Mahindra 2810, T290, T330, T300 Service Manual

TRACTORS

2810/T290/T300/T330

SERVICE MANUAL

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

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. INSTRUMENTS -------------------------------------------------------1-21

2. CONTROLS ----------------------------------------------------------- 1-23

3. FILLING DIAGRAM AND CAPACITY TABLE----------------1-24

4. MAINTENANCE CHART -------------------------------------------1-25

Chapter 1 .Introduction

This tractor service manual is for qualified service personnel engaged in servicing and overhauling 2810/T290/T300/T330 tractor.Use of this publication is not recommended for field operators since they usually do not have access to special tools and shop equipment essential for most servicing.

Servicing procedures outlined herein contain sufficient information to return all component parts of a tractor to new condition. In discussion of each component parts,it is assumed that a complete overhaul is been performed,consequently,

complete disassembly and reassembly are outlined.The mechanic is relied upon to decide how far disassembly must be carried when complete overhaul is not required.

Study unfamiliar service procedures thoroughly and clearly understood before attempting disassembly. Specific data essential for proper overhaul,such as running clearances and torque values,have been provided in interline of Inspection and reassembly procedures of each group section.

This manual was compiled from latest information available at time of publication. Manufacturer reserves the right to make changes at any time without notice.

Whenever the terms "left"and "right" are used, They means as viewed by the operator when seated in the operator's seat.

1-1

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.

-Do not use an open pail for transporting fuel.

-Use of an approved fuel container.

-Dispose of all fuel-soaked rags in covered containers where cigarettes cannot be dropped

carelessly.

-Do not smoke and avoid open flame when charging,jumping,or boosting batteries.

-Batteries give off gas which is flammable and explosive.

-Do not charge batteries in a closed area. Provide proper ventilation to avoid explosion of

accumulated gases.

Avoid acid burns.

-Wear safety goggles when handling battery electrolyte.It contains sulfuric acid which is a

poison and can cause blindness.Avoid it contacting eyes,skin,or clothing. sulfuric acid will eat through clothing and can cause severe burns to skin.

AVOID HIGH-PRESSURE FLUIDS

1) Before beginning work on hydraulic system components,turn off engine and operate

hydraulic control levers to relieve internal hydraulic pressure.

2) Oil under pressure can penetrate skin and lead to personal injury.Treat sources of oil

pressure with extreme care,wearing safety goggles.

3) If hydraulic leak develops,correct immediately.Escaping hydraulic oil can have extremely

high pressure. A stream of high pressure oil may easily penetrate skin just like modern

needless vaccination equipment,but with the exception that hydraulic fluid may cause blood

poisoning. It is imperative that connections are tight and that all lines and pipes should be in good condition. If injured by escaping hydraulic fluid,see a doctor at once.

1-2

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.

SERVICE TIRES SAFELY

Tire changing can be dangerous and should be done by trained personnel using proper tools and

equipment.

Do not re-inflate a tire that has been run flat or seriously under-inflated.Have it checked by qualified personnel.

Use wheel handling equipment adequate for weight involved when removing and installing wheels.

1-3

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.

Hazard or unsafe practice that can lead in injury or death.

CAUTION

Instructions for the correct operation of the machine which, if followed, will ensure that it performs at it’s best

IMPORTANT

Hazard or unsafe practice that can lead to severe injury or death.

WARNING

Serious hazard with a very high level of risk of either serious injury or death

DANGER

MEANING OF SIGNSIGN

1-5

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

DANGER

WARNING

CAUTION

SIGNAL WORDS.

A signal word—DANGER, WARNING OR CAUTION—is used with safety alert symbol.

DANGER identifies the most serious hazards. Safety signs with signal Word —DANGER OR WARNING—are typically near specific hazards. General precautions are listed on CAUTION safety signs.

READ SAFETY INSTRUCTION

Carefully read all safety instructions given in this manual for your safety. Tempering with any of the safety devices can cause serious injuries or death. Keep all safety signs in good condition. Replace missing or damaged safety signs.

Keep your tractor in proper condition and do not allow any unauthorized modifications to be carried out on the Tractor, which may impair the function/safety and affect Tractor life.

PROTECTION CHILDREN

Keep children and others away from the Tractor while operating. BEFORE YOU REVERSE

- Look behind Tractor for children.

- Do not let children to ride on Tractor or any implement.

1-6

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. In the event of damage or alteration, the ROPS must be replaced prior to further operation of the Tractor.

The seat belt must be worn during machine operation when the machine is equipped with a certified ROPS.

Failure to do so will reduce or eliminate protection for the operator in the event of a roll over.

PRECAUTION TO AVOID TIPPING Do not drive where the Tractor could slip or tip. Stay alert for holes and rocks in the terrain, and other hidden

hazards. Slow down before you make a sharp turn. Driving forward out of a ditch or mired condition could cause

Tractor to tip over backward. Back out of these situations if possible

PARK TRACTOR SAFELY Before working on the Tractor ; Lower all equipment to the ground. Stop the engine and remove the key

KEEP RIDERS OFF TRACTOR Do not allow riders on the Tractor. Riders on Tractor are subject to injury such as being stuck by

foreign objects and being thrown off of the Tractor

1-7

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.

STAY CLEAR OF ROTATING SHAFTS Entanglement in rotating shaft can cause serious injury or death. Keep PTO shield in place at all times. Wear close fitting clothing. Stop the engine and be sure PTO

drive is stopped before making adjustments, connections, or cleaning out PTO driven equipment.

ALWAYS USE SAFETY LIGHTS AND DEVICES

Use of hazard warning lights and turn signals are recommended when towing equipment on public roads unless prohibited by state or local regulations.

Use slow moving vehicle (SMV) sign when driving on public road

during both day & night time, unless prohibited by law

PRACTICE SAFE MAINTENANCE Understand service procedure before doing work. Keep the surrounding area of the Tractor clean and dry. Do not attempt to service Tractor when it is in motion. Keep body and clothing away from rotating shafts. Always lower equipment to the ground. Stop the engine. Remove the key. Allow Tractor to cool before any work repair is

caused on it. Securely support any Tractor elements that must be raised for

service work. Keep all parts in good condition and properly installed. Replace worn or broken parts. Replace damage/missing decals. Remove any buildup of grease or oil from the Tractor. Disconnect battery ground cable(−) before making adjustments on

electrical systems or welding on Tractor

1-8

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. Battery gas can explode.

Never check battery charge by placing a metal object across the poles.

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, cause holes in clothing and cause blindness if found entry into eyes.

For adequate safety always;

1. Fill batteries in a well-ventilated area.

2. Wear eye protection and acid proof hand gloves

3. Avoid breathing direct fumes when electrolyte is added.

4. Do not add water to electrolyte as it may splash off causing severe burns.

If you spill acid on yourself;

1.Flush your skin with water.

2.Flush your eyes with water for 10-15 minutes. Get medical attention immediately.

SERVICE TRACTOR SAFELY

Do not wear a necktie, scarf or loose clothing when you work near moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jeweler to prevent electrical shorts and entanglement in moving parts.

WORK IN VENTILATED AREA

Do not start the Tractor in an enclosed building unless the doors & windows are open for proper ventilation, as tractor fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area remove the exhaust fumes by connecting exhaust pipe extension.

1-9

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.

SAFETY STARTER SWITCH

1. Clutch operated safety switch is provided on all Tractors which allow the starting system to become operational only when the Clutch pedal is fully pressed.

2. Do not By-pass this safety starter switch or work on it. Only Authorized Dealers are

recommended to work on safety starter switch.

3. On some models Safety Starter switch is provided on transmission High-low shifter lever and

in PTO shifter lever.The tractor can be started only if High-low shifter lever is in neutral position.

Safety Starter Switch is to be replaced after every 2000 hours/4 years, whichever is earlier

1-10

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.

FAILURE TO FOLLOW ANY OF THE INSTRUCTIONS ABOVE CAN CAUSE SERIOUS INJURY TO THE OPERATOR.

● Do not permit anyone but the operator to

ride on the tractor. There is no safe place for rider.

● Lock brakes together, use warning lights

and SMV emblem while driving on roads.

● Lower equipment, place gear shift levers

in neutral, stop engine, remove the key and apply parking brake before leaving the tractor seat.

● Air pressures are specified by the

manufacturer.

● Before starting and operating

know the operating and safety instructions in the operators Manual and on the tractor.

● Clear the area of bystanders.

● Locate and know operation of controls.

● Start engine only from Operator’s

seat with depressed clutch pedal, transmission in the neutral, PTO

disengaged and hydraulic control in lower

position

● Slow down on turns, rough ground and

slopes to avoid upset.

WARNING

Location: On FENDER LH Part No.: 1260-904-070-1A

TO AVOID POSSIBLE

PERSONAL INJURY, THIS GUARD MUST BE KEPT IN PLACE

WARNING

Location: ON PTO guard Part No.: 1260-904-069-0A

1-11

CAUTION

TO PROTECT ENGINE AND HYDRAULIC COMPONENTS.

● Idle Engine for 1 minute before shut down or full load operation.

● Do not exceed 1/2 throttle for first 5 minutes of operation

WARNING

KEEP HANDS AND

CLOTHING

AWAY FROM ROTATING

FAN AND

BELTS TO

PREVENT

SERIOUS INJURY

Location: On Dash cover side RH Part No.: 1260-904-064-0

Location: On Radiator bracket side LH & RH Part No.: 1260-904-061-0

BEFORE OPERATE THE TRACTOR,READ THE OPERATOR’S MANUAL THOROUGHLY,TO UNDERSTAND THE IMPORTANT FUNCTIONS AND CONTROLS.

CAUTION

WARNING

The cooling system operates

under pressure.

● It is dangerous to remove

the radiator cap while the system is hot.

● Always turn the cap slowly

to the first stop and allow pressure to escape before removing the cap

completely.

● When operating below 32°F, use suitable anti-

freeze solution as coolant

Location: On dash cover side LH Part No.:1260-904-067-0A

Location: On Radiator bracket side LH&RH Part No.:1260-904-063-0

1-12

DANGER

BLINDNESS CAN

RESULT FROM

BATTERY EXPLOSION.

KEEP SPARKS OR OPEN

FRAMES AWAY FROM

BATTERY.

DO NOT JUMP START.

BURNS CAN RESULT FROM BATTERY ACID.

IN CASE OF CONTACT FLUSH IMMEDIATELY WITH WATER

WARNING

● Pull only from drawbar. Pulling from any other

point can cause rear overturn.

● Do not operate with unshielded PTO.

● Disengage PTO and stop engine before

servicing tractor or attaching and detaching

implements.

● When towing equipment use a Safety chain

FAILURE TO FOLLOW ANY OF THE INSTRUCTIONS ABOVE CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER

PERSONS.

Location: On battery bracket RH Part No.: 1260-904-066-0

Location: On rear frame Part No.: 1260-904-065-0A

WARNING

● Start engine only from operators seat. If sa fety start

switch is bypassed engine can start with transmission in gear.

● Do not connect or short across terminal on starter

solenoid. Attach booster cables as shown on battery decal and

operator’s manual.

Starting in gear causing runaway can result in serious injury.

Location: On dash over side LH Part no: 1260- 904-062-0A

1-13

UNIVERSAL SYMBOLS

Some of the universal Symbols have been shown below with an indication of their meaning.

Engine speed (rev/minX100)

Pressuredopen slowly

Corrosive substance

Hours, recorded

Continuous Variable

”Tortoise” slow or minimum setting

Engine coolant temperature

Warning

”Hare” fast or maximum setting

Fuel level

Hazard warning

Transmission oil pressure

Engine stop control

Neutral Turn signal

Lights Fan

Transmission oil temperature

Horn

Power take off engaged

parking brake

Engine oil pressure

Power take off disengaged

Work lamps

Air filter Lift arm/raise

Differential lock

Battery charge

Lift arm/lower

See operator’s manual

1-14

SECTION 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS

The tractor serial number is shown on the left hand side of the tractor as shown in the picture. The engine number is stamped on the top of the engine block.

Tractor Serial Number

Engine Serial Number

Tractor Serial Number

1.MODEL NAME PLATE

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

30NC V 01 0001

Production serial No Production month Production year Production Model

1-15

3.Engine model and engine serial number plate on the head cover.

1-16

SECTION 2. SPECIFICATIONS

3128Out put(ps/rpm)

Engine

Constant mesh(Synchromeshed 3

and 4thin main shift

in both forward and reverse)

Transmission

12V50AAlternatorDrive Train

1.2KWStarter Capacity

Electronic with cell motorStarting system

12V60AHBatteryElectrical

ForcedLubrication type

Throttle typeInjection pump

1-2-3Firing order

23:122:1Compression ratio

3.26inX3.64in

(83mmX92.4mm)

3.14inX3.64in

(80mmX92.4mm)

Bore and Stroke

1,4991,393Displacement

3Number of Cylinder

2800rpm2,700rpmRated Speed

Vertical,water cooled 4 cycle DieselType

D15033A139A-DY1Model

KUBOTADAEDONGMaker

Horizontal RoundMuffler

Dry type with paper elementAir cleaner

1.85US gal (7L)Coolant capacity

Water cooled,forced circulationCooling system

Hydrostatic PowerSteering

Bevel gears with diff-LockDifferential lock

DieselFuel

Wet DiskBrakes

StandardMFWD(4WD)

8.7 US gal (33L)Fuel Tank capacity

T290/T300/T3302810MODEL

1-17

Clutch

Dimensions

11.2-24 4PLYRear

7-16 4PLYFront Tire size

294(11.6”)

3290(129”)

T290/T300/T330

Central axle

Center pin

325(12.8”)

1640(64.6)

2,366(93.1”)

1315(51.8”)

3150(124”)

Multiple wet disk

Dry single disc,mechanic

2810

Rear

Front

Min. Ground Clearance

Wheel base

Overall Height

Overall width

Overall length

Axle type

PTO

Main

MODEL

Implement

Position controlSelf-control

Category 13-Point hitch category

Trailer hitchDrawing method

3-Point hitchMounting method

HydraulicOperation

1-18

Traveling speeds:Km/h (Mile/h)

1.251.281.301.334

0.900.930.940.963

0.700.720.730.752

0.510.550.530.551

3.944.054.084.204

2.862.932.963.043

2.222.282.302.372

1.611.671.681.721

7.087.297.347.552

5.175.315.355.501

ReverseForwardReverseForward

2810NEWT290/T300/T330

Main shift

Range shift

12.94

9.37

13.41

9.71

Speed

3 9.119.44

12.5913.03

PTO shaft

1 3/8, 6 splineShaft Diameter.Spline teeth

540/2541Speed(PTO rpm/Engine rpm)

2810NEWT290/T300/T330Model

1-19

SECTION 3. GEAR TRAIN DIAGRAMS

FIG.1-3 GEAR TRAIN DIAGRAM

1-20

SECTION 4. PRECAUTION FOR TRACTOR OPERATION

1. INSTRUMENTS

①key switch ②temperature gauge ③tachometer ④Hour meter ⑤Fuel gauge ⑥Light switch,indicators and horn ⑦hazard warning light switch ⑧ PTO Mode switch

Note;

- Oil pressure warning light and charge light on the monitor array will light when the main switch is turned from OFF to ON

- All lights on the panel go out automatically when the engine is started and its speed is increased to a specific level.

- Do not panic if some lights on the monitor light array do not go out while the engine is at idle speed just after its starting.They will go out automatically when the engine speed reaches as a specific

level.

1-21

MONITOR LIGHT ARRAY

①High Beam Lamp ②Low Beam Lamp ③PTO Monitor Lamp ④Cruise Control Lamp ⑥Fuel Empty Warning Lamp ⑦Oil pressure lamp ⑧Charge lamp ⑨Glow signal Lamp ⑩Turn Signal Lamp

1-22

2. CONTROLS

1-23

3. FILLING DIAGRAM & CAPACITY TABLE

33ℓ(8.717 US gal)

As required

8.2ℓ(2.166US gal)

32ℓ(8.453 US gal)

5.7ℓ (1.51 gal)

7ℓ

T290/T300/T330

Quantity Liter (gal.)

2810NEWMODEL

As requiredGreaseBALL JOINT7

As requiredGreaseClutch pedal shaft 6

32ℓ(8.453 US gal)Gear oil #80TRANSMISSION CASE3

5.7ℓ (1.51 gal)Engine oilENGINE2

7ℓFresh clean

Water(L.L.C)

RADIATOR1

33 ℓ(8.717 US gal)Diesel fuelFUEL TANK8

FINAL DRIVE CASE(B)5

8.2ℓ(2.166US gal)Gear oil #80 or #90FRONT AXLE4

FillingsFilling pointNo.

TABLE 1-7

Tire size and inflation

TABLE 1-8

1711.2-24REAR

25.67-16FRONT

INFLATION (p s i)TIRE SIZEWheels

1-24

4. MAINTENANCE CHART

○ inspection,replenish,and adjustment

● Replacement △ Cleaning and/or washing ★ Consult your Dealer

□ ENGINE

Electrolyte level

Hose clamps

Fan belt

Fuel filter

Fuel

Radiator fin & screen

Radiator

Radiator coolant

Air cleaner

Oil filter

Engine oil

Inspection

items

Check after ○every 100hrs.and replenish if necessary

○○○○○○

○

About 5(0.20in) deflection pushed with a finger

○

Wash after every 100hrs.and replace after 300 hrs.

●△○△○○●△○△○△○

Tank should be fullEveryday and before

work

○

Clean cooling fins and cores

△△△○

○

Fill coolant up to radiator throat

Replace every year

○

Clean a●fter every 100hrs.Replace element that has been washed more than 5 times

△△△△△

●●●

Level is between upper and lower limits

Replace after every 100hours

●●●●●●○

6 0

5 5

5 0

4 5

4 0

3 5

3 0

2 5

2 0

1 5

1 0

Judgment

criteria mm(in)

Intervals after that

Inspection and servicing intervals

Hour of operation

(X10 on hour meter)

Daily

1-25

○ inspection,replenish,and adjustment

● Replacement △ Cleaning and/or washing ★ Consult your Dealer

Replenish every 50 hrs (Everyday in dusty condition)

○○○○○○○○○○○○

Greasing each nipple

All should be tighten

○

Wheel tightening bolts

Check after ○every 300 hrs

○

Retightening ball joints of

steering system

Every lever should work positively

Lever

performance

Interlocked brakes should work simultaneously

Brake performance

Free Play:30 to 40mm

Brake pedal free play

Free Play:20 to 30mm

Clutch pedal free play

Clean hydraulic suction filter at the same time.

Replace after initial 50 hrs,then after every 300 hrs.

●●○

Transmission oil

Electric wiring

Loose bolts and nuts

Front wheel hub greasing

Toe-in

Steering wheel free play

Inspection

items

Check every year

○○○

○

Inject grease after every 300 hrs

2 to 6 mm(0.08~0.24 in)

Check ever★y 0 hrs

★

Ab.50(1.97) on circumstance

○

6 0

5 5

5 0

4 5

4 0

3 5

3 0

2 5

2 0

1 5

1 0

Judgment

criteria mm(in)

Intervals after that

Inspection and servicing intervals

Hour of operation

(X10 on hour meter)

Daily

□ TRANSMISSION

1-26

Check after ○every 100 hrs.Replace after every 600hrs

○○○○●

4WD front axle housing oil

Check after ○every 100 hrs.

○○○○

Rubber pipes

Check after 300 hours

★

Adjusting accelerator pedal and throttle lever

All should work properly

Electric Parentheses

Hydraulic fluid filter

Oil leaks in clutch housing

Inspection

items

Replace after initial 100 hrs.and then after every 300 hrs

●●

Check every year by removing the plug installed in the front bottom of clutch chamber

6 0

5 5

5 0

4 5

4 0

3 5

3 0

2 5

2 0

1 5

1 0

Judgment

criteria mm(in)

Intervals after that

Inspection and servicing intervals

Hour of operation

(X10 on hour meter)

Daily

1) Every terminal should be connected securely

2) Wiring should not interfere with other parts.

3) Fatigued wiring should be replaced.

4) Wiring should be held in each clamp properly.

1-27

Chapter 2

Disassembly and reassembly of major components

SECTION 1. GENERAL PRECAUTIONS AND SEPARATION

AND REINSTALLATION------------------------------------2-1

1. Before operation-----------------------------------------------------------

2-1

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. SEPARATION OF MAJOR COMPONENTS ---------2-5

1. Separation of the front axle and axle bracket ---------------------------2-5

2. Separation of the engine and front axle bracket --------------------------2-6

3. Separation of the engine and front transmission ---------------------------2-7

4. Separation of the front transmission and Spacer transmission--------------2-10

5. Separation of the Spacer transmission and rear trans mission--------------2-14

6. Separation of the rear transmission and rear axle housing ------------------2-17

7. Separation of the rear transmission and Cylinder case ----------------------2-18

Chapter 2

Disassembly and reassembly of major components

SECTION 1. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION

2. PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING STANDARDIZED PARTS.

(1) Roller or Ball bearings

1) When a bearing is fitted in by the outer race,use an installer which is an specially designed to push

only the outer race and vice versa.

2) The installer must be designed to install the bearing on the shaft in a parallel position.

3) When installing a bearing which appears the same on both sides, install it so that the face which has the identification number faces in a direction for easy visual identification.All the bearings which are to be installed in the transmission case should be placed so that their identification number faces outward.

4) If a shaft or hole where a bearing is to be installed has a stopper, the bearing should be pushed in

completely until it is seated against

the stopper.

5) Installed bearings should turn smoothly.

(2) Oil seals

1) Oil seals installer should be designed so as not to deform the oil seals.

1.BEFORE OPERATION

1) Always be safety-conscious in selecting clothes to wear and suitable tools to use.

2) Before disassembly, be sure that you familiarize yourself with the assembled condition for subsequence in reassembly.

3) Keep parts and tools in proper order during operations.

4) When servicing electrically charged

parts,be sure to disconnect the negative battery terminal.

5) To prevent oil or water leaks,use the liquid gasket as required.

6) When lifting up only the front or rear part

of the tractor,be sure to wedge the grounded wheels.

8) When the tractor is jacked up, be sure to

support the entire tractor with something like a stand.Lifting it up with a jack only is dangerously unstable procedure.

9) When replacing parts,use authorized,

genuine TYM parts only.TYM assumes no responsibility for accidents,operating problems or damage caused by the use of imitation parts.

Also,the use of unauthorized parts will result in relatively poor machine performance.

2-1

2) During installation,be careful not to damage the lips,and assure that it is pushed in parallel to the shaft or hole.

3) When oil seals are installed,there should be no turnover of the lips nor dislocation of the springs.

4) When a multi-lip seal is installed, the

grooves between lips should be filed with grease, not adhesive.

(3) O-rings

1) O-rings should be coated with grease before installing.

2) Installed O-rings should have no slack or twist.

3) Installed O-rings should maintain proper air tightness.

(4) Snap rings

1) Snap ring installers should be

designed so as not to permanently deform the snap rings.

2) Installed snap rings should be

seated securely in the groove.

3) Be careful not to overload the snap ring to the extent that it is permanently deformed.

4) How to install the snap ring:

When installing a snap ring,install it as shown in the figure with its round edge side turned toward the part to be retained.This round edge is formed when the snap ring is pressed out.

(5) Spring(roll) pins

1) Spring pins should be driven in properly as tightly.

2) Spring pins should be installed so that their seams should face the direction from which the load is applied.

Fig.2-2

3) The roll pins installed in the transmission or other parts where much force is applied should be retained with the wire.

(6) Cotter pins

When installed, cotter pins should be bent securely at the ends as shown in the figure

Fig.2-3

Fig.2-1

(7) Bolts and nuts

1) Special bolts are installed at several locations,so be sure not to interchange them other bolts.

2) Bolts and nuts should be tightened to their specified torque wrench.

3) When locking the bolts or nuts with wire or a lock washer,

2-2

,Be sure to wind the wire paying sufficient attention to its winding direction and bend the lock washer for secure looking.

4) When locking bolts and nuts with an adhesive,apply the adhesive on the thread and tighten securely.

5) Apply an adhesive(THREE BOND

TB1104) to parts through which there is any possibility of oil leaks,such as stud bolts and tapped-through parts.

6) Each lock nut must be tightened securely.

7) When tightening bolts and nuts, refer to the tightening torque table.

(8) After installation, each grease

fitting should be filled with grease.

1) When installing grease fittings of

type B and C,be sure to turn the fitting tips in a direction that will provide easy access for a grease gun.

(9) Other precautions

1) Be sure not to damage any finished surfaces or parts.

2) Always refrain from forcing installation.

3) Each lever knob should be installed

coated with an adhesive

(SUPER THREE CEMENT TB1702)

4) Each contact surface should be coated with an adhesive(THREE BOND TB 1215)

and tightened evenly with bolts. Adhesive coated surfaces should be installed within 30 minutes after application of the adhesive.

The contact surfaces should be flawless and free

from foreign matter,and especially from grease before application of the adhesive.

5) Precautions for applying adhesives.

- The surface or the thread where and adhesive is to

applied should be completely free of chips.

- The surface or the thread where an a dhesive is to be applied should be completely free of oil-ness.

2-3

SECTION 2. OPERATION CHART FOR DISASSEMBLY

AND REASSEMBLY BY MAJOR BLOCKS

2-4

SECTION 3. SEPARATION OF MAJOR COMPONENTS

1.SEPARATION OF THE FRONT AXLE AND AXLE BRACKET

Note: 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 securely with a crane or stands.

2) Support the front axle with a jack

3) Remove both right-hand and left-hand tie rods.

4) Remove the pivot metal bolts.

5) Remove the front axle assembly forward.

FIG.2-5 Drive shaft

(2) Installation

1) Install the front axle assembly.

2) Install both pivot metals(supports)

FIG.2-4 Front axle

Note: Apply grease to the bushing and fill the oil seal with

grease ahead of time.Install the oil seal carefully not to allow its lips to turn over.

3) install both of the right and left tie rod.

FIG.2-6 Front axle

2-5

1.SEPARATION OF THE ENGINE AND THE FRONT AXLE BRACKET

5) Open the front grille.

6) Detach the head light wiring.

7) Remove the other wiring

8) Remove the inlet pipe from the air cleaner.

9) Remove the air cleaner.

Parts which can be inspected during This operation

-Air cleaner

-Radiator

-Power steering system

-Engine front part.

Note: Here the air cleaner can be moved as an assembly.

10) Remove the upper hose,lower hose.and drain hose from the radiator.

Note: The radiator should be drained of the coolant ahead of time.

11) Remove the fuel filter.

(1) Removal

1) Hold or support the engine with a crane or stands.

2) Hold or support the front bracket or the axle bracket in a manner that the part other than the engine can be removed if required.

3) Remove the side covers (RH and LH) and engine hood.

Fig.2-9 Fuel filter

FIG.2-7 Wiring harness

12) Remove the radiator from the axle bracket

4) Disconnect the positive and negative battery

cables.

Fig.2-10 Radiator

2-6

FIG.2-8 Battery

FIG.2-11

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.

Note: When the pipes related to the hydraulic system are removed,their openings should be covered with plastic caps or the like to keep out dust or other foreign matter.

(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.

6) Connect the upper, lower and drain radiator

hoses.

7) Install the air cleaner assembly and the inlet

pipe of the air cleaner.

8) Connect the wiring of the head lights and

other harness.

9) Connect the ground strap and the battery

cables.

10) Install the engine hood.

11) Install the side covers.

12) Fill the radiator with coolant.

2) Support the engine on the bottom with a jack or stands.

3) Hold the transmission with a garage jack or a

crane so that the transmission side can be moved when needed.

4) Remove both side covers (RH and LH) and

engine hood.

FIG.2-12

FIG.2-13

3.SEPARATION OF THE ENGINE AND THE FRONT TRANSMISSION.

Parts which can be inspected during this operation.

-Fly wheel

-Main clutch

(1) Removal

1) Drain the transmission of the oil ( In the case of the 4WD version),remove the front wheel drive shaft.

2-7

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.

10) Remove the mounting bolts and dismounting the

dash panel

FIG.2-15

Note:

-Tilt the steering column rearwards.

-Lift up the panel set and disconnect the wiring couplers.

7) Remove the cover.

FIG.2-18 hardware Disassembly

11) Disconnect the rubber hose from the suction pipe.

FIG.2-16

2-8

(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.

3) Disconnect the two power steering

system hoses.

4) Remove the fuel hose.

5) Disconnect the the inlet pipe.

6) Loosen the right hand pivot metal

tightening bolts beforehand.

7) Separate the engine from the front axle

bracket.

(3) INSTALLATION

REASSEMBLY IN REVERSE ORDER OF REMOVAL.

1) Install the engine on the front axle bracket.

2) Retighten the right hand pivot metal tightening bolts.

3) Connect hoses.

4) Assemble the engine and the front transmission.

Note:

- Apply small mount of grease to each of the sliding

parts. Be careful not to apply excessive amount of grease as this could cause clutch slipping.

- During operation, be sure to avoid any of the

reassembly operations that may place load upon the input gear.

5) Install the hydraulic system piping.

6) Install the dash panel.

7) Install the wiring and rods.

8) Install the covers.

9) Connect the panel set wiring and then install the

panel.

10) Connect the wiring for the engine.

11) Connect the battery terminals.

12) Install the engine hood and side cover.

12) Wedge both sides of the front axle to prevent the engine from tilting.

FIG.2-19 Wedging

13) Remove the clutch housing and engine tightening bolts and move the engine forward.

FIG.2-20 Engine

2-9

4.SEPARATION OF THE FRONT TRANSMISSION AND SPACER TRANSMISSION

7) Remove the slow-return check valve knob

Parts which can be inspected during This operation

-PTO clutch

-Linear shift gears and related parts

-Main change gears

Slow return check valve

1) Removal A:Removal of the whole floor.

1) Remove the side covers(LH and RH).

2) Disconnect the negative battery cable.

3) Detach all the wiring relevant to the removal of

the floor.

FIG.2-23 Slow return check valve

8) Remove the diff-lock pedal

Remote Control Valve Lever

FIG.2-21

4) Disconnect the throttle lever cable from the fuel

injection pump and accelerator pedal cable from the pedal.

5) Disconnect the clutch rod and brake rods under

the floor.

6) Disconnect the steering cylinder at the hydraulic

pump

FIG.2-25 Diff-lock pedal

Diff-lock pedal

2-10

9) Remove the parking brake.

10) Remove the main shift and transmission range

shift levers.The levers can be separated in the

middle.

11) Remove the control rods of the PTO shift and

4WD shift levers from the transmission.

12) Remove the position control levers.

FIG.2-28 Rubber mounting

16) Lift up the floor slightly with a hoist.

17) Disconnect the linear shift control cable, fuel hoses,and gauge coupler between the fuel tank and floor.

FIG.2-26 Range shift lever

FIG.2-29

FIG.2-27 position control lever

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.

2-11

18) Lift the floor gradually taking care not to allow the shaft of the slow return check valve and its hole in the floor to interfere with each other.

Slow return check valve

FIG.2-33 Front wheel drive

FIG.2-31 Slow return check valve

3) Disconnect the brake rods.

Slow return check valve

FIG.2-35 Optional

Note: Lift up the floor gradually making sure that all relevant wiring. Piping, and links are disconnected.

FIG.2-34 Brake rod.

4) When the tractor is equipped with an optional remote control valve ,remove the remote control piping.

FIG.2-32 Floor

B: Division of the chassis.

1) Drain the transmission of oil

2) Remove the front wheel drive shaft

2-12

5) Remove the suction and delivery pipes.

6) Remove the delivery pipe for the PTO clutch.

7) Remove the reverse shift metal(support)

(5) Install the front wheel drive shaft. (6) Position the floor taking care not to allow

wiring or other parts to be pinched under it

(7) With the floor lifted up a little, install the fuel

hose and fuel gauge coupler on the fuel sub-

tank and connect the linear shift control cable. (8) Fix the floor at the four rubber mounts. (9) Install all levers,knobs, and Rods. (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

T290/T300T330/2810NEW : 32ℓ

FIG.2-36 Reverse shift metal

FIG.2-37 Transmission

8) Hold the clutch housing and space transmission case with a crane or jack.

9) Remove the bolts which tighten the front

transmission and spacer transmission cases.

10) Move the rear part of the tractor rearwards by turning the rear wheels by hand, and

then the spacer and rear transmission assembly will be separated from the front transmission.

Note: When moving the rear part of the tractor. be careful not to allow the garage jack to shift from the spacer transmission case.

Remarks

The rear transmission and spacer transmission

cases should be separated and the reverse shift metal(support) removed in order to take care out or provide access to the main shift and transmission range shift gears. For further details,refer to Chapter 5. Transmission.

2.installation Reassemble in reverse order of disassembly.

(1) Assemble the front and spacer transmission.

Make sure that the turning lock of the PTO clutch is securely seated in the groove in the

spacer transmission case. (2) Install the reverse shift metal(support) (3) Install the PTO clutch delivery piping. (4) Install brake rods.

2-13

5.SEPARATION OF THE SPACER TRANSMISSION AND REAR TRANSMISSION

(8) Remove the operator’s seat (9) remove the position control lever (10) Remove the lever guide. (11) When the tractor is equipped with an optional

remote control valve,remove the remote control valve and relevant parts from the bracket.

Parts which can be inspected during This operation

- Drive pinion gear

- Speed range gear(Transmission range shift)

- Main change gear.

- 4WD drive gear

Slow return check valve

FIG.2-40 slow return check valve knob

1) Removal (1) remove side cover(LH and RH) (2) Disconnect the negative battery cable (3) Remove the slow-return check valve knob.

FIG.2-42 Remote control valve ( optional )

(12) remove the back panel. (13) remove the fuel tank cover (14) Drain the fuel of fuel tank. (15) Remove the fuel tank and tank stay. (16) Remove the floor frame. (17) Drive in a chock between the front axle

housing and axle bracket.

(4) Remove the diff-lock pedal (5) Remove the parking brake (6) Remove the speed range shit and transmission

range shift levers.

The lever can be separated in the middle

(7) Disconnect the PTO change and 4WD change

rods from the transmission.

FIG.2-43.Chock

(18) Place a jack under the bottom of the spacer

transmission case to support

(19) Lift up the rear transmission and remove the

right and left rear wheel

FIG.2-41 operator’s seat

2-14

(20) Remove two rubber mounts.

FIG.2-44 Frame rubber mounts.

Rubber mounting bolts

FIG.2-46 sub change metal

(29) Remove all the spacer-rear transmission

case tightening bolts and nuts except the bottom bolt.

(21) Lift up the rear end of the floor/fender

assembly by about 10 mm,and place wood between the spacer transmission case and floor

panel (22) Drain the transmission of oil (23) Remove the assembly of the remote control

valve and piping. (24) Remove the suction and delivery pipe

(30) Install the rear wheels(LH and RH) and the

remained bolts.Then turn the rear wheels by hand to move the rear transmission case away from the spacer transmission case.

FIG.2-47 space transmission bolt

FIG.2-45 suction filter

(25) Remove the front wheel drive shaft (26) Remove the brake rods. (27) Remove the main change metal and

sub change metal(Support)

(28) Remove the 4WD shift metal

2-15

6.SEPARATION OF THE REAR TRANSMISSION AND REAR AXLE

HOUSING

(31) Install the rear wheels(LH and RH) and the

remained bolts.Then turn the rear wheels by hand to move the rear transmission case away from the spacer transmission case.

Parts which can be inspected during This operation

- Diff Lock

- Brakes

-Final gears

2) Installation Reassemble in reverse order of disassembly. Note:

•The 4WD drive shaft should be installed on the rear transmission ahead of time.

(1) Join the rear and spacer transmission cases.

Note:

During the operation,be careful not to damage needle bearings, the cut –away part in the gear should be turned downward without fail so as to

clear the gear to be positioned underneath.

(2) Install the main change shifter link and each

change metal. (3) install the brake rods and front drive shaft. (4) Install the hydraulic piping. (5) Install two rear rubber mounts. (6) Install exterior parts. (7) Fill the transmission case with oil

T290/T300/T330/2810NEW:32ℓ

1) Removal As both sides can be disassembled in the same

way,only side with the diff-lock installed will be

explained here. (1) Drain the transmission case of oil (2) Lift up the rear transmission and remove the

rear wheel on the diff-lock side.

FIG.2-51 Rear wheel

(3) Remove the diff-lock pedal

Diff-lock pedal

FIG.2-52 Diff-lock pedal

2-16

FIG.2-55 Rear axle housing

(4) Remove the brake rods. (5) Remove the 3-point linkage and related parts.

2) Installation

Reassemble in reverse order of disassembly.

(1) join the rear axle and rear transmission

Note:

Make sure that the diff-lock shifter is fitted into

the groove in the dif-lock metal

(2) Reinstall the other removed parts.

(3) Mount the rear wheel.

(4) Refill the transmission with oil up to the

specified level

-Level up to fill the oil can be sought from the rear side of rear transmission case(Window)

FIG.2-53 3-point linkage

(6) Support the floor panel with a trestle or the

like.

(7) Remove the rubber mount along with the

bracket.

FIG.2-54 Frame rubber mounts.

Rubber mounting bolts

(8) Remove the rear axle housing tightening bolts. (9) Remove the brake case from the rear

transmission case.

(10) Detach the brake assembly from the rear

transmission case.

2-17

7.SEPARATION OF THE REAR TRANSMISSION AND CYLINDER CASE

(10) Detach the delivery pipe from the cylinder

case.

(12) Remove the slow-return check valve along

with the shaft.

(13) Remove the 3-point lift link and related

parts from the lift arm. (14) Remove the Cylinder case tightening bolts. (15) Detach the cylinder case assembly from

the rear transmission

Parts which can be inspected during This operation

- Control valve

- Control linkage

- Piston and lift crank linkage

- PTO change 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

1)Removal (1) Remove the operator’s seat.

FIG.2-59 cylinder case

2) Installation Reassemble the reverse order of disassemble. (1) Tighten the cylinder case on the rear

transmission case to the specified torque.

5.4~6.87 Kgf.m (39.8~50.6lb.fts)

Tightening torque

FIG.2-58 operator’s seat

(2) Remove the position lever (3) Remove the lever guide(RH) (4) When the tractor is equipped with an

optional remote control valve,remove the remote control lever and related parts from

the bracket. (5) Remove the back panel (6) Remove the tank cover (7) Remove the wiring for the rear combination

lamps and trailer socket coupler. (8) Drain the fuel of fuel tank. (9) Remove the fuel tank and tank stay bracket .

(2) After reassembly, make sure that the system

functions properly.

2-18

Chapter 3

ENGINE ACCESSORIES

SECTION 1. RADIATOR ---------------------------------------------------3-1

1. General description ------------------------------------------------------3-1

2. Radiator

--------------------------------------------------------------------------------------------3-2

3. Specifications---------------------------- --------------------------------------------------------3-3

4. Removal of the radiator-------------------------------------------------------------------3-3

5. Inspection of each part

--------------------------------------------------------------------3-3

6. Radiator reassembly ------------------------------------------------------3-5

7. Daily inspection -----------------------------------------------------------3-5

8. Trouble shooting ----------------------------------------------------------3-6

SECTION 2. AIR CLEANER SYSTEM----------------------------------3-7

1. General description--------------------------------------------------------3-7

2. Double elementary air-cleaner ----------------------------------------3-8

3. Inspection of each part--------------------------------------------------3-9

4. Cleaning of the air cleaner----------------------------------------------3-9

5. Element installation------------------------------------------------------3-10

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.

Coolant then circulates through the cylinder block and water pump only to provide a uniform and fast warm-up period. Once the engine has reached operating temperature,the thermostat opens and coolant is pumped from the bottom of the radiator via the lower hose into the cylinder block. Here it circulates through the block and around the cylinders.

From the cylinder block,coolant is directed through the cylinder head and into the thermostat housing.With the thermostat open,coolant passes through the housing and upper radiator hose into the top of the radiator where it is circulated to dissipate heat.

FIG.3-1

FIG.3-2

3-1

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 ② Radiator cap ③Hose,Radiator ④Insulator ⑤Net comp ⑥Net bracket ⑦Hose radiator ⑧Hose ⑨Insulator ⑫Clamp

3-2

3. SPECIFICATIONS

7 ℓ(contains in cylinder block)Coolant capacity

4.2 mmRadiator fin pitch

4 trainsCore train number

Flat water tube with corrugate finsRadiator core type

1.8 Kgf/㎠Test pressure

0.9±0.15Kgf/ ㎠Pressure valve opening pressure

8.185㎡Thermal radiator area

T290/T300/T330/2810NEWDescription

4. REMOVAL OF THE RADIATOR

1) Release the clamp and remove the upper hose.

2) Release the clamp and remove the lower hose.

3) Release the hose clamp and remove the water drain hose.

Excessively compressed air may damage the cores, so perform the air delivery carefully,watching the pressure gauge. Water leaks are inspected by watching for rising air bubbles.

Note:

- Refer to the paragraph”SEPARATION OF THE

ENGINE AND THE FRONT AXLE BRACKET in chapter 2 for operation up to this step.

-When removing the radiator,take care not to

damage the radiator cores and oil cooler.

5. INSPECTION OF EACH PART

(1) Inspection for radiator water leaks.

Water leaks are liable to occur at the fitting portion between the upper tank and the core

section or between the lower tank and the core

section. If any water leak should occur there,repair the leak by soldering.Besides making a visual check,a more complete inspection should be accomplished as follows:

FIG.3-4

b.Leak test with a radiator cap tester

With the inlet and outlet pipes plugged up and the

radiator filled with water,replace radiator cap with a radiator cap tester as shown in the figure. Pump up the pressure in the radiator to the specified value and check to see if there are any leaks in the radiator. When the radiator is water-tight,the pressure indicated on the pressure gauge does not increase,but if there are leaks,the pressure decreases.This tester is also applicable for leak tests for the whole cooling system,not only for the radiator.The test method is the same as mentioned above.

a. Leak test with compressed air.

Place the radiator as shown in the figure. Close the openings for water inlet and with something like a rubber plug and apply compressed air (1㎏f/㎠ or 14.2psi) through the drain pipe into the radiator.

3-3

FIG.3-5

-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 conditions,check the net daily and clean it if necessary.

-Cleaning the radiator cores

Clean the radiator cores by applying water spray or compressed air so as to for a right angle with the radiator cores,moving water application in parallel.

Note:

When cleaning the radiator cores with pressurized water,be sure to apply it at a right angle to the cores. Slanted application might deform their cooling fins.

3) Visual inspection of the exterior parts

When the radiator exterior is corroded,cracked,or badly damaged,replace the radiator.Also replace damaged or fatigued water hoses. Retighten loose hose clamps securely if water is leaking through the hose clamps securely ,or replace them if necessary.

4) Inspection of the radiator cap.

Check the radiator cap to see if it functions normally,using a radiator cap tester as following.

1.8Kgf/ /㎠Testing Pressure

2) Inspection for radiator clogging

To inspect the radiator cores to see if they are clogged with fur or rust,remove the radiator cap and check for transparency of the coolant,and for rust or fur formation around the radiator throat inside the radiator.

If some rust or fur has formed or the coolant transparency is very poor,the radiator should be cleaned.

a. Cleaning the radiator inside.

-Place the radiator upside down and supply pressurized water from a faucet to the lower tank, draining through the upper tank,as shown in the figure to wash out accumulated deposits.

FIG.3-7

FIG.3-6

3-4

0.04-0.05 Kgf/ ㎠ (0.57-0.71psi)

Vacuum valve

Opening pressure

1.05 Kgf/ ㎠ (14.93 psi)

Pressure valve

Opening pressure

FIG.3-8

6. RADIATOR REASSEMBLY

Reassemble the radiator in the reverse order of disassembly.

Note:

- The rubber hoses should be clamped securely and must not interfere with the cooling fan.

- The radiator cores must not interfere with the cooling fan.

7. DAILY INSPECTION

1) Coolant level inspection and coolant

replacement

When the radiator is hot after operation,be sure to wait until the coolant cools down sufficiently before removing the radiator cap. If this is not done,heated vapor might burst out and cause burns.Use fresh water from a faucet as the coolant. When the coolant is replenished or changed,let the engine idle for a while for the coolant to circulate sufficiently in the cooling system and replenish if necessary after stopping the engine.

2)Antifreeze

When The weather is cold,use an antifreeze to prevent the engine from freezing.The freezing point differs according to the mixture ration of water and antifreeze.Therefore,prepare an antifreeze solution which will have a freezing point 5℃ lower than the estimated lowest atmospheric temperature in your environment.

Precaution for filling antifreeze.

- The radiator interior should be washed clean ahead of time.

- As concerns of mixing ratio of an antifreeze, follow its manufacture's instructions.

- Antifreeze should be blended well with water before filling.

- When the coolant level is lowered due to evaporation,maintain the level by adding water, not by using an antifreeze solution.

- When the coolant level is lowered due to leaks, maintain the level by adding an antifreeze solution of the same mixing ratio.

- As antifreeze corrodes point,take care not to spill it on painted parts.

-The tractor is filled with a permanent type antifreeze (Mobile Long Life Coolant)

when shipping(mixing ratio:50%)

-Function test: The pressure type radiator cap has a pressure valve

and a vacuum as shown in the figure. Both valves are held against there seats by springs

while the pressure in the cooling system remains within a specified range,thus keeping the cooling system air-tight.

When the pressure in the radiator rises higher than the specified valves,it overcomes the force of the pressure valve spring and open the pressure valve to release excess pressure through the overflow pipe as shown in the figure.

When the coolant temperature falls enough to cause the vapor to condense in the cooling system and decrease the coolant volume,the radiator pressure becomes negative.When this occurs,the vacuum valve opens to let outside air into the radiator as shown in the figure,

thus preventing the radiator from being deformed.

FIG.3-9

3- 5

8. TROUBLE SHOOTING

(3)Replace.(3) Unbalanced fan

(2)Retighten or replace(2) Loose or bent fan

(1)Replace(1) Poor water pump bearing4) Noisy cooling

fan

(5) Inspect cylinder head and

Replace gasket

(5) Water leakage through cylinder

head gasket

(4)Repair or replace(4) Leaking water pump

(3)Replace radiator cap(3) Fatigued pressure valve spring

(2)Retighten or replace(2) Loosely clamped or broken water

hose

(1)Repair or replace(1) Leaking radiator3)Lose of coolant

(1)Replace(1) Poor thermostat2) Overcooling

(9) Clean radiator exterior.(9) Clogged air ways

(8) Adjust injection timing.(8) Improper injection timing

(7)Clean radiator and water

passages.

(7) Clogged water passages

(6)Repair or replace.(6) Poor water pump or water leaks

(5)Replace.(5) Poor thermostat

(4)Replace.(4) Oily fan belt

(3)Adjust belt tension or replace.(3) Loose or broken fan belt

(2)Replace radiator cap.(2) Fatigued pressure valve spring

(1)Replenish coolant and inspect water leaks.

(1) Low coolant level1) Overheating

(6)Replace(6) Cracked cylinder head or body

(4)Replace.(4) Poor fan belt

(2) Decrease radiator working area

by radiator masking.

(2) Excessive low atmospheric

temperature

(10) Inspect cylinder head and

replace cylinder gasket

(10) Fuel gas enters water jacket due

to broken cylinder gasket

CountermeasuresCausesProblems

TABLE 3-1

3- 6

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.

Under the influence of suction generated by the engine,unfiltered air flows through air inlet tube(4) and is

forced into a high-speed centrifugal motion.By this circulating action most of the dust and dirt particles

are separated from the air and collected in the dust unloading valve(3).The remaining dust is removed as

the air flows through the paper element(1) before being drawn into the engine.

FIG.3-10

① Paper element ② Packing ③Dust unloading valve ④Air inlet ⑤Air outlet

3-7

2.ELEMENT AIR CLEANER

(1) SPECIFICATIONS.

M odel 2810NEW/T290/T300/T330

Type Dry,paper element filtering type

Rated intake air volume (㎡/min.(cu.ft/min) 2. 6(91.8)

air venting r esistance (㎜Ag) 120 or less

Cyclone efficiency (%) 45 or over

Total filtering efficiency (%) 99. 9 or over

Dust holding capacity(gr) 700

Filtering area(㎡)(sq.in)

Outer element

1.32(2046)

inner element

0.16(248)

Filter material

Outer element

AS 42

inner element

AS 44

Remarks

Tested dust : SAE FINE

Dust density : 1.0 gr /㎡(0.93gr/sq.f t)

2) DISASSEMBLY (1) Element removal

Remove the wing bolt which clamps the paper element and take out the element.

1:Air cleaner 2: Cover 3: Washer 4: Body comp 6: Element,air(Ext.) 7: Element,air(In) 8: Wing Nut

9. Packing 10:Packing 12: pipe,inlet 16: Clamp,75 27: Hose,inlet 28: Gasket

FIG.3-11

3-8

Note:

Especially note the glue portions of the paper and metal parts.

3. INSPECTION OF EACH PART

1) Inspection of the cleaner body (1) Check the cleaner exterior for cracks,

deformation,or damage and repair or replace if necessary.

(2) Check each packing for fatigue or damage

and replace if necessary.

4. CLEANING THE AIR CLEANER

Clean the air cleaner after 100 hours of operation or less depending on conditions in the following manner.

1) When the air cleaner is cleaned or the element is replaced,dust accumulated inside the air cleaner body should be removed with a cloth.As inhaled dust causes engine wear,remove a dust accumulated inside the inlet pipe,the rubber hose which connects in the inlet pipe and the air cleaner,the inlet manifold,and inlet port.

(1)When accumulated dust is dry.

-When removing the dust in the element,hold

the element by a hand and pat the side wall

with other hand.Never hit the element against

a stone or a concrete wall because that might

cause its side wall to peel off.

-apply compressed air from inside of the element to

blow dust off while turning the element by hand.

2) Inspection of rubber hoses Check the rubber hoses for fatigue or

damage and replace if necessary.

3) Inspection of the paper element

To check the element for damage,Dry it sufficiently after washing and put an electric bulb in to the element and look for damage.

FIG.3-13 Element

Note: The compressed air to be applied should not have a pressure of more than 7㎏/㎠(99.6psi) Maintain sufficient distance between the air gun

and the element.

(2)When accumulated dust is oily.

-Use a solution of TC 101 element detergent or the quality household neutral detergent.

Leave the element in the solution for approximately 30 minutes and then wash it by dipping it in and out of the solution.

FIG.3-12 Element check

3-9

-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). An element which has been washed 5 times must be replaced with a new one.

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 wing bolt retaining the element should be tightened sufficiently so that it will not become loose during operation

3-10

CHAPTER 4 Clutch system

SECTION 1. GENERAL DESCRIPTION ----------------------------- 4-1

SECTION 2. SPECIFICATIONS ----------------------------------------- 4-2

SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY---4-3

1. Main clutch -------------------------------------------------------------------4-3

2. Clutch shaft and related parts----------------------------------------------4-6

3.Final adjustment of the clutch pedal---------------------------------------4-7

SECTION 4. TROUBLESHOOTING-----------------------------------------4-8

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.

The plate is held against the flywheel by the pressure springs and pushes the clutch disc against the flywheel.The clutch disc,which is sandwiched between the pressure plate and the flywheel,is mounted on the splined part of the input gear.It can move in an axial direction,but is locked in the rotational direction.It transmits engine power to the transmission by means of friction.Twelve coil spring are installed between the clutch cover and the pressure plate along the circumference,which are the pressure springs.

To disengage the engine power,the force of the diaphragm spring acting on the pressure plate must be eliminated.For this purpose the release lever is installed.By depressing the clutch pedal, the release lever pushes off the pressure plate from the clutch disc,thus providing clearance between the friction surfaces of the flywheel,the clutch disc,and the pressure plate.Thus the engine is disengaged.

Fig.4-1 Main clutch disc.

4-1

SECTION 2. SPECIFICATIONS

4-2

2.0 (0.079)Clearance between lever plate

and release bearing (㎜) (in)

Clutch pedal

Ø25.0 (0.984)Large dia. (㎜) (in)spline hub

Ø225±1.0×Ø150±0.8Outer dia. ×inner dia. (㎜)

Y-02, Y-07Facing material

Dry singleTypeClutch disc.

20～30 (0.79～1.18)Clutch pedal free play(㎜) (in)

0.7 MAX (0.028)Lateral deviation (㎜) (in)

8.4 ±0.3 (0.331)Disc thickness (free) ㎜ (in)

Ø21.7 (0.854)Small dia. (㎜) (in)

1.0 MAX (0.039)Vertical deviation (㎜) (in)

0.4 MAX (0.016)Surface deviation (㎜) (in)

13No.of splines

Description and assembly standard

values

ItemsParts

Table 4-1

SECTION 3. DISASSEMBLY, INSPECTION, AND REASSEMBLY

FIG. 4-3 Clutch assembly

4.bolt(S)

6.Main clutch

7.Clutch disc

8.Clutch cover

9.Pin(B)

12.Input metal

13.Seal bolt

14.Nut

15.Washer spring

18.Metal sleeve

19.Seal bolt

20.O-ring

21.Sleeve

22.Clutch release bearing

23.Tension spring

1.MAIN CLUTCH 1-1.Disassembly Note: Generally it is impossible to separate diaphragm spring type clutch cover. It is principle to replace the clutch with assembly if pressure plate,diaphragm spring are needed to be replaced.

1) DISASSEMBLY Separate the engine from the front transmission referring to the paragraph "SEPARATION OF MAJOR COMPONENT in chapter 2.“

2) Remove the clutch assembly from the

flywheel.

Note: When removing the bolts,loosen them gradually

in diagonal sequence. Take care not to let oil get on the clutch facing. 1-2.Inspection of the clutch disc. Install the disc on the input gear and inspect the

rotation play.If the measurement deviates from the specified value,Replace the disc.

Fig 4-4 Clearance for spline.

4-3

1-3. Inspection of pressure plate and flywheel.

1) Inspect the diaphragm spring surface for up-and-down,scratches,stepped wear,or oil stains.

2) Check the height differences of diaphragm springs.

3) If damage is found on the pressure plate. The clutch cover must be replaced.

4) Shallow scratches may be repaired with a sand paper,but excessive wear or damage must be replaced.

1-5.Inspection of guide ball bearing

(flywheel)

1. If the bearing does not turn smoothly due to damage or seizure,replace the bearing.

1-6.Reassembly of main clutch

Reassemble them in reverse order of disassembly in accordance with the 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 resolving or sliding parts prior to reassembly.

3) When installing the clutch disc on the

flywheel,turn the longer protrusion of the hub towards the flywheel.The reverse installation will damage the clutch cover or the disc.When installing the dual clutch assembly,use a special tool.

Note: Tighten the bolts with specified Torque.

4) The dimension between flywheel surface ⓐ

and clutch face is 36.0 ±1.0 (P type),

35.0 ±1.0 (IP type). And needless to adjust.

Fig. 4-5 pressure plate,flywheel.

Note: The causes of oil stains must be located and necessary corrective measures must be taken.

1-4.Inspection of pressure plate

1) Inspect the pressure plate friction surface for up-and-down,scratches,stepped wear,or oil stains.

2) Measure the deviations of pressure plate.If the measurements are beyond the usable limits,replace the pressure plate.

3) If Wearing only outside but inside of diameter is within usable limits,replace regardless clearance.

4-4

(2)Inspection of sleeve

Ensure smooth movement of the sleeve.If it does not move smoothly,clean and grease it. Use heat-proof grease.

(3) Inspection of tension springs.

If there are some broken tension springs, replace them.

(4) Inspection of the fork.

Inspect the contact faces of the fork and the sleeve.If there is abnormal wear,make repairs or replace the fork or the sleeve.

(5) Inspection of the clutch shaft.

The clutch shaft must be revolve smoothly

3) Reassembly

Reassemble the disassembled parts in reverse order of disassembly,pursuant to the following instructions.

(1) Each sliding part should be coated with

heat-proof grease.

(2) The clutch fork taper pin should be locked

securely with wire.

(3) Smooth movement of each part should be

conformed.

(4) The release bearing must be installed in the

correct direction.

2.CLUTCH SHAFT AND RELATED PARTS.

1) disassembly (1) Remove the tension spring and extract the

sleeve

(2) Remove the wire which is retaining the

taper pin.

①Clutch shaft comp ②Release fork ③Taper pin ④Wire ⑤Grease fitting

Fig4-8 Main clutch and related parts

(3)Remove the grease fittings from the clutch

shaft ends.

(4)Turn the release fork upward and pull out

the taper pin.Then draw the clutch shaft.

2) Inspection

(1)Inspection of release bearing

The release bearing is of the grease-sealed type,but when the grease in the bearing reaches a low level or the bearing does not turn smoothly due to damage or seizure, replace the bearing. Note: The release bearing should not be washed.

Fig 4-9 Release bearing

4-5

3.FINAL ADJUSTMENT OF THE CLUTCH PEDAL Clutch pedal play

1) Loosen the lock nuts on the clutch rod and adjust the clutch rod length to achieve 20～30㎜ (0.79～1.18 in.) pedal play.Retighten the lock nut securely.

Note: One lock nut has a right hand thread and the other has left-hand threads,so take care not to interchange them.

2) Adjust the clearance between the safety switch and the bolt head to 38 ±1㎜(1.496 in.) so that the switch will turn on only when the clutch is disengaged to allow the engine to start.

3) Inspect the clutch action.

-Inspection of clutch action and slippage. While the engine is running,the

transmission gears must be shifted smoothly with the brakes applied.

-Inspection of clutch slippage While accelerating the engine gradually,

the engine must stop when the clutch is engaged gradually with the parking brakes applied and the speed shift levers to 4X4.

Fig 4-10 Main clutch

Note:

Adjust the turnbuckle through the opening in the panel with the rubber cap removed.

Fig 4-11 Dash cover

4-6

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.

3) Increased fuel consumption.

These symptoms are apt to be mistaken for engine problems.Clutch slippage that is not repaired will result in serious damage such as excessive wear of the clutch facing,the clutch cover,and even flywheel or clutch seizure.

TEST METHOD If the parking brakes are applied and the transmission gears shifted to top speed and the engine stops,then the clutch is normal.But if the engine does not stop,it shows that the clutch is slipping.

Replace-Excessive wear of clutch facing

Adjust-No play in the release bearing

Repair or replace-Deviation of flywheel or pressure plate

Repair or replace-Oil stained or hardened clutch facing

Replace-Broken or fatigued pressure spring

CountermeasuresProbable causes

2.PROBLEM :Poor disengage When the clutch does not disengage properly,the transmission gears make noise when shifted,or shifting

or the gears is difficult.

Adjust -Insufficient play of the release bearing

Remove rust or replace and apply grease-Worn or rusted splined section of the clutch disc hub

Replace-Dried pilot bearing

Adjust-Excessive play of the release bearing

Replace-Excessive deviation of the clutch disc

CountermeasuresProbable causes

3. PROBLEM :juddering

Replace-Deviation or deflected wear of pressure plate or flywheel

Replace-Hardened clutch facing

Replace-Oil-stained clutch facing

Adjust-Difference in release lever heights

Repair or replace.-Deviation in clutch facing

Replace-Fatigued pressure springs

CountermeasuresProbable causes

4-7

4. PROBLEM: Abnormal noises There are abnormal noises emanating from the clutch.

Replace-Cracked disc plate

Replace-Broken or insufficiently lubricated release bearing Replace-Seized or worn pilot bearing

CountermeasuresProbable causes

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.

Repair or replace-Deviation or deflected wear of flywheel or pressure plate Replace-Fatigued pressure spring

Replace-Oil stained clutch facing Replace-Worn clutch facing or loose rivets

CountermeasuresProbable causes

4-8

CHAPTER 5 Transmission

SECTION 1.GENERAL DESCRIPTION------------------------------------5-1

1.Wheel driving system----------------------------------------------------------5-1

2.PTO drive system--------------------------------------------------------------5-1

3.Power train diagrams---------------------------------------------------------5-2

4.Construction and function of synchromesh mechanism------------- 5-2

SECTION 2. SPECIFICATIONS---------------------------------------------5-2

1. Wheel drive system----------------------------------------------------------5-2

2. PTO drive system------------------------------------------------------------5-2

SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY--5-3

1. input shaft and reverse change gear(Front transmission) ------ 5-5

2. Main change,sub-change,and 4WD change gears. --------------5-11

3. Rear transmission-------------------------------------------------------5-16

4. PTO clutch----------------------------------------------------------------5-18

5. Shifters and related parts----------------------------------------------5-20

SECTION 4. TROUBLESHOOTING-------------------------------------5-25

1. Wheel drive system------------------------------------------------------5-25

2. PTO drive system----------------------- --------------------------------5-26

3. Power train diagrams---------------------------------------------------5-27

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 (Linear shift mechanism)

Front transmission

Transmission

Space transmission

Main Change gears Sub-change gears (speed range) Front drive change gears

Rear transmission

Ring gear Differentials Dif-lock

Fig.5-1 Wheel drive system

1) The standard transmission produces 12 speeds forward and reverse :F1 and R1 by reverse change gears;4 speeds by main change gears;3 speed by sub-change gears.

2) Synchromesh transmission has 3rd and 4th speed stages of the main change gears synchronized. Therefore,between these stages,gear shifting while traveling is possible (synchromesh version)

Note:

1st and 2nd speed stages of main change must be surely stopped traveling.

2. PTO DRIVE SYSTEM

1) The PTO drive system is composed of the independent PTO clutch and the PTO change gears.

2) The PTO change gears are housed behind the ring gear,which produce 1 PTO speed.

5-1

3.POWER TRAIN DIAGRAMS

Refer to page 5-49 and 50 at the end of this chapter.

4.CONSTRUCTION AND FUNCTION OF THE SYNCHROMESH MECHANISM

①Shifter ②Hub ③Block pin ④Synchro-ring ⑤Synchro-cup ⑥Thrust piece ⑦spring ⑧spline of hub(2) ⑨spline of synchro-cup(2) ⑩constant mesh gear ⑪spline of gear(10) ⑫constant mesh gear ⑬Spline of gear(12) ⑭Spline hub ⑮Spline of spline hub(14)

16.Snap ring C(for shaft)

Fig.5-2 Synchromesh

2)The synchromesh mechanism includes the

components staged below

(1)Synchro-hub

The synchro-hub is composed of the hub(2), block pin(3),synchro-ring(4),thrust piece(6),and spring(7).Synchro-ring(4)has a conical friction surface on its circumstance.Block pin(3) prevents hub(2) from sliding until the torque, imposed upon the pin due to the speed differential caused when shifting gears,disappears. Thrust piece(6)is composed of an outer split pin and an inner and is held together as one unit by the expansion force of the spring. It has a tapered shape as shown in Fig.5-15

when the hub is position to side and also serves as a lock pin to keep the synchro mechanism engage.

(2) Synchro-cup

It has a conicial friction surface which forms a pair with synchro-ring(4).It meshes with the gears(10) and (11) through the splined part.

3)Function principles(operating procedures)

The synchromesh mechanism operates in the 4 stages mentioned below to complete the transmission from NEUTRAL to ENGAGEMENT

5-2

3rd stage: When hub(2)is pushed further,the tapered surface in

the hole of the hub and the tapered surface on the block pin are pressed tightly against each other,this pushes synchro-ring(4) against synchrocup(5).Consequently,as shown fig.5-6,the synchroring and the synchro-cup are pressed more tightly against each other by the resultant turning force of the rear wheel and the thrust of the shifter.Ultimately,the revolving speeds of the synchro-ring and the synchro-cup become the same.

1st stage: When force(F) is applied to shifter(1) through the gear shift lever,hub(2) is pushed in the direction of the arrow.Following movement of the hub,other parts such as block pin(3), synchro-ring(4),and thrust piece(6) also move in the same direction by means of spring(7), without allowing the hub to clear the groove in thrust piece(6) until such time as the friction surface of synchro-ring (4)comes into contact with the friction surface of synchro-cup (5).

(1)Thrust (2)Resultant force (3)Turning force

Fig. 5-6 Synchro-ring and cup

4th stage : When synchro-ring(4) and synchro-cup(5)

reach the same speed,the friction force disappears.Then the resistance between hub(2)and block pin(3) also disappears to allow the hub to clear the groove on the block pin and to sit on the large diameter area of the pin. At the same time,thrust piece(6) which has a tapered shape and hub(2) advance smoothly on the pin to complete the meshing between spline(8) of the hub and spline(13) of the gear.

Fig. 5-4 1st stage

2nd stage:

At the moment when both the friction surfaces come

into contact,the ring turns by as much as the surplus

space in hub(2) for block pin(3)as shown in Fig.5-5

Fig.5-5 Block-pin

Fig. 5-7 Complete Synchro-ring and cup

5-3

SECTION 2. SPECIFICATIONS

1. WHEEL DRIVE SYSTEM

Column shift

Linear shiftOperation

methods

1 /4.363Drive pinion-Ring gear

0.2619 (11/42)

0.8276 (24/29)

2.6429 (37/14)

Low

Mid

High

Speed range shift

0.4250 (17/40)

0.5833 (21/36)

0.7500 (24/32)

1.0357 (29/28)

3rd 4th

Main speed shift

Side shift (RH)Speed range shift

32 ℓT290/T300/T330/2810NEW Transmission

case

Oil capacity

0.4524 (19/42)

0.4398 (19/30 ×25/36)

forward

reverse

Speed shift rangeReduction

ratios.

Engine rated rpm: 2800 RPMSpeed shift range

Side shift (RH)Main speed shift

THF 500Oil

2) PTO DRIVE SYSTEM

Wet,multi-disc,hydraulic-operated clutch

THF500 (In common with transmission oil)Used oil

Number of clutch plates

Type

CW viewed from the rearRotation direction

Φ35 mm, 6 straight splinesPTO shaft size

540 @ Engine 2,541rpmPTO shaft speed

12/37,15/34,18/30,21/27Reduction ratio

Speed shift range

PTO clutch

Rear PTO

Multiple Wet Disk CLUTCH

INDEPENDANTTYPE

T290/T300/T330/2810NEWMODEL

5-4

SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY

1. INPUT SHAFT AND REVERSE CHANGE GEARS (FRONT TRANSMISSION)

Fig.5-8

1.clutch release bearing

2.Sleeve

3.Spring,tension

4.Bolt(seal)

5.Metal sleeve

6.O-ring(G)

7.Bolt(seal)

8.Nut

9.Washer spring

10.Input metal

11.Ball bearing

12.Gear (helical/30)

13.Gear (helical/30)

14.Gear (helical/25)

15.Ball bearing

16.Ball bearing(HL1)

17.Washer(20X34X03)

18.Gear (helical/42)

19.Snap ring

20.Needle bearing

21.Shaft,shuttle(215)

22.Synchronizer

23.Needle bearing

24.Snap ring

25.Gear( helical/36)

26.Washer(20X34X03)

27.Ball bearing(HL1) 28.Front transmission case 29.Plate(1.25X90) 30. Seal bolt 31.Oil seal

32.Ball bearing(HL1) 33. Gear(helical/19) 34.Ball bearing 35.Oil seal 36.Oil seal(D) 37.Snap ring

38.Ball bearing 39.Gear (helical/19)

5-5

c. Pull out input gear(19T) rearwards. d. Remove the sleeve metal tightening bolts

and take off sleeve metal. e. Draw PTO drive gear forwards. f. Pull out main change shaft firstly,and remove

counter shaft and PTO shaft.

1.1 DISASSEMBLY

(1)Removal of input shaft and related parts separate the engine from the front transmission referring to the paragraph 3.(1) of SECTION 4. SEPARATION OF MAJOR COMPONENT in Chapter 2.

a. Remove input metal as an assembly using

two push bolts(M8X2) Note: Be sure to screw in the bolts evenly

Fig.5-11

Fig.5-9 Input metal and related parts

b. Remove plate.(The tightening bolts are applied

with adhesive on their threads.)

Fig.5-10 Plate

5-6

1.2 INSPECTION

Before and after disassembly,inspect each part for points mentioned below,and replace if necessary.

9.5 Kgf

(20.9lbs)

13.0-18.8 Kgf (28.7-41.5lbs)

Synchro-hub thrust for shifting

-51.17 ㎜

(2.015 in)

Assembled width of synchromesh assembly

0.3 ㎜

(0.012 in)

0 ㎜(0 in)Stepped wear of teeth

0.5 ㎜

(0.020 in)

0.1 - 0.2 ㎜

(0.004-0.008 in)

Backlash of each gear (measured in meshed condition)

Usable limitsStandard valuesInspection items

-Inspect bearings such as ball bearings and needle bearings for abnormalities in rotation such as irregularity,hitching,etc.by turning them with pressure applied by hand.Replace defective ones.

-Seriously worn or damaged parts should also be placed.

5-7

1.3 REASSEMLBY

(1) Sub Assembly of reverse shaft and related parts.

Fig.5-12

a.Install Synchro-cups(34) on gear(16) and gear(21) respectively and retain them securely with snap

rings C

b.Install synchro-hub comp(35) and above sub- assemblies on reverse shaft(18)

Note: As each synchromesh assembly maintains a specified installed width,be sure not to mix different pairs of the synchro-hub comp,and the synchro-cup

c. Install washers (15 and 22) and install the bearings positively.

Note: As these washers have their own directions of installation,be strict to install them correctly.

5-8

(2) installation of each sub-assembled shaft.

Install each sub- assembled shift into the reverse metal(Support).

Note: When installing the PTO clutch assembly,apply a thin coat of grease to the seal rings and install it taking care not to damage these rings.

Fig.5-13

5-9

(3) installation of input metal and related parts.

Fig.5-14

Reassemble in reverse order of disassembly,following the next instructions.

a.Install the idle shaft(120 so that the end with the tapped hole faces rearwards,that is ,on the

snap ring installed side.

b.Apply adhesive to the threads of the bolts (M8 ×20) which tighten the bearing retaining plate.

c.Oil seals should be installed in their correct direction.As an oil seal is a special eccentric

seal,be careful not interchange these seals.

d. Before installing sleeve metal(support)(1) on input metal(support)(6),apply grease to the O-ring

to prevent its damage.

5-10

(4) installation of PTO shaft

① Pay attention to the direction of installation and check to see all the parts turns smoothly. ② When pushing the RBB's(6205 and 6005)into the gear,be careful only to push their outer races. ④ When installing the PTO clutch assembly,Apply a thin coat of grease to the seal rings and

install it taking care not to damage these rings.

⑤ When installing seal rings,apply fresh oil ahead of time and install them carefully so as not

to damage them.

⑥ PTO brake disc should be assembled to the groove of front transmission case.

Fig.5-15

(1) When pushing the RBB’s (6205)in to the gear,be careful only to push their inner races. (2) Pay attention to the direction of installation and check to see all the parts turns smoothly.

5-11

2. PTO CLUTCH

2-1. DISASSEMBLY

(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

Fig.5-16

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. Pull out PTO drive shaft rearwards. b.Pull out PTO drive gear forwards. c.Remove snap ring (D95 for hole),and take

bake-up plate,disc assembly,and driving plates.

d.While holding return spring(43) compressed

with a special tool,remove snap ring

e. Disassemble into separate parts;piston,return

sparing,brake disc,and cover assembly.

2.2 INSPECTION

a. Cover assembly

-Replace a cover assembly which has a damaged or worn sliding surface.

-If there is any damage to the cover assembly

and the piston seal ring,these parts should also be replaced.

b. Disc assembly

- If the thickness of a disc assembly exceeds the usable limit mentioned below or combined width of the disc assembly and driven plate is less than

23.8mm(0.937 in),replace both the disc

assembly and driven plate.

5-12

Fig.5-17

Fig.5-19

-Inspection for disc thickness and serration wear.

0.2mm (0.008 in)

-Surface flatness

1.9mm (0.075 in)

2.2±0.1mm (0.087 in)

Disc thickness

Usable limitSpecified valuesInspection Items

e. If the combined thickness of the return

plate and brake disc deviates from the specified value, replace both parts.

5mm (0.2 in)

5.5 ±0.18

(0.217 in)

Combined thickness of return plate and brake disc

Usable limitSpecified valuesInspection Items

Fig.5-20

c. Driven plate

-Inspection for deformation and burning.

-A seriously damaged or worn disc should be replaced.

Fig.5-18

0.2mm (0.008 in)

-Surface flatness

Usable limitSpecified valuesInspection Items

d. Brake disc

-Inspection for deformation and burning.

-A seriously damaged or worn disc should be replaced.

0.2mm (0.008 in)

-Surface flatness

2.5 mm (0.098 in)

3±0.1mm (0.118 in)

Disc thickness

Usable limitSpecified valuesInspection Items

f. Also inspect other parts for wear and

deformation and replace them if necessary

Note: Seal ring and the two seal rings should be

replaced as a pair

5-13

2.3 REASSEMBLY

Fig.5-22

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 the respective specified torque table.

-Every time a gear is installed,its smooth rotation should be checked.

-Every snap ring should be seated securely in its groove.

a. When installing seal rings, apply fresh

oil ahead of time and install them carefully so as not to damage them.

b. Install the return plate with the

press-processed side turn towards the brake disc.

4.Bearing ball (6205) 5.Gear,helical 35T

6.Bearing,ball (6005)

e. Install washer in correct direction. f. After reassembly,check to see that gear

turns smoothly by locking the PTO clutch

Fig.5-21

① Return plate ②Brake Disc

Fig.5-23

c. When installing the return spring,use a

special tool; the snap ring should be securely seated in the groove.

d.When pushing the RBB’s (6205 and 6005)

into the gear,be careful only to push their outer races.

5-14

3.MAIN CHANGE,SUB-CHANGE,AND 4WD CHANGE GEARS.

(1)Synchromesh transmission version.

Fig.5-24 Synchromesh transmission version

5-15

Fig.5-25 Main change gear and related parts.

5-16

3.1 DISASSEMBLY

Fig.5-26

Separation the spacer transmission case and rear transmission case from each other referring paragraph 5.(1) in SECTION 4.SEPARATION OF MAJOR COMPONENTS in chapter 2.

With this operation,the transmission is divided into parts A and B part A includes main speed shift and mechanism and part B includes speed shifting and 4WD shifting mechanisms.(fig.5-26)

Note: The separation of the gears mentioned in the figure is possible without dividing the front transmission

and the spacer transmission from each other

5-17

(1) Disassembly of main change gears(main speed shift),part of sub-change gears(speed range shift)

and shifters.

Fig.5-27

a. Remove the tightening bolts and pull out the

assembly of the space metal(18)

b.Pull out assembly of the reverse shifter

metal,main speed shift gears,and shifters rearwards by tapping it with a plastic hammer.

Note: Take care not allow the gear to drop as it is free when the above assemble is removed.

c.Remove the shift stays from the shift metal

and remove the gears assemblies as shown Fig.5-29.

d. Remove bearings and gears from each shaft.

Fig.5-28

5-18

Fig.5-29.

Fig.5-31

Fig.5-30

2.Disassembly of the sub-change gears

(Speed range shift) a.Remove the sub-shifter and shifter stay. b.Remove the space transmission case c. Pull out the PTO shaft ,4WD shaft and gear

d. Remove the snap ring from the end of the

pinion gear shaft e. Remove the hub f. Remove the sub-change gears.

5-19

3.2 INSPECTION

Before and after disassembly,inspect each part for points mentioned below,and replace if necessary.

0.5 mm (0.020 in)

0 mmThrust play of fixed gears

-51.17

(2.015in)

Assembled width of synchromesh

assembly

0.5mm (0.020 in)

0.1-0.2mm(0.004-0.008in)Backlash of each gear(measured in meshed condition)

0.5 mm (0.020 in)

Wear in each shifter

9.5Kgf (20.9 lbs)

13.0-18.8Kgf (28.7-41.4lbs)

Synchro-hub thrust for shifting Neutral Engaging

0.3 mm (0.012 in)

0mmStepped wear of teeth

Usable limitsStandard ValueInspection Item

+0.18

-0.424

- Inspect bearings such as ball bearings and needle bearings for abnormalities in rotation such as irregularity,hitching,etc. by turning them with pressure applied by hand.Replace defective ones.

- Serious worn or damaged parts should also be replaced.

5-20

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.

-Every time a gear installed,its smooth rotation should be checked.

-Every snap ring should be seated securely in its groove.

-As each synchromesh assembly maintains a specified width,be sure not to mix different pairs of the synchro-hub comp.and the synchro-cup.

-Remember to install the snap rings.

(1) Installation of main change gears

Fig.5-32

5-21

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. Sub assemble the shifter stay,spring, and steel ball(Fig.5-33) and install the sub-assembly on

the spacer transmission case(Fig.5-34).

c. Align the holding parts in the reverse shift metal with RBB’s of the sub assemblies of the

counter gears and main change gears, straight pins,etc.,and install the reverse shift metal on the spacer transmission case.

Apply adhesive oil

Fig.5-33 Main shift lever linkage

Fig.5-34

(2)Reassembly of sub-change gears(speed range shift)

-Reassemble the parts in reverse order of disassembly following next precautions.

and tighten the lock of nut is 8～11㎏f·㎝

-Be sure to rotate the pinion several times and crimp

the lock until the crimped part touched the bottom of the groove

a.Never forget to install needle roller bearing and

collar

Fig.5-35

5-22

b. Pay attention to the installed direction of gear

Fig.5-36

5-23

4. Rear transmission case

Fig.5-38

5-24

3-1. DISASSEMBLY

Separate the spacer transmission and the rear transmission from each other and then remove the hydraulic cylinder case.referring to paragraph 7.(1) of SECTION 4. SEPARATION OF MAJOR COMPONENTS in Chapter 2.

(1) Ring gear,Drive pinion,and related parts.

Fig.5-39

1.Diff case (L) 2.Diff case(R) 4.Bolt 5.Nut 6.Diff pinion(12) 7.Collar 8.Lock plate

9.Bevel gear(20) 10.Thrust collar(45X58X1) 11.Shaft diff pinion 12. Metal Diff case(L)

13.Metal Diff case(R) 14.Shim(A) 15.Shim(B) 16.Bolt(S) 17.Ball bearing

18.Diff lock clutch 19.Bevel (9-52) 20.Gear spur/25 21.TRB 22.Nut 23.TRB

25. Metal pinion 26.Bolts 27.Shim(0.1) 28.Shim(0.2) 29.Wheel pinion(10/LH)

30. Wheel pinion(10/RH) 31.Ball bearing(HL1) 32.Collar(39.8X52X04)

33.Snap ring(Shaft) 34.Snap ring(Hole)

5-25

a.Dismount diff-case (RH) and diff-case

metal(LH) by installing push bolt as shown in Fig.5-40

f. Remove the pinion metal(support) tightening

bolts and take put drive pinion(19) and related parts as an assembly.The number of installed shims should be written down or memorized for later reference.

Fig. 5-40

Pinion metal

shim

b.The number of installed shims(14) should be

written down or memorized for later reference.

Fig.5-42

g. Release the lock of nut and remove the nut

Fig.5-43

Fig. 5-41

h.Push out drive pinion(19) from drive pinion

metal on a press.

i.Remove the bearing from the drive pinion with

a special tool.

c. Remove ring gear(2) as a set. d.When disassembling the ring gear set further,

remove bearing(31) with a puller.

e. Pull out diff pinion shaft(11) and take out dif-

pinions(6) and dif-side gears(8).

5-26

(2) PTO shaft and related parts.

Fig.5-29

1.O-ring 2.Plug(PTO) 3.Bolt 4.Ball bearing(HL1) 5.Collar 6.Gear spur/37

7.Snap ring 8.Collar(35X50X2) 9.Ball bearing 10.Shim(B) 11.Shim(0.5)

12.Snap ring 13.Seal oil 14. Cover(plate) 15. PTO shaft 16.Seal

a.Remove the rear hitch and the trailer hitch b.Remove bolt (3) and Extract PTO plug(2) rearwards c.Extract PTO shaft(15) rearwards and remove the change gears and related parts. d.Remove gear,spur /37(6)

5-27

3-2. INSPECTION

Fig.5-30

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.

-As the drive pinion and the ring gear make a pair,they

should be replaced together even if only one is found to be defective.

-Backlash between the drive pinion and the ring gear

(1) Drive pinion (2) Tapered roller bearing (3) Drive pinion metal (4) Tapered roller bearing (5) Nut (M30X1.0) (6) Gear

0.1-0.2 mm (0.004-0.008 in)

Backlash

b.Be sure that the starting torque of

the drive pinion meets the specified level.

-Backlash between the diff-pinion and the dif-side gear.

0.1-0.2 mm (0.004-0.008 in)

Backlash

8-11 Kgf.m (0.08-0.11KN.cm)

Starting torque

Fig.5-31

-When the backlash exceeds 0.5mm,also inspect the thrust collar for wear,defective collars should be replaced.

-Disengaging the resistance of PTO shifters.

17 Kgf (38 lbs)Usable limit

18-22Kgf (40-49lbs)Standard Value

c.After the starting torque has been

adjusted to the specified level,crimp the lock of the nut at one point as illustrated.

* Measured at the shifter

d. Tighten the drive pinion metal(support)

by providing it with the same shimming thickness that it had when it was disassembled.

Fig.5-32

3-3. REASSEMBLY

Reassemble the parts in reverse order of disassembly,

following these instructions.

(1) Ring gear,Drive pinion,and related parts.

a. Apply oil to the drive pinion and related parts

ahead of time.Then install them and tighten the

assembly to the specified torque.

1.4Kgf.m (9.36 ft.lbs)Tightening torque

5-28

When the drive pinion or the ring gear has been replaced, the proper number of shims to be installed should be determined based upon the following procedure:

9.0-11 Kgf.m (39.8-69 ft.lbs)

Ring gear tightening torque

5.5-7 Kgf.m (39.8-69 ft.lbs)

Drive pinion metal

tightening torque

Fig.5-34

Note:

- As shown in Fig5-34,there are two kinds of differential side gears.Although are case hardened,the one installed on the side of the diff-lock is treated further and colored black. Take care not to mix them when assembling.

- Apply multi-purpose,quality grease to the parts mentioned below:

• Tooth surfaces of dif-pinions and dif-side

gears

• Friction surfaces of dif-pinion shafts and

dif-pinions.

f.The Backlash between dif-pinion and dif-side

gear should be within as range of 0.1 to

0.2mm(0.004-0.008 in) and these parts should turn smoothly.

Note: When assembling without replacing the pinion

gear and ring gear with new ones,provide the same shimming thickness as that provided before disassembly.

e. Install the differential gears.

g. Install the differential gear assembly.

5.5-7 Kgf.m (39.8-69 ft.lbs)

Diff-case metal

tightening torque.

5-29

Fig.5-33

Fig.5-35

Note: When reassembling the used pinion

and ring gear,reinstall the same thickness of shims as was installed before disassembly in each shimming position.

h.Backlash adjustment between the drive pinion and the ring pair(Fig5-35)

i.As the drive pinion and the ring gear make a

pair,be sure not to mate them with other parts

from differential tractors. ⅱAdjust the shimming to backlash of 0.1-0.2 mm (0.004-0.008 in). The standard shimming is 0.4mm (0.016 in) on both sides.

Fig.5-36

5-30

Note: Strike the circumference of the ring gear both sides with a copper hammer by turning the ring gear

manually,and check to see that the backlash remains unchanged.The backlash should be checked at four points 90 degrees apart to each other.

ⅲ.inspection of the tooth bearing Apply an even coat of oil-dissolved minimum on the drive pinion teeth and turn the drive pinion on

the ring gear to check the tooth bearing by observing the bearing traces on the ring gear.

Inadequate backlash.Move differential case shims from left side to right side.See”Assembly and installation”.

Root contact

Too much engagement.Add some drive pinion support shims.See TRANSMISSION:”REAR TRANSMISSION ASSEMBLY-Setting cone center.”

Heel contact

Too little engagement.Remove some drive pinion support shims.See Transmission:REAR TRANSMISSION ASSEMBLY-Setting cone center.

Toe contact

Excessive backlash.Move differential case and shims from right side to left side.See”Assembly and installation”.

Tip contact

When drive pinion and ring gear are meshed correctly with each other and their backlash is within specified range,contact is in middle of ring gear tooth and is approximately 75% of total tooth width.

Correct Contact

INSTALLATION OF A NEW PAIR OR RING GEAR AND DRIVE PINION

1.use a new pair of ring gear and drive pinion delivered from the manufacturer.Never mix its components with those of other pairs.

Note: Every ring gear-dive pinion pairs is adjusted and inspected for tooth contact individually at factory.

2.Adjust the backlash between the ring gear and drive pinion to be 0.1-0.2mm(0.004-0.008 in) by shimming the drive pinion metal and right and left dif-case metal and make sure that their tooth contact is proper

5-31

(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. c.After installation,the slide coupling should smoothly slide and mesh with the designated gears.

Fig.5-37 PTO 2 speed

Fig.5-38 PTO 1 speed

5-32

Mahindra 2810, T290, T330, T300 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual