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TYM T264 Workshop Manual
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TYM T264 Workshop Manual

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TYM
WORKSHOP MANUAL
for tractors
Model T264 HST
Zip code (570-941) TongYangMoolSan CO., LTD. 7-45, Wanggungnonggongdanji-gil, Iksan-si, Jeollabuk-do, Republic of Korea
■ TEL. : ++82-63-830-1951~4, FAX : 82-63-836-1484 ■www.tym.co.kr

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  • Page 1 WORKSHOP MANUAL for tractors Model T264 HST Zip code (570-941) TongYangMoolSan CO., LTD. 7-45, Wanggungnonggongdanji-gil, Iksan-si, Jeollabuk-do, Republic of Korea ■ TEL. : ++82-63-830-1951~4, FAX : 82-63-836-1484 ■www.tym.co.kr...
  • Page 2 HST TRACTOR T264 SERVICE MANUAL Chapter 1. Introduction ------------------------------------ Chapter 2. Disassembly and reassembly of major point ------ Chapter 3. Engine accessories ------------------------------------ Chapter 4. HST system --------------------------------------------- Chapter 5. Transmission ----------------------------------- Chapter 6. Front axle (4WD) --------------------------------- Chapter 7. Rear axle and Brakes --------------------------------- Chapter 8.

  • Page 3: Table Of Contents

    Chapter 1 Introduction 1-01 INTRODUCTION------------------------------------------------------------- 1-02 SAFETY INTRODUCTION------------------------------------------------- 1-04 WARNING SIGNS IN THIS MANUAL---------------------------------- 1-05 SAFETY SIGNS---------------------------------------------------------------- 1-10 SAFETY DECALS----------------------------------------------------------- 1-13 UNIVERSAL SYMBOLS--------------------------------------------------- SECTION 1. TRACTOR TYPES AND PUNCHED 1-14 IDENTIFICATION MARKS ----------------------------- 1-16 SECTION 2. SPECIFICATIONS------------------------------------------ 1-19 SECTION 3. GEAR TRAIN DIAGRAMS------------------------------- 1-20 SECTION 4.
  • Page 4 Chapter 1 .Introduction This tractor service manual is for qualified service personnel engaged in servicing and overhauling T264HST 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 5 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 6 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 7: Warning Signs In This Manual

    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 injury or death.

  • Page 8: Safety Signs

    SAFETY SIGNS RECOGNIZE SAFETY INFORMATION This symbol, Safety-Alert Symbol, means ATTENTION! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message SIGNAL WORDS. A signal word―DANGER, WARNING OR CAUTION―is used with DANGER safety alert symbol.
  • Page 9 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. The ROPS, mounting hardware, and seat belt should be checked after the first 100 hours of Tractor and every 500 hours thereafter for any evidence of damage, wear or cracks.
  • Page 10 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 11 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 12 TRACTOR RUNAWAY 1.The tractor can start even if the transmission is engaged position causing Tractor to runaway and serious injury to the people standing nearby the tractor. For additional safety keep the pull to stop knob (fuel shut off control) in fully pulled out position. Transmission in neutral position, Foot brake engaged and PTO lever in disengaged position while attending to Safety Starter Switch or any other work on Tractor.

  • Page 13: 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 ● Before starting and operating know the operating and safety instructions in the operators Manual and on the tractor ●...
  • Page 14 1-11...
  • Page 15 1-12...

  • Page 16: Universal Symbols

    UNIVERSAL SYMBOLS Some of the universal symbols have been shown below with an indication of their meaning Engine speed Pressured- Corrosive rev/minX100) open slowly substance ”Tortoise” Hours, Continuous Slow or recorded variable minimum Setting Engine ”Hare” fast or coolant Warning maximum temperature setting...

  • Page 17: Section 1. Tractor Types And Punched Identification Marks

    1.MODEL NAME PLATE The plate indicates the model and type of the tractor. ① Model name ② Production I.D No. The production I.D reference number is as shown below T264 M 00001 Production serial No Production year Production Model 1-14...
  • Page 18 2. Engine Model Identification and serial number location. 4) Assignment standard for engine model 1) Engine identification location code Ex) A1100N2 2) Engine EPA decal (A) This decal represents that this engine is in compliance with the U.S.EPA exhaust Emission regulation. 3) Engine number (B) The Engine number is stamped on the cylinder block.

  • Page 19: Section 2. Specifications

    SECTION 2. SPECIFICATIONS Model T264 HST Engine Maker Model A1100N2 Type Vertical, Water Cooled 4-Cycle Diesel 24.1(18) Horse power , HP (㎾) 2600 Rated Speed Number of cylinders Displacement,cu in(cc) 71.7(1,175 cc) Bore and stroke,mm(in) 78X82(3.07X3.23) Compression ratio 21.5 : 1...
  • Page 20 MODEL T264 HST Type Independent Control Electro-Hydraulic Clutch Multiple wet Disk Rear PTO Shaft SAE 1-3/8, 6 spline Speed 540rpm@Engine 2,600rpm Hydraulics Control system Open Center Working pressure 1,813psi( 125bar) Pump capacity Main 4.4 GPM(16.6 LPM) Steering 2.632GPM(8.8LPM) Type SAE Category Ⅰ...
  • Page 21 Traveling speeds:Km/h (Mile/h) Model Range shift T264HST 0 ~ 7.9 (4.9) 0 ~ 20.8 (12.9) 0 ~ 7.2 (4.5) 0 ~ 19.1 (11.9) 0 ~ 6.3 (3.9) 0 ~ 16.7 (10.4) 0 ~ 7 (4.3) R4-1 0 ~ 18.7 (11.6) 1-18...

  • Page 22: Section 3. Gear Train Diagrams

    SECTION 3. GEAR TRAIN DIAGRAMS FIG.1-3 GEAR TRAIN DIAGRAM 1-19...

  • Page 23: Section 4. Precautions For Tractor Operations

    SECTION 4. PRECAUTION FOR TRACTOR OPERATION 1. INSTRUMENTS 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 ② Low beam lamp is operated on the combination switch ③ PTO Monitor Lamp This lamp will turn on when PTO clutch is engaged. ④ Cruise Control Lamp This lamp will turn on when cruise control is engaged. ⑥ Fuel Empty Warning Lamp This lamp shows warning that the fuel in fuel tank goes empty.

  • Page 25: Controls

    2. CONTROLS ①Turn Brake Pedals ② Parking Brake Lever ③ Differential Lock Pedal ④ Front Wheel Drive(4WD) Lever ⑤ Range Shift Lever ⑥ PTO Lever ⑦ Speed Control Pedals ⑧ Joy stick Lever ⑨ Hand Throttle Lever ⑩ Position Control Lever ⑪...
  • Page 26 Below 0°C(32°F)…SAE 10W or 10W30 Tractor transmission and (API GL-4 Grades) TRANSMISSION CASE 14.5ℓ (5.81 US gal) hydraulic oil THF500 TYM Standard : FRONT AXLE Gear oil #80 or #90 4.5ℓ (1.19 US gal) FUEL TANK Diesel fuel 25ℓ (6.6 US gal)

  • Page 27: Maintenance Chart

    4. MAINTENANCE CHART Periodical check and service table ○ Check, Top-up or adjust ● Replace △ Clean or wash ★ Consult the service Dealer Item Service interval(hour meter,mark) Comment ○ ● ● ● ● ● ● To correct level on Engine oil the dipstick Or every year...
  • Page 28 ○ Check, Top-up or adjust ● Replace △ Clean or wash ★ Consult the service Dealer Item Service interval(hour meter,mark) Comment ○ Free play of steering wheel ★ ★ Check every 300 hours Toe-in Grease in front Grease every 900 hours wheel hub ○...
  • Page 29 Chapter 2 Disassembly and reassembly of major components SECTION 1. GENERAL PRECAUTIONS AND SEPARATION AND REINSTALLATION ------------------------------ 1. Before operation ------------------------------------------------- 2. Precautions to be followed when installing standardized parts. ----------------------- SECTION 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCKS ------------ SECTION 3.

  • Page 30: And Reinstallation

    (2) Oil seals 9) When replacing parts,use authorized, genuine 1) Oil seals installer should be designed so as TYM parts only.TYM assumes no not to deform the oil seals. responsibility for accidents,operating 2) During installation, be careful not to damage...
  • Page 31 (3) O-rings 3) The roll pins installed in the transmission or 1) O-rings should be coated with grease other parts where much force is applied before installing. should be retained with the wire. 2) Installed O-rings should have no slack or (6) Cotter pins twist.
  • Page 32 5) Precautions for applying adhesives. 4) Each contact surface should be coated with an The surface or the thread where and adhesive adhesive (THREE BOND TB 1215) and tightened is to applied should be completely free of chips. evenly with bolts. Adhesive coated surfaces should The surface or the thread where an adhesive is be installed within 30 minutes after application of to be applied should be completely free of oil-...

  • Page 33: Section 2. Operation Chart For Disassembly

    SECTION 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCKS...

  • Page 34: Section 3. Separation Of Major Components

    SECTION 3. SEPARATION OF MAJOR COMPONENTS 1.SEPARATION OF THE FRONT Note: AXLE AND AXLE BRACKET When working on the 4WD version,the drive shaft should be removed ahead of time. Parts which can be inspected during This operation -Center pivot -Final case -Differential gear (1) Removal 1) Hold the front hitch or the front bracket...

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

    2.SEPARATION OF THE ENGINE AND THE FRONT AXLE BRACKET 6) Disconnect the positive and negative battery Parts which can be inspected during This operation cables. -Air cleaner -Radiator -Power steering system -Oil cooler -Engine front part. (1) Removal 1) Hold or support the engine with a crane or stands.
  • Page 36 Note: 13) Remove the battery and battery bracket. The radiator should be drained of the coolant 14) Remove the two hoses for the power ahead of time. steering system. 11) Remove the fuel filter. 15) Remove the mounting bolts of the right hand pivot metal(support) ahead of time.

  • Page 37: Separation Of The Engine And Transmission

    (2) installation Reassemble in reverse order of removal. 1) Install the axle bracket on the engine. 2) Retighten the right-hand pivot metal (support) mounting bolts. 3) Connect the piping of the power steering system. 4) Install the battery bracket and battery. 5) Install the radiator and oil cooler on the front axle bracket.
  • Page 38 5) Disconnect the battery cables. 8) Disconnect the hydraulic hose from the power steering (orbitrol) FIG.2-16 6) Disconnect the panel instrument set removing bolts(4 nos.) FIG.2-18 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. 2) Disconnect the upper, Lower ,and drain hoses from the radiator.

  • Page 40: Separation Of The Transmission And Rear Axle Housing

    4.SEPARATION OF THE TRANSMISSION AND REAR AXLE HOUSING (4) Remove the brake rods. (5) Remove the 3-point linkage and related parts. Parts which can be inspected during This operation - Diff Lock - Brakes - Final gears - MID PTO gears. 1) Removal As both sides can be disassembled in the same way,only side with the diff-lock installed will be...
  • Page 41 (6) Support the floor panel with a trestle or the like. 2) Installation (7) Remove the rear axle housing tightening bolts. Reassemble in reverse order of disassembly. (1)Install the brake (LH and RH) (2) join the rear axle and transmission Note: Make sure that the diff-lock shifter is fitted into the groove in the dif-lock metal...

  • Page 42: Separation Of The Transmission And Mid Pto

    5.SEPARATION OF THE TRANSMISSION AND MID PTO GEARS (15) Detach the MID PTO case assembly from Parts which can be inspected during This operation the transmission. -MID PTO gears. Inspection and service of the rear transmission should be performed following the instructions in the paragraph : 5 SEPARATION OF THE REAR TRANSMISSION AND SPACER TRANSMISSION...

  • Page 43: Separation Of The Transmission And Cylinder Case

    6.SEPARATION OF THE TRANSMISSION AND CYLINDER CASE (10) Detach the delivery pipe from the cylinder Parts which can be inspected during This operation case. - Control valve (12) Remove the slow-return check valve along - Control linkage with the shaft. - Piston and lift crank linkage (13) Remove the 3-point lift link and related - PTO change gears.
  • Page 44 Chapter 3 ENGINE ACCESSORIES SECTION 1. RADIATOR --------------------------------------------------- 1. General description ------------------------------------------------------ 2. Radiator -------------------------------------------------------------------------------------------- 3. Specifications ---------------------------- -------------------------------------------------------- 4. Removal of the radiator ------------------------------------------------------------------- 5. Inspection of each part -------------------------------------------------------------------- 6. Radiator reassembly ------------------------------------------------------ 7. Daily inspection ----------------------------------------------------------- 8. Trouble shooting ---------------------------------------------------------- SECTION 2.

  • Page 45: General Description

    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 46 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...

  • Page 47: Specifications

    3. SPECIFICATIONS Description T264HST Radiator core type Flat water tube with corrugate fins Core train number 4 trains Radiator fin pitch 2.0 mm Thermal radiator area 7.1362㎡ 0.9±0.15Kgf/ ㎠ Pressure valve opening pressure Coolant capacity 3.5ℓ (contains in cylinder block), Test pressure 1.5Kgf/㎠...
  • Page 48 -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 49: Radiator Reassembly

    6. RADIATOR REASSEMBLY 0.9 Kgf/ ㎠ Pressure valve Reassemble the radiator in the reverse order of Opening pressure (12.79 psi) disassembly. 0.04-0.05 Kgf/ ㎠ Vacuum valve Note: Opening pressure (0.57-0.71psi) - The rubber hoses should be clamped securely and must not interfere with the cooling fan. -Function test: - The radiator cores must not interfere with the The pressure type radiator cap has a pressure valve...

  • Page 50: 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 51: 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 52 2.ELEMENT AIR CLEANER (1) SPECIFICATIONS. Model T264HST Type Dry, paper element filtering type Rated intake air volume (㎡/min.(cu.ft/min) 2.6(91.8) 110 or less air venting resistance (㎜Ag) Cyclone efficiency (%) Total filtering efficiency (%) 99.0 or over Dust holding capacity (gr) Filter material Element PAPER...

  • Page 53: 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 54: Element Installation

    5.ELEMENT INSTALLATION Install the element in the reverse order of disassembly, but follow these instructions. 1) Each tightening bolt must be secured and care must be taken not to miss the packing and washers. 2) Before installing the element,clean the rubber packing on the top of the element. Note : The element should be tightened sufficiently so that it will not become loose during operation 3-10...
  • Page 55 CHAPTER 4 HST system SECTION 1. SPECIFICATIONS------------------------------------------ SECTION 2. COMPONENT LOCATION------------------------------- 1. Hydraulic hoses and lines------------------------------------------------ 2. Hydrostatic transmission------------------------------------------------ 3. Transmission main pump case------------------------------------------ 4. Transmission back plate and motor----------------------------------- 5. Hydrostatic control linkage ------------------------------------ 6. Hydrostatic system schematic------------------------------------------ SECTION 3. TROUBLE SHOOTING------------------------------------ SECTION 4.

  • Page 56: Section 1. Specifications 1

    SECTION 1. SPECIFICATIONS 1 General Hydraulic Reservoir Capacity----------------------------------------------------------------14.5ℓ(3.83 us gal) Pump or motor Roller Bearing( From back plate to Top surface of bearing)------- ---------------------------------------------------------------------2.0 mm±0.3 mm(0.078 ±0.011 in) Roller Bearing in Motor Housing(Recess From Top of Counter bore) ---------------- --------------------------------------------------------------------2.0 mm±0.3 mm(0.078 ±0.011 in) Spring pin in Back plate(From Back plate to Top surface of pin)--------------------4.0 mm(0.015 in) HYDROSTATIC PUMP Manufacturer -------------------------------------------------------------------------------------------------THI...
  • Page 57 SECTION 1. SPECIFICATIONS 2 Item Specification Displacement Pump 0~25㎤/rev. 25 ㎤/rev. Motor Charge pump 3.7 cc/rev Swash plate angle(Pump) 0~±16..3°(deg) Swash plate angle (Motor) 16.3°(Deg) Direction of Rotation(View from input shaft end) Charge relief setting Pressure( at 2700 rpm ) 9~10 Kgf/㎠...

  • Page 58: Section 2. Component Location

    SECTION 2. COMPONENT LOCATION 1.Hydraulic Hoses and lines. 1.hydraulic oil cooler 2. Gear pump 3. Cooler return Line 4. Loader Valve 5. Power steering Unit...

  • Page 59: Hydrostatic Transmission

    2.Hydrostatic Transmission ③ ② ⑤ ① ④ 1. Front drive shaft 2. Hydrostatic unit 3. Back Plate 4. Filter 5. Input shaft From engine...
  • Page 60 3. HST main pump case...
  • Page 61 3. HST main pump case 1 2.Body(Back plate) 17.Seal cover (M) 19.Needle bearing 21.Ball bearing 23.Oil seal 29.Plug(Relief) 31.Spring seat 32.Valve(Relief) 33.Seat(Relief) 34.Spring1(Relief) 35.Spring2(Relief) 36.Washer(Relief) 37.Nut(Relief) 38.Plug(Neutral) 39.Spool(Neutral) 41.Spring(Neutral) 48.Snap ring 50.Snap ring 51.Snap ring 53.O-ring 54. O-ring 55.O-ring 57.O-ring 59.RO Plug 62.Socket bolt 64.Eye bolt...
  • Page 62 3. HST main pump case 2 4-6 (2)

  • Page 63: Hydrostatic Control Linkage

    5.Hydrostatic control linkage 1.Holder comp 2.Bolt 3.Washer spring 4.Nut 5. PIN COMP, REVERSE 6. BOLT 7. PIN COMP , FORWARD 8. BOLT 9.C-RING 10. ARM COMP , FORWARD 11.Washer 12.WASHER 13. BUSH , 20X23X20 14.WASHER 15. BEARING 16. PIN , SPLIT 17.CAM SUB ASSY 18.ARM COMP , CAM 19.BEARING , BALL 20.WASHER , PLAIN 21.PIN , SPLIT 22.BUSH , 20X23X20...

  • Page 64: Hydrostatic System Schematic

    6. Hydrostatic system schematic...

  • Page 65: Section 3. Troubleshooting

    SECTION 3. TROUBLESHOOTING Problem or symptom Check or Solution Check flex plate coupling between • engine and pump Hydraulic level low in transaxle • • • Low charge pressure (see Tests and • • • Adjustments Section) Main drive pressure relief valve stuck •...

  • Page 66: Section 4. Diagnostics

    SECTION 4. DIAGNOSTICS Test conditions: - Operator in seat - Key switch in RUN position Test/Check point Normal If Not normal 1. Control pedals Pedal should move freely Check linkage from pedals to pump Test conditions: - Start engine and run at slow idle Test/Check point Normal If Not normal...

  • Page 67: Section 5. Theory Of Operation

    SECTION 5. THEORY OF OPERATION HYDROSTATIC SYSTEM Function: The hydrostatic system provides a means to transfer. Power from the engine to the final drive to the wheels. It also provides infinitely variable speed control, forward or reverse, by foot pedal operation. Principles of Operation: The hydrostatic system is a closed loop fluid power system that consist of a charge pump on the left front side of the engine.and an...

  • Page 68: Section 6.Tests And Adjustments

    SECTION 6. TESTS AND ADJUSTMENT 1.HYDROSTATIC PEDAL AND NEUTRAL ADJUSTMENT Reason: To ensure that tractor does not move unless the forward or the reverse pedal is depressed. Procedure: 1.Operate the hydrostatic control pedals.They should return by themselves to the neutral position. If pedals do not operate properly, check pedals and linkage for damage or wear.

  • Page 69: Hydrostatic Pump Pressure Test

    2. HYDROSTATIC PUMP 4.Start engine and run until hydraulic oil is PRESSURE TEST warm. 5.Stop engine. Reason: 6.Cycle all controls to relieve any pressure To ensure that internal parts of the hydrostatic that may be in the hydraulic system pump are not worn excessively, and the relief valves are operating properly.

  • Page 70: Charge Pump Pressure Test

    13.Slowly depress forward directional pedal and Procedure: observe gauge. Gauge should slowly rise to 1.Park tractor on a level surface and set park approximately 130~170kgf/cm (1848~2417psi) brake. and relief valve will open with an audible 2.Turn key switch to OFF position. squealing noise if the pressure rise to over 350 3.Shift transmission to NEUTRAL.

  • Page 71: Hydraulic System Bleed Procedure

    4. HYDRAULIC SYSTEM BLEED PROCEDURE Reason: To remove air trapped in the hydraulic system which will prevent proper operation. Procedure: IMPORTANT : If contamination is found in hydraulic system filter or inside reservoir, flush entire hydraulic system. NOTE : Fill the hydraulic oil filter with new oil before installing. 1.Install a new hydraulic oil filter.

  • Page 72: Section 7.Repair

    SECTION 7. REPAIR 1.TRACTOR SPLITTING (FRONT) 6.Remove the joy stick Note: It is not necessary to remove the flywheel housing from the engine unless engine is being removed. Split the tractor between the tunnel and flywheel housing as outlined in the story below.
  • Page 73 8.Remove the slow return levers. 10.Remove the fuel line. 9.Remove the operator’s platform. (LH, RH) (RH) (LH, RH) Note : Lift up the floor gradually making sure that all relevant wiring and clamping are disconnected 4-17...
  • Page 74 11.Remove the hydraulic line. 1.hydraulic oil cooler 2. Gear pump 3. Cooler return Line 4. Loader Valve 5. Power steering Unit 4-18...
  • Page 75 12.Disconnect the input drive shaft and couplers by removing snap ring and sliding couplers onto engine until clear of stub shaft. ③ ② ① ⑤ ④ 16.Disconnect the linkage from hydrostatic control system 13.Remove the 4WD shaft couplers by removing snap ring and sliding couplers onto shaft until clear of stub shaft 14.Remove the brake linkage, and remove brake...
  • Page 76 18.Lift the engine with the hoist and hold the front axle bracket with a stands or the like 19.Remove 12 screws connecting tunnel to the rear transmission case. 7.Install the brake linkage, and connect brake rods from tractor 20.Gently pry around edges of flanges to separate tractor halves.
  • Page 77 2. HYDRAULIC TRANSMISSION REMOVAL & INSTALLATION Removal : 1.Park tractor on level surface.Stop engine and release hydraulic pressure by operating all controls. CAUTION Avoid injury from escaping hydraulic oil under pressure. Relieve system pressure by stopping engine and operating hydraulic components 2.Separate tractor engine and tunnel sections (See TRACTOR SPLITTING(FRONT).

  • Page 78: Hydrostatic Transmission Disassembly

    1. Hydrostatic Transmission Disassembly Fig.: Body Disassembly Fig.:Complete assembly IMPORTANT: The HST housing is aluminum material and can be easily damaged by steel tools. Be careful not to damage machined surfaces. Do not use screw driver or other sharp objects. Cap Screws 5.
  • Page 79 Note : The relief valve is dual purpose valve. The 12. Inspect ball bearing. The bearing should spin valve contains two springs. A weak spring in the freely.If replacement is necessary, press bearing plug(check valve when other circuit is in use) and out from the outer side of body.
  • Page 80 NOTE : 1. Remove pump and motor valve plate. The cylinder block of pump and motor are interchangeable, but it is recommended that the cylinder blocks go into original position (before disassembly) during assembly. 4. Remove cylinder block, retainer, spherical bush, piston, spring from the parts of rotating assembly.
  • Page 81 6. Remove snap ring of pump at rear side. 9. Remove swash plate obliquely. 7. Remove the shaft of pump by using rubber hammer. 10. Remove shoe plate of motor side in the housing. 8. Remove the cover and o-ring of right and left side, for removing swash plate.
  • Page 82 2. Hydrostatic Transmission Inspection 4. Inspect the outside of the pistons. Replace if scored of worn. 1.Inspect the bronze side of the valve plate for wear 5. Inspect the shoes. Replace if loosed on the ball Replace the valve plate if any wear, scoring or end of piston or if shoe face area is worn or scratched exist.
  • Page 83 2. Apply a small amount of grease to back of shoe plate and install shoe plate into swash plate. 13. Inspect oil seal and DX bush in the cover on the left of housing. Replace if worn or damaged. 3. Install shoe plate for motor in housing. 14.
  • Page 84 5. Install covers to both ends of swash plate. Note : Old O-rings, gasket and seals are apt to leak. Always install new O-rings, gasket and seals during assembly. 6. Rotate swash plate and feel for smooth operation. 7. Install the shaft of pump into the housing, and install snap-ring onto the shaft at the rear side of housing.
  • Page 85 12. Install relief valves and neutral valves. If the valves is not new, install original holes before disassembly. 13. Install the body assembly onto the housing assembly. 14. Install four socket head cap screws into the body and two socket head cap screws into the housing. 4-29...
  • Page 86 CHAPTER 5 Transmission SECTION 1.GENERAL DESCRIPTION----------------------------------- 1.Wheel driving system--------------------------------------------------------- 2.PTO drive system------------------------------------------------------------- 3.Power train diagrams-------------------------------------------------------- SECTION 2. SPECIFICATIONS--------------------------------------------- 1. Wheel drive system---------------------------------------------------------- 2. PTO drive system------------------------------------------------------------ SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY-- 1. HST system and change gear(front transmission)--------------------- 2. Mid transmission case------------------------------------------------------- 1) PTO Input gear------------------------------------------------------------ 2) PTO counter shaft--------------------------------------------------------- 3) PTO clutch------------------------------------------------------------------...

  • Page 87: 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: Damper Change gears Front drive change gears Transmission PTO Clutch MID PTO change gears REAR PTO change gears Fig.5-1 Wheel drive system 2.

  • Page 88: Section 2. Specifications

    SECTION 2. SPECIFICATIONS 1. WHEEL DRIVE SYSTEM T264HST Speed shift range Engine rated rpm: 2600 rpm Main speed shift Speed range shift L (Low) 0.53 (19/21 * 17/29) Reduction ratio H (High) 1.49 (19/21 * 28/17) Drive pinion-Wheel gear 0.03 (9/55 * 12/71) Operation Speed range shift Side shift - LH...

  • Page 89: Section 3.Disassembly,Inspection,And Reassembly

    DISASSEMBLY SECTION 3. , INSPECTION, AND REASSEMBLY 1.HST system and change gears (front transmission). 1. Input shaft From engine 2. HST unit 3. Back Plate 4.PTO clutch Fig.5-2...
  • Page 90 1.1 Disassembly. (1) Removal of HST system and related parts. Separate the engine from the rear transmission referring to the paragraph of SECTION 7. REPAIR in CHAPTER 4. 1.HST Unit 2.Pin 3.Case, rear transmission 4.Washer,spring 5.6.7.8.Bolt, Nut, Stud bolt Fig.5-3 Fig.5-4 1.COUPLING 2.BEARING , BALL 3.SHAFT , PTO COUNTER...
  • Page 91 1-2. REASSEMBLY Reassemble them in reverse order of disassembly in accordance with the following instruction. - Installation of coupling PTO and related parts. (1) When installing the coupling PTO on the flywheel, be sure to install the bolts to flywheel. (2) Apply a thin coat of molybdenum disulfide-based grease(Three bond TB1901 or equivalent) to revolving or sliding parts prior to reassembly.
  • Page 92 2. Rear Transmission 1) PTO counter shaft Sub ASS’Y 1.PTO counter shaft 11T 2.Bearing,Ball(6305) 3.Bearing,Ball(6204) Fig.5-6 (1) Pay attention to the direction of installation and check to see all the parts turns smoothly. (2) When pushing the BRG’s (6204, 6305)in to the shaft, be careful only to push their inner races. (3) When installing the PTO Clutch assembly, Apply a thin coat of grease to the seal rings and install it taking care not to damage these rings.
  • Page 93 3) PTO CLUTCH (3-1) DISASSEMBLY Fig.5-8 1.Shaft,PTO clutch 2.Bearing ball(6005) 3.Clutch ass’y case 4.Seal B 5.Piston 6.Seal A 7.Ring, Piston 8.Brake disc 9.Plate, return 10.Disc 11.Plate 12.Spring 13.Plate assy 14.Snap ring 15.Hub 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 94 -Inspection for disc thickness and serration wear. Inspection Specified values Usable Items limit Disc 2.6±0.1mm(0.102 in) 2.4mm thickness (6pcs) (0.094 in) Surface 0.2mm flatness (0.008 in) Fig.5-11 e. If the combined thickness of the return plate and brake disc deviates from the specified value, replace both parts.
  • Page 95 (3-3) REASSEMBLY Fig.5-13 Reassemble the parts in reverse order of disassembly, following these instructions. c. When installing the return spring, use a Note: special tool; the snap ring should be securely -Each parts should be washed clean before seated in the groove. reassembly.
  • Page 96 HST REASSEMBLY Apply adhesive(TB1215) Apply adhesive(TB1901) HST Unit-Rear Case Fig.5-16 Reassemble them in reverse order of disassembly in accordance with the following instruction. - Installation of clutch damper and related parts. (1) When installing the clutch damper on the flywheel, be sure to install bolts to flywheel. (2) Apply a thin coat of molybdenum disulfide-based grease(Three bond TB1901 or equivalent) to revolving or sliding parts prior to reassembly.
  • Page 97 (4-1). Forward and reverse 1) HST holder comp ④ ① ③ ⑤ ② Fig.5-17 1.HST UNIT 2.Bolt 3.Washer plain 4..Holder comp 5.Nut (1) When reassembling holder comp, take care directions. (2) After installing holder comp, be sure not to skip the parts. 5-11...
  • Page 98 Forward and reverse arm assembly 1. HOLDER COMP 2. BOLT , HEX 3. WASHER , SPRING 4. NUT , HEX/2 5. PIN COMP, REVERSE 6. BOLT , HEX/S 7. PIN COMP , FORWARD Holder comp 8. BOLT , HEX/S 9. C-RING , SHAFT 10.

  • Page 99: Mid Pto Stopper

    3) MID PTO STOPPER ASSEMBLY 1.CASE , MID PTO 2.PLUG , SQUARE 3.PIN , PARALLEL/A 4.BOLT , HEX/S 5.SHAFT , MID PTO COUNT 6.GEAR , SPUR 32T 7.BEARING , BALL 8.C-RING , HOLE 9.COLLAR , 17X24X6 10.C-RING , SHAFT 11.CAP COMP , MID PTO SHAFT 12.BOLT , HEX /S 13.SEAL , OIL/D...

  • Page 100: Mid Pto Stopper Operation

    4) MID PTO STOPPER OPERATION Fig.5-22 ① When PTO switch is ON at engine works, The hydraulic fluid of PTO Valve flows to PTO clutch through hydraulic pipe, and let PTO shaft rotate which is engaged to Gear. ② The fluid flows to actuator and piston operates to protrude. ③...

  • Page 101: Rear Transmission

    3. Rear transmission case Fig.5-23 5-15...
  • Page 102 3-1. DISASSEMBLY Separate the axle bracket and the rear transmission from each other and then remove the hydraulic cylinder case.referring to paragraph 4 of SECTION 3. SEPARATION OF MAJOR COMPONENTS in Chapter 2. (1) Ring gear, Drive pinion, and related parts. 1.SHAFT, DIFF LOCK 8.O-RING , P 2.PIN , SPRING...
  • Page 103 a. Disconnect Mid PTO case by loosening bolts f. Remove the metal bearing tightening bolts and as shown in Fig.5-25 take put drive pinion and related parts as an assembly. The number of installed shims should be written down or memorized for later reference.
  • Page 104 (2) PTO shaft and related parts. Fig.5-29 PTO lever, stay Fig.5-30 PTO gears a. Remove the rear hitch and the PTO guide b. Pull out the spring pin (17) with a special tool c. Pull out the arm comp(10) d. Extract PTO shaft stay(2) rearwards and take out shifter(1). e.
  • Page 105 3-2. INSPECTION Before and after disassembly, inspect each part for the items mentioned below. Parts which deviate from the specified values should be Taper Roller Bearing replaced. -Wash clean all disassembled parts and check them for wear, damage, deformation, Burning , etc.
  • Page 106 When the drive pinion and the ring gear has been Note: replaced, the proper number of shims to be - As shown in Fig5-32, there are two kinds of installed should be determined based upon the differential side gears. Although are case before page.
  • Page 107 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(Fig5-34) 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 108 Note: Strike the circumference of the ring gear both sides with a copper hammer by turning the ring gear manually,and check to see that the backlash remains unchanged.The backlash should be checked at four points 90 degrees apart to each other. ⅲ.inspection of the tooth bearing Apply an even coat of oil-dissolved minium on the drive pinion teeth and turn the drive pinion on the ring gear to check the tooth bearing by observing the bearing traces on the ring gear.
  • Page 109 (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 110: Shifter And Related Parts

    4. SHIFTERS AND RELATED PARTS. 4.1. CONSTRUCTION (1) Forward and reverse control linkage mechanism. Holder comp Fig.5-37 Magnetic cruise 1. HOLDER COMP 19. BEARING , BALL 2. BOLT , HEX 20. WASHER , PLAIN 3. WASHER , SPRING 21. PIN , SPLIT 36.
  • Page 111 (2) range shifter (Speed range shift) mechanism Fig.5-38 2. HOOK COMP, RANGE 3. HUB COMP ,RANGE 4. O-RING , P 5. PLATE 6. BOLT , HEX/S 7. PIN , SPRING 8. BUSH , 16X18X33 9. LEVER COMP , RANGE 10. LINK 11.
  • Page 112 (3) Front drive change (4 WD shaft) mechanism 2. BOSS 3. SPRING , SHIFTER 4. BALL , STEEL 5. ARM COMP , 4WD 6. O-RING , P 7. ARM COMP 8. PIN , SPRING Fig.5-40 9. BOLT , HEX/S 10. LEVER COMP , 4WD(LOW) 11.
  • Page 113 (4) Rear PTO mechanism Counter shaft PTO shaft Fig.5-42 7.PIN , SPLIT 8.BOLT , SET M8X16 9.ARM SET , PTO 1.FORK , PTO 2.STAY , PTO 10.ARM COMP , PTO 3.E-RING 4.O-RING , P 11.LEVER COMP , PTO(LOW) 5.BALL , STEEL 6.SPRING , SHIFTER 12.O-RING , P 13.PLATE , CHANGE 14.PIN , SPLIT...
  • Page 114 - REAR PTO counter shaft 1.PTO counter shaft 11T 2.Bearing,Ball(6305) 3.Bearing,Ball(6204) Fig.5-45 Note: - When pushing the Bearings(6305,6204) into the gear , spur 11T, be careful only to push their inner races. - Every time a gear is installed, its smooth rotation should be checked. - REAR PTO shaft 1.Shaft PTO 2.Snap ring...
  • Page 115 (5) MID PTO (5-1) MID PTO CASE ASSY 1.CASE , MID PTO 2.PLUG , SQUARE 3.PIN , PARALLEL/A 4.BOLT , HEX/S 5.SHAFT , MID PTO COUNT 6.GEAR , SPUR 32T 7.BEARING , BALL (6203) 8.C-RING , HOLE 9.COLLAR , 17X24X6 10.C-RING , SHAFT 11.CAP COMP , MID PTO SHAFT 12.BOLT , HEX /S...
  • Page 116 (5-3) Mid PTO counter Gear 1Gear,spur 25T 2.snap-ring(hole) 3.Bearing,Ball(6203) Fig.5-50 Note : When pushing the BRG’s(6203) into the gear, be careful only to push their outer races. (5-4) MID PTO shaft sub Fig.5-51 (5-5) MID PTO shift metal SUB Note : Refer to the rear PTO shift mechanism. It is used by the rear PTO shift at that time. 5-30...
  • Page 117 6) Drive pinion Sub assembly 1.C-RING , SHAFT 2.GEAR , SPUR 21T 3.BOLT , HEX/S 4.METAL , PINION 5.PIN , PARALLEL/A 6.METAL , BEARING 7.SHIM , 0.1 8.SHIM , 0.2 9.BEARING, TAPER ROLLER(30304J) 10.GEAR , SPUR 17-27T 11.C-RING , SHAFT 12.GEAR , SPUR 17T 13.BEARING , BALL(6306) 14.BEARING , BALL/HL1(6306)
  • Page 118 7) Sub change counter shaft 1.C-RING , SHAFT 2.GEAR , SPUR 21T 19.BEARING , BALL/HL1 (6206) 20.GEAR , SPUR 19-28T 21.BEARING , NEEDLE. ROLLER (KT252913) 22.GEAR , SPUR 28T 23.WASHER , 20X34X3 24.BEARING, BALL/HL1(6304) Fig.5-53 Note: 1.Apply grease when installing Needle bearing. 2.After installation, be sure to slide smoothly.
  • Page 119 Note: 1.When assembling without replacing the pinion gear and ring gear with new ones, provide the same shimming thickness as that provided before disassembly. 2.Backlash between diff-pinion and diff-side gear should be within as range of 0.1 to 0.2mm (0.004-0.008 in) and these parts should turn smoothly. 3.When reassembling the used pinion and ring gear, reinstall the same thickness of shims as was installed before disassembly in each shimming position.

  • Page 120: Section 4.Trouble Shooting

    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 Replace worn or deformed shifters Gears make a noise...

  • Page 121: 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 122: Power Train Diagrams

    Power Train Diagram Fig.5-60 5-36...
  • Page 123 CHAPTER 6 FRONT AXLE CHAPTER 6. FRONT AXLE(4WD)----------------------------------------- SECTION 1.GENERAL DESCRIPTION----------------------------------- SECTION 2. SPECIFICATIONS--------------------------------------------- SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY-- 1. Center pivot----------------------------------------------------------------- 1-1. Disassembly-------------------------------------------------------------- 1-2. Inspection---------------------------------------------------------------- 1-3. Reassembly-------------------------------------------------------------- 2. Front differential---------------------------------------------------------- 2-1. Disassembly-------------------------------------------------------------- 2-2. Inspection---------------------------------------------------------------- 2-3. Reassembly-------------------------------------------------------------- 3. Final case-------------------------------------------------------------------- 6-10 3-1. Disassembly-------------------------------------------------------------- 6-11 3-2.
  • Page 124 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 125: Chapter 6. Front Axle(4Wd)

    SECTION 2. SPECIFICATIONS T264HST Wheel alignment Toe-in (mm) Camber 3°± 1° Caster 3°± 1° Front axle Pivot metal (F) bore (mm) Φ55 Pivot metal (R) bore (mm) Φ65 Pivot metal (F) bush (mm) 50X55X20 Pivot metal (R) bush (mm) 60X65X30 Housing (F) Diameter (mm) Φ50 Housing (R) Diameter (mm)

  • Page 126: Section 3.Disassembly,Inspection,And Reassembly

    SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY 1. CENTER PIVOT Fig.6-3 1.HOUSING, FRONT AXLE 2.CAP ASSY , OIL 3.PLUG , SQUARE R1/2 4.CONNECTOR 5.HOSE . 500 6.CLIP , HOSE D=12.5 7.METAL ASSY , RR PIVOT 8.METAL , RR PIVOT 9.BUSH , 60X65X30 10.NIPPLE , GREASE/B-PT 11.O-RING , G65 12.O-RING , G60 13.METAL ASSY , FR PIVOT...

  • Page 127: Disassembly

    2) FRONT AXLE BUSH BORE DIAMETER 1.1.DISASSEMBLY 1) Dismount the front wheel drive shaft, Measure the bore diameter of the roll referring to the pertinent paragraph in chapter 2. bush in the pivot metal (F). If the measured value 2) Remove the right and left tie rods. exceeds the usable limit, replace the bush.
  • Page 128 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 129: Front Differential

    2. FRONT DIFFERENTIAL Fig.6-10 1.DIFF ASSY , FR 2.GEAR , BEVEL 25T 3.CASE , FR DIFF 4.PINION , DIFF 10T 5.WASHER , THRUST 6.GEAR , 20T DIFF SIDE 7.WASHER , THRUST 8.SHAFT , DIFF PINION 9.PIN , SPRING 5X25 10.PIN , SPRING 3X25 11.BEARING , BALL 6210 12.C-RING , SHAFT 40 13.PINION , BEVEL 8T...

  • Page 130: Disassembly

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

  • Page 131: Reassembly

    2-3.REASSEMBLY Specified thrust play 0.1-0.3 Reassembly the parts in reverse order of mm(in) (0.004-0.011 in) disassembly,following these instructions. Note: 1)Each friction surface should be coated with grease in advance. TRB and collar should be replaced as a pair. 2)The bevel pinion and the ring gear make a distinct pair after a mesh adjustment (1) Bevel pinion (8) performed at the factory.
  • Page 132 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 133: Final Case

    3. FINAL CASE ⓐ. Front gear case 1. 1.CASE , FINAL DRIVE A 2.GEAR , BEVEL 11T 3.BEARING , BALL 6007 4.COLLAR , 53X62X2 5.C-RING , HOLE 62 6.GEAR , BEVEL 18T 7.BEARING , BALL 6006 8.SEAL , OIL 9.BEARING , BALL 6009 10.C-RING , HOLE 68 11.BEARING , BALL 6008 12.C-RING , SHAFT 40...
  • Page 134 Ⓑ. Front gear case 2. 1.CASE , RH FINAL DRIVE B 2.CASE , RH FINAL DRIVE B 3.SHAFT 4.GEAR , BEVEL 8T 5.BEARING , BALL 6006 6.SHIM 7.C-RING , HOLE 55 8.CAP , 55 9.PLUG , SQUARE R3/8 10.GEAR , BEVEL 44T 11.BEARING , BALL 6207 12.WASHER , 35X45X2 13.C-RING , SHAFT 35...

  • Page 135: Inspection

    Note: The removed cap(55) (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.

  • Page 136: Reassembly

    Wheel shaft cover 3.3 REASSEMBLY 1) Every snap ring(13) 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 44T) to the following parts.
  • Page 137 - 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 427mm 274mm 1) When installing the steering cylinder,Be sure that the rods are not damaged.
  • Page 138 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 139: Section 4.Trouble Shooting

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

  • Page 140: Rear Axle And Brakes

    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 141: Section 2. Specifications

    SECTION 2. SPECIFICATIONS MODEL T264HST Type Spur gear (71T) Final reduction gears Reduction ratio 0.17 (12/71) Friction Type Wet, multi-disc, Mechanically operated Plate Diameter Φ77 x Φ124.5 mm Thickness ±0.1 Lining material Paper (JEP-205S) Brake system Number of plates 2 on each side diameter Φ77 x Φ126 mm Thickness...

  • Page 142: Section 3.Disassembly,Inspection,And Reassembly

    SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY Separate the rear axle housing from the rear transmission referring to paragraph SECTION SEPARATION OF MAJOR BLOCKS in Chapter 2 1) REAR AXLE HOUSING AND BRAKE SYSTEM Fig.7-2 Fig.7-3 Metal brake Friction plate separator plate 1.CAM 2.METAL ,BRAKE LH 3.METAL ,BRAKE RH 4.PLATE COMP , DISC 1.HOUSING, AXLE 2.SHAFT , WHEEL PINION LH 3.BEARING , BALL...
  • Page 143 1.1 Disassembly 1) Release the bolt and nut and remove them. 2) Extract the snap ring(15) and the bearing(11) with a puller and remove wheel gear(13) 3) Remove the brake metal tightening bolts and remove brake metal(5) with wheel pinion(7,2) and disc brake assembly on it.
  • Page 144 4) Wheel shaft 2) Metal brake Check the shaft for abnormalities like wear, Check the metal brake, and brake rod for damage, etc, and replace a defective one. abnormality. Replace defective parts. Replace the metal brake whose thickness exceeds the usable 5) Bearings limit.
  • Page 145 4) Replace the oil seal. Install the bearing and the snap ring into the axle housing, and then press in the oil seal by applying force only to the circumference as shown in the figure( Fig.7-9) Apply force only to the shaded parts Take care not to deform these portions Fig.7-9 5) press the wheel shaft.
  • Page 146 SECTION 4. TROUBLESHOOTING Problem Causes countermeasures 1) Rear axle · Worn or damaged bearing Replace Noises · Worn gear or wheel shaft Replace 2) Brake system Depress pedals · Insufficient depressing of brake pedals positively · Improper pedal free play (1)Insufficient braking force Adjust ·...

  • Page 147: Disassembly

    Chapter 8 Power assisted steering system SECTION 1.GENERAL DESCRIPTION-------------------------------- SECTION 2. SPECIFICATIONS------------------------------------------ 2.1 Gear pump-------------------------------------------------------------- 2.2 Steering valve------------------------------------------------------------ 2.3 Oil tank------------------------------------------------------------------- SECTION 3. FUNCTION--------------------------------------------------- 3.1 Technical Data----------------------------------------------------------- SECTION 4.DISASSEMBLY,INSPECTION,AND REASSEMBLY 4.1 Major component------------------------------------------------------- 4.2 Special tools-------------------------------------------------------------- 4.3 Disassembly-------------------------------------------------------------- 4.4 Inspection----------------------------------------------------------------- 4.5 Reassembly--------------------------------------------------------------- SECTION 5.

  • Page 148: 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.

  • Page 149: Section 2. Specifications

    SECTION 2. SPECIFICATIONS 1) GEAR PUMP MODEL T264HST Delivery (cc/rev) 1000 rpm 4.4LPM Pump performance 1800 rpm 8.1LPM (kgf/cm 2600 rpm 11.7LPM Maximum pressure (kgf/cm Rated operation speed (rpm) 500~3000 Rotation direction C.C.W as viewed from shaft end 2. Power steering valve Unit(orbitrol) MODEL T264HST Displacement (cc/rev)

  • Page 150: Section 3. Function

    SECTION 3. FUNCTION SHINJIN is a hydrostatic steering unit which can be used with an add-on steering column, SHINJIN-T or with the steering column integrated with the unit. The steering unit consists of a rotary valve and a rotary meter. Via a steering column the steering unit is connected to the steering wheel of the vehicle.
  • Page 151 3.1 TECHNICAL DATA SINJIN Max. input flow 16 l/min [4.22 US gal/min] Ambient temperature Min. –30°C [–22°F] Max. +60°C [140°F] Surface treatment Permissible temperature assuming 120°C [248°F] for 20 minutes non-activated steering unit -30 °C Oil temperature Min. [-27°F] +90 °C Max.
  • Page 152 SHOCK VALVES (Reference) The shock valves protect the steering unit against shocks from external forces on the steering cylinder. The shock valves in the steering unit limit the max pressure drop from L to T and from R to T. The shock valves are set at 1 l/min [0.27 US gal/min].

  • Page 153: Section 4.Disassembly,Inspection,And Reassembly

    SECTION 4. Disassembly, Inspection, And Reassembly 1. Major component of steering valve (Reference) Fig.8-2 1.Dust seal ring 2. Housing spool and sleeve 3.Ball 4. Ball stop 5.Shaft seal 7.Bearing 10.Ring 11. Cross pin 12.Set of springs 13.Cardan shaft 14.Spacer 15.O-ring 16. Distributor plate 17.Gear wheel set 18.O-ring 19.End cover 20.O-ring 22.Special screw 23.

  • Page 154: Special Tools

    2.SPECIAL TOOLS F. Fork for fitting cardan shaft (OMM) A.Holding tool, code no. SJ150L9001-01 SJ 151G9000 -1 G .Ordinary hand tools. Socket spanner (5/8 in) B .Assembly tool for shaft seal ø17.5, Ratchet spanner, 1/2” code no. code no. SJ150L4011 - 01 Torque wrench: 0-70 Nm (0-7 da Nm) Allen keys: 5 &...

  • Page 155: Reassembly

    STEP 3. STEP 9. -Cross pin(11) -Special. Screws (22, 23) Press the pin out of the spool set. Remove the screws with a 16 mm a/flats Carefully press the spool out of the sleeve. (5/8”) spanner. -Springs (12) -End cover (19) Press the neutral position springs out of the Remove end cover sideways.
  • Page 156 STEP 2. Note: -Shaft seal (5) The ring must be able to rotate unimpeded by the springs. With the assembly tool the shaft seal must into the housing. STEP 6 Note that the small guide piece at the front of the tool must remain in the hole for the output -Cross pin (11) shaft when the tool itself is drawn out of the...
  • Page 157 STEP 8. STEP 12 -O-rings (18) -Ball (3) Place the O-rings in the grooves on each side Place the emergency steering ball in port P. of the gearwheel rim. -Ball stop (4) -Gear ring ( 17 ) Place the ball stop in port P. Place the gearwheel rim over the distributor plate so that all holes are in line with each -Ball (37)
  • Page 158 STEP 17. (Test) a.Lift OSPM out of the tool and prepare it for testing. The pressure relief valve can be set either on a test panel or in a system with pressure-gauge read-off. b.Insert plastic plug. STEP 18. Dust seal (1) Guide the dust seal ring down over the shaft end press into place in the housing with assembly tool.

  • Page 159: 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 tightly. -Replace column spline (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 160 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 161 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 162 Chapter 9 Hydraulic system SECTION 1. GENERAL DESCRIPTION ------------------------------- SECTION 2. SPECIFICATIONS ------------------------------------------ SECTION 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM ------------------------------------------------------- 1.Hydraulic system ------------------------------------------------------- 2.Flow-divider -------------------------------------------------------------- 3.Flow-control valve(Slow-return check valve) ----------------------- 4.Safety valve(main relief valve)----------------------------------------- 5.Gear pump --------------------------------------------------------------- 9-10 6.Filter----------------------------------------------------------------------- 9-15 SECTION 4.

  • Page 163: 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.

  • Page 164: Section 2. Specifications

    SECTION 2. SPECIFICATIONS Model T264HST Piston And cylinder Hitch lift capacity, lb.(kg) at 24 inches behind 1,102(500) link arms Control Valve Cylinder port leaks (㏄/min) (under a pressure of 9800kpa(100 ㎏f/㎠) With gear oil SAE 80W Main relief Valve Cracking pressure (㎏f/㎠) Relief pressure (㎏f/㎠) Gear Pump Delivery(94~96% efficiency): liter (cu.in) mm...

  • Page 165: Section 3. Major Component Of The Hydraulic System

    SECTION 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM 1.HYDRAULIC SYSTEM Fig.9-2 1.Shaft,lift 2.Cylinder case 3.Arm comp, lift 4.Snap ring 5.Seal oil/D354805 6.Bush 35x42x40 ⑥Bush 40x46x40 7.Crank, lift 8.Spring pin (6x40) 9.Rod, piston 10.Ring 11.O-ring P70 12.Piston, hyd. 13.Cylinder comp 14.O-ring 15.Valve assy, main control 16.Bolts (M8x45) 17.Valve assy, flow control...

  • Page 166: Flow-Divider

    2.FLOW-DIVIDER GENERAL DESCRIPTION This valve is installed to bypass working fluid of a specified pressure from the main circuit into the PTO circuit through a fixed orifice. It includes a changeover valve for engaging and disengage the PTO clutch by means of a solenoid and a sequential valve for PTO circuit's over the main circuit. (1) PTO Solenoid valve (2) Hydrostatic unit Fig.9-3...
  • Page 167 -When the solenoid is switched 「ON」 The fluid from the steering valve flows to port P2 through oil cooler and the pressure-reducing valve The pressure of the PTO clutch circuit are the same and will be set as relief valve in the hydrostatic unit.
  • Page 168 -When the solenoid is switched 「OFF」: The fluid in the PTO clutch is unloaded to the bank through port P2. Consequently pressure P2 at PTO valve block becomes zero, whereas the pressure at P2 is port A through T2. Then the force imposed upon the left side of spool P2 overcomes the force imposed upon the right side by spring force.

  • Page 169: Flow-Control Valve(Slow-Return Check Valve)

    3.FLOW-CONTROL VALVE(SLOW-RETURN CHECK VALVE) 3.1. GENERAL DESCRIPTION This valve regulates the lowering speed of the lift by controlling the unloading flow from the lift cylinder to the tank. ①Dust seal ②Snap ring ③Collar ④Body ⑤0-ring ⑥Adjust screw ⑦Back-up ring ⑧0-ring ⑨Stop ring ⑩Poppet ⑪Spring...
  • Page 170 3.2 OPERATIONS 2) Up position 1) DOWN position The flow port A,overcoming the force of spring(11),pushes up poppet (10) and The fluid from port B pushes up stop ring (9) choke(C)is fully opened regardless of the of poppet(10) until the ring comes into position of adjust screw(6).Thus the fluid contact with adjust screw(6),as it reaches flows to port B and the cylinder,which...
  • Page 171 2) PRECAUTIONS FOR DISASSEMBLY 4. RELIEF VALVE (Reference) 1)GENERAL DESCRIPTION AND REASSEMBLY This valve regulates the maximum pressure in (1)Tightening torque of lock nut (9)5.0∼6.0 the whole hydraulic circuit.The regulated ㎏f·㎠(36.2∼43.4 ft.lbs) pressure can be set with the adjust screw. (2)Install seat(2)and then tap ball(3)(5/16) lightly so as to provide tight seating.

  • Page 172: Gear Pump

    5.GEAR PUMP 1) GENERAL DESCRIPTION This pump induces fluid from one side and delivers it from the each 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 single pump system.

  • Page 173: Filter

    6. FILTER O-ring (G45) Suction Filter Fig. 9-30 Filter Bolt(M10 X25-7T) 1)GENERAL DESCRIPTION The tractor is equipped with two oil filters: suction filter(1) and line filter(4),for better filtration. 2)SPECIFICATIONS -Suction filter Applicable oil DONAX TD or RPM THF 500 Rated flow rate(ℓ/min.) Filtration density (mesh) 150 mesh 450 ㎠...

  • Page 174: Section 4. Remote Hydraulic Control

    SECTION 4. REMOTE HYDRAULIC CONTROL 1.Remote hydraulic control valve( OPTIONAL) 1.VALVE , DETENT 2.O-RING , P10 3.O-RING , P16 4.BOLT , HEX M10X90 6.UNION , O-RING 7.PIPE , AUX VALVE 8.COUPLING A 9.LEVER COMP, AUX VALVE 10.BOLT , HEX/S M8X25 11.GRIP , LEVER/RED Fig.
  • Page 175 2.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 176 4. SPECIFICATIONS Maximum flow (ℓ/min) 45 LPM Maximum pressure(Kgf/㎠) A and B port leak Oil temperature:50℃(122℉) 9 cc/min below Under a load of 100Kgf/㎠ Recommended fluid THF 500 Operating temperature range -20℃~80℃ Fig. 9-33 Remote hydraulic pump 4.1 HYDRAULIC CIRCUIT P:From pump T:To tank A, B : High pressure port,...

  • Page 177: Section 5.Hydraulic System

    SECTION 5. HYDRAULIC SYSTEM 1.HYDRAULIC CYLINDER 1)Hydraulic system must be washed clean, and care must be taken not to let any foreign substances. 2)The O-ring and back-up ring should be coated with grease ahead of time. Install with care so as not to damage them.
  • Page 178 Cylinder O-ring Back-up ring O-ring Piston Note : Must follow the correct order Fig.9-35. Piston Fig.9-36.Lift arm 8)Adjust the angle of the roll bush from horizontal is 30° 9)Apply grease to the roll bush. 10)Apply grease to the cylinder case and lift arm face Which touched with each other. 11) When assemble the lift crank on the lift shaft, mesh their splines using the alignment marks which were put there before disassembly.
  • Page 179 Fig.9-38. Assembly marks 13)Rap the plug with sealing tape. 14)Tighten the slow return valve to the specified torque 1000∼1200 ㎏f-㎝ and be sure not to damage the O-ring. 9.5∼10.5mm at the full closed valve Tightening torque : 10∼12kgf-m Apply oil Fig.

  • Page 180: Linkage(Internal)

    2. LINKAGE (INTERNAL) 1) Before installing the linkage, apply grease to relayed drive parts. 2) Drive in the roll pin into the linkage pin through the rod and lock the pin. 3) Be sure not to over operate within specified spool stroke(7mm between up and down at neutral position)

  • Page 181: Linkage(External)

    3.LINKAGE (EXTERNAL) Starting torque : 6∼8kgf.cm Bolts Fig. 9-41Linkage(external) Note : Bolts(7) should be tightened after setting the lever up with 6~8 kgf.cm of starting torque 9-23...

  • Page 182: Main Control Valve

    4. MAIN CONTROL VALVE 4.1 GENERAL DESCRIPTION This valve controls the lifting and lowering operation of the hydraulic cylinder. It has especially been developed to control the working height of the implement. It consists of a feed back valve; direction control valve, flow-control unloading valve, and holding check valve.

  • Page 183: Operation

    4.4 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.9-47 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 184 2) Lifting position Fig.9-48 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 185 3) Lowering position Fig.9-49 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 186 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 187 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 188 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 189 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 190: Section 7. Troubleshooting

    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.

  • Page 191: Section 1. General Description

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

  • Page 192: Section 3. Battery

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

  • Page 193: 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 194 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 195: 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 196: 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 197: 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 198: Stop Light Switch

    -Lighting 4. STOP LIGHT SWITCH Color code (Yellow (Red / (Red) (Orange / Green) / red) Yellow) 9 : B1* 5 : T 4 : 1 10 : 2 ● ● ● ● ● ● :Terminals Fig.10-15 Stop light switch : Switching positions Capacity 10~20A (DC12V)
  • Page 199 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.

  • Page 200: Trailer Socket(7P)

    8.Trailer socket (Reference) A hella’s 7-pin trailer socket is equipped as an optional equipment.Lamp on a trailer can be operated through the socket. A type B type Fig.10-23 Wire Description Color Specification Hous A type B type A type B type A type B type Turn signal (LH)

  • Page 201: Section 5. Earthing Point

    SECTION 5. EARTHING POINT 3) In the dash cover 1)Front axle bracket 1) Front axle bracket (RH) Fig.10-24 Earthed at upper tapped hole in the axle bracket. 3) Earthed at upper tapped hole in the dash panel. Fig.10-25 2) Contact surfaces of the axle bracket and engine where they tightened together Fig.10-26 10-11...

  • Page 202: Section 6. Wiring Diagram

    SECTION 6. WIRING DIAGRAM(A3) 10-12...

  • Page 203: 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 204 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 205 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 Cruise does Burnt out fuse Inspect and renew.Check circuit before re- not operate...
  • Page 206 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 207 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 208 CONVERSION TABLES M illimeters to inch es Inches to millimeters 0.0394 1.0236 2.0079 2.9921 1/64 0.3969 25/64 9.9219 13/16 20.6375 0.0787 1.0630 2.0472 3.0315 1/32 0.7938 13/32 10.3188 53/64 21.0344 0.1181 1.1024 2.0866 3.0709 3/64 1.1906 27/64 10.7156 27/32 21.4313 0.1575 1.1417 2.1260...
  • Page 209 L en gth Fee t to M eter s 0.0000 0.3050 0.6100 0.9150 1.2200 1.5250 1.8300 2.1350 2.4400 2.7450 8.0532 3.3550 3.6600 3.9650 4.2700 4.5750 4.8800 5.1850 5.4900 5.7950 21.1097 6.4050 6.7100 7.0150 7.3200 7.6250 7.9300 8.2350 8.5400 8.8450 34.1661 9.4550 9.7600 10.0650...
  • Page 210 Are a S quar e in ch es to s qu ar e c en ti mete rs 0.000 6.462 12.924 19.386 25.848 32.310 38.772 45.234 51.696 58.158 64.620 71.082 77.544 84.006 90.468 96.930 103.392 109.854 116.316 122.778 129.240 135.702 142.164 148.626 155.088...
  • Page 211 V ol u me G all on s ( U.S ) to L i te rs US gal US gal Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters 0.000 3.785 7.571 11.356 15.142 18.927 22.712 26.498 30.283 34.069 37.854 41.639 45.425...
  • Page 212 M ASS P ou nds to Kil ograms 0.000 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 4.536 4.990 5.443 5.897 6.350 6.804 7.258 7.711 8.165 8.618 9.072 9.526 9.979 10.433 10.886 11.340 11.794 12.247 12.701 13.154 13.608 14.062 14.515 14.969 15.422...
  • Page 213 P r e s s u re P ou nds pe r s qu are i nc h e s to Ki l ograms pe r s qu ar e c e nti me te rs lb/in2(PSI) lb/in2(PSI) Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2...
  • Page 214 Tor qu e Foot pou nds to Ki l ogr am me te r s ft lbs Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m 0.138 0.276 0.414 0.552 0.690 0.828 0.966 1.104 1.242 1.380 1.518 1.656 1.794 1.932 2.070 2.208...
  • Page 215 Tem perature Fahrenheit to Centigrade Centigrade to Fahrenheit ˚F ˚C ˚F ˚C ˚C ˚F ˚C ˚F -28.9 35.0 -22.0 96.8 -26.1 37.8 -18.4 100.4 -23.3 40.6 -14.8 104.0 -20.6 43.3 -11.2 107.6 -17.8 46.1 -7.6 111.2 -17.2 48.9 -4.0 114.8 -16.7 51.7 -0.4...
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