns to neutral position. In this state,orifice(7) is closed and orifice (6) is opened,so the pressure in chamber(13) becomes lower than that in chamber(15) and spool (B) (unloading valve 1) is shifted leftwards a little to let pump delivery fluid flow out through orifice(35).As pump delivery pressure becomes lower than cylinder holding...
Page 232 4) Reassembly -Unloading valve(2) and related parts. -Inspection of the disassembled parts. Install the spool and confirm that the returns Place all the disassembled parts side by side on smoothly by the spring force after it is a clean surface.Check o-rings for damage and compressed by pushing the stopper bolt end and replace defective ones.Inspect the friction check that it slides smoothly.
Page 233: Flow-Divider
2.FLOW-DIVIDER( PTO solenoid valve) 2.1 GENERAL DESCRIPTION This valve is installed to bypass working fluid of a specified pressure from the main circuit into the PTO circuit through a fixed orifice.It includes a changeover valve for engaging and disengage the PTO clutch by means of a solenoid and a sequential valve for PTO circuit's over the main circuit.
Page 234 -When the solenoid is switched 「ON」 The fluid from the pump flows to port B through port P,the pressure-reducing valve,and the changeover valve. The pressure of the PTO clutch circuit and that of passage(2) are the same and will be set as P₂.The pressurized fluid acts on the left-hand side of the valve,passing through port ;...
Page 235 -When the solenoid is switched 「OFF」: The fluid in the PTO clutch is unloaded to the bank through port B.Consequently pressure P2 at passage(2) becomes zero,whereas the pressure at passage (1) is P1.Then the force imposed upon the left side of spool (P1)overcomes the force imposed upon the right side (P2+spring force),so that the spool is pushed rightwards to connect port P and part A.
Page 236 2.3. OPERATIONS The operations of this valve will be explained by reference to the operation diagrams in Fig.9-31 and 33. Port P is connected to the pump;port A is connected to the main circuit(port P of the control valve) ; port B is connected to the clutch cylinder;port T is connected to the tank.
Page 237 which renders the pressure in chambers(17, 18, and 19) the same as the pressure at port P. When the main circuit pressure is higher than the pressure regulated by spring(621): 15kgf/cm (214 psi), pressure-reducing valve spool(611) works to maintain the pressure in chamber(17), the pressure- reducing valve secondary pressure, at a specified level.
Page 238 ㆍWhen the main circuit pressure is lower than the regulated pressure: when the main circuit pressure is lower than the pressure regulated a port B, the sequential valve work to increase the pressure at port P to maintain the regulated pressure. When the solenoid is switched on, in the same way as mentioned in the previous paragraph, passage(18) and chamber(10) are interconnected and a part of the fluid delivered from the pump is branched and flows from port B to the cylinder.
Page 239 Circuit diagram in the ON position Fig.9-34 9-27...
Page 240 2.4 DISASSEMBLY AND INSPECTION Fig.9-35 Ref. No. Part Name Orifice(choke) Solenoid O-ring Changeover valve spool Changeover valve spring Casing O-ring Pressure reducing valve spool Shim(optional) Pressure-reducing valve spool Piston Sequential valve spool Fig.9-36 Sequential valve spring Blank plugs Plugs 9-28...
Page 241 1) Remove the solenoid clamping bolts with an · A changeover valve spring whose free length setscrew wrench and separate the assembly is less than the specified or which is distorted into the solenoid and the valve. should be replaced. ·...
Page 242 · A pressure-reducing valve spring whose free length Free length of Specified value: 22(0.87) is less than specified or which is distorted should be sequential valve replaced. Usable limit:21.5(0.847) spring mm(in) Free length of pressure Specified value: reducing valve spring 30(1.18) 2.5 REASSEMBLY mm(in)
Page 243 3. PRESSURE CONTROL VALVE (1) Flow-divider(PTO clutch valve) (2) Front Transmission case (3) Relief Valve (4) Pressure control valve Fig.9-43 3.1. GENERAL DESCRIPTION This valve is composed of the body,plunger,piston,springs,and plug.It serves to absorb shocks which are given when the PTO clutch engages. 3.2.
Page 244 2) When the clutch is in half-engaged state: When the clutch cylinder is completely activated,the pressure in circuit(1) starts rising at point P1 on the graph in Fig.9-49.When the pressure reaches point P2,the piston starts moving to the right overcoming the force of spring(6 and 7). Here the flow through chock(2) causes some difference in pressure between circuit (1) and chamber (3) .
Page 245 2) When the clutch is engaged completely When the piston(6) moves to the end,there is no flow through chock(2) and the pressures in chamber (3) and circuit(1) become equal,that is,the pressure which the plunger receives on both sides are the same.Consequently,plunger(7) is pushed back to the left by the force of spring(9),which closes the passage from port B to port T.With this,the pressure in circuit(1) starts rising at point P3 up to the supplied pressure.Thus the clutch engagement is maintained.
Page 246 4. FLOW-CONTROL VALVE(SLOW-RETURN CHECK VALVE) 4.1. GENERAL DESCRIPTION This valve regulates the lowering speed of the lift by controlling the unloading flow from the lift cylinder to the tank. ①Dust seal ②Snap ring ③Collar ④Body ⑤0-ring ⑥Adjust screw ⑦Back-up ring ⑧0-ring ⑨Stop ring ⑩Poppet...
Page 247 4.2 OPERATIONS 1) DOWN position 2) Up position The fluid from port B pushes up stop ring The flow port A,overcoming the force of (9) of poppet(10) until the ring comes into spring(11),pushes up poppet (10) and contact with adjust screw(6),as it reaches choke(C)is fully opened regardless of the chamber(R).
Page 248: Safety Valve
5.SAFETY VALVE( Optional) 5.2 OPERATION 5.1 GENERAL DESCRIPTION With the chock closed completely by turning the This valve is installed in the slow return check adjust screw tightly clockwise,the implement valve circuit and able to be installed in the cylinder mounted on the lift is held at a specified case instead of Bolt.When the adjust screw of the height.While the tractor is traveling on roads in the...
Page 249 ③Remove the plug in the hyd. pump flange and engage the pressure gauge and measure it. Measurement the Pressure must be done 3 times and should be set within specified pressure. Specified relief T390 160 ±5 ㎏f·㎠ pressure T430 T431...
Page 250: Gear Pump
7.GEAR PUMP 7.1 GENERAL DESCRIPTION Gear pump (Model: 4110.T390(T400).T430(T450).T431(T451) Fig. 9-57 Gear pump 1.Flange 2.Housing 3.Drive gear 4.Gear 5.Bushing 6.Bushing seal 7.Bushing 8.0-ring 9.Cover 10.Cap ring 11.0-ring 12.Housing 13.Drive gear 14.Gear 15.Oil seal 16.Socket bolt 17.Washer 18.Key 19.Snap ring 20.Ball 7.2 OPERATIONS.
Page 251 ③Remove front and rear pump. 7.3 DISASSEMBLY Be sure not to be damaged the o-ring or steel NOTE: ball ①Before disassembling the pump,wash the outside clean.In the course of disassembling operation,all disassembled parts should be kept aside in a clean place such as on clean paper or cloth and be handled carefully so as to prevent them from becoming dirty or damaged.
Page 252 3) REASSEMBLY ④Tightening sequence and torque of the pump ① Install the rear pump. cover tightening bolts. ▶Install the bushing seal to bushing. ▶Tightening torque: 2.5∼2.8㎏f·m ▶Install the bushing,drive gear,gear,and bushing to the housing. ▶Install the o-ring to the cover. ▶Install the cover to the housing.
Page 253 4) INSPECTION AND REPAIR (3) Bushing ① With clean working fluid,surfaces are (1)Check all disassembled parts for damage rarely scratched and should be smooth. and wash undamaged or usable parts in clean diesel fuel or kerosene except rubber ② If there are many scratches on the bore parts.Inspect all parts referring to these walls,or on parts which are in contact with points,and repair or replace defective parts.
Page 254 Remove the plug in the delivery pipe on the right- hand side of the transmission case and install a compression gauge to measure the pressure. Keep the engine speed at 2600 rpm and shift the position control lever at the highest position. T390 T430 T431 Delivery[liter/min] 29.8 27.7...
Page 255: Filter
8.1 GENERAL DESCRIPTION The tractor is equipped with two oil filters: suction filter(1) and line filter(4),for better filtration. 8.2 SPECIFICATIONS 1)Suction filter Model T390(T400)/T430(T450)/T431(T451) Applicable oil DONAX TD or RPM THF 500 Rated flow rate(ℓ/min.) Filtration density 25 ㎛ Filtration area 11000㎠...
Page 256: Section 5.Remote Hydraulic Control(Optional)
SECTION 5. REMOTE HYDRAULIC CONTROL 1.GENERAL DESCRIPTION - A hydraulic operated implement can be driven and controlled with this optional remote hydraulic control valve set. - The valve is connected between the gear pump and the main control valve and is given a priority to draw hydraulic power.
Page 257: Specifications
3. REMOTE HYDRAULIC CONTROL VALVE 3.1 SPECIFICATIONS Normal flow ℓ/min Maximum flow ℓ/min Maximum pressure Kgf/㎠ (psi) System pressure Kgf/㎠ (psi) A and B port leak Oil temperature:50℃(122℉) 9 cc/min Under a load of 100Kgf/㎠ Recommended fluid THF 500 Operating temperature range -20℃~80℃...
Page 258: Section 6. Troubleshooting
SECTION 6. TROUBLESHOOTING Problems Causes Countermeasures 1.Lift does 1) Insufficient engine speed Raise engine speed slightly not rise 2) Insufficient transmission oil Maintain oil level by replenishing with the same kind of oil 3) Air taken in through suction Tighten securely or replace broken parts. 4) Clogged suction filter Clean.
Page 259 Problems Causes Countermeasures 2.Too low 1)Above causes can also be Repair according to above instructions. rising speed of possible lift 2) Too small a spool stroke in Inspect,readjust,or replace link mechanism if necessary. control valve 3)Broken compensator spring Replace spring. (unloading valve 1) in control valve 4)Stuck poppet...
Page 260 Problems Causes Countermeasures 8.Pump noise 1) Partially clogged suction filter or Clean. suction piping. 2) Air inhaled through suction Inspect and retighten. piping and intake pipe connections for pump 3) Loosened pump cover tightening Inspect and retighten bolts. 4) Too rich oil viscosity Replace with fluid of adequate viscosity.
Page 261 Problems Causes Countermeasures 14.Independent 1) Stuck pressure-reducing valve Lap after correcting flaws with oil stone PTO clutch is too spool quick in engaging 2) Fatigued or broken pressure- Replace. reducing valve spring 3) Worn or broken sealing of PTO Replace clutch 4) Worn friction plates or driven Replace...
Page 262 Chapter 10 Electrical accessory and instruments SECTION 1. GENERAL DESCRIPTION -----------------------------10-1 SECTION 2. SPECIFICATIONS --------------------------------------- 10-1 SECTION 3. BATTERY----------------------------------------------------10-2 1.1. Inspection----------------------------------------------------------------10-2 1.2. Inspection of electrolyte level----------------------------------------10-2 1.3. Inspection of electrolyte specific gravity--------------------------10-2 1.4. Battery testing chart--------------------------------------------------10-3 SECTION 4. Meters and switches----------------------------------------10-5 1.
Page 263: Chapter 10 Electrical Accessory And Instruments
All the controls,meters, and indicators are arranged around the operator’s seat for easy Maneuverability readability,and convenience. SECTION 2. SPECIFICATIONS MODEL T390/T400/T430/T450 PART NAME Specification(w) Quantity 1.lighting Head lights...
Page 264: Section 3. Battery
SECTION 3. BATTERY Note: When the distilled water is added,charge the 1.INSPECTION battery to mix it well into the electrolyte before measuring the specific gravity. 1.1 INSPECTION OF ELECTROLYTE LEVEL As the battery repeats charging and discharging a.Temperature correction of the hydrometer during operation.The water content in the electrolyte reading gradually evaporates, and as a result,the level should...
Page 265: Battery Testing Chart
1.4 BATTERY TESTING CHARTS Step 1. VISUAL INSPECTION Check for obvious damage such as cracked or broken case that shows loss of electrolyte,thermal damage,etc. Obvious damage No obvious damage Replace battery Check electrolyte level Electrolyte level is below top of Electrolyte level is above top of plates in one or more cells plates in all cells...
Page 266 Step 3 Load test 1.Connect voltmeter and ampere load equal to ½ the cold cranking amperes(18℃) rating of the battery for 15 seconds. 2. Observe voltage at 15 seconds with load on.Disconnect load 3.Place thermometer in one cell to take temperature of electrolyte. 4.Refer to voltage table Voltage below table value Voltage equal to or above table...
Page 267: Section 4. Meters And Switches
SECTION 4. METERS AND SWITCHES 1.METERS The generated pulses are converted into voltage 1.1 Removal output through a converter.Then the voltage is divided into three different phase coils through a a. Disconnect the cable from the negative post. IC circuit.The tachometer pointer is swung by b.
Page 268: Thermometer
b.Inspection -Fuel meter Note: Connect the fuel gauge to form a circuit with the 1) Figures in parentheses are reference value resisters as shown Fig.10-6 and check to see if 2) Inspect each position in order F to E the gauge pointer swings to each position: F.1/2 3) Read values in three minutes.
Page 269: Combination Switch
(2) Inspection a.The main switch circuit,switching positions, and terminals are as shown in the figures. Check the continuity across respective terminals referring to the switch circuit diagram. Replace a defective switch as an assembly Fig.10-12 (3) Release the ring nut with a conventional screw drive(-) and remove the combination switch.
Page 270: Stop Light Switch
-Lighting 4. STOP LIGHT SWITCH Color code (Red (Red/ (Red/ (Red/ Green White Yellow ● ● ● ● ● ● Fig.10-15 Stop light switch :Terminals : Switching positions Capacity 10~20A (DC12V) -Flasher Stroke to ON 3 ±0.5mm Color Total stroke code (Green) (White/...
Page 271 Each fuse is connected as follows Fig.10-18 The circuit has 8 blade type fuses in its wiring circuit.When a fuse has blown replace it with one of the same value. Fig.10-19 Note: Using a large capacity fuse or wire burn out the wiring system. Use fuse tongs to replace fuses 10-9...
Page 272 8.Trailer socket A hella’s 7-pin trailer socket is equipped as a standard equipment.Lamp on a trailer can be operated through the socket. Fig.10-23 Socket No. Description Color Specification Wire Housing Earth AVSS 2.0 Small light(Tail light) AVSS 0.85 Turn signal (LH) AVSS 0.85 Stop Light AVSS 0.85...
Page 273: Section 5. Earthing Point
SECTION 5. EARTHING POINT Fig.10-24 1) Front axle bracket (RH) Earthed at upper upper tapped hole in the axle bracket A. Fig.10-26 3) Right surface of the frame comp.Where the battery bracket is to be installed. Fig.10-25 2) Contact surfaces of the axle bracket and engine where they tightened together 10-11...
Page 274 Fig.10-27 Hood frame 10-12...
Page 275: Section 6. Wiring Diagram
SECTION 6. WIRING DIAGRAM(T390/T430) 10-13...
Page 276: Section 7. Troubleshooting
SECTION 7. TROUBLESHOOTING Important: Whenever effecting a repair the reason for the cause of the problem must be investigated and corrected to avoid repeating failure. The following table lists problems and their possible causes with the recommended remedial action 1. LIGHTING SYSTEM Problems Causes Countermeasures...
Page 277 Problems Causes Countermeasures Individual Burnt out bulb Check and renew turn signal Corroded or loose bulb contacts Inspect,clean,and renew light does not illuminate Poor ground connection or damage Inspect,clean,and tighten connections or wiring renew wiring Turn signal Faulty bulb Check and renew pilot light is Defective flasher unit Check and renew...
Page 278 Problems Causes Countermeasures Inoperative Burnt out fuse Inspect and renew.Check circuit before re- horn connecting power Loose or broken wires of Inspect circuit,tighten connections,or renew connections wiring Defective horn switch Check and renew Defective horn Check and renew 3.GLOW SYSTEM Problems Causes Countermeasures...
Page 279 4. STARTING SYSTEM Problems Causes Countermeasures Starter motor Discharged battery Check battery and charge or renew does not spin Defective stop light switch Check and renew Defective key switch Check and renew Defective starter motor connections Check,clean and tighten connections or loose battery connections Faulty starter motor Inspect,repair,or renew...
Page 280 Problems Causes Countermeasures Intermittent Alternator drive belt is slipping Check and adjust belt tension or renew or low Loose connection or broken cable in Inspect system,tighten connections and alternator charge system repair or renew faulty wiring output Defective alternator Check and repair or renew Warning light Faulty external charging circuit Inspect system,clean and tighten...
Page 281 CHAPTER 11. Service standards and other information SECTION 1. SERVICE STANDARDS ------------------- 11-1 1.Engine accessories -------------------------------------- 11-1 2.Clutch damper-------------------------------------------------- 11-2 3.Transmission -------------------------------------------- 11-2 4.Front axle ------------------------------------------------- 11-3 5.Rear Axle--------------------------------------------------------- 11-4 6.Power steering system ---------------------------------------- 11-4 7.Hydraulic system ----------------------------------------------- 11-4 8.Electrical equipment-------------------------------------------- 11-7 SECTION 2.
Page 282: Section 1. Service Standards
CHAPTER 11. Service standards and other information SECTION 1. SERVICE STANDARDS. Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 1.ENGINE ACCESSORIES(CHAPTER 3) 1) RADIATOR Coolant capacity 3.9 ℓ Radiator alone 9.0 ℓ Whole cooling system Radiator cap valve operating pressure 1.1 ±0.15㎏f·㎠...
Page 283 Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 2. MAIN CLUTCH (CHAPTER 4) 8.0 ±0.3㎜ 6.5 ㎜ Rivet head depression CLUTCH DISC should maintained at (0.315 in) (0.256 in) ASSEMBLY more than 0.2 ㎜ (Dry single plate) Facing wear 0.3 ㎜...
Page 284: Transmission
Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 3. TRANSMISSION (CHAPTER 5) 1) FRONT AND SPACER TRANSMISSIONS TRANSMISSION OIL CAPACITY 33 ℓ SHIFTER DISENGAGING LOAD 18 - 22 ㎏f Measured at the Main shift 17 ㎏f shifters (both for...
Page 285 Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 2) REAR TRANSMISSION (1) DRIVE PINION & RING GEAR Starting torque 0.11-0.13 ㎏·m Backlash 0.1 ∼ 0.2 ㎜ 0.5 ㎜ Backlash and tooth bearing should be adjusted properly when reassembled...
Page 286 Part names and Nominal Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 4. FRONT AXLE (CHAPTER 6) 1) Front drive axle (4WD) (Updated version) Tire inflation Front : 2.2 ㎏f/㎠ Rear : 1.8 ㎏f/㎠ Wheel alignment ①Toe-in : 2 ∼...
Page 287 Pedal play at the 30 ∼40 ㎜ 6. POWER STEERING SYSTEM( CHAPTER 8) 1) GEAR PUMP (Updated version) Theoretical value/revolution T390/T400 : 2,800 rpm Capacity T390/T400/T430/T450 : 4.8cc T430/T450 : 2,600 rpm P=150 ㎏f/㎠ Oil temperature : 50℃ Direction of revolution 7.HYDRAULIC SYSTEM (CHAPTER 9)
Page 288 Standard value Usable limits Service instructions inspection items dimensions for reassembly and remarks 2) Dynamic lift T390/T400/T430/T450 1300 ㎏f·㎠ 3) Cylinder case bush Left side 55 ×60 ×50 Ø 55 ㎜ Ø 55.2 ㎜ Wear limit: 0.2 ㎜ Right side 60 ×65 ×50...
Page 289 8) MAIN RELIEF VALVE (Updated version) 3510/4110/T390 135 ±5 ㎏f/㎠ /T400/T430/T450 9) MAIN GEAR PUMP (Updated version) 3510/4110/T390 T390/T400: 26.026 ℓ Efficiency of 92 % at 2600 rpm /T400/T430/T450 T430/T450: 28.39 ℓ 10) SUCTION FILTER (Updated version) T390/T400:43 ℓ/min Rated flow T430/T450:57 ℓ/min...
Page 290: Electrical Equipment
8.ELECTRICAL EQUIPMENT 1)BATTERY (1)BATTERY TERMINAL POST Terminal voltage 12 V 10.8 V Charge or replace Corrosion Repair or replace (2) BATTERY CELLS Damage Replace battery (3) ELECTROLITE Cloudy fluid Replace battery Specific gravity 1.24 - 1.26 Correct Level As specified on Replace with distilled case water.
Page 291 (3) Turn signal switch color coding Replace a defective ●Turn signal ● ● switch switch assembly. ● ● (4) Horn switch color Replace a defective coding ●Horn switch switch assembly. ● ● (5) PARKING AND LIGHT SWITCH Replace a defective Continuity across each terminal ●...
Page 292 (9) HAZARD WARNING SWITCH Replace a defective ○ ○ ○ ○ switch assembly. Continuity across each terminal ○ ○ ○ ○ ○ ○ ○ ○ 10 9 11-11...
Page 293 SECTION 2.TIGHTENING AND STARTING TORQUE SPECIFIED FOR MAJOR PARTS 1. 3510/4110/T390/T430 TIGHTENING PARTS Bolt and Nut Tightening torque (Hardness) (㎏f·m) 1)Front axle housing (4WD type) ①Axle bracket ∼ Engine tightening bolts M 16 (7T) 16.0 ∼ 18.0 ②Front pivot metal(support)tightening bolts M 12 (7T) 9.0 ∼...
Page 294: Section 3. Conversion Tables
SECTION 3. CONVERSION TABLES MILLIMETERS TO INCHES TO MILLIMETERS INCHES 0.0394 1.0236 20..79 2.9921 1/64 0.3969 33/64 13.0969 0.0787 1.0630 2.0472 3.0315 1/32 0.7937 17/32 13.4937 0.1181 1.1024 2.0866 3.0709 3/64 1.1906 35/64 13.8906 0.1575 1.1417 2.1260 3.1102 1/16 1.5875 9/16 14.2875 0.1968...
Page 295 LENGTH FEET TO METERS METERS TO FEET MILES TO KILOMETERS KILOMETERS TO MILES 11-14...
Page 296 AREA SQUARE INCHES TO SQUARE CENTIMETERS SQUARE CENTIMETERS TO SQUARE INCHES VOLUME CUBIC INCHES TO CUBIC CENTIMETERS CUBIC CENTIMETERS TO CUBIC INCHES 11-15...
Page 297 GALLONS (U. S.) TO LITERS VOLUME LITERS TO GALLONS (U. S.) GALLONS (IMP.) TO LITERS LITERS TO GALLONS (IMP.) 11-16...
Page 298 POUNDS TO KILOGRAMS MASS KILOGRAMS TO POUNDS KILOGRAMS TO NEWTON NEWTON TO KILOGRAMS 11-17...
Page 299 POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS PRESSURE KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS 11-18...
Page 300 FOOT POUNDS TO KILOGRAMMETERS TORQUE 11-19...
Page 301 TEMPERATURE FAHRENHEIT TO CENTIGRADE CENTIGRADE TO FAHRENHEIT 11-20...

This manual is also suitable for:

T400 T430 T450

TYM T390 Service Manual

T390/T400/T430/T450

Chapter 1. Introduction

Chapter 2 . Disassembly and Reassembly of Major Point

Chapter 3 . Engine Accessories

Chapter 4 . Clutch System

Chapter 5. Transmission

Chapter 6. Front Axle (4WD)

Chapter 2 Disassembly and Reassembly of Major Components

Chapter 7 . Rear Axle and Brakes

Chapter 8. Power Steering System

Engine Accessories

Table of Contents

Chapter 5 Transmission

Front Axle

Chapter 8 Power Assisted Steering System

Table of Contents

Chapter 9 Hydraulic System

Hydraulic System

Chapter 10 Electrical Accessory and Instruments

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for TYM T390

Summary of Contents for TYM T390

This manual is also suitable for:

Table of Contents