Tm215f-Tm217f-Iseki Manuel d'ATELIER PDF

ISEKI TM TRACTOR SERVICE MANUAL
CONTENTS
CHAPTER 1. GENERAL INFORMATION ....................................................................................................................... 5
§1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS ......................................................................... 5

1. MODEL NAME PLATE ................................................................................................................................. 5
2. CHASSIS PRODUCTION NUMBER ........................................................................................................... 5
3. ENGINE MODEL AND SERIAL NUMBER ................................................................................................... 5
§2. SPECIFICATIONS ............................................................................................................................................... 6
Engine .................................................................................................................................................................. 6
Transmission ........................................................................................................................................................ 6
Power take-off (PTO) ........................................................................................................................................... 6
Hydraulics ............................................................................................................................................................ 6
Electrical system .................................................................................................................................................. 7
Capacities ............................................................................................................................................................ 7
Track setting ........................................................................................................................................................ 7
Maximum axle loading ......................................................................................................................................... 7
Tyre size............................................................................................................................................................... 7
General dimensions ............................................................................................................................................. 8
§ 4. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION ........................................................ 9
1. BEFORE OPERATION ................................................................................................................................ 9
2. PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING STANDARDIZED PARTS ............................... 9
CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS ........................................................ 13
§1. OPERATION CHART FOR DISASSEMBLING AND RE-ASSEMBLING BY MAJOR BLOCKS ........................ 13
§2. DISASSEMBLY OF FUNCTIONAL BLOCKS .................................................................................................... 14
1 EXTERIOR PARTS .................................................................................................................................... 14
2 SEPARATION OF THE ENGINE FROM THE CLUTCH HOUSING .......................................................... 15
3 REMOVAL OF THE ENGINE ..................................................................................................................... 16
4 SEPARATION OF THE CLUTCH HOUSING FROM THE FRONT TRANSMISSION CASE .................... 16
5 REMOVAL OF THE CYLINDER CASE ..................................................................................................... 16
6 REMOVAL OF THE CHANGE METAL (SUPPORT) .................................................................................. 17
7 SEPARATION OF THE FRONT TRANSMISSION CASE FROM THE REAR TRANSMISSION CASE .... 17
8 REMOVAL OF THE MID-PTO ................................................................................................................... 17
9 SEPARATION OF THE REAR AXLE HOUSING FROM THE REAR TRANSMISSION CASE ................. 17
10 REMOVAL OF THE FRONT AXLE ............................................................................................................ 18
11 REMOVAL OF THE RADIATOR ................................................................................................................ 18
CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES .................................................................................... 19
1. SPECIFICATIONS ............................................................................................................................................. 19
ENGINE ............................................................................................................................................................. 19
2. TIGHTENING TORQUE OF MAJOR FASTENERS .......................................................................................... 20
3. RADIATOR ......................................................................................................................................................... 21
3.1. CONSTRUCTION .............................................................................................................................................. 21
3.2. REMOVAL AND RE-INSTALLATION ................................................................................................................. 21
3.3. INSPECTION ..................................................................................................................................................... 21
4. COOLING FAN AND BELT ................................................................................................................................ 22
4.1. SPECIFICATIONS ............................................................................................................................................. 22
4.2. ADJUSTMENT OF BELT ................................................................................................................................... 22
5. AIR-CLEANER ................................................................................................................................................... 23
1
TM TRACTOR SERVICE MANUAL
5.1. REMOVAL AND RE-INSTALLATION ................................................................................................................. 23

5.2. INSPECTION ..................................................................................................................................................... 23
5.3. CLEANING THE ELEMENT .............................................................................................................................. 23
6. FUEL SYSTEM .................................................................................................................................................. 24
6.1. FUEL SYSTEM DIAGRAM ................................................................................................................................ 24
6.2. INSPECTION ..................................................................................................................................................... 24
6.3. FUEL FILTER ..................................................................................................................................................... 24
7. TROUBLESHOOTING ....................................................................................................................................... 25
CHAPTER 4. CLUTCH SYSTEM .................................................................................................................................. 27
1. CONSTRUCTION .............................................................................................................................................. 27
2. DISASSEMBLY .................................................................................................................................................. 27
3. INSPECTION ..................................................................................................................................................... 28
4. PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 29
CHAPTER 5. TRANSMISSION ...................................................................................................................................... 33
1. GEAR-TYPE TRANSMISSION ............................................................................................................................. 33

1.1. POWER TRAIN .................................................................................................................................................. 33
1.2. CONSTRUCTION .............................................................................................................................................. 35
1.3. DISASSEMBLY .................................................................................................................................................. 35
1.4. INSPECTION ..................................................................................................................................................... 36
1.5. PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 36
2. HST TRANSMISSION ....................................................................................................................................... 37
2.1. POWER TRAIN .................................................................................................................................................. 37
2.2. CONSTRUCTION .............................................................................................................................................. 39
2.3. DISASSEMBLY .................................................................................................................................................. 39
2.4. INSPECTION ..................................................................................................................................................... 40
2.5. PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 40
3. MID-PTO ............................................................................................................................................................ 41
3.1. CONSTRUCTION .............................................................................................................................................. 41
3.3. INSPECTION ..................................................................................................................................................... 41
3.4. PRECAUTION FOR RE-ASSEMBLY ................................................................................................................ 41
CHAPTER 6. REAR AXLE AND BRAKES ................................................................................................................... 43
1. GENERAL DESCRIPTION ................................................................................................................................ 43

2. CONSTRUCTION .............................................................................................................................................. 44
3. REAR AXLE HOUSING AND DIFFERENTIAL GEARS ..................................................................................... 45
3.1. DISASSEMBLY .................................................................................................................................................. 45
3.2. INSPECTION ..................................................................................................................................................... 45
3.3. PRECAUTIONS FOR RE-ASSEMBLY AND ADJUSTMENT ............................................................................. 45
4. BRAKES ............................................................................................................................................................ 47
4.1. SPECIFICATIONS ............................................................................................................................................. 47
4.2. CONSTRUCTION .............................................................................................................................................. 47
4.3. DISASSEMBLY .................................................................................................................................................. 48
4.4. INSPECTION ..................................................................................................................................................... 49
4.5. PRECAUTIONS FOR REASSEMBLY ............................................................................................................... 49
4.6. BRAKE ADJUSTMENT ...................................................................................................................................... 49
CHAPTER 7. MANUAL STEERING SYSTEM .............................................................................................................. 51
§1. CONSTRUCTION .............................................................................................................................................. 51

§2. DISASSEMBLY, INSPECTION, AND REASSEMBLY ........................................................................................ 52
1. DISASSEMBLY .......................................................................................................................................... 52
2
2. INSPECTION ............................................................................................................................................. 53
3. REASSEMBLY AND ADJUSTMENT ......................................................................................................... 54
4. TROUBLESHOOTING ............................................................................................................................... 56
CHAPTER 8. FRONT AXLE .......................................................................................................................................... 57
§1 CONSTRUCTION .............................................................................................................................................. 57
1. SECTIONAL VIEWS .................................................................................................................................. 57
2. MAJOR COMPONENTS ........................................................................................................................... 58
§2. DISASSEMBLY .................................................................................................................................................. 59
1. FRONT AXLE AND DIFFERENTIAL GEARS ............................................................................................ 59
2. FINAL CASE AND RELATED PARTS ....................................................................................................... 60
DISASSEMBLY OF THE FINAL CASE ASSEMBLY .......................................................................................... 60
§3. INSPECTION ..................................................................................................................................................... 60
§4. PRECAUTIONS FOR RE-ASSEMBLY .............................................................................................................. 61
§3. TROUBLESHOOTING ....................................................................................................................................... 62
CHAPTER 9. HYDRAULIC SYSTEM ............................................................................................................................ 63
§1. GENERAL DESCRIPTION ................................................................................................................................ 63

1. HYDRAULIC SYSTEM DIAGRAMS .......................................................................................................... 63
1.1. STANDARD TYPE ..................................................................................................................................... 63
1.2. HU & U TYPES .......................................................................................................................................... 64
1.3. HYDRAULIC SYSTEM MAIN PIPING ....................................................................................................... 66
1.4. HYDRAULIC SYSTEM PIPING ................................................................................................................. 67
§2. SPECIFICATIONS ............................................................................................................................................. 69
§3. CONSTRUCTION, DISASSEMBLY AND INSPECTION OF MAJOR COMPONENTS ..................................... 70
1. SUCTION FILTER ..................................................................................................................................... 70
2. HYDRAULIC PUMP (GEAR PUMP) .......................................................................................................... 70
3. FLOW CONTROL VALVE AND METAL (U) ............................................................................................... 71
3.1. CONSTRUCTION AND COMPONENTS ................................................................................................... 71
3.2. INSPECTION OF FLOW CONTROL VALVE ............................................................................................. 72
4. AIR-BLEEDING OF THE HYDARULIC CIRCUIT ...................................................................................... 72
5. CYLINDER CASE ...................................................................................................................................... 73
5.1. CONSTRUCTION AND COMPONENTS ................................................................................................... 73
5.2. DISASSEMBLY .......................................................................................................................................... 74
6. MAIN CONTROL VALVE ........................................................................................................................... 75
6.1. CONSTRUCTION ...................................................................................................................................... 75
6.2. FUNCTION ................................................................................................................................................ 76
6.3. DISASSEMBLY, INSPECTION AND REASSEMBLE OF THE MAIN CONTROL VALVE .......................... 77
§4. REASSEMBLY OF MAJOR COMPONENTS .................................................................................................... 79
§5. TROUBLESHOOTING ....................................................................................................................................... 81
CHAPTER 10. HYDROSTATIC TRANSMISSION ......................................................................................................... 85
1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS ......................................................................... 85

2. OPERATING DIAGRAM OF HST ...................................................................................................................... 86
3. FUNCTION ........................................................................................................................................................ 87
3.1. VARIABLE TYPE PUMP .................................................................................................................................... 87
3.2. FIXED TYPE MOTOR ........................................................................................................................................ 88
3.4. VALVES ............................................................................................................................................................. 88
4. DISASSEMBLY AND REASSEMBLY ................................................................................................................ 91
4.1. REQUIRED TOOLS ........................................................................................................................................... 91
4.2. PRESS-IN JIGS ................................................................................................................................................. 92
4.3. PRECAUTIONS FOR DISASSEMBLY .............................................................................................................. 93
4.4. DISASSEMBLY .................................................................................................................................................. 93
4.5. CRITERIA FOR REPLACING WORN PARTS ................................................................................................... 97
4.6. PRECAUTION BEFORE REASSEMBLY .......................................................................................................... 98
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4.7. REASSEMBLY ................................................................................................................................................... 98

4.7. LIST OF MAJOR COMPONENTS OF HST ..................................................................................................... 107
5. HST CONTROL PEDALS ................................................................................................................................ 108
5.1. DIMENSIONS OF PEDALS ............................................................................................................................. 108
5.2. NEUTRAL ADJUSTMENT ............................................................................................................................... 109
CONFIRMATION ITEMS AFTER ADJUSTMENT ............................................................................................ 109
6. TROUBLESHOOTING ..................................................................................................................................... 110
CHAPTER 11. POWER-ASSISTED STEERING SYSTEM ......................................................................................... 111
§1. CONSTRUCTION ............................................................................................................................................ 111

§2. MAJOR COMPONENT .................................................................................................................................... 112
§3. INTEGRAL ORBIT ROLL ................................................................................................................................. 113
1. COMPONENTS ....................................................................................................................................... 113
2. DISASSEMBLY ........................................................................................................................................ 114
2.1. DISASSEMBLY OF ROTOR SIDE .......................................................................................................... 114
2.2 DISASSEMBLY OF CONTROL SIDE ...................................................................................................... 115
2.3. INSPECTION ........................................................................................................................................... 116
3. RE-ASSEMBLY ....................................................................................................................................... 116
3.1. RE-ASSEMBLY OF CONTROL SIDE ...................................................................................................... 116
3.2. RE-ASSEMBLY OF GEROTOR SIDE ..................................................................................................... 118
§4. TROUBLESHOOTING ..................................................................................................................................... 120
CHAPTER 12. ELECTRICAL SYSTEM ...................................................................................................................... 123
1. FUSES, FUSIBLE LINKS AND SLOW-BLOW FUSE ...................................................................................... 123

2. SAFETY SYSTEM WIRING DIAGRAM ........................................................................................................... 124
3. TROUBLESHOOTING ..................................................................................................................................... 125
3.1. BATTERY ......................................................................................................................................................... 125
3.2. METERS, GAUGES, AND SWITCHES ........................................................................................................... 125
CHAPTER 13. SERVICING DATA ............................................................................................................................... 129
1. SPECIFICATIONS & CAPACITIES .................................................................................................................. 129

Engine Oil ........................................................................................................................................................ 129
Engine Coolant ................................................................................................................................................ 129
Fuel Tank ......................................................................................................................................................... 129
Transmission & Differential Housing (Including Hydraulic System) ................................................................. 129
Front Axle ......................................................................................................................................................... 129
Grease Fittings ................................................................................................................................................ 129
2. LUBRICATION/FILL POINTS ........................................................................................................................... 130
3. PERIODIC MAINTENANCE SCHEDULE ........................................................................................................ 131
4. SERVICE STANDARDS .................................................................................................................................. 132
APPENDIX ................................................................................................................................................................. 137
1. PRECAUTIONS FOR REASSEMBLY ............................................................................................................. 137

1.1. MECHANICAL TRANSMISSION ..................................................................................................................... 137
1.2. HYDROSTATIC TRANSMISSION ................................................................................................................... 139
1.3. FRONT AXLE AND DRIVE MECHANISM ....................................................................................................... 141
1.4. REAR AXLE AND BRAKES ............................................................................................................................. 143
2. WIRING DIAGRAM .......................................................................................................................................... 145
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CHAPTER 1: GENERAL DESCRIPTION
CHAPTER 1. GENERAL INFORMATION
§1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS
Each tractor is identified by means of the tractor TO ENSURE PROMPT, EFFICIENT SERVICE
model and serial numbers. As a further identifica- WHEN ORDERING PARTS OR REQUESTING
tion, the engine and chassis are also provided REPAIRS FROM AUTHORIZED ISEKI DEAL-
with identification numbers. ER, RECORD THESE NUMBERS IN SPACES
PROVIDED.
2 3 1
KM/H
3
000 1 H
21
RPM
x1000
(1) Model name plate (3) Cast engine model name and punched
(2) Punched model name and serial number on engine serial number on the right side wall
the right side of the front frame the cylinder block
Fig. 1-1
1. MODEL NAME PLATE 2. CHASSIS PRODUCTION NUMBER

T00E F 00001
Chass production serial number
1
MODEL TMOOOO 4WD
2 TYPE EOO
Manufacturer's model name
3 NO. OOOOOOO O 4 T92E: TM215 ; T93E: TM217
3. ENGINE MODEL AND SERIAL

NUMBER
ISEKI & CO., LTD. TOKYO/JAPAN
(1) TM215 or TM217

F .................. Standard transmission with 4WD 1
FH ............... HST transmission with 4WD
M ................. Mid-PTO
U ................. Power-assisted steering sytem
(2) Type
E41 .............. Agricultural tyres
E42 .............. Turf tyres
(3) Production No. 2

(4) Production date
The year of 1977 is alloted to “G,” and the following years (1) Engine model
are expressed alphabetically except for “I.” (2) Serial Number
Fig. 1-2 Fig. 1-3
5
§2. SPECIFICATIONS
Models ....................................................................................................................................... TM215 ................................................. TM217
Sub-models ................................................................................................................ F ....... FMU ... FHU ... FHMU F ......... FU ..... FMU ... FHU ... FHMU
Engine
Make ................................................................................................................................................................................ ISEKI Diesel
Model ........................................................................................................................................... E393 ................................................... E3100
Type ................................................................................................................................................................. Indirect injection, overhead valve
Displacement .............................................................................................................................. 928 cc ................................................. 1006 cc
Number of cylinders ................................................................................................................................................................. 3
Bore ................................................................................................................................................... 74 mm .................................................. 74 mm
Stroke ................................................................................................................................................. 72 mm .................................................. 78 mm
Engine horsepower (gross)@ engine rpm ...................................................................................... 15.5/2500 ............................................... 17/2500
PTO horsepower (estimate) ................................................................................................... 13.5 .................... 13 ............................. 15 ............................. 14
Firing order ......................................................................................................................................................................... 1 – 3 – 2
Compression ratio ................................................................................................................................................................. 22.5:1
Low idle speed ..................................................................................................................................................................... 950 rpm
High idle speed ................................................................................................................................................................... 2750 rpm
Valve clearance (cold) – intake and exhaust ...................................................................................................................... 0.25 mm
Air cleaner ................................................................................................................................................................. Single – dry element
Engine cooling ....................................................................................................................................................... Liquid, forced circulation
Cold starting .................................................................................................................................................................. Glow plugs (3)
Transmission
Primary ................................................................................................................................ F3/R1 ............... Infinite ...................... F3/R1 ...................... Infinite
Range ........................................................................................................................................................................................ 2
Gear selections .................................................................................................................... F6/R2 ................ F2/R2 ....................... F6/R2 ....................... F2/R2
Clutch ................................................................................................................................................................ Dry single disc (Dia: 184 mm)
Brakes ............................................................................................................................................................. Mechanically acutuated dry shoes
Speed range (km/h) Forward 1 ........ 1.2 ................. 0 to 8.4 ......................... 1.2 ........................ 0 to 8.8
2 ........ 2.1 ................ 0 to 19.5 ........................ 2.3 ....................... 0 to 20.6
3 ........ 3.5 ........................................................ 3.7
4 ........ 5.9 ........................................................ 6.2
5 ....... 10.6 ...................................................... 11.3
6 ....... 17.4 ...................................................... 18.5
Reverse 1 ........ 1.9 ................. 0 to 5.9 ......................... 2.0 ........................ 0 to 6.2
2 ........ 9.5 ................ 0 to 13.7 ....................... 10.1 ...................... 0 to 14.5
Power take-off (PTO)

Control ........................................................................................................................................................................... Lever and pedal
Rear PTO shaft ........................................................................................................................................... 35 mm (1.375 in) diameter – six spline
Output ......................................................................................................................................................................... Clockwise rotation
Speeds @ engine rpm ...................................................................................................... 540 @ 2308 ....... 540 @ 2398 .............. 540 @ 2308 .............. 540 @ 2398
................................................................................................................................. 1000 @ 2385 ..... 1000 @ 2399 ............ 1000 @ 2385 ............ 1000 @ 2399
Mid PTO (accessory) shaft ......................................................................................................................... 25 mm (1 in) diameter – fifteen spline
Output .................................................................................................................................................................. Clockwise rotation
Speeds @ engine rpm .............................................................................................. 2000 @ 2446 ..... 2000 @ 2400 ............ 2000 @ 2446 ............ 2000 @ 2400
Hydraulics
Main hydraulic system
Pump ............................................................................................................................................................... Gear pump (Open centre)
Output – maximum .................................................................................................................................................. 18.0 litres/min
Pressure – relief valve setting .................................................................................................................................... 140 kgf/cm3
Rear linkage type ......................................................................................................................................................... Three-point hitch
Control .............................................................................................................................................. Operated by single ‘position’ control lever
Lift capacity ................................................................................................................................................. 480 kg measured at link ends
6
Models ...................................................................................................................................... TM215 .................................................. TM217

Sub-models ................................................................................................................ F ....... FMU ... FHU ... FHMU F ......... FU ..... FMU ... FHU ... FHMU
Steering system type ......................................................................................................................................... Manual/ Power-asisted (Option)

Pump .................................................................................................................................................................... Gear/ Flow divider
Output – maximum .................................................................................................................................................. 5.5 litres/mikn
Pressure – relief valve setting .................................................................................................................................... 105 kfg/cm3
Electrical system
System voltage .................................................................................................................................................... 12 volt - negative (-) ground
Battery .............................................................................................................................................................................. 36 hA (5 hr)
Charging .................................................................................................................................................... 40 amp alternator with internal regulator
Capacities
Engine crankcase with filter ............................................................................................................................................... 2.7 litres
Transmission and differential housing (including hydraulics) (litres) ........................... 13.5 ..... 14.0 ..... 15.0 ..... 15.0 13.5 ..... 14.0 ..... 14.0 ..... 15.0 ..... 15.0
Fuel tank ............................................................................................................................................................................ 13.5 litres
Cooling system ................................................................................................................................................................... 5.1 litres
Front axle - four-wheel drive .............................................................................................................................................. 2.7 litres
Track setting
Front four-wheel drive
Agricultural tyres (dished in only) ...................................................................................................................................... 750 mm
Turf tyres (dished in only) ................................................................................................................................................... 870 mm
Rear four-wheel drive
Agricultural tyres (adjustable wheels) ........................................................................................ 770 to 950 mm .................................... 800 to 910 mm
Turf tyres (dished in only) ................................................................................................................................................... 900 mm
PTO shafts
Rear PTO
Speeds ..................................................................................................................................................... 540 rpm and 1000 rpm (Clockwise rotation)
Shaft daimeter and spline teeth .................................................................................................................................... 35 mm, 6-spline
Mid-PTO
Speeds ................................................................................................................................................................ 2000 rpm (Clockwise rotation)
Shaft diameter and spline teeth ................................................................................................................................... 25 mm, 15-spline
Maximum axle loading

Front four-wheel drive - both models .................................................................................................................................. 650 kg
Rear axle - both models ....................................................................................................................................................... 750 kg
Total limit: ........ 1200 kg
Tyre size
Front
Agricultural tyre ..................................................................................................................... 5 – 12 4PR ......................................... 5.00 – 12 4PR
Turf tyre ............................................................................................................................................................... 20.5 × 8.00-10 4PR
Rear
Agricultural tyre ..................................................................................................................... 8 – 16 4PR ............................................. 8-18 4PR
Turf tyre ............................................................................................................................................................... 29 × 12.00-15 4PR
7
General dimensions
A2
A1
B D
Fig. 4
Models .............................................................................................................................................. TM215 ................................................. TM217

Sub-models ....................................................................................................................... F ....... FMU ... FHU ... FHMU F ......... FU ..... TMU ... FHU ... FHMU
Agricultural tyres/turf tyres

A1 Height over steering wheel ............................................................................................... 1280 mm/1270 mm .............................. 1300 mm/1270 mm
A2 Height over ROPS .................................................................................................... Ask your local ISEKI dealer. .............. Ask your local ISEKI dealer.
B Minimum width ................................................................................................................... 1000/1190 mm .................................. 1000 mm/1190 mm
C Overall length ........................................................................................................................... 2545 mm .............................................. 2545 mm
D Wheelbase ................................................................................................................................ 1425 mm .............................................. 1425 mm
E Minimum ground clearance ....................................................................................................... 255 mm ................................................ 280 mm
Turning radius (4WD engaged) without brakes ........................ 2600 mm ........... 2600 mm .................. 2700 mm .................. 2700 mm
with a brake ............................ 1900 mm ................ — ........................ 1900 mm ....................... —
Turning radius (4WD disengaged) without brakes ........................ 2400 mm ........... 2400 mm .................. 2400 mm .................. 2400 mm
with a brake ............................ 2100 mm ................ — ........................ 2100 mm ....................... —
Weight (without ROPS and seat) ................................................................................... 555kg .... 570kg ... 585kg ... 595kg 570kg ... 575 kg ... 585kg .. 600kg .. 610kg
8
§ 4. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION

1. BEFORE OPERATION installer which is specially designed to push only
the outer race and vice versa.
1) Always be safety-conscious in selecting clothes to
wear and suitable tools to use. 2) The installer must be designed to install the bearing
on the shaft in a parallel position.
2) Before disassembly, be sure that you familiarize
yourself with the assembled condition for subse- 3) When installing a bearing which appears the same
quent reference in re-assembly. on both sides, install it so that the face which has the
identification number faces in a direction for easy
3) Keep parts and tools in proper order during opera- visual identification. All the bearings which are to
tions. be installed in the transmission case should be
placed so that their identification number faces out-
4) Before servicing electrically charged parts, be sure ward.
to disconnect the negative battery terminal.
4) If a shaft or a hole where a bearing is to be installed
5) To prevent oil or water leaks, use liquid gasket as has a stopper, the bearing should be pushed in com-
required. pletely until it is seated against the stopper.
6) When reassembling disassembled parts, discard 5) Installed bearings should turn smoothly.
used gaskets, O-rings, or oil seals and install new
ones. (2) Oil seals
7) When lifting up only the front or rear part of the 1) Oil seal installer should be designed so as not to
tractor, be sure to wedge the grounded wheels. deform the oil seals.
8) When the tractor is jacked up, be sure to support the 2) During installation of an oil seal, be careful not to
entire tractor with something like a stand. Holding it damage the lips, and assure that it is pushed in
up with a jack only is a dangerously unstable proce- parallel to the shaft or hole.
dure.
3) When oil seals are installed, there should be no
9) When replacing parts, use authorized, genuine turnover of the lips nor dislocation of the springs.
ISEKI parts only. ISEKI assumes no responsibility
for accidents, operating problems or damage caused 4) When a multi-lip seal is installed, the grooves be-
by the use of imitation parts. Also, the use of unau- tween lips should be filled with grease, not adhe-
thorized parts will result in relatively poor machine sive.
performance.
5) Use a lithium-based grease.
2. PRECAUTIONS TO BE FOLLOWED
WHEN INSTALLING STANDARDIZED 6) There should be no oil or water leaks through the
PARTS installed soil seals.
(1) Roller or ball bearings (3) O-rings
1) When a bearing is fitted in by the outer race, use an 1) O-rings should be coated with grease before install-
ing.
9
2) Installed O-rings should not be twisted or slack.
3) Installed O-rings should maintain proper air tight-

ness.
F
(4) Snap rings F
1) Snap ring installers should be designed so as not

to permanently deform the snap rings.
F
2) Installed snap rings should be seated securely in
the groove. Fig. 1-6
3) Be careful not to overload the snap ring to the 3) The roll pins installed in the transmission or other
extent that it is permanently deformed. parts where much force is applied should be re-
tained with wire.
4) How to install the snap ring:
(6) Cotter pins
When installing a snap ring, install it as shown in
the figure with its round edge side turned toward When installed, cotter pins should be bent secure-
the part to be retained. This round edge is formed ly at the ends as shown in the figure.
when the snap ring is pressed out.
Snap ring
Snap ring
Fig. 1-7
(7) Bolts and nuts
Round edge side 1) Special bolts are installed at several locations, so

Fig. 1-5 be sure not to interchange them with other bolts.
(5) Spring (roll) pins 2) Bolts and nuts should be tightened to their speci-
fied torques with a torque wrench.
1) Spring pins should be driven in properly and
tightly. 3) When locking the bolts or nuts with wire or a lock
washer, be sure to wind the wire paying sufficient
2) Spring pins should be installed so that their seams attention to its winding direction and bend the
face the direction from which the load is applied. lock washer for secure locking.
4) When locking bolts and nuts with an adhesive,

apply the adhesive on the thread and tighten se-
curely.
10
5) Apply an adhesive to parts through which there is

a 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 tight-

ening torque table.
(8) Grease fittings
1) After installation, each grease fitting should be

filled with grease.
2) When installing grease fittings of types 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 the installation.
3) Each lever knob should be coated with an adhe-

sive before installation.
4) Each contact surface should be coated with an

adhesive and bolts tightened evenly. 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, especially grease before ap-
plication of the adhesive.
5) Precautions for applying adhesives
– The surface or the thread where an adhesive is to

be applied should be completely free of chips.
– The surface or the thread where an adhesive is to

be applied should be completely free of oil and
grease.
11
12
CHAPTER 2: DISASSEMBLING INTO
MAJOR FUNCTIONAL COMPONENTS
CHAPTER 2. DISASSEMBLING INTO MAJOR

FUNCTIONAL COMPONENTS
§1. OPERATION CHART FOR DISASSEMBLING AND RE-ASSEMBLING BY

MAJOR BLOCKS
Battery Power-assisted steering
Radiator Axle Bracket Front Axle cylinder
Centre pivot 4WD differential gears
4WD final case
Engine Flywheel
Clutch
Clutch Housing
HST model Gear transmission model

Input shaft Input shaft
4WD drive-shaft 4WD drive-shaft
HST unit Input metal (support) (4WD change
Plate gears)
HST metal (support) Change metal (support)
Mid-PTO system (main/range change system)
Range shift gears Front Transmission Mid-PTO system
PTO shift gears Input gears
Drive pinion Main shift gears
Range shift gears
4WD shift gears
PTO shift gears
Drive pinion
Rear Transmission PTO metal (PTO shaft)

Ring gear (Differential system)
Rear Axle Wheel shaft

Final reduction gears
Brake system
Diff-lock (RH)
Cylinder case
Control linkage
Valve system
Position and arm
13
§2. DISASSEMBLY OF FUNCTIONAL BLOCKS
1
EXTERIOR PARTS
1.1. SIDE COVERS, HOOD AND FRONT
i. Remove the side cover.

ii. Open the front grille.
iii. Disconnect the cable couplers.
Important:
The negative battery cable should be disconnected ahead of time to prevent short circuit.
iv. Remove the front grille.
v. Remove the hood.
1.2. SEAT, FENDERS AND RELATED PARTS
Gear transmission model
i. Remove the seat.

ii. Remove the dif-lock pedal.
iii. Remove the main change lever knob.
iv. Remove the levers (range change lever and position control lever).
v. Remove the change cover.
vi. Remove the fender stays.
vii. Remove the fenders.
viii. Remove the seat bracket.
HST model
i. Remove the seat.

ii. Remove the HST pedals.
iii. Remove the range change lever knob.
iv. Remove the levers (Mid-PTO change lever and position control lever).
v. Remove the change cover.
vi. Remove the fender stays.
vii. Remove the fenders.
viii. Remove the seat bracket.
1.3. FLOOR AND RELATED PARTS
Gear transmission model
i. Remove the brake spring (RH).
14
ii. Remove the throttle wire (RH).
iii. Disconnect the couplers of the stop light switch.
iv. Remove the floor.
HST model
i. Remove the brake spring (RH).

ii. Disconnect the couplers of the stop light switch.
iii. Remove the floor.
1.4. STEERING POST, METER PANEL AND RELATED PARTS
i. Remove the steering wheel.

ii. Remove the steering column cover around the throttle lever.
iii. Remove the rear cover of the steering column and also disconnect the couplers of the wiring inside the
cover.
iv. Disconnect the couplers of the cables.
v. Manual steering: Remove the steering arm from the steering post.
vi. Power-assisted steering: Disconnect the pipes from the orbit-roll.
vii. Remove the steering post assembly.
viii. Remove the meter cable.
ix. Remove the meter panel along with the dash cover.
2
SEPARATION OF THE ENGINE FROM THE CLUTCH HOUSING
i. Drain transmission oil.

ii. Remove the hood and other parts referring to 1.1 and 1.3. of 1.
iii. Remove the bolts of 4WD shaft cover and remove the 4WD shaft cover from the pivot metal (sup-
port).
iv. Disconnect the couplers of the wiring at the right bottom of the steering wheel column.
v. Remove the throttle wire.
vi. Disconnect the fuel pipe from the fuel filter.
Note: Plug the pipe to prevent fuel from spilling.
vii. Remove the fuel filter along with the stay.
viii. Disconnect the delivery and suction pipes from the gear pump.
ix. Disconnect the fuel tank along with the fuel tank bracket.
x. Remove all the bolts but one which tighten the engine and clutch housing.
Important: One bolt should remain there for safety to prevent the engine and clutch housing from
being separated completely.
xi. Use wooden chocks between the front axle and the front axle bracket so that both sides to hold the
engine securely.
xii. Support the transmission case with a garage jack and hoist the engine with a chain block. Then re-
move the last bolt.
15
xiii. Separate the engine from the clutch housing carefully.
3
REMOVAL OF THE ENGINE
i. Separating the engine from the clutch housing referring to 2.

ii. Disconnect the earthing bolts at the right side of the front axle bracket.
iii. Drain the engine coolant.
iv. Detach the coolant drain hose.
v. Detach the water pipes.
vi. Remove the bolts tightening the engine and front axle bracket.
Note: For safety the engine should be lifted with a chain block for safety ahead of time.
vii. Detach the front axle bracket.
4
SEPARATION OF THE CLUTCH HOUSING FROM THE FRONT TRANSMISSION CASE

ii. Remove the floor referring to 1 to 3.
iii. Remove the 4WD drive shaft.
iv. Remove the change cover.
v. Remove the brake rod.
vi. Remove the delivery and suction pipes.
vii. Remove the parking brake rod from the parking brake lever.
viii. Remove the bolts which hold the clutch housing and front transmission case together.
ix. Separate the clutch housing from the front transmission case.
Note: When connecting the clutch housing and front transmission case together, shift the main shift and
range shift levers to a position other than the neutral position.
5
REMOVAL OF THE CYLINDER CASE
i. Remove the seat.

ii. Remove the seat bracket on the cylinder case.
iii. Remove the position control lever.
iv. Remove the bolt of the delivery pipe at the right side of the cylinder case.
v. Remove the top link bracket.
vi. Remove the bolts which hold the cylinder case and rear transmission case together.
vii. Separate the cylinder case from the rear transmission case.
16
6
REMOVAL OF THE CHANGE METAL (SUPPORT)
i. Remove the seat.

ii. Remove the dif-lock pedal.
iii. Remove the change cover.
iv. Remove the seat bracket on the change metal.
v. Remove the bolts which hold the change metal and front transmission case together.
vi. Separate the change metal from the rear transmission case.
7
SEPARATION OF THE FRONT TRANSMISSION CASE FROM THE REAR TRANSMIS-
SION CASE

ii. Remove the cylinder case and change metal referring to 5 and 6.
iii. Remove the brake rod.
iv. Remove the parking rod from the parking brake lever.
v. Remove the bolt at the delivery pipe on the rear axle housing (RH).
vi. Remove the PTO metal (support).
vii. Put out the bearings and PTO gear onto the PTO drive shaft.
viii. Remove the bolts which hold the front and rear transmission cases together.
ix. Separate the front transmission case from the rear transmission case.
8
REMOVAL OF THE MID-PTO

ii. Remove the rod from the mid-PTO lever.
iii. Remove the mid-PTO assembly.
9
SEPARATION OF THE REAR AXLE HOUSING FROM THE REAR TRANSMISSION CASE

ii. Drain transmission oil in the rear axle from the bottom of the rear axle housing.
iii. Remove the fenders referring to 1 to 2.
iv. Remove the brake rod.
v. Remove the delivery pipe.
vi. Remove the parking brake shaft along with the bracket.
17
vii. Remove one of the rear tyres.

Note: Support a part of the joint of the front and rear transmission cases on a garage jack.
viii. When removing the right-hand rear axle housing , remove the dif-lock pedal.
ix. Remove the bolts which hold the rear axle housing and rear transmission case together.
x. Separate the rear axle housing from the rear transmission case.
10
REMOVAL OF THE FRONT AXLE
i.Remove the bolt of 4WD shaft cover and remove the 4WD shaft cover from the pivot metal (support).
ii.Remove the 4WD drive shaft along with the 4WD shaft cover.
iii.Manual steering: Disconnect the drag rod from the drag arm.
iv. Power-assisted steering: Disconnect the hose from the orbit-roll.
v. Remove the front tyres.
Note: The front part of the tractor should be lifted up with a chain block ahead of time.
vi. Drain the front axle oil from the bottom of both final cases.
vii. Remove the centre pivot and the setting bolts from the front axle bracket, and then the front axle can
be removed downward.
Note: As the front axle is a very heavy component, remove it carefully while supporting it with a
garage jack.
11
REMOVAL OF THE RADIATOR
i. Remove the hood, side cover and front grille referring to 1.1 of 1.
ii. Drain the coolant.
iii. Disconnect the upper and lower hoses.
iv. Disconnect the drain hose.
v. Remove the radiator shroud.
vi. Remove the radiator along with the radiator stay.
18
CHAPTER 3: ENGINE SERVICE DATA
AND ACCESSORIES
CHAPTER 3. ENGINE SERVICE DATA AND

ACCESSORIES
For detail information about the engines, please refer to the relevant service manual which is available sepa-
rately.
1. SPECIFICATIONS
TRACTORS ....................................................................................................................... TM215 ........................................... TM217
ENGINE
Model .................................................................................................................................................. E393 ................................................... E3100
Type ....................................................................................................................................................................... 4-cycle, indirect injection
Cylinders/Total displacement ........................................................................................................... 3/928 cc ............................................... 3/1006 cc
Bore & Stroke ............................................................................................................................ 74 mm × 72 mm .................................. 74 mm × 78 mm
Compression ratio ................................................................................................................................................................. 22.5:1
PERFORMANCE
Engine output [ps(kW)/engine rpm] ............................................................................................... 15.5/2500 ............................................. 17.0/2500
Low idle speed (rpm) ............................................................................................................................................................. 950
High idle speed (rpm) ............................................................................................................................................................ 2750
Fuel consumption (g/ps-h) ................................................................................................................... 220 ....................................................... 215
Maximum torque (Bm/rpm) ............................................................................................................. 50/1800 ................................................ 55/1800
FUEL SYSTEM
Injection pump type ....................................................................................................................... Bosch, PFR .......................................... Bosch, PFR
(NP-PFR3MD) (ND-PFR3M)
Nozzle type .......................................................................................................................................................................... Throttle
Governor ........................................................................................................................................................................ In the gear case
Fuel shut-off ................................................................................................................................................................. Electric solenoid
LUBRICATION SYSTEM
Type ............................................................................................................................................................................. Forced circulation
Oil pump type ..................................................................................................................................................................... Trochoid
Oil filter type ...................................................................................................................................................................... Full flow
Relief valve pressure (kgf/cm2) .......................................................................................................................................... 4.0 – 4.5
Oil capacity (litre) ................................................................................................................................................................... 3.1
COOLING SYSTEM
Cooling fan .......................................................................................................................................................... Diameter: 330 mm, 7 blades
Drive ....................................................................................................................................................................................... Belt
Pulley ratio ............................................................................................................................................. Crankshaft pulley/fan pulley: 101/78 = 1.29
AIR SYSTEM
Type ............................................................................................................................................................................. Natural aspiration
Air cleaner ..................................................................................................................................................................... Single element
ELECTRICAL SYSTEM
Alternator ................................................................................................................................................................................ 40 A
Starter motor ........................................................................................................................................................................ 1.4 kW
Starting aid ....................................................................................................................................................................... Glow plugs
19
TIMING
Valve timing
Inlet open .................................................................................................................................................... BTCD 10°
close .................................................................................................................................................... ABDC 46°
Exhaust open .................................................................................................................................................... BBDC 46°
close .................................................................................................................................................... ATDC 10°
Valve clearance (mm) ............................................................................................................................................................. 0.25
Fuel injection timing ......................................................................................................................................................... BTDC 19°
Nozzle opening pressure (kgf/cm2) ....................................................................................................................................... 120
Thermostat close (°C) ................................................................................................................................................. 76.5

open (°C) ................................................................................................................................................... 90
2. TIGHTENING TORQUE OF MAJOR FASTENERS (kgf·m)
Cylinder head Cylinder head bolts ................................................................. 5.5 – 6.5

Rocker shaft holder ................................................................ 1.9 ±0.5
Injection nozzles ..................................................................... 4.5 ±0.5
Glow plugs ............................................................................. 1.75 ±0.25
Cylinder block Bearing caps ........................................................................... 5.0 ±0.5

Oil pan .................................................................................... 0.8
Crankshaft Connecting rod bearing caps .................................................. 3.0 ±0.3

Flywheel ................................................................................. 9.5 ±1.0
Crankshaft pulley ................................................................... 18.5 ±1.9
Timing gear case Gear case ................................................................................ 1.9 ±0.5
Others Inlet/Exhaust manifold ........................................................... 1.9 ±0.5

Fan .......................................................................................... 0.8 ±0.2
Starter motor ........................................................................... 8.4 ±0.8
1.9 ±0.5 kgf·m

1.75 ±0.25 kgf·m
5.5 — 6.5 kgf·m
4.5 ±0.5 kgf·m

1.9 ±0.5 kgf·m
0.8 ±0.2
0.2 kgf·m
9.5 ±1
1 kgf·m
1.9 ±0.5 kgf·m
8.4 ±0.8 kgf·m

3.0±0.3 kgf·m
18.9 ±1.9 kgf·m
3.0 ±0.3 kgf·m

5.0±0.5 kgf·m 0.8 kgf·m
Fig. 3-1
20
AND ACCESSORIES
3. RADIATOR 3.3. INSPECTION
3.1. CONSTRUCTION (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.
a. Leak test with compressed air
Air hose
Air bubbles Pressure
Plug gauge
Plug
Leaking
portions
Compressor
Overflow pipe
Radiator Water basin
Fig. 3-2 Fig. 3-3
3.2. REMOVAL AND RE-INSTALLATION

Note:
Remove and re-install the radiator in accordance Never allow the test pressure to exceed 1 kgf/cm2
with the instructions in CHAPTER 2. (14.2 psi).
Note: b. Leak test with a radiator cap tester

- Coolant should be replaced if it becomes con-
taminated with rust or sludge. Testing pressure 1.0 kgf/cm2 (14.2 psi)
- Before adding new coolant, flush the inside of
radiator and engine block with clean water.
Precautions for filling antifreeze
- As concerns the mixing ratio of antifreeze, fol-

low its manufacturer’s instructions.
- Antifreeze should be blended well with water
before filling.
- When the coolant level is lowered due to evapo-
ration, maintain the level by adding water, not Fig. 3-4
by using antifreeze solution.
- When the coolant level is lowered due to leaks,
maintain the level by adding an antifreeze solu-
tion of the same mixing ratio.
- As antifreeze corrodes paint, take care not to
spill it on painted parts.
21
(2) Inspection for radiator clogging Re-tighten loose hose clamps securely if water is
leaking through the hose clamps, or replace them
a. Cleaning the inside of radiator if necessary.
4. COOLING FAN AND BELT
Lower tank
4.1. Specifications
Cooling fan ........................................... 330 mm, 7 blades

Drive ................................................................ Belt
Radiator cores Pulley ratio .................................... Crankshaft pulley/fan pully:
101/78 = 1.29
Upper tank 4.2. Adjustment of belt
To adjust belt tension, loosen the alternator pivot

Fig. 3-5 bolt and nut and tensioning bracket bolt. Pull
outward on top of the alternator to correctly ten-
– Cleaning with a detergent sion belt and tighten the bolt first and then tighten
the pivot bolt.
b. Cleaning the radiator exterior
Note:
– Cleaning the net (wire mesh) Do not pry against the alternator housing or pul-
ley. Only pry against the alternator mounting
After the tractor has been operated in dusty con- flange carefully to prevent damage.
ditions, check the net daily and clean it if neces-
sary.
– Cleaning the radiator cores
Clean the radiator cores by applying water spray

or compressed air so as to form a right angle with
the radiator cores, applying moving water in a X
parallel direction.
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 cool-
ing fins.
Fig. 3-6
(3) Visual inspection of the exterior parts
Belt deflection at X point ........................... 8 – 10 mm
When the radiator exterior is corroded, cracked,
or badly damaged and the radiator core fins are
crushed or damaged, replace the radiator. Also
replace damaged or fatigued water hoses.
22
AND ACCESSORIES
5. AIR-CLEANER i. Prepare solution of warm water and non-
foaming detergent .
5.1. Removal and re-installation ii. Soak the element for thirty minutes.
iii. Agitate the element in solution until oil and
Release clips and uncover. Remove the element. soot are loosened.
Examine the element and seals for damage and iv. Rinse the element until rinse water becomes
brittleness. If the element is damaged in any way clear.
it must be replaced. v. Allow the element to completely dry. Do not
Re-install in reverse order of removal and clip dry by using compressed air or heat.
securely.
– After cleaning (or washing) the element exam-
ine for pin holes, punctures, or tears. If the
element paper, canister or seal show any signs
of physical damage, the element must be re-
placed.
Note:
Replace an element which has already been
washed five times.
Fig. 3-7
5.2. Inspection
– Inspect the air cleaner visually for cracks, de-

formation or other damage. Repair damage if
possible, or replace it.
– Check the rubber packing at each joint, rubber
pipes, and the evacuator valve. Fig. 3-8
– Inspect the paper element.
5.3. Cleaning the element
Element may be cleaned (if in serviceable condi-

tion) using following procedures:
– Using compressed air not to exceed 200 kPa,

remove loose dirt, grass, chaff, etc. from the
inside of element. Be careful not to damage
element pleats with air flow.
– If the element is coated with oil or soot:
23
6. FUEL SYSTEM – Inspect the filter element, sediment bowl and

O-ring (3)
6.1. Fuel system diagram – Examine the small O-ring in the filter head and
replace as necessary.
6.4. Air-bleeding
Procedure
a. Fill the fuel tank.

b. Turn the fuel cock (1) to “OPEN.”
ON
c. Loosen the air-bleeding screw (2) and let air
bubbles out.
d. Loosen the air-bleeding screw (3) of the fuel
injection pump and let air bubbles out of the
pump.
Fig. 3-9 CAUTION: Fuel emitted from loosened injection

lines is under high pressure. Keep hands and face
6.2. Inspection away when the engine is cranked. Clean all spilled
fuel following air-bleeding procedure(s).
Use only clean diesel fuel of correct grade. Intro-
duction of water or dirt into the fuel tank or other
part of the fuel system can cause repeated plug-
ging of the fuel filter and possible injection pump
and injector damage.
3
6.3. Fuel filter
To replace the fuel filter element or clean sedi- 2

ment, turn the fuel valve to the OFF position
(top).
Fig. 3-11
3 5
2
1
Fig. 3-10
24
AND ACCESSORIES
7. TROUBLESHOOTING
Problems Causes Countermeasures
(1) Overheating 1) Low coolant level Replenish coolant and inspect for water
leaks.
2) Fatigued pressure valve springs Replace radiator cap.
3) Loose or broken fan belt Adjust belt tension or replace.
4) Oily fan belt Replace.
5) Faulty thermostat Replace.
6) Faulty water pump or water leaks Repair or replace.
7) Clogged water passages Clean radiator and water passages.
8) Improper injection timing Adjust injection timing.
9) Clogged air passages Clean radiator exterior.
10) Fuel gas enters water jacket due to Inspect cylinder head and replace
broken cylinder gasket. cylinder gasket.
(2) Over-cooling 1) Faulty thermostat Replace.

2) Excessive low atmospheric Decrease radiator working area by
temperature radiator masking.
(3) Loss of coolant 1) Leaking radiator Repair or replace.

2) Loosely clamped or broken water Re-tighten or replace.
hose
3) Fatigued pressure valve spring Replace radiator cap.
4) Leaking water pump Repair or replace.
5) Water leakage through cylinder Inspect cylinder head and replace gasket.
head gasket
6) Cracked cylinder head or body Replace.
(4) Noisy cooling fan 1) Faulty water pump bearing Replace.

2) Loose or bent fan Re-tighten or replace.
3) Unbalanced fan Replace.
4) Faulty fan belt Replace.
25
26
CHAPTER 4: CLUTCH SYSTEM
CHAPTER 4. CLUTCH SYSTEM
1. CONSTRUCTION a Ø184
b Ø127
c Ø240
d* 3 ±1.0
e 7.8 ±0.3
*Difference in lever height from each
other should be within 1.0 mm.
a
b
c
e
d
Fig. 4-1
2. DISASSEMBLY
(1) Seperate the clutch housing from the engine, referring to 2 of Chapter 2.
(2) Remove the clutch assembly from the flywheel.
Note:
• When loosening tightening bolts, loosen them gradually in diagonal order.
• Be careful to keep the clutch disc facings from oil.
Reference:
• Two reamer bolts are used to determine the installed position of the clutch housing.
27
3. INSPECTION c. Hardened lining surfaces must be repaired by use

of sandpaper, or be replaced with new ones.
(1) Inspection of clutch disc
d. When loose rivets are found, replace the clutch
Check the clutch disc for wear or cracks on the disc assembly because those rivets will loosen
facing, loose rivets, broken torsion springs, or again even if they are re-tightened.
wear of the hub splines.
e. Install the disc on the input gear and inspect the
a. Measure the depression of the rivets. If the rotational play. If the measurement deviates from
depression is 0.2 mm or less and cracks or burnt the specified value, replace the disc.
damage are found on the surface, the disc must be
replaced. Usable limit
Rotational play of
0.3 mm
the hub spline
Usable limit (0.012 in.)
Rivet depression
0.2 mm (0.008 in.)
f. Measure the deviations of the clutch disc. If the
measurements are beyond the usable limits,
replace the clutch disc assembly.
Revet
depression
Usable limit
Surface deviation 0.4 mm (0.016 in.) or less
Lateral run-out 1.0 mm (0.039 in.) or less
Vertical run-out 1.0 mm (0.039 in.) or less
Clutch disc
Dial gauge
Fig. 4-2
Note:
Be sure to replace any clutch disc which has 0.2 Fig. 4-3
mm or less in rivet depression. Use of a disc with
insufficient rivet depression will result in serious g. Standard thickness and usable limit of the clutch
damage to the flywheel and the pressure plate. disc are as shown in the table below. A disc
assembly whose thickness is or will be less than
b. Any oil-stained clutch disc must be replaced. the usable limit in a short period of use should be
However, slight oil stain may simply be removed replaced with a new one.
by use of a volatile solvent.
Standard value Usable limit*
Note: 7.8±0.3 mm 6.6 mm (0.260 in.)
The causes of oil stains must be located and nec- (0.307±0.012 in.)
essary corrective measures must be taken. 8.3±0.3 mm 7.0 mm (0.276 in.)
(0.327±0.012 in.)
*Rivet depression should be more than 0.2 mm (0.008 in.).
28
b. Check the clutch cover and diaphragm springs for

distortion, deformation, loss of tension, and dam-
age. If any defective parts are found, replace the
clutch cover assembly.
(3) Inspection of release bearing
The release bearing is a lubrication-free type, so

it should never be washed in cleansing oil. Wipe
it clean with a cloth and check its smoothness by
turning it manually. Replace a defective bearing.
Fig. 4-4 4. PRECAUTIONS FOR RE-ASSEMBLY

h. Check damper springs for damage and fatigue. A Reassemble in reverse order of disassembly, fol-
defective one should be replaced with a new one. lowing the next precautions.
Usable limit (1) Keep oil from getting on the clutch disc, pressure
Damper spring play
1.5 mm (0.06 in.) plate, and flywheel.
(2) Inspection of clutch cover assembly (2) Install the clutch disc with the longer spline boss
turned towards the transmission.
a. Check the pressure plate’s friction surface for defor-
mation, scratches, stepped wear, and oil stain. If it is (3) When installing the clutch assembly on the fly-
defective, replace the clutch cover assembly. wheel, align the clutch and the flywheel using the
clutch centering tool. Then tighten the clutch on
Flatness of pressure plate surface: the flywheel to the specified torque.
Standard value Usable limit Tightening torque 1.5–2.2 kgf·m

less than 0.05 mm 0.5 mm (0.06 in.) (11–16 ft.lbs)
(0.002 in.)
Note:
First align the clutch with the flywheel using the
two reamer bolts. Then install other bolts and tight-
en them evenly to the specified torque.
Fig. 4-5
Fig. 4-6
29
(4) Tighten yoke set bolt securely with adhesive

applied.
(5) Apply a thin coat of molybdenum disulphide-

based grease to the spline parts of the input shaft
and clutch disc in advance.
(6) Pack the inside of the sleeve with grease and

apply grease to the outer circumference of the
sleeve guide in advance. After installation, make
sure they slide smoothly.
Use a heat-resistant grease.
(7) Apply an even coat of adhesive (THREE BOND

TB1215) to the contact surfaces of the engine rear Fig. 4-8
plate and clutch housing before assembling them.
(8) Adjust the free play of the clutch pedal “A” to be 20

to 30 mm at the pedal top by adjusting the clutch
rod.
Clutch pedal free play “A” 20 – 30 mm

(at pedal top) (0.8 – 1.2 in.)
Fig. 4-7
30
5. TROUBLESHOOTING
1. PROBLEM: Clutch slippage
The initial stage of clutch slippage is very hard to detect, but the following suspect symptoms are
noticeable.
(1) The tractor is not generating adequate power when performing heavy duty operations.
(2) Output is not commensurate with increase 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 seizures.
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.
Probable causes Countermeasures
a. No play in the release bearing Adjust.
b. Broken or fatigued diaphragm spring Replace.
c. Excessive wear of clutch facing Replace.
d. Oil stained or hardened clutch facing Repair or replace.
e. Deviation of flywheel or pressure plate Repair or replace.
2. PROBLEM: Poor disengaging
When the clutch does not disengage properly, the transmission gears are noisy when shifted, or shifting or
the gears is difficult.
31
32
Fig. 5-1
23T
20T
ENGINE
32T 33T 1.1. POWER TRAIN

CLUTCH 25T
19T
15T 14T
1. GEAR-TYPE TRANSMISSION
11T 58T
33T 34T
30T
24T
20T
17T 16T 42T
7T
33
33T
30T
26T
21T 20T
18T
8T 19T
11T
15T
19T
PTO
34T
12T
47T
CHAPTER 5. TRANSMISSION
15T
MID-PTO
CHAPTER 5: TRANSMISSION
a. Speed shifting steps of rear wheel driving gears
Gear combinations
Preliminary Transmission Main shift Final reduction Reduction

reduction range ratio
Forward 15/33 L 14/34 1st 17/32 7/42✻11/58 0.00314

2nd 24/25 0.00568
3rd 30/19 0.00934
H 33/16 1st 17/32 0.01574

2nd 24/25 0.02845
3rd 30/19 0.04679
Reverse 15/33 L 14/34 1st 24/23✻20/32 0.00386

H 33/16 1st 24/23✻20/32 0.01933
b. Speed shifting steps of front wheel driving gears
Gear combinations
Preliminary Transmission Main shift Final reduction Reduction

reduction range ratio
Forward 15/33 L 14/34 1st 17/32 20/30✻8/21✻ 0.00473

2nd 24/25 11/15✻12/47 0.00854
3rd 30/19 0.01405
H 33/16 1st 17/32 0.02368

2nd 24/25 0.04280
3rd 30/19 0.07039
Reverse 15/33 L 14/34 1st 24/23✻20/32 0.00580

H 33/16 1st 24/23✻20/32 0.02907
c. Final reduction ratio of front wheel shaft and rear wheel shaft
Front: Rear = 1 : 0.6647
34
1.2. CONSTRUCTION
Fig. 5-2
1.3. DISASSEMBLY
(1) Separate the clutch housing from the front trans- (7) Remove the input gear.
mission case referring to 4 of Chapter 2.
(8) Remove the reverse shaft and take out the reverse
Note: gear.
In the following operations, the directions in which
the thrust collars are installed should be memo- (9) Remove the drive pinion and take out the assem-
rized or written down. bly of the 4WD change gear, range shift counter
gear and main shift counter gear along with relat-
(2) Separate the transmission case from the rear ed parts.
transmission case referring to 7 of Chapter 2.
(10) Remove the PTO shaft and take out the PTO
(3) Remove the input shaft along with the spline change gears, mid-PTO counter gear and related
boss. parts.
(4) Remove the input metal (support). (11) Remove the shifter and shifter stay.
(5) Remove the 4WD output gear.
(6) Remove the change shaft and take out the main
and range shift gears.
35
Fig. 5-3
1.4. INSPECTION
(1) Check each gear and shaft for damage, tooth (2) Before installing the PTO drive shaft, set the PTO
bearing, etc. change gear to the shifter.
(2) Make sure that all radial roller bearings and (3) After assembly, make sure that each shift lever
needle roller bearings turn smoothly and have no moves smoothly.
flaws.
Operating load
(3) Make sure that the oil seal lips and lip contact at lever top
surfaces on shafts have no flaws.
4WD shift lever 6 kgf
1.5. PRECAUTIONS FOR RE-ASSEMBLY
PTO shift lever 4 kgf
(1) When assembling, pay attention to the installing
direction of the gears, collars, etc. Never forget to
install bearings and collars.
36
Fig. 5-4
HST
2.1. POWER TRAIN
19T
ENGINE CLUTCH 29T

2. HST TRANSMISSION
19T
35T
17T 11T 58T
25T
19T
18T
7T
19T
32T 42T
PTO
37
29T
18T 19T
24T
30T 30T
21T 17T
8T 34T
11T
15T
12T
47T 15T
MID-PTO
a. Speed shifting steps of rear wheel driving gears
Gear combinations
HST Preliminary Transmission Final reduction Reduction

efficiency reduction range ratio
Forward 0.92 19/17 L 19/29 7/42✻11/58 0.02129

H 29/19 0.04961
Reverse 0.65 19/17 L 19/29 0.01504

H 29/19 0.03505
b. Speed shifting steps of front wheel driving gears
Gear combinations
HST Preliminary Transmission Final reduction Reduction

efficiency reduction range ratio
Forward 0.92 19/17 L 19/29 19/30✻18/17✻8/21 0.03222

H 29/19 ✻11/15✻12/47 0.07507
Reverse 0.65 19/17 L 19/29 0.02277

H 29/19 0.05304
c. Final reduction ratio of front wheel shaft and rear wheel shaft
Front: Rear = 1 : 0.6608
38
2.2. CONSTRUCTION
Fig. 5-5
2.3. DISASSEMBLY
(1) Separate the clutch housing from the front (7) Remove the input gear.
transmission case referring 4 of Chapter 2.
(8) Remove the reverse shaft and take out the reverse
Note: gear.
In the following operations, the directions in which
the thrust collars are installed should be memo- (9) Remove the drive pinion and take out the
rized or written down. assembly of the 4WD change gear, range shift
counter gear and main shift counter gear along
(2) Separate the transmission case from the rear with related parts.
(10) Remove the PTO shaft and take out the PTO
(3) Remove the input shaft along with the spline change gears, mid-PTO counter gear and related
boss. parts.
(4) Remove the input metal (support). (11) Remove the shifter and shifter stay.
(5) Remove the 4WD output gear.
(6) Remove the change shaft and take out the main
and range shift gears.
39
2.4. INSPECTION
Fig. 5-6 direction of the gears, collars, etc. Never forget to

install bearings and collars.
(1) Check each gear and shaft for damage, tooth
bearing, etc. (2) Before installing the PTO drive shaft, set the PTO
change gear to the shifter.
(2) Make sure that all radial roller bearings and
needle roller bearings turn smoothly and have no (3) After assembly, make sure that each shift lever
flaws. moves smoothly.
(3) Make sure that the oil seal lips and lip contact Operating load
surfaces on shafts have no flaws. at lever top
4WD shift lever 6 kgf

2.5. PRECAUTIONS FOR RE-ASSEMBLY
PTO shift lever 4 kgf
40
3. MID-PTO
3.3. INSPECTION
(1) Check each gear and shaft for damage, tooth

bearing, etc.
Fig. 5-7 (2) Check to see that each bearing turns smoothly
without hitching.
3.1. CONSTRUCTION
(3) Make sure that the oil seal lips and lip contact
(1) Separate the mid-PTO assembly from the front surfaces on respective shafts have no flaws.
3.4. PRECAUTION FOR RE-ASSEMBLY
(2) Remove the wire and roll pin.
(3) Remove the countershaft and take out the counter direction of the gears, collars, etc. Never forget to
gear and related parts. install bearings and collars.
(4) Remove the cap and snap ring. (2) After assembly, make sure that each shift lever
moves smoothly.
(5) Remove the shaft assembly rearward.
Operating load
(6) Remove the mid-PTO lever assembly from the at lever top
4WD lever. Gear HST
PTO shift lever transmission transmission
11 kgf 6 kgf
41
42
CHAPTER 6: REAR AXLE AND BRAKES
CHAPTER 6. REAR AXLE AND BRAKES
1. GENERAL DESCRIPTION
The rear axle system is of the central axle type, which contains the final reduction gears, differential gears, dif-
lock, and brakes.
The power from the engine is transmitted to the right and left wheel pinions through the differential gears, and
to the rear wheels.
A inner shoe-expansion, mechanically-operated brake system has been adopted, which can produce superior
braking force with excellent durability. It is a dry-type of simple construction, so it is very easy to service.
The dif-lock mechanism which is housed in the right-hand rear axle housing can lock the differential gears by
depressing the dif-lock pedal while equalizing the rotational speeds of both wheels.
Fig. 6-1
43
2. CONSTRUCTION
14
A 13
12
10 9
29
6
5
4
3 2 28
27
Dif-lock pedal 8 7
(Mechanical 15 26
3
transmission models) 11
4 25
A
A
Dif-lock lever
(HST models)
18
19
44
A
17
16
1 20
(1) & (2) Bevel pinion set (Dif- (15) Wheel pinion (11T, RH)
pinion gear & dif-ring (16) Wheel pinion (11T, LH)
gear) (17) Wheel gear (58T)
(3) Dif-pinion (12T) (18) Shims
(4) Pinion thrust collar (19) Dif-case metal (LH)
(5) Dif-side gear (14T) (20) Oil seal (TC0458)
(6) Thrust collar (21) Snap ring
(7) Pinion shaft holder (22) Oil seal (QLE488011.5)
(8) Differential case (23) Wheel shaft
(9) Dif-pinion shaft (24) PTO drive shaft 21
(10) Dif-lock shift fork (25) Washer (20 × 28 × 2) 22
(11) Dif-lock clutch (26) Sleeve 23
(12) Shifter stay (27) PTO shaft
(13) Dif-lock cam (28) Seal ring
(14) O-ring (P10A) (29) Oil seal (TC355558)
Fig. 6-2
3. REAR AXLE HOUSING AND DIFFERENTIAL GEARS
3.1. DISASSEMBLY i. As drive pinion and ring gear make a pair, take
care not to interchange either of them with one
REAR AXLE HOUSING of other pairs.
ii. Adjust the backlash to be 0.2 to 0.25 mm by
a. Drain the transmission oil. shimming
b. Remove the PTO shield cover.
c. Remove the cylinder case referring to Chapter 2- Standard shimming thickness 0.4 mm
5.
d. Remove the PTO metal and PTO shaft assembly. iii. After adjustment, tap the outer circumference
e. Remove the rear axle housing referring to Chap- with a copper hammer and make sure that the
ter 2-9. backlash does not change. Check backlash at
four points 90 degrees apart from each other.
DIFFERENTIAL GEARS
b. After reassembling, each gear and related part
f. Remove the right and left dif-case metal. should move smoothly.
Note:
When the dif-case metal is too tightly fit into the
rear transmission case to be removed manually,
use push bolts. The push bolts should be screwed
in evenly and gradually.
g. Remove the differential assembly.
h. Remove the bearings from both sides of the dif-
ferential assembly.
i. The differential assembly can be disassembled by
removing the dif-pinion shaft.
Note: Fig. 6-3
The lock pin should be removed ahead of time.
3.2. INSPECTION
a. Check each gear and shaft for damage, tooth

bearing, etc.
b. Check the bevel pinion for the differential and
pinion thrust collar for wear.
c. Check to see that each bearing turns smoothly
without hitching.
d. Make sure that the oil seal lips and lip contact
surfaces on shafts have no flaws.
3.3. PRECAUTIONS FOR RE-ASSEMBLY AND

ADJUSTMENT
a. Backlash adjustment between the drive pinion

and ring gear
45
TOOTH BEARINGS
Correct bearing When the drive pinion and the ring gear are meshed correctly with each
Inner circumference other, and their backlash is within the specified range (0.1 - 0.2 mm), the
bearing trace is positioned at the middle of the ring gear tooth and is
approximately three fourths of the total tooth width.
Outer circumference
Face bearing This shows that the drive pinion and the ring gear are meshed too shallowly
and their backlash is too large. This will result in rapid wearing of the
tooth top.
This bearing must be repaired by shifting some the left dif-case metal
shims to the left side.
Flank bearing This shows too deep a meshing of the drive pinion and the ring gear and
too small a backlash. This will cause stepped tooth wear. Repair this in
the reverse way of repairing the face bearing.
46
4. BRAKES
4.1. SPECIFICATIONS
Type Dry, inner-shoe expansion, mechanically operated
Brake drum Diameter Ø114 mm (Ø4.49 inches)
Lining width 30 mm (1.18 inches)
Free play of brake pedals 30 – 40 mm (1.18 – 1.57 inches)
4.2. CONSTRUCTION
Fig. 6-4
47
4.3. DISASSEMBLY
1
2
3
4
5
6
8
(1) Brake drum (7) Brake cover

(2) Snap ring (for shaft) (8) Brake cam comp.
(3) Brake shoe (9) Wheel pinion
(4) Tension spring
(5) Snap ring (for shaft)
(6) O-ring
Fig. 6-5
Disassembly of the brake system is possible b. Remove the snap ring and take out the brake
without separating the rear axle housing from the drum. Then extract the wheel pinion.
rear transmission case.
a. Remove the brake cover and detach the brake

shoes from the brake cam.
48
4.4. INSPECTION 4.6. BRAKE ADJUSTMENT
a. The usable limit of the brake shoe thickness is 2.2 Correct free-play A of each individual brake
mm (0.087 in.) at the middle. pedal is 20 to 30 mm (7/8" to 1-1/8").
Usable limit 2.2 mm (0.087 in.) Note:

• Through use, free-play will increase and brake bal-
ance will be affected. Adjust and balance brakes
before free-play becomes excessive.
•• HST models do not have individual wheel brakes.
A
Fig. 6-6
Fig. 6-8
b. Check the brake drum for damage such as
abnormal wear, cracks, etc., and replace when PARKING BRAKES
defective.
When above adjustment is completed, check
4.5. PRECAUTIONS FOR REASSEMBLY operation of parking brakes. Depress the pedal
fully and apply parking brakes. It should have
Reassemble in reverse order of disassembly, keep- brakes locked with lever approximately in center
ing the following precautions. of travel. If not, adjust the lock nuts (A) correctly.
Make sure lock nuts are secured when brake
a. The brake shoes and inner surface of the brake adjustment is completed.
drum should be free from oil or dust.
b. Apply heat-resistant grease to the points indicated

in Fig. 6-7.
Mechanical transmission models
A
Apply grease.
HST models
Fig. 6-7
49
5. TROUBLESHOOTING
Insufficient braking force • Poorly adjusted pedal play Readjust.
• Oil leaks in brake chamber Repair or replace.
• Worn or seized lining Replace lining.
Overheated brakes • Excessive pedal play Readjust.
• Poorly centred shoes Readjust.
• Improper brake operation Operate brakes properly.
Unbalanced braking • Improperly adjusted pedal play Readjust.
• Oil leaks in brake chamber Repair.
• Linings on one brake are worn or seized. Replace linings.
Brake pedals do not • Broken return springs Replace.

return smoothly.
• Poorly lubricated moving parts Remove rust and lubricate
properly.
Abnormal noise • Worn or damaged bearings Replace.
• Worn or damaged parts like wheel gears, Replace.

wheel pinions, wheel shafts, etc.
50
CHAPTER 7: MANUAL STEERING SYSTEM
CHAPTER 7. MANUAL STEERING SYSTEM
§1. CONSTRUCTION
The steering system is a mechanical ball-screw type.
It is constructed as illustrated and functions as shown in the diagram.
Steering wheel
Steering
wheel shaft
Ball screw
Knuckle Pitman arm

spindles Steering wheel shaft
Drag arm Drag rod
Tie rod
Knuckle arm
Steering wheel column
Fig. 7-1
Lock nut Thrust ball bearing
Adjust nut Ball screw
Worm sector
Pitman arm
Grease filling
Fig. 7-2 Drag rod
51
§2. DISASSEMBLY, INSPECTION, AND REASSEMBLY
1. DISASSEMBLY
(1) Draw out the Pitman arm with a puller.
Note:
Make sure that aligning marks are applied to
both sector shaft and Pitman arm. If they are not,
apply them before disassembly.
Aligning marks Sector shaft
Fig. 7-5
(5) Shift the sector shaft to the neutral (straight trav-

elling) position by turning the worm and pull off
Pitman arm
the sector shaft.
Fig. 7-3
(2) Drain the gear box of oil through the filler by

removing the plug.
(3) Remove the lock nut for the adjusting screw and
then remove the bolts which tighten the side cov-
er.
Fig. 7-6
(6) Remove the bolts which tighten the rear cover

and take out the rear cover and shims. Then draw
out the ball-nut assembly.
Fig. 7-4
(4) Hold the side cover to prevent it from turning and

remove the side cover by turning the adjusting
screw clockwise.
Fig. 7-7
52
Note: Therefore it must always be kept level.

• Never put the ball-nut assembly upright. If this is • Never disassemble the ball-nut assembly.
done, the ball-nut slides down by its own weight
and hits the disappearing end of the worm screw (7) Removal of the bearings and seals from the gear
groove, which leads to damage of the ball-tube. box, cover, etc., should be done only if required.
2. INSPECTION
Wash disassembled parts in fresh light oil or cleansing oil and then inspect them carefully following the
next criteria.
Part names Inspection items Criteria for

part replacement
Ball nut assembly Ball-nut performance If its starting torque exceeds 0.5 kgf·m
(3.6 ft·lbs) even after washing it
clean, or if it does not work smoothly,
replace the assembly.
Ball groove of worm If it is damaged by dents or exfoliation,

Deformed ball tube or tube clamps If the starting torque is more than
0.5 kgf·m (3.6 ft·lbs), replace the
assembly.
Loose tube clamps or tightening Tighten them to 15 – 25 kgf·cm

screws (1.1 – 1.8 ft·lbs).
Thrust play of ball-nut If the play exceeds 0.1 mm (0.004 in.),

Sector shaft Cracks, deformation, wear, etc. Replace a defective shaft.
Distorted serrations Replace the shaft.
Clearance between T-groove and If the clearance exceeds 0.15 mm

shims (0.006 in.) replace the shaft.
(5 kinds of shims are available.)
Bearings Dented or exfoliated racing surfaces
Dents caused by the balls or rollers Replace any bearings which have
suffered such damage.
Cracks or exfoliation
Deformed cages
Other parts Cracks, deformation, and other Replace any parts which have suffered
damage. such damage.
53
Note: starting torque of the system should be adjusted

Be sure to replace the following parts as an to a specified level by shimming.
assembly.
Starting torque 2 – 5 kgf·cm
• Ball-nut assembly (0.14 – 0.36 ft·lbs)
The worm, ball-nut, and balls are adjusted
Note:
exclusively as an assembly. Therefore none of the
• Five kinds of shims in thickness are available [mm
components can be replaced as an independent
(in.)]:
part.
0.05, 0.07, 0.08, 0.10, 0.20 (0.0020, 0.0028,
0.0031, 0.0039, 0.0079)(5 kinds)
• Gear box assembly and side cover assembly
• Increasing or decreasing rate of starting torque
The assemblies which have roll bushes should be
by shimming:
replaced as an assembly.
Starting torque increases or decreases about 0.01
kgf·m (0.072 ft·lbs) by an increment of 0.01 mm
3. REASSEMBLY AND ADJUSTMENT
(0.0004 in.) of shimming.
• Start adjusting the starting torque with a thicker
All disassembled parts should be washed clean
shim. Then try thinner shims until the proper torque
and all seals should be coated with grease in
is obtained.
advance.
• The bearings are pre-loaded, so turn the steering
shaft several time before measuring the starting
(1) When the bearings for the worm have been
torque.
removed, install their outer races into the gear
box and rear cover respectively.
(5) After the shimming adjustment, tighten the rear
cover to the specified torque.
Fig. 7-8
(2) When the oil seal has been removed, install it into Fig. 7-9
the gear box.
Tightening torque 1.7 – 2.8 kgf·m
(3) Install the ball-nut assembly with the bearings (12.3 – 20.3 ft·lbs)
into the gear box. The bearings and ball-nut
(6) Set the adjusting screw and a shim into the T-
should be coated with sufficient grease in
groove in the sector shaft end. And adjust the
advance.
clearance to be less than 0.05 mm (0.002 in.) by
trying the following shims.
(4) Install the shims and then the rear cover. Here
54
Tightening torque 1.7 – 2.8 kgf·m

(12.3 – 20.3 ft·lbs)
(9) Install the Pitman arm on the sector shaft by

matching the aligning marks and tighten them to
the specified torque. Then adjust the backlash
with the adjusting screw at top of the Pitman arm.
Fig. 7-10
Five kinds of shims are available [mm (in.)]:
1 2
+0.035 (0.0014) +0.065 (0.0037)
+0.015 (0.0006) +0.045 (0.0018)
1.5 (0.059) 1.5 (0.059)
3 4
+0.095 (0.0037) +0.125 (0.0049)
+0.075 (0.0030) +0.105 (0.0041)
1.5 (0.059) 1.5 (0.059)
5
+0.155 (0.0061)
+0.135 (0.0053) Fig. 7-12
1.5 (0.059)
Tightening torque 14 – 18 kgf·m
(101 – 130 ft·lbs)
(7) Set the ball nut midway on the worm and insert
the sector shaft into the gear box. Backlash at top of 0.5/190 or less
Pitman arm
Note:
Be sure to engage the rack and gear correctly. One (10) Secure the adjusting screw with the lock nut.
tooth shift is the most common mistake.
(8) Apply adhesive to the side cover packing in

advance. Tighten the side cover to the specified
torque. (Refer to Fig. 7-11.)
Fig. 7-13
Lock nut tightening 3.0 – 4.0 kgf·m

torque (0.18 – 0.69 ft·lbs)
Fig. 7-11
55
11) After reassembly, check the following items. b. Steering starting torque when assembled
completely:
a. Steering shaft’s starting torque in the neutral
(straight travelling) position and with the sector Starting torque 12.5 kgf·cm (0.90 ft·lbs) or less
shaft installed:
c. Working angles of sector shaft
Starting torque 2.5 – 9.5 kgf·cm
(0.18 – 0.69 ft·lbs) Working angles 38° each in both directions
4. TROUBLESHOOTING
Symptoms Presumable causes Countermeasures
Steering wheel is • Poor ball-nut assembly Wash ball-nut assembly or

heavy to turn. replace.
(when heavy
throughout whole • Poor bearings Reassemble them. (Poor shimming or
operation) improper assembling is presumable.)
• Other abnormal friction parts Replace.
System is noisy. Insufficient lubrication Lubricate each friction part.
Steering wheel Broken or deformed parts

cannot be turned.
• Broken ball-nut assembly
• Broken sector shaft Replace broken ones.
• Broken bearings
• Other broken parts
Free play of steering • Poorly adjusted adjusting screw Adjust it properly.

wheel is excessive.
• Worn ball-nut assembly Replace it.
Hitched steering • Deformed covers Replace a defective one.

wheel operation
(when it becomes • Poorly assembled Reassemble.
heavy at a specified
point or points)
Insufficient steering Poorly assembled (misalignment Reassemble.

angles (sector shaft) between sector gear and ball-nut)
Oil leaks Deformed or damaged parts Replace a damaged cover.

Replace damaged seals like packings,
O-rings, Oil seals, etc.
Or wash, apply liquid packing
to contacting surfaces, and reassemble.
Others Damaged parts Replace.
56
CHAPTER 8: FRONT AXLE
CHAPTER 8. FRONT AXLE
§1CONSTRUCTION
1. SECTIONAL VIEWS
FRONT AXLE (Front view)
FRONT WHEEL DRIVE (Side view)
Fig. 8-1
57
2. MAJOR COMPONENTS
22
23
27 25
24
26
31
29 28
30 1
4
2
30
3
29
31
18
19
5
21
17
6
58
7
32 16
HST type
8 20
9 10
(1) O-ring (P71)

(2) Rear pivot metal (support) 33 14
(3) Bush (62x67x30) 15
(4) O-ring (G70)
(5) Axle housing
(6) Oil seal (20) Oil seal 34
(7) Bush (35x39x26) (21) Bush (20x38x26)
(8) Front pivot metal (support) (22) Oil seal (21)
(23) Snap ring (52C) 11
(9) Final case (A)
(10) Final case (B) (24) Collar (48x52x17)
(25) Snap ring (52C) 12
(11) Wheel cover
(12) Seal (QLNY35571116) (26) Collar (25x32x3) 13
(13) Front wheel shaft (27) Bevel pinion set
(14) Knuckle arm (28) Front differential case
(15) Tie-rod (29) Bevel gear (15)
(16) Drag rod (Manual steering) (30) Bevel pinion (11)
(17) Plate (31) Washer
(18) Bearing unit (32) O-ring (G90)
Fig. 8-2 (33) Oil seal
(19) Joint B assembly
(34) Bevel gear (47T)
§2. DISASSEMBLY
1. FRONT AXLE AND DIFFERENTIAL GEARS
22
23
24
25
26
27
31
29 28
30
30
29
31
Fig. 8-3
(1) Remove the steering cylinder (power-assisted steering models), drag rod (manual steering models) and
tie-rod.
(2) Remove the final case assembly from the front axle end.
(3) Separate the front axle from the front axle bracket.
(4) Remove the drive pinion.
(5) Remove the differential assembly, left to right.
59
2. FINAL CASE AND RELATED PARTS
DISASSEMBLY OF THE FINAL CASE ASSEMBLY
(1) Remove the knuckle arm.
(2) Divide the final case assembly into the final case (A) and final case (B).
14
32
10
34
11
33
Fig. 8-4
§3. INSPECTION
(1) Check the gears for damage and tooth bearing. surfaces of the shafts for damage.
Pay special attention to the oil seals of the
(2) Check the bevel gears and thrust collars of the rotating parts of the final case and wheel shaft.
differential for wear. Shaft seals are used for these parts. When oil
leaks through these oil seals, replace them. They
(3) Make sure that each bearing turns smoothly. should also be checked for thrust play and right
angle play to the axis.
(4) Check the oil seal lips and the seal contacting
60
(5) Check the bushes for the front and rear pivot (3) After installing the front axle on the axle bracket,
metals (supports) for wear. When they are worn adjust the fore-and-aft play of the front axle to the
out exceeding the usable limit, replace them. specified valve.
Standard value Usable limit (4) Front axle end-float: Fore and aft play of the front
axle (1) in its supports should be 0.1 to 0.3 mm
+0.05
Front bush bore Ø35 +0.034 mm 0.2 mm (0.004-0.012"). End-float is measured with axle
raised off the ground.
+0.186
Rear bush bore Ø62 +0.116 mm 0.2 mm Loosen the lock nut (2) and turn the adjusting
bolt (3) as needed to achieve correct measure-
* Bush bore should be measured when the bushes are ment. Tighten the lock nut.
installed.
§4. PRECAUTIONS FOR RE-ASSEMBLY
(1) When replacing the shaft seals of the rotation

parts of the final case and wheel shaft, never hit
the surface of the flange of the sleeve. Damaged
flange surfaces will cause oil leaks.
1
Jig
Sleeve 2 3
Fig. 8-7
Improper Proper
Fig. 8-5 Note:

Excessive end-float will cause noise. This noise
(2) When sub-assembling the differential, insert the will be more pronounced when using 4WD.
spring pin so as for the seal to turn in the direction
of external force applied. After inserting the
spring pin, retain it with wire.
Seam of roll pin should face
in direction in which load is
applied.
Fig. 8-6
61
§3. TROUBLESHOOTING
Problems and probable causes Countermeasures
• Steering wheel hard to turn:
1) Too low tyre inflation Inflate to specified pressure: 1.8 kgf/cm2 (25.6 psi)
2) Broken thrust bearing Replace.
3) Stuck or broken ball joint of tie-rod end Grease or replace.
4) Seizure or poor lubrication of axle end bush Grease or replace.
• Vibrating or pulling steering wheel:
1) Unbalanced wheels Adjust balance.

2) Wheel deflection Repair or replace.
3) Unequal diameter of both tyres Adjust inflation or replace.
4) Loose, worn, or damaged wheel axle bearing Repair or replace.
5) Loose, worn, or damaged wheel steering Retighten or replace.
wheel shaft
6) Worn final case bush Replace.
7) Loose final case—front axle tightening bolts Retighten.
8) Loose front wheel (tyre) tightening nuts Retighten.
• Steering wheel tends to turn to the right or left while traveling on straight paved road:
1) Deflected wear of tyre Replace.

2) Different tyre diameters Adjust inflation or replace.
3) Damaged final case bearing Replace.
• Excessive or eccentric wear of tyre:
1) Improper tyre inflation Adjust.

2) Worn front wheel shaft bearing Replace.
3) Poorly adjusted toe-in Readjust correctly: 2 – 6 mm (0.08 – 0.24 in.)
4) Front wheel drive (4WD) is always engaged. Engage 4WD only when required.
• Noise:
1) Loose fasteners Tighten correctly to specified torque.

2) Worn or damaged final case bearing Replace.
3) Worn bush Replace.
4) Wear or poor movement of tie-rod end Lubricate or replace.
5) Excessive backlash of differential and bevel gear Adjust.
• Different steering angles in both directions:
1) Lengths of RH and LH tie-rods are different. Adjust.
62
CHAPTER 9: HYDRAULIC SYSTEM
CHAPTER 9. HYDRAULIC SYSTEM
§1. GENERAL DESCRIPTION
1. HYDRAULIC SYSTEM DIAGRAMS arm

Lift
1.1. STANDARD TYPE

Cylinder W
Position control lever
Link mechanism
Safety
valve
Main control
valve
(Remote hydraulic control port)
Relief
Sub-control valve
valve
Gear
pump
Suction filter
Reservoir
Fig. 9-1
MAIN CYLINDER
W
SAFETY VALVE
Craking pressure: LOWERING RATE
155 kg/cm2 CONTROL VALVE
Relief pressure: C
190 kg/cm2
CONTROL
VALVE
T3
T1
T2
MAIN RELIEF
VALVE
Relief pressure:
P P1 140 kg/cm2
MAIN PUMP
7.91 cc/rev. x 2500 rmp x 0.912/1000 = 18 litres/min.
STRAINER
(100 mesh)
Fig. 9-2
RESERVOIR
63
1.2. HU & U TYPES
arm
Lift
W
Position control lever
Cylinder
Link mechanism
Oil cooler
Safety
HU type valve
(A)
Main control
valve
(B) Mini-orbit (Remote hydraulic control port)
Oil filter
roll
Relief
Sub-control valve
valve
U type
Flow-control
HST valve
Gear
pump
Suction filter
Reservoir
In type HU, fluid flows from the mini-orbit roll to the oil cooler and HST via line A.
In type U, fluid returns from the mini-orbit roll to the delivery pipe via line B.
Fig. 9-3
64
Fig. 9-4
OIL COOLER
SAFETY VALVE
Cracking pressure: 2.0 kg/cm2 Cracking pressure:
155 kg/cm2
Relief pressure:
190 kg/cm2
OIL FILTER MAIN CYLINDER
(10µ) W
POWER STEERING
CYLINDER LOWERING RATE
CONTROL VALVE
HU type
B. pressure B
Max. 10 kg/cm2 C
Pgβ CONTROL
VALVE
U type
Relief pressure:
105 kg/cm2
T3
T1
65
T2
MINI-ORBIT ROLL Pgλ

MAIN RELIEF
VALVE
HST UNIT T Relief pressure:
P 140 kg/cm2
P1
FLOW-
DIVIDER
5.51 litres/min.
L/C FILTER
MAIN PUMP
7.91 cc/rev. x 2500 rmp x 0.912/1000 = 18 litres/min.
STRAINER
(100 mesh)
RESERVOIR
1.3. HYDRAULIC SYSTEM MAIN PIPING (1) Suction filter (5) Front delivery pipe
(2) Suction pipe (6) Rear delivery pipe
(The drawing shows type U & HU.) (3) Hydraulic pump (7) Cylinder case
(4) Metal (U)
1 4
5 3
Fig. 9-5
66
(1) Hydraulic pump
4
(2) Metal (U)
(3) Hose (650) 8
(4) Oil cooler
(5) Clamp
Hose and battery (6) Hose (1350)
cable should be (7) Oil filter
clamped together. (8) HST unit
(The drawing shows type H.)
1.4. HYDRAULIC SYSTEM PIPING
5
Hose and battery cable should
be clamped on axle bracket.
67
Hose should be clamaped
along with battery cable.
2 6
A
1
7
Two hoses should be
clamped on underside
of floor stay.
OUT
IN
3
Fig. 9-6
1 2
T
L
P 3 8
R
(The drawing shows type HU.)
68
Hose should pass
under axle bracket.
Hose should be clamaped

along with battery cable.
Two hoses should be

clamped on floor stay.
Two hoses and battery cable
should be clamped together. A
5 4 7
(1) Hydraulic pump (on right side of engine)

(2) Metal (U) (on right side of engine)
OUT
(3) Mini-orbit roll
(4) Clamp
(5) Clamp IN
Two hoses should be
(6) Oil cooler clamped on underside
(7) Oil filter of floor stay.
Fig. 9-7 (8) HST unit
§2. SPECIFICATIONS
Suction filter Rated flow rate 11 litres/min.

Filtering density 100-mesh
Filtering area 80 cm2 (12 cu.in.) or more
Gear pump Working oil temperatures -30 to 90°C

Theoretical delivery 7.91 cc
Maximum pressure 200 kgf/cm2 (2844 psi)
Flow-control valve Working oil temperatures -20 to 100°C

Leaking when fully closed 1 cc (0.16 cu.in.)/min. or less
[under a cylinder load of 100 kgf/cm2 (1422 psi)
and at an oil temperature of 50±5°C]
Relief valve Cracking pressure 120 kgf/cm2 (1707 psi) or more

[Leak: less than 300 cc (4.8 cu.in.)/min.]
Relief pressure 140/+3/-0 kgf/cm2 (1911/+43/-0 psi)
(under a flow rate of 15 litres/min.)
Leak 0.1 cc (0.16 cu.in.)/min. or less
[under a pressure of 100 kgf/cm2 (1422 psi)]
Main control valve Maximum flow rate (p–c) 18 litres

C-port leak 5 cc (0.8 cu.in.)/min. or less
Piston and cylinder Piston diameter Ø65 mm (Ø2.56 in.)

Cylinder bore Ø65 mm (Ø2.56 in.)
Piston stroke 75 mm (1.95 in.)
Lift capacity (at lower link end) 480 kgf (1411 psi)
Safety valve Cracking pressure 155/+5/-0 kgf/cm2 (2250/+71/-0 psi)

(under a flow late of 0.3 litre/min.)
Relief pressure 190 kgf/cm2 (2702 psi) or more
(under a flow rate of 20 litres/min.)
Leak 0.1 cc (0.016 cu.in.)/min. or less
69
§3. CONSTRUCTION, DISASSEMBLY AND INSPECTION OF MAJOR COMPONENTS
1. SUCTION FILTER
The filter is installed in the bottom of the transmission case. It has a reusable paper element, which should
be washed clean periodically.
1
2 (1) Suction filter
3 (2) Spacer
4
(3) O-ring (P21)
(4) O-ring (P28)
5 (5) O-ring (P28)
(6) Set bolt
6
Fig. 9-8
2. HYDRAULIC PUMP (GEAR PUMP)
6 8 7 9 10
3 (1) Body
(2) Rear cover
(3) Drive gear
(4) Driven gear
(5) Side plate
(6) Bush
(7) Gasket (type 8)
(8) Gasket
(9) Oil seal (TC14287)
(10) Snap ring
(11) Steel ball
Fig. 9-19 2 11 4 5 1
Note:
As the hydraulic pump is a precision device, the original performance of the pump cannot always be re-
stored after it has been disassembled. Consequently, it is recommended a defective pump be replaced with
a new pump assembly.
70
3. FLOW CONTROL VALVE AND METAL (U)
Hydraulic fluid is divided into the power-assisted steering system (mini-orbit roll assembly) and HST unit
through the flow control valve housed in the metal (U) (valve casing).
3.1. CONSTRUCTION AND COMPONENTS
FLOW CONTROL VALVE METAL (U)
6 7 4 1 10 3 5 2 9 11
8
CF EF
11
8
9
10
Fig. 9-10
1
(1) Body (7) O-ring
5 (2) Spool (8) O-ring
(3) Spring guide (9) O-ring
(4) Spring (10) O-ring
(5) Spool stopper (11) Filter
2 (6) Plug
3
4
7
6
Fig. 9-11
To mini-orbit roll (types U & HU)
To control valve
From mini-orbit roll (type U)
To oil cooler (type H)
From transmission case
Fig. 9-12
71
3.2. INSPECTION OF FLOW CONTROL VALVE
When hydraulic fluid is not divided as intended,

diasssemble the flow control valve, wash disas-
sembled parts and reassemble them. After reas-
sembly, remove the filter and confirm that the
spool slides smoothly from filter-mounted side.
4. AIR-BLEEDING OF THE HYDARULIC CIR- Fig. 9-14

CUIT
After transmission oil has been replaced, bleed

air from the hydraulic oil circuit by loosening
plug (1).
Note:
Never remove the plug, as oil will be ejected
through the plug hole when the engine is started.
Power-assisted steering models
Manual steering models
Fig. 9-13
HST model has a hydrostatic cartridge oil filter,

which is located under the left step. Replace the
cartridge afte the first 50 hours and then every
200 hours.
72
5. CYLINDER CASE
5.1. CONSTRUCTION AND COMPONENTS
(1) Cylinder case 2 4

(2) Cylinder head
(3) Relief valve 1 5 6
(4) O-ring (G60)
(5) O-ring (P55)
(6) Backup ring
(7) Piston
(8) O-ring
(9) Lift crank 9
(10) Lift shaft
(11) Bush (40 x 43 x 30)
(12) Bush (40 x 39 x 30)
(13) Support pin 8
(14) Position arm
(15) Link shift arm 7
(16) Support link
(17) Spool link
(18) Crank link
(19) Control valve 19
(20) Adjusting pin
20
14
1
12
2
13
8
4 5 6 7
15
16
18
17
9
10
11
19
Fig. 9-15
73
5.2. DISASSEMBLY
1
8
2 20
A
15
18
17
16 A
13
19
Fig. 9-16
(1) Remove the cylinder case assembly referring to Note:

Chapter 2-5. Make sure that aligning marks are applied on both
(2) Remove the position lever assembly and position lift arms and lift shaft. The lift shaft can be with-
control arm. drawn only leftwards.
(3) Remove the tension spring, spring hook, and the (8) Take out the lift shaft leftwards.
pin connecting the spool link. Note:
(4) Remove the spring pin of the adjusting screw. Make sure that aligning marks are applied on the
(5) Remove the main control valve assembly along lift shaft and lift crank.
with the adjusting pin. (9) Take out the link mechanism along with the lift
(6) Remove the safety valve assembly and then the crank.
cylinder head. (10) Separate the rod and lift crank along with the lift
(7) Extract the lift arm (RH). crank.
(11) Draw out the piston from the cylinder head side.
74
6. MAIN CONTROL VALVE
6.1. CONSTRUCTION
1
2
14 3
5
12 8
6
13 10 11
(1) Body
(2) Main spool
(3) Socket set screw
(4) Compensator spool
(5) Check valve guide
(6) Steel ball
(7) Compensator spring
(8) Check valve spring
(9) Plug
4
(10) Plug
(11) Sunk plug
7 (12) O-ring
9 (13) O-ring
12 (14) Relief valve assembly
10
2
13
1
11
4
6
5
8 14
12
9
Fig. 9-17
75
6.2. FUNCTION
NEUTRAL POSITION LOWERING POSITION
LIFTING POSITION
Fig. 9-18
76
6.3. DISASSEMBLY, INSPECTION AND RE- • The steel ball and its seating surface on the body
ASSEMBLE OF THE MAIN CONTROL should be free of flaws.
VALVE • Adjust the relief pressure with the adjusting
screw by loosening the lock nut in advance.
As the main control valve is a precision compo-
nent, it is not recommended to be disassembled Cracking pressure 120 kgf/cm2 (1707 psi)
unnecessarily. [under a leaking rate
of 300 cc/min. or less]
MAIN CONTROL VALVE BODY
When disassembling, abide by the following pre-

cautions:
a. Be sure to use clean cleansing fluid.

b. Clean the inside of the valve body by washing
and blowing it with compressed air.
c. When the valve or spool is found with minor Valve
Adaptor
flaws, correct them with an oil stone or replace
them with new ones.
d. A deformed or broken spring should be replaced
with a new one.
e. All used O-rings should be replaced with new
ones. Fig. 9-20
f. Reassemble the parts while applying fresh oil to
them. After adjustment, be sure to tighten the lock nut
to the specified torque. Then stake it without fail
INSPECTION OF THE RELIEF VALVE
Tightening torque 3.5 – 4.0 kfg·m
7 5 (36) (25.3 – 28.9 ft·lbs)
15
T
M20, P1.5
6 1 8 4 3
(1) Valve body (6) Lock nut

(2) Seat (7) Adjusting bolt
(3) Steel ball (8) Spring holder
(4) Spring seat
(5) Spring
Fig. 9-19
77
INSPECTION OF THE SAFETY VALVE After adjustment, be sure to retain the adjusting
screw with the lock nut and then stake the nut
1 10 9 without fail.
(30.3)
2
11 Tighten the lock nut to the specified torque.
Tightening torque 3.5 – 4.0 kfg·m

(25.3 – 28.9 ft·lbs)
Note:
If copper packing (9) is damaged or deformed,
8 7 6 5 4 3 replace it with a new one.
(1) Valve body (6) O-ring

(2) Seat (7) Lock nut
(3) O-ring (8) Adjusting bolt
(4) Steel ball (9) Packing
(5) Spring seat (10) Spring
Fig. 9-21
Install the valve on a nozzle tester as shown in

Fig. 9-21 and adjust the cracking pressure to the
specified value by turning the adjusting screw
with a screwdriver.
Cracking pressure 155 +- 50 kgf/cm2 (2505 +- 71

0 psi)
[under a leaking rate

of 300 cc/min. or less]
Valve
Adaptor
Fig. 9-22
78
§4. REASSEMBLY OF MAJOR COMPONENTS
Reassemble in reverse order of disassembly by follow- (7) When installing the safety valve assembly, mount
ing the following instructions. the O-ring (P12) using a thin coat of grease. Do
this carefully to assure it is not damaged. Then
(1) Carefully and thoroughly clean all parts. Never tighten the valve to the specified torque.
allow foreign matter to enter the system.
Valve tightening torque 8.5 – 10.0 kgf·m
(2) When installing the lift crank and lift arm on the (61.5 – 72.3 ft·lbs)
lift shaft, align their marks. The difference in
height above the ground between both lift arms Safety valve
must be maintained within 6 mm when they are O-ring (P12)
lowered by 8 degrees from level.
(3) When installing the adjusting pin, apply grease to

the groove for O-ring and over the friction sur-
face.
Adjusting pin
O-ring Packing
Safety valve
Sub-control
cover
Control valve
Fig. 9-23
(4) Before installing the control valve, secure the O-

ring with grease so that it will not drop.
When installing the adjust pin through the cylin-
der case, make sure the projection of the valve,
with which the descending speed of the valve is
adjusted, is securely seated in the groove in the
end of the adjusting pin. Temporarily tighten the Fig. 9-24
valve to conform that the adjusting pin turns
smoothly before securely tightening the valve. (8) When installing the sub-control cover and the
cylinder head, make certain that the oil holes are
(5) Before and after installing the valve assembly, not clogged.
confirm that the spool works normally.
(9) Adjust the starting torque of the control lever to
(6) After having installed the parts inside the cylin- between 1.5 and 1.8 kg with the aid of the two
der case: shaft, crank, links, etc., make sure the nuts (M8).
spool link, the related parts, and the spool work
smoothly.
79
Adjusting nuts
Fig.9-25
(10) When installing the suction pipe assembly, se-

curely clamp the rubber hose connecting pipes A
and B so as not to let air in.
Centring deflection between pipes A and B
should be maintained within 4 mm. Take care not
to apply excessive stress to the connecting rubber
hose during installation.
80
Lift does not rise. Insufficient engine speed Raise engine speed slightly.
Insufficient transmission oil Maintain oil level by replenishing with

the same kind of oil.
Air taken in through suction piping Tighten securely or replace broken

parts.
Clogged suction filter Clean.
Broken or poorly fuctioning hydraulic Inspect pump and repair or replace

pump if necessary. Pay particular attention
to shaft seal because a broken seal
sometimes intakes air.
Poor link mechanism Inspect, adjust, repair, or replace

if necessary.
Excessive load on lift Decrease load.
Broken cylinder Replace.
Too low viscosity of transmission oil As it will cause oil leaks or internal
wear, replace with gear oil of SAE 80.
Maladjusted relief valve Readjust.
Excessive internal leaks Inspect cylinder and valves. Replace

damaged seals, and repair.
(Check each part systematically.)
Broken control valve

(Even when spool is shifted to up position, lift does not rise.)
• Stuck compensator plunger Repair flaws by lapping with oil stone.
• Clogged orifices or slanted orifices Clean them with compressed air

in pilot passage or a sharp point.
• Broken or fatigued relief valve Replace spring.

spring
• Bitten or stuck check valve plunger Repair flaws by lapping with oil stone.
Broken flow-control valve
• Stuck poppet After disassembling and cleaning,

repair flaws by lapping with oil stone.
81
Too low rising speed Afore mentioned causes can also be Repair according to above instructions.
of lift possible.
Too small a spool stroke in control Inspect, readjust, or replace link

valve mechanism if necessary.
Broken compensator spring in Replace spring.

control valve
Lift lowers even Flow-control valve

when adjusting knob
is closed fully with • Stuck poppet After disassembling and cleaning,
adjusting handle. repair flaws by lapping with oil stone.
(When engine is
stopped.) • Poor poppet seat Replace valve.
• Poor O-ring Replace.
Safety valve
• Oil leaks due to poor sealing Inspect and re-tighten each joint.
• Poor seating Replace valve.
Lift does not lower. Flow-control valve knob is turned to Turn knob to down position.
the lock position.
Seized lift shaft Apply grease and repair or replace

bushings or bushings and shaft if
necessary.
Stuck poppet of slow-return check Lap after disassembly, cleaning, and

valve repair flaws with oil stone.
Broken control valve
• Stuck main spool After disassembling and cleaning,

repair flaws by lapping with
oil stone or replace unit as an assembly.
Lift lowering speed Above mentioned causes can also Repair or adjust according to
too slow be possible. instructions mentioned above.
Insufficiently lowered control Lower lever sufficiently.

lever
Excessively closed flow-control Open valve sufficiently.

valve
When hydraulic control Maladjusted lever stopper check valve Readjust lever stopper guide position.
lever is raised,
relief valve beeps. Poor link mechanism Inspect, readjust, repair, or replace
link mechanism if necessary.
82
Fluid overheating Excessively high working pressure Inspect and adjust.
Too high or low viscosity of working Replace with fluid of adequate

fluid viscosity.
Insufficient fluid Maintain specified level by

replenishing.
Too high internal friction of pump Replace.
Pump noise Partially clogged suction filter or Clean.

suction piping.
Air inhaled through suction piping Inspect and re-tighten.

connections
Air inhaled through intake pipe Inspect and re-tighten.

connection for pump
Loosened pump cover tightening bolts Inspect and re-tighten.
Too rich oil viscosity Replace with oil of specified viscosity.
Trapped foreign matter Disassemble and clean.
Broken or worn pump parts Inspect and replace defective parts.
Excessive wear, Dirty fluid Eliminate foreign matter and inspect

deflection or filters.
damage of pump
Circuit pressure exceeds pump Adjust relief valve or replace
capacity if necessary.
Oilless operation due to insufficient Inspect transmission oil level and

oil quantity maintain specified oil level by
replenishing.
In either case, clean, and repair pump

parts and replace damaged ones
if necessary.
Oil leaks outside Broken or fatigued oil seal or O-ring Replace.

pump.
Oil leaks from Poorly connected piping Inspect, clean, and eliminate dust.
piping or joints Repair flaws with oil stone if
necessary. Re-tighten.
Faulty O-rings Replace.
Broken piping Replace with a new one

after washing clean related parts.
Oil leaks around lift Faulty oil seal Replace oil seal or bushing
arm. if necessary.
83
84
CHAPTER 10: HYDROSTATIC TRANSMISSION
CHAPTER 10. HYDROSTATIC TRANSMISSION
1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS
(1) Case (28) Valve (65) Ball bearing

(2) Port block (30) Poppet (66) Ball bearing
(3) Cylinder block (33) Plug (67) Oil seal
(4) Slant board (34) Plug (69) Snap ring 55
(5) Piston (36) Snap ring (72) Washer 51
(6) Valve plate (37) Snap ring (74) Plug
(7) Valve plate (38) Snap ring (75) Spring
(8) Pump shaft (41) Spring holder (76) Piston 53
50
(9) Motor shaft (42) Oil seal (79) Shim A 54
(10) Trunnion shaft (47) O-ring (80) Shim B
(11) Bore plug (48) O-ring (81) O-ring
(13) Thrust bearing (49) Gasket (82) O-ring
(14) Ball bearing (50) Pin 50
(15) Needle bearing (51) Guide
(16) Bush (52) Ping
(17) Bush (53) Pin
(18) Sliding piece (54) Cradle bearing 50
(19) Cover (55) Socket head 18
(20) Spring bolt 38
55
(21) Spring (61) Oil seal 67
(22) Spring (62) Pin
(27) Valve (64) Cover 65 50 69 10 66 72 71 64
48 34 34 48 27 20 3 20 5 41 13 17 4
14
6
37
15 61
38 8
80 36
80 42
19
74 38
74
82
9
76 76
11
81 81
79
79
75
75 42 36
33
15
33 47 37
7
47 21 2
21 48 34 34 48 30 28 22 20 3 5 41 17 13 1 14
Fig. 10-1
85
Fig. 10-2
Neutral
High pressure
Charge pump relief valve
Input
shaft
PTO
shaft
2. OPERATING DIAGRAM OF HST
Neutral
86
Output valves
shaft
Check valves
Low pressure relief valve
Oil reservoir
Cooler
Filter
Strainer
NEUTRAL POSITION
3. FUNCTION
3.1. VARIABLE TYPE PUMP
Nine pistons are housed in the cylinder block, which is connected to the engine and revolves as the engine
does, while the slant board does not. When the slant board and shaft are perpendicular to each other,
cylinder displacement volumes A and B do not vary, so no delivery or suction takes place.
Spline Piston
A
Slant board
INPUT
Shaft
Cylinder block B
Fig. 10-3
If the slant board is angled by α degrees, displacement volumes A and B become different from each
other: A > B. If the shaft turns in the direction of “Q,” delivery of fluid takes place as the displacement
volume varies from B to A. Consequently if delivery and suction pipes are connected to the two arched
ports respectively, a pump mechanism is formed. In this case, “Ps” is the suction port and “Pd” is the
delivery port.
α
A
INPUT
B Pd Ps
Fig. 10-4
87
3.2. FIXED TYPE MOTOR
Nine pistons are housed in the cylinder block. A valve plate with two arched ports, Ps and Pd, is in contact
with one end of the cylinder block. The ports are connected to the delivery pipe or the suction pipe
respectively.
When pressurized fluid is led into the cylinder block port Ps, the fluid pushes the piston, which causes the
cylinder block to turn. This further causes the shaft to turn in the direction of “a” through the spline-
meshed part between the cylinder block and shaft. Thus a motor mechanism is formed.
Sland board Piston Cyinder block

Valve plate
Shaft
OUTPUT
a
Pd Ps
;;
;; ;;
Fig. 10-5
3.4. VALVES
;;;;
;;
LOW PRESSURE RELIEF VALVE AND SUCTION CHECK VALVE
The low pressure relief valve works to maintain

the specified charge pressure from the gear
;;
;; ;;
pump. Charge pressure replenishes the lowered Relief
valve
flow rate of the charge fluid due to leaks by
letting fluid into the case through the check
valve.
;;;;
Excessive fluid is drained to the case through the
low pressure relief valve.
When the tractor is parked on a slope with the
engine shut off, some reverse torque which is
applied to the output shaft through the rear axle
causes the high pressure side to leak. In this state,
if no fluid were replenished to the closed circuit,
Suction valve
air would become trapped inside the circuit,
The suction valve lets higher pressurized fluid automatically from
spoiling the braking effect of the circuit and the case into the low pressure circuit to maintain the specified pres-
allowing the tractor to start rolling down the sure in the low pressure circuit.
slope. The suction check valve however prevents

materialization of this no braking effect by Fig. 10-6
replenishing the closed circuit.
88
HIGH PRESSURE RELIEF VALVE
A direct type both-direction relief valve is installed across the main passages A and B.
When the pressure in the passage A is higher, surface “a” of the poppet receives pressure which pushes the
poppet overcoming the force of the spring and opens the valve: to the left as shown in the figure. When the
valve opens, the fluid in the passage A flows to the passage B.
When the pressure in the passage B is higher, surface “b” of the poppet receives pressure which pushes the
poppet overcoming the force of the spring and opens the valve: to the left as shown in the figure. When the
valve opens, the fluid in the passage B flows to the passage A.
6 7 9 1 8 10 2 11 4 5 3
;;
;;; ;; (1) Body
;;
;;; ;;
(2) Poppet
(3) Nut
(4) Shim A
(5) Shim B
(6) O-ring
(7) O-ring
;;
;;;;;
(8) O-ring
(9) Backup ring
(10) Backup ring
(11) Spring
A b B
• 1 mm increase in shimming thickness of shims (4) and (5) increases 40 to 50 kgf in spring force.
Fig. 10-7
89
NEUTRAL VALVE
The neutral valve ensures the neutral position of the HST when the engine is started.
While the angle of the slant board is small and delivery rate is low, the fluid flows through orifice “f” into
the case (passage B: drain circuit) and the motor does not turn: thus the neutral position is maintained.
;;;;;;;;
As the angle of the slant board becomes larger, flow rate through orifice “f” increases and pressure drop
across the orifice also increases.
When the pressure difference thus generated pushes the valve to the left and disconnects the passage A
from the passage B, all flow in the passage A is directed to the motor. The motor starts turning.
;;;;;;;;
;;;;;;;; f
B
A
Fig. 10-8
Note:
Sometimes air is trapped in the orifice “f” after reassembling the HST unit. Consequently try repeating
forward and reverse travel several times to make sure there is no hitching when the tractor starts travelling.
CHECK VALVE
The check valves are installed symmetrically in both sides across the charge passage “C.”
The check valve prevents the fluid from the high pressure passage “A” from flowing into the charge
passage “C” and replenish the charge fluid in the passage “B.”
The check valve in the high pressure side “A” closes and that in the low pressure side “B” is pushed open
by the charge pressure and the check valve end in the high pressure side.
• When the pressures in both the high and low pressure sides become high and both valves are closed, the
trunnion is hard to operate. To overcome this state, the end of the valve in the high pressure side pushes
that of the valve in the low pressure side to open the latter valve forcibly.
90
;; ; ; ;;
;;;;;;
;;;
A C B
Fig. 10-9
4. DISASSEMBLY AND REASSEMBLY
This section describes the disassembly and reassembly procedures and precautions of the two-axle type
HST unit model HVFD-21C21-M.
4.1. REQUIRED TOOLS
Ref. .................................. Name ....................................................................................... Size and specified values
1 .............. Plastic hammer ...................................................................... Hammering light alloy parts: 0.3 kgf
2 .............. Screw driver (conventional) .................................................. Nominal 150 mm
3 .............. Snap ring pliers (for hole type) ............................................. H-2, H-3
4 .............. Snap ring pliers (for shaft type) ............................................ S-1, S-3
5 .............. Hexagonal spanner ................................................................ Face-to-face width:: 5 mm

6 mm
8 mm
10 mm
6 .............. Torque wrench ...................................................................... Specified torque: 7.2 kgf·m

5.2 kgf·m
5.0 kgf·m
3.75 kgf·m
3.0 kgf·m
1.75 kgf·m
7 .............. Hexagonal bits for torque wrench ......................................... Face-to-face width: 5 mm

6 mm
8 mm
10 mm
8 .............. Socket for torque wrench ...................................................... Face-to-face width: 26 mm
91
4.2. PRESS-IN JIGS
30
Z 0.01
3.2a
0.01 0.02 Z
3.2a
øD1
R 0.2 R 0.2
Oil seal press-in jig
øD1 should be - 1 mm of the nominal diameter of the oil seal to be pressed in.
30
Z 0.01
3.2a
3.2a
0.01 0.02 Z
ø74
R 0.2 R 0.2
Bush (17) press-in jig
70
Z 0.01
0.01 0.02 Z
3.2a
3.2a
ø30
ø21
R 0.2 R 0.2
R 0.2 R 0.2
Bearing press-in jig
30
Z 0.01
3.2a
0.01 0.02 Z
3.2a
ø32
R 0.2 R 0.2
Bearing press-in jig
Fig. 10-10
92
4.3. PRECAUTIONS FOR DISASSEMBLY c. Remove the oil seal (61) from the cover (19).
a. Clean the exterior of the casing completely first The oil seal should be removed using the jig and a
taking care to cover all ports to avoid the entry of hand press.
dust.
b. Drain the case of oil. Hand press
c. Select a clean, dust-free place to work in to pre-
vent dust affecting precision parts.
d. Handle disassembled parts carefully to avoid 19 Jig
ø26 mm
damage like dents, scratches, etc. by dropping or
striking them.
61
4.4. DISASSEMBLY
(1) Removal of the cover

Fig. 10-13
a. Remove the four screws (M8) (71).
(2) Removal of the port block
a. Remove the eight socket head bolts (55).
Fig. 10-11
b. Remove the cover (19) from the case (1)

Fig. 10-14
b. Remove the port block (2).
When the operation above has been done, take

the following precautions.
– Take care not to allow the valve plate to fall.

– As the low pressure relief valve (28) and spring
(22) become free, take care not to miss them.
– Remember to remove the two knock pin when
the port block is removed.
Fig. 10-12
93
(3) Removal of the valve plate (5) Removal of the cylinder block of the motor
Remove the valve plates (6) and (7). Remove the following parts from the case (1):
cylinder block (3), piston (5), and thrust bearing
A valve plate is lifted up easily with a convention- (13).
al screw driver inserted into one of the grooves.
22 28
Fig. 10-17
50
(6) Removal of the motor shaft
Fig. 10-15 a. Remove the snap ring (37) from the case (1) and
then remove the bore plug (11).
(4) Removal of the cylinder block of the pump and
slant board b. After removing the bore plug (11), remove the
snap ring (11) installed behind the plug.
Remove the following parts from the case (1):
cylinder block (3), piston (5), spring (20), spring
holder (41), thrust bearing (13), slant board (4),
cradle bearing (54), bush (16), and thrust bearing
(18).
3 4 54
20 Fig. 10-18
41
c. Remove the shaft (9) from the case (1) by driving
the shaft end A with a plastic hammer.
5 13 18 16
Fig. 10-16
94
Shaft end A
Fig. 10-19
Fig. 10-21
(7) Removal of the pump shaft
d. Pry off the oil seal (67) from outsides the case.
a. Remove the snap ring (37) from the case (1).
e. Remove the snap ring (38) from the case.
b. Remove the shaft (8) from the case (1) by driving
the shaft end A (port block side) with a plastic
hammer.
Shaft end A
Fig. 10-22
(9) List of friction parts relevant to the pistons and

cylinder block.
Fig. 10-20
(4) Slant board (pump)
(8) Removal of the trunnion shaft (3) Cylinder block
(5) Piston
a. Remove the three screws (M8) (71). (6) Valve plate (pump)
(7) Valve plate (motor)
b. Remove the snap ring (69) and then remove the (13) Thrust bearing
trunnion cover (64). The two knock pin (50) (20) Spring
should also removed. (41) Spring holder
c. Drive the outside end of the trunnion pin with a The friction parts for the pump and for the mo-
plastic hammer and remove it towards the inside tor should be kept separately.
of the case.
95
13 4 3 6
20
41
7
5
Fig. 10-23
(10) Disassembly of the port block
a. Disassembly of the relief valve
Remove the relief valve (27).
b. Disassembly of the check valve
Remove the plug (PF3/8) (33), and then spring

(21) and poppet (30).
c. Removal of the neutral valve
Remove the plug (PF 1/2) (74) and then remove

the shims (79) and (80). After that, remove the
spring (75) and piston assembly (76).
27
75
76 75 80 80
30 21 33
Fig. 10-24
96
4.5. CRITERIA FOR REPLACING WORN PARTS
Friction parts which have worn and exceed the specified limit should be replaced with a new one.
No. Name Inspection items CRITERIA for correction or replacement
1 Piston a. Friction surfaces of i. When flaws, dents, or damage are found on such
pistons and cylinder surfaces, it is impossible to correct these corresponding
block parts, so replace them with new ones.
ii. The maximum clearance of the piston in the cylinder

bore is set at 0.025 mm when shipped.
If the clearance exceeds 0.035 mm, replace the piston
set with a new one.
b. Piston sphere When flaws, dents, or damage are found, replace the
piston with a new one.
2 Cylinder block Friction surface i. When the stepped difference between the friction
against valve plate surface and non-friction surface is in a range of 0.005 to
0.010 mm, correct the difference by lapping.
ii. When flaws, dents, or damage are found, correct them

by lapping.
iii. If 0.01 mm of lapping cannot correct the damage,

replace the cylinder block with a new one.
3 Valve plate Friction surface same as above

against cylinder
block
4 Thrust bearing Friction surface When pitting or flaking is found, replace the bearing
against piston with a new one.
97
4.6. PRECAUTION BEFORE REASSEMBLY
a. Wash disassembled parts in fresh cleansing oil and blow them with clean compressed air.
b. Handle the cleansed parts carefully to avoid damage such as dents, scratches, etc.
c. All removed sealing parts should be discarded and replaced with new ones.
d. All fasteners should be tightened to specified values.
e. Apply lithium-based grease to oil seals and O-rings: especially to the lips of oil seals.
f. As for the jigs for installing oil seals, bearings and bore plugs, refer to Fig. 10-10.
4.7. REASSEMBLY
(1) Reassembly of the trunnion shaft tape to protect the oil seal lips.
a. Install the snap ring (38) into the case (1).

Install the oil seal (67).
Pushed-in extent: 1.2 mm below

case surface
Install the oil seal using the press-in jig and a hand
press.
67
Fig. 10-27
1.2 mm
c. Insert the two straight pins (50) along with the

38 respective washers (72) into the case (1).
Fig. 10-25
b. Insert the trunnion pin (10) from inside the case.
Fig. 10-28
d. Install the screws (71) and tighten them to the

Fig. 10-26 specified torque.
Before inserting the trunnion pin the snap ring Tightening torque 1.75±0.17 kfg·m
groove on the pin should be wrapped with paper (face-to-face width: 5 mm)
98
m
0.2 m
17.5±
17
Fig. 10-29
1
e. Install the snap ring (69).
Fig. 10-31
Fig. 10-32 shows the state after finishing the step

above.
Fig. 10-30 Fig. 10-32
f. Press in the bush (17) into the case (1). (2) Reassembly of the slant board
Distance between the bush end and the bottom of a. Press in the bush (17) into the slant board (4).
the bore.
Distance between the bush end and the bottom of
Install the oil seal using the press-in jig and a hand the bore.
press.
press.
99
4 b. Install the snap ring (36) on the shaft (8).

17.5±0.2 mm
17
Fig. 10-33
b. Install the guide assembly (51) on the slant board.
Fig. 10-36
c. Install the shaft assembly (8) into the case (1).
d. Install the snap ring (37) into the case (1).
Fig. 10-34
(3) Reassembly of the pump shaft
a. Press in the bearing (14) onto the shaft (8).
When pressing in the bearing, use the jig to

apply force only to the inner race of the bearing.
Never apply stress to the balls and the outer
race.
press.
Fig. 10-37
(4) Reassembly of the motor shaft
a. Press in the bearing (14) onto the shaft (9).
When pressing in the bearing, use the jig to

Fig. 10-35 apply force only to the inner race of the bearing.
Never apply stress to the balls and the outer
race.
100
Install the oil seal using the press-in jig and a hand d. Install the snap ring (37) into the case.
press.
Fig. 10-38
b. Install the snap ring (36) onto the shaft (9).
Fig. 10-41
(5) Reassembly of the cylinder block in the pump

side
a. Install the pin (53), cradle bearing (54), and bush

(16) into the case.
Fig. 10-39
c. Install the shaft assembly (9) into the case and

install the snap ring (37). Then press in the bore
plug (11).
Press-in extent 5.2 ±0.2 mm

from case end
press.
11 Fig. 10-42
5.2 mm
b. Install the sliding piece (18) on the trunnion pin

(10) and then install the sliding piece so that it
37 engages the slant board (4).
Fig. 10-40
101
(6) Reassembly of the cylinder block in the motor

side
a. Install the thrust bearing (13) into the case.
Install the thrust bearing so that the races of dif-

ferent thickness (5.5 mm and 3 mm) are posi-
tioned as illustrated below.
13
m
5.5 m
Fig. 10-43
3 mm
c. Install the thrust bearing (13) into the slant board.
Install the thrust bearing so that the races of dif-

ferent thickness (5.5 mm and 3 mm) are posi-
tioned as illustrated below. Fig. 10-46
13
b. Install the assembled cylinder block onto the
shaft (9).
5.5 mm
3 mm
Fig. 10-44
d. Install the assembled cylinder block onto the

shaft (8).
Fig. 10-47
(7) Reassembly of the port block
a. Press in the needle bearing (2) into the port block

so that the bearing end projects 2.5 mm above the
port block surface and the punched marking of
Fig. 10-45
102
the manufacturer is in position A.
Press-in extent 2.5 mm

above port block surface
press.
2 15 A
Fig. 10-50
2.5 mm
• High pressure relief valve assembly (27).
Tightening torque 3.75±0.3 kfg·m

(face-to-face width: 26 mm)
Fig. 10-48
b. Press in the two oil seals (42).
Press-in extent 3 mm
below port block surface
27
20
c. Install the snap ring (38).
38 Fig. 10-51
• Neutral valve assembly {composed of the parts

(76), (75), (79), (81), and (74)}
3 mm
42
(face-to-face width: 10 mm)
2 15
Fig. 10-49
d. Install the valves as follows:
• Low pressure relief valve (28)
Apply grease to the valve ahead of time to prevent

it from coming out. Fig. 10-52
103
• Check valve assembly {composed of the parts 8. Preparation for final assembly of the case
(30), (21), (47), and (33)}
a. Install the straight pins (50) into the case (1).
(face-to-face width: 8 mm) b. Apply thin coat of lithium-based grease to the
surface contacting the gasket and apply the gas-
ket (49) to the case (1).
Fig. 10-53
d. Install the valve plates (6) and (7). Fig. 10-55
As the pump and the motor use different valve c. Set up the spring (22) in the case.
plates, install them properly as illustrated below.
Apply grease to the spring ahead of time to pre-
Valve plate (6) (pump side) vent it from falling out.
Surface of cylinder block side

(brass coloured) Valve plate (7) (motor side)
Fig. 10-56
– Take care not to allow the valve plates to fall.
Surface of cylinder block side – Make certain that the piston assemblies are
Fig. 10-54 (brass coloured) properly housed in the cylinder blocks.
104
– Make sure that the spring for the low pressure Press-in extent Flush with cover surface
relief valve is properly positioned in the case.
– Before installing the port block onto the pump press. 60
and motor shafts, the splined parts of the shafts
should be wrapped with paper tape to protect the
lips of the oil seals in the port block.
19
Fig. 10-59
b. Install the O-ring (82) and two straight pins (5)

into the case.
Fig. 10-57
(10) Installation of the port block
a. Tighten the eight socket-head bolts (55) to the

specified torque.
Fig. 10-60
Tightening torque 5 ±0.5 kgf·m
(face-to-face width: 8 mm) c. Install the assembled cover (19) on the case and
secure it with the screws (71). The screws should
be tightened to the specified torque.
Tightening torque 1.75±0.17 kgf·m
Fig. 10-58
(11) Reassembly of the cover
a. Press in the oil seal (61) into the cover (19)

Fig. 10-61
105
(11) Comfirmation items after reassembly
a. After reassembly, confirm that the shafts (8) and

(9) turn smoothly using an adjustable wrench or
the like.
Fig. 10-62
Fig. 10-63
b. Also confirm that the trunnion turns smoothly.
106
4.8. LIST OF MAJOR COMPONENTS OF HST

A
54 53 8
4
51 B
17
13
16
5
41 18
20
3 9
50 17
6 71
34 10 C 19
15 50
65
74 48 38 82
81 49 61
80 2
79 50 13 37
75 76 36
5
-1 14
-2 41 1
-3
20
33 59
47 -7
-10 3
21 58
30 -8
-1
27 7
-6 15
42 -9 C
-2
37
-11 11
38 -4 37
-3 A 36
-2 -5
55 48 -1
-8 14
76 -3
34 75 B
79 64
80 50
30 67 71
81 50
21 74 72
47 22
33 28 66
69
(1) Case (20) Spring (52) Ping (79) Shim A

(2) Port block (21) Spring (53) Pin (80) Shim B
(3) Cylinder block (22) Spring (54) Cradle bearing (81) O-ring
(4) Slant board (27) Valve (55) Socket head (82) O-ring
(5) Piston (28) Valve bolt
(6) Valve plate (30) Poppet (58) Name plate
(7) Valve plate (33) Plug (59) Drive screw
(8) Pump shaft (34) Plug (61) Oil seal
(9) Motor shaft (36) Snap ring (62) Pin
(10) Trunnion shaft (37) Snap ring (64) Cover
(11) Bore plug (38) Snap ring (65) Ball bearing
(13) Thrust bearing (41) Spring holder (66) Ball bearing
(14) Ball bearing (42) Oil seal (67) Oil seal
(15) Needle bearing (47) O-ring (69) Snap ring
(16) Bush (48) O-ring (72) Washer
(17) Bush (49) Gasket (74) Plug
(18) Sliding piece (50) Pin (75) Spring
(19) Cover (51) Guide (76) Piston
Fig. 10-64
107
5. HST CONTROL PEDALS
5.1. DIMENSIONS OF PEDALS
Pla
y:
30
mm
Brake pedal
Bolt (B) Bolt (A)
Trunnion pivot Neutral arm HST pedal
(236 mm)
St
an
da
rd
le Reverse
ng
th speed
: 16 limitter
2
m
Ad
m
(76 mm)
(72 mm)
ju
st
:2
0
m
3 mm
m
Standard length: 10
Adjust: 19 mm
Rod (M8 x 110)

Rod (65)
Fig. 10-65 (Neutral position)
108
5.2. NEUTRAL ADJUSTMENT
ADJUSTMENT
The neutral adjustment should be done after all • Under the conditions mentioned above, with the
parts have been reassembled and the engine is range shift in H, depress the HST forward pedal
ready for starting. to start the tractor and then release the pedal to
check to see that the wheels properly stop turn-
• Install the rod (M8×110) and rod (65) in according.
ance with the standard dimensions.
• When neutral setting is not achieved, find the
Rod (M8x110) 162 mm neutral position by turning the neutral arm.
Rod (65) 103 mm
• After neutral adjustment, make sure that the
• Neutral is adjusted by the set position of the neu- heights of both HST peals are the same. If they
tral arm. Consequently the neutral arm should be are not, correct by adjusting both rods.
temporarily set at the centre of both slots in the
trunnion pivot with the bolt (A) and bolt (B).
CONFIRMATION ITEMS AFTER ADJUSTMENT
Pedal operation While engine is stopped:
• Depressforward and reverse pedals • Pedals should depress smoothly.
• Pedals should return smoothly

when they are released.
• Confirm reverse speed • Reverse speed should be set at

75% of forward speed.
(Limitter height: 20 mm)
While engine is running

at 2000 rpm or higher speed:
• Depress forward and reverse pedals • Acceleration should be smooth.
Neutral While engine is running at full throttle:
• With HST at neutral,

check neutrality at each range speed. Tractor should not start travelling.
Stopping While engine is running at full throttle: • Stopping distance without brakes
• With range shift in H and at full throttle, Less than 8 m

release the pedal when tractor travels without any excessive shock
more than 5 m after having reached
maximum speed.
109
6. TROUBLESHOOTING
1. The output shaft does • Defective HST pump or motor If the trunnion shaft is positively
not turn with activated, replace the HST unit with
the control lever tilted a new one.
in either direction.
• A defective check valve Replace with a new one.
• Defective unloading valve Measure the pressures in the high and

low pressure circuits and then
disassemble and wash the valve and
reassemble it.
Adjust it if necessary.
2. The output shaft does • Worn trunnion lever and linking Replace worn parts with new ones.
not stop with parts
the control lever
shifted in the neutral
position.
3. Insufficient output • High pressure oil is leaking from Replace the HST unit with a new one.
shaft speed the pump or motor due to
wearing.
• Defective check valve seat Replace with a new part.
• Unloading valve is stuck in Disassemble and wash the valve and

working position. reassemble it.
Adjust it if necessary.
4. Oil leaking through • Due to broken oil seals or Replace defective parts with new ones.
shafts and sealing O-rings Oil seals should be installed taking care
parts not to damage their lips.
• Clogged air breather in the oil Clean the air breather. If it is badly
reservoir cap causes temperature clogged, replace the cap with a new
rise and resulted thermal one.
expansion of the oil in the Replace a damaged oil seal with a new
reservoir, which causes internal one.
pressure rise and leads to oil seal
damage.
110
CHAPTER 11: POWER-ASSISTED STEERING SYSTEM
CHAPTER 11. POWER-ASSISTED STEERING SYSTEM
§1. CONSTRUCTION
The steering unit (mini-orbit roll) controls hydraulic power and activates the front wheels directly through
the power steering cylinder. It features minimized vibration at the steering wheel because vibration of the
front wheels is not directly transmitted to the steering wheel.
Hydraulic fluid divided into the system through the flow-divider valve is controlled by the orbit roll to
activate the cylinder.
In accordance with the operation of the steering wheel, the rotary valve and metering device built in the
orbit roll controls the direction and flow rate of the hydraulic fluid and activates the power-assisted
steering system works.
Power-steering
cylinder
L R
Steering wheel
Mini-orbit roll
Flow-divider
P T
To main circuit
Main pump
Fig. 11-1
111
§2. MAJOR COMPONENT
Metal (U) and flow-divider assembly Delivery pipe (type U) Tank hose
To suction pipe (type U)

[To suction filter of HST
(type HU)]
R
T
L
L
From P
R metal (U) R
Cylinder Delivery pipe assembly Mini-orbit roll assembly
Fig. 11-2
112
§3. INTEGRAL ORBIT ROLL
1. COMPONENTS
1 Bolts 6 19 • Adjusting plug (1)

2 Retainer bolt assembly 1 20 • O-ring (1)
3 • Retainer bolt (1) 21 • Spring (1)
4 • Spring pin (1) 22 • Poppet (1)
5 Ball 1 23 • Collar (1)
6 End cap 1 24 Bearing races 2
7 Gerotor 1 25 Thrust needle bearing 1
10 Spacer plate 1 26 Seal 1
11 Drive 1 27 Oil seal 1
12 Control valve assembly 1 28 Dust seal 1
13 • Housing (1) 29 Retaining ring 1
14 • Sleeve (1) 30 Seal bushing 1
15 • Spool (1) 31 O-rings 3
16 • Pin (1) 33 Seal 1
17 • Centring springs (4) 34 O-ring 1
18 • Flat springs (2)
Fig. 11-3
113
2. DISASSEMBLY
• When repairing the steering unit, a clean workplace is essential.

• Before disconnecting piping, clean around the ports of the unit.
• Remove dust accumulating around the joint of the unit with a wire brush.
Note:
The unit should be held in a vice during operation, although almost of all the illustrations below for easy
viewing do not show a vice.
2.1. DISASSEMBLY OF ROTOR SIDE d. Remove O-ring (31) from end cap (6).
a. Hold the unit with the rotor side turned upward in e. Remove seal (33) and O-ring (34) from gerotor
the vice, inserting copper plates or the like be- (7).
tween the unit and vice, and lightly tighten the
unit. Overtightening may damage the unit. f. Remove gerotor (7) taking care not to let the star
rotor fall out.
g. Remove O-ring (31) from the gerotor.
O-ring
Gerotor
Fig. 11-4 Fig. 11-6
b. Remove the six bolts (1) and the retainer bolt h. Remove drive (11).
assembly (2) using a 5/16" socket wrench.
i. Remove spacer plate (10) and then remove O-
c. Remove the end cap. ring (31) from housing (13).
Housing
Bolt
End cap Spacer plate
O-ring Driver
O-ring
Fig. 11-5 Fig. 11-7
114
j. Turn the housing upside down and remove d. Remove dust seal (28) with a screwdriver taking
ball (5) taking care not to allow it to fall into a care not to damage the seal bushing.
groove, a side hole, etc.
e. Remove two bearing races (24) and thrust needle
2.2 DISASSEMBLY OF CONTROL SIDE bearing (25).
a. Remove housing (13) from the vice and place it Bearing race
on cloth. Thrust needle
Pry the end of retaining ring (29) out of the bearing
groove using a small screwdriver and remove the
ring from the housing.
Bearing race
Fig. 11-11
f. Pull off spool (15) and sleeve (14) from housing

(13).
Note:
Pull off the spool and sleeve assembly in the op-
posite direction of the flange while turning it right
and left.
Fig. 11-8
b. Turn spool (15) and sleeve (14) so that pin (16)

becomes level. Then push the spool and sleeve to
remove seal bushing (30).
Fig. 11-12
Seal bushing g. Pull off pin (16).
Fig. 11-9
Pin
c. Remove oil seal (27) from seal bushing (30).
Fig. 11-13
Oil seal
Dust seal Seal bushing h. Push out spool (15) a little and push off centring
springs (17) and flat springs (18).
Fig. 11-10
115
Refrain from drying them with cloth or paper, as

lint and paper waste can contaminate the hydrau-
lic system, which will lead to system trouble.
Never file parts or polish them with coarse sand-
paper.
Note:
Fig. 11-14 Apply fresh grease to O-rings ahead of time.
i. Pull off spool (15) out of sleeve (14). We recommend used O-rings and seals be re-
placed with new ones whenever possible.
Note:
Pull off the spool in the direction shown by the 3. RE-ASSEMBLY
arrow head while turning it right and left.
3.1. RE-ASSEMBLY OF CONTROL SIDE
a. Insert the spool (15) into sleeve (14) while turn-

ing the spool slowly. Control sleeve
Spring groove
Spring groove
Fig. 11-15
j. Remove O-ring (26) from housing (13).

Fig. 11-17 Control spool
O-ring Note:
Make sure that the spool turns smoothly by hold-
ing the spool’s splined part.
b. Align the spring grooves of the spool and sleeve

and insert centring springs (17) and flat springs
(18) using a jig #600057. Set the spring ends
Relief valve flush with the sleeve circumference.
Fig. 11-16
Note:
Never adjust the relief valve. When it is defective,
replace control valve assembly (12).
2.3. INSPECTION
Check the contact surfaces of all components.

Replace defective ones. Wash all metal parts in
clean solvent and dry them with pressurized air. Fig. 11-18
116
Note: Thrust needle

Set the four centring springs (17) and the two flat bearing Bearing races
springs (18) together with the cut-away parts
turned downward. O-ring
c. Insert pin (15) into the holes of the sleeve and

spool and set both pin ends flush with the circum-
ference of the sleeve.
Pin Fig. 11-21
g. Set dust seal (28) into seal bushing (30).

Fig. 11-19
Retaining ring
d. Insert the assembly of spool (15) and sleeve (14) Dust seal
from the back of housing (13).
Oil seal
Seal bushing
Fig. 11-22
Fig. 11-20 Note:

Install the dust seal with the flat surface turned
Note: toward the bushing.
Insert the spool/sleeve assembly carefully without
jamming it, while turning it right and left. Make h. Push oil seal (27) into seal bushing (30)
sure that the assembly turns smoothly. securely by pushing it with your fingers.
e. Place housing (13) on a clean level surface and i. Insert seal bushing (3) into spool (15) while
insert O-ring (26). turning the bushing.
f. Insert the two bearing races (24) and thrust nee- Note:
dle bearing (25). Drive the bushing into the spool securely using a
plastic hammer.
Note:
The thrust needle bearing should be sandwiched j. Insert retaining ring (29) into the groove of
with the bearing races. housing (13).
117
Screw driver blade

c. Place spacer plate (10) as shown and align the oil
Dust seal holes.
Retaining ring
Note:
Seal bushing
The bolt hole and oil holes are different.
X-ring seal
d. Insert drive (11).

O-ring
Port surface
Drive
Pin should be parallel

Fig. 11-23 to port surface.
Note:
Push open the retaining ring with a screwdriver
so that it is seated completely and fully expanded Pin
in the groove. Fig. 11-26
3.2. RE-ASSEMBLY OF GEROTOR SIDE Note:

Provide a guide line on the drive end face parallel
a. Insert ball (5) into the bolt hole and make sure with the pin axis with a felt pen for correct instal-
that the ball is seated in the proper position. lation.
e. Insert O-ring (31) on gerotor (7).
Fig. 11-24
Note: Fig. 11-27

Make sure that the spool/sleeve assembly is de-
formed a little when the ball is installed. f. Install O-ring (34) and seal (33) on gerotor (7).
b. Insert O-ring (31) into housing (13). g. A: line from a bottom land of the rotor to the
opposite bottom land
B: guide line for the pin axis

C: Pin axis
D: Port surface
A, B, and C should be parallel to each other.
Fig. 11-25
118
Bottom lands of star rotor A k. Apply oil to the threads of retainer bolt assembly
(2) and bolts (1) ahead of time. Then insert them
into end cap (6)
B
Apply a line
on drive end
surface.
C 6 4
D
1 2
3 7
Pin
5
Port face
Fig. 11-28
Fig. 11-30
h. Turn O-ring (31) on gerotor (7) toward spacer
plate (10) and install the gerotor on the drive by Note:
aligning the bottom land to bottom land line of Make sure that there is no pinching of the O-ring
the gerotor with the guide line on the drive. then tighten the bolts in the sequence mentioned
above to the specified torque.
Note:
When the bolt holes of the gerotor and placer plate Temporary tightening torque 1.1 kgf·m
do not align to each other, turn the gerotor hous-
ing alone. Final tightening torque 2.1 kgf·m
i. Insert O-ring (31) on end cap (6). Note:

Fit a handle to the spool and make sure that the
j. Place end cap (6) on gerotor (7) and align bolt spool turns smoothly.
holes.
Screw
End cap
O-ring
Fig. 11-29
119
Problems Presumable causes Countermeasure
Steering wheel is heavy to turn. 1. Orbit roll

a. Off-set column centre Repair. (If bolts which tighten
column on orbit roll are loosended
and make steering wheel lighter to
turn, the cause of trouble is
an off-set centre of column.)
b. Seized spool/sleeve assembly due Replace assembly.
to trapped foreign matter
c. Back pressure too high Correct.
d. Seven end cap bolts too tight Correct.
2. Pump
a. It is not operating. Operate it.
b. Worn or damaged pump Replace.
c. It is rotating in reverse. Correct.
d. Insufficient pump delivery Correct pressure and flow rate.
3. Relief valve
a. Defective Replace.
b. Too low set pressure Correct regulation pressure.
4. Flow-divider
a. Seized piston Disassemble, clean, reassemble.
5. Cylinder
a. Insufficient pressure receiving area Replace with proper cylinder.
6. Priority valve (load sensing)

a. Seized spool Disassemble, clean, reassemble.
b. Clogged damping orifice Disassemble, clean, reassemble.
c. Insufficient control pressure Replace with proper spring.
of spring
d. Low regulation pressure of Correct regulation pressure.
relief valve
Steering wheel does not return to 1. Orbit roll

neutral position when it is released or a. Seized spool/sleeve assembly Replace.
it has a tendency to turn by itself. b. Back pressure too high Correct.
c. Off-set centre from that of column Correct.
Cylinder does not react smoothly to 1. Orbit roll

turning of steering wheel or not at all. a. Trapped air within gerotor Bleed.
2. Pump
a. Insufficient delivery against Increase delivery rate.
steering system requirement
120
Problems Presumable causes Countermeasures
3. Cylinder
a. Trapped air Bleed.
b. Broken piston seal Replace.
4. Overload/anti-cavity valves
a. Leaking Replace valves.
Steering wheel operates in reverse. 1. Orbit roll

a. Incorrect valve timing Correct.
2. Piping
a. Mistake in port connection Correct.
Oil leakage Worn oil seal (X-ring)
1. Through shafts (circumference of a. Contaminated working fluid Provide proper countermeasure to

splined part) prevent oil contamination
b. Back pressure too high Correct.
2. Contact surfaces between housing, Broken O-rings

spacer plate, gerotor, and end cap
a. Pinched rings Replace.
121
122
CHAPTER 12: ELECTRICAL SYSTEM
CHAPTER 12. ELECTRICAL SYSTEM
1. FUSES, FUSIBLE LINKS AND SLOW-BLOW FUSE
• A: the main fuse box is located inside the right-hand fan cover.
• B and D: A green fusible link is located respectively.
• C: 40-amp. slow-blow in line fuse is located.
(a) Headlamps 12V 45/40W 1 5A

(b) Front turn signal lamps 12V 21W
(c) Front small lamps 12V 5W 5A
(d) Stop lamps 12V 21W
(e) Tail lamps 12V 10W 3 10A
(f) Rear turn signal lamps 12V 12W
(g) License plate lamp 12V 5W 4 20A
6 5A
5 10A
cb
7 20A
A f
10 5A
e
11 5A d
a
E
7-pin
socket
(OPT)
a
B D d
C
e
f
cb
1 2 3 4
Ref. Amperage Circuit No. Function

1 Left 1 5A 1 PTO
2 Right
3 Left 2 5A — —
4 Right
3 10A 3 Stop lamps
4 20A 4 Direction indicator
5 5A 6 Engine stop relay
6 10A 5 Cab (AC)
7 20A 7 Warning flash lights
8 5A 10 Tail lamps (LH)
9 5A 11 Tail lamps (RH)
Fig. 12-1 * Work light (rear) is an accessory.
123
2. SAFETY SYSTEM WIRING DIAGRAM
MID-PTO
SWITCH
0.85 LY
301 :0.5 BW 0.85 RG
700 :0.5 W 0.85 LY
REAR PTO
SWITCH
700 :0.5 W
202 :0.5 R
202 :0.5 R
SWITCH
SAFETY
302 :0.5 RW
302 :0.5 RW
RELAY
99G :0.5 B
13 :2 BY
31 :2 BY
FUSE (5A)
MAIN SWITCH
31 :2 BY 2 BY
32 :2 LR 2 LR
50
2 R
BR
R
30
14 :3
STARTER
SLOW-BLOW
FUSE (50A)
MOTOR
BY
R
13 :2
25 :3
S
B
BATTERY
30 B
Fig. 12-2
20 B
124
3. TROUBLESHOOTING
3.1. BATTERY
Inspection items Problems Countermeasures
a. Exterior parts
Container, cover, Fluid leaks due to cracks Repair or replace battery.

and sealing parts
Vent plugs Corrosion or breakage Repair or replace battery.
As excessive resistance between

terminal post and clamp brings
about a voltage drop and results in
faulty starter operation.
Measure voltage drop with a voltmeter

while turning starter with fuel shut off.
When voltmeter reading is more

than 0.2 to 0.3, it is excessive.
Clean post and clamp, and tighten
them securely.
Pole plates Whitened (sulphated) Replace battery.

(only when housed Positive plates should be dark brown
in a transparent casing) and negative ones should be grey.
Positive plate grids are broken.
Deposit (only when Accumulated up to lower ends of Perform charging test and judge
housed in a transparent pole plates, shorting them battery condition.
casing)
b. Voltage Total voltage is less than 12V. Perform charging test and judge
battery condition.
c. Electrolyte Pole plates appear above electrolyte. Maintain electrolyte level and judge
battery condition by applying
charging test.
d. Specific gravity of Specific gravity of some cells is Perform charging test and judge
electrolyte less than 1.200 and variation among battery condition.
cells is over 0.05.
3.2. METERS, GAUGES, AND SWITCHES
a. Tacho/hourmeter and meter cable
Pointer does not Faulty meter assembly Replace meter assembly.

work. Broken meter cable Replace cable assembly.
125
Pointer moves but Faulty meter Replace.

is very unstable. Poorly lubricated meter cable Lubricate.
Meter cable is being broken. Replace.
b. Fuel gauge and sensor unit (switch)
Pointer does not Open circuit Repair.

move. Faulty sensor assembly Replace sensor assembly.
Faulty gauge assembly Replace gauge assembly.
Faulty battery Recharge or take necessary
countermeasures.
Faulty earth Repair.
Faulty pointer Poorly contacted terminals Repair.

movement Faulty sensor assembly Replace sensor assembly.
Faulty gauge assembly Replace gauge assembly.
c. Turn signal and hazard warning switch
Both lamps do not flash. Open circuit Repair

Burnt-out bulbs Replace.
Faulty tun signal switch Replace switch assembly.
countermeasures.
Faulty flasher unit Replace unit.
d. Head lamp switch
Lamps do not light Burnt-out bulbs Replace.

up as indicated Open circuit Repair.
when switch is Faulty battery Recharge or take necessary
turned to each countermeasures.
position (Small, Faulty battery grounding Repair.
Low, High) Faulty starter switch Replace switch assembly.
Faulty light switch Replace switch assembly.
Blown-out fuse Replace.
Head lamps are dim Faulty battery capacity Recharge.

with switch turned to Poorly contacted terminals Repair.
Low or High. Faulty bulbs Replace.
Faulty light switch Replace switch assembly.
e. Starter switch
Glow plugs and Faulty battery Recharge or take necessary

heater signal do not countermeasures.
heat up red. Faulty circuit wiring Repair.
Burnt-out heater signal Replace.
Faulty starter switch Replace switch assembly.
Faulty glow plugs Replace.
126
Starter does not work Faulty battery Recharge or take necessary

when starter switch countermeasures.
is turned to Start. Faulty circuit wiring Repair.
Poorly contacted terminals Repair.
Faulty starter assembly Refer to Engine manual.
Faulty horn relay Replace.
Faulty safety switch Replace.
f. Horn and horn switch
Horn does not sound. Faulty horn switch Replace switch assembly.
Faulty engine oil viscosity Replace with proper viscosity oil.
Faulty horn Replace horn assembly.
Poorly contacted terminals Repair.
Faulty horn relay Replace relay.
g. Oil pressure pilot light
Light is lit during Low engine oil level Replenish oil level.
operation Faulty engine oil viscosity Replace with proper viscosity oil.
Clogged oil filter element Replace element.
Faulty oil pressure switch Replace switch assembly.
Broken oil pump Replace pump assembly.
h. Charge pilot light
Light is lit during Faulty wiring Repair.

operation. Faulty alternator Repair or replace alternator assembly.
countermeasures.
Loose fan belt Retighten or replace belt.
127
128
CHAPTER 13: SERVICING DATA
CHAPTER 13. SERVICING DATA
1. SPECIFICATIONS & CAPACITIES
Engine Oil
Use engine oil of the appropriate SAE viscosity. Oil must meet or exceed; MIL-L-2104C requirements, API Service “CD”.
TM215 TM217
Capacity (litres) ............................................................................................ 2.7 .................................................... 2.7
Recommended Viscosity:
78 °F (25 °C) and Above ......................................................... SAE 30 W, 10 W - 30 ...................... SAE 30 W, 10 W - 30
32° - 78 °F (0° - 25 °C) ............................................................ SAE 20 W, 10 W - 30 ...................... SAE 20 W, 10 W - 30
Below 32 °F (0 °C) .................................................................. SAE 10 W, 10 W - 30 ...................... SAE 10 W, 10 W - 30
Recommended Change Intervals:

Initial Oil and Filter Change ............................................................... 50 hours ............................................ 50 hours
Oil and Filter Change, Thereafter ................................................ Every 150 hours .............................. Every 150 hours
Engine Coolant
Freezing Protection (Original factory Fill) .................................................. -34 °C (-30 °F) ................................ -34 °C (-30 °F)
Recommended Coolant ................................................................ 50/50 mixture ethylene .................... 50/50 mixture ethylene
glycol and water glycol and water
System Capacity (litres) ............................................................................... 5.1 .................................................... 5.1
Fuel Tank
Capacity (litres) ........................................................................................... 13.5 .................................................. 13.5
Fuel recommended,
Above 4 °C (39 °F) ............................................................................ No. 2 or No. 2-D .............................. No. 2 or No. 2-D
Fuel Recommended,
Below 4 °C (39 °F) ............................................................................ No. 1 or No. 1-D .............................. No. 1 or No. 1-D
Transmission & Differential Housing (Including Hydraulic System)

Capacity (litres)
F ............................................................................................................. 13.5 .................................................. 13.5
FU (with power-assisted steering) ........................................................... — .................................................... 14.0
FMU (with Mid-mount PTO and power-assisted steering) ................... 14.0 .................................................. 14.0
FHU (with HST and power-assisted steering) ....................................... 15.0 .................................................. 15.0
FHMU (with HST Mid-mount PTO and power-assisted steering) ........ 15.0 .................................................. 15.0
Recommended Lubricant .................................................................. Shell DONAX TD ............................ Shell DONAX TD
or equivalent or equivalent
Recommended Change Interval .......................................................... First 50 hours ................................... First 50 hours
every 200 hours thereafter every 200 hours thereafter
Front Axle
Capacity (Common Reservoir) (litres) ......................................................... 2.7 .................................................... 2.7
Recommended Change Lubricant ....................................................... SAE 80 GL-4 ................................... SAE 80 GL-4
Recommended Change Interval ........................................................ Every 300 hours .............................. Every 300 hours
Grease Fittings
Greasing Interval (All Fittings) .......................................................... Every 50 hours ................................ Every 50 hours
Recommended Grease ............................................................... Lithium-base grease No. 2 ............. Lithium-base grease No. 2
NOTE: Change intervals stated above are for normal usage. Due to adverse operating conditions that may be experienced
(extremely dusty or muddy), change intervals may need to be more frequent.
129
2. LUBRICATION/FILL POINTS
General layout of lubrication, fill and drain Ref. Description: Type:

locations on the tractor:
1 Fuel Tank Diesel Fuel
2 Radiator Engine Coolant
3 Engine Engine Oil
4 Transmission Case Hydraulic Oil
5 Front Axle Hydraulic Oil
6 Axle Pivots Grease
7 Clutch Shaft Grease
8 Brake pivots Grease
9 Drag Rod & Tie-rod Grease
10 Steering Gearbox Hydraulic Oil
11 Knuckle Arm Grease
HST models
9 11 5
8
9
4
6
1
8
10
Transmission oil level
7 Greasing point
2 9 3 9 Oil filler
Oil drain
Engine oil level
Level point
9 11
Radiator filler
Radiator drain
Fig. 13-1
130
3. PERIODIC MAINTENANCE SCHEDULE
Recommended Interval, Each: Item To Action

Day 50 hr 100 hr 200 hr 300 hr Year Check Required
● All controls, switches Inspect and repair
● All fasteners, hardware Check and tighten
● Hoses, fan belt, wiring Inspect and repair
● Grease fittings Lubricate
● Engine oil level Replace
(*) ● Engine oil & filter Check and replenish
● Transmission oil level Replace and clean
(*) ● Transmission oil & screen Replace cartridge
(*) ● Hydrostatic oil filter Replace cartridge
● Front axle oil level Replace
● Front axle oil Clean of debris
● Air screens & radiator Check and replenish
● Radiator coolant Drain, flush & replace
● Fan belt tension Check and adjust
● Air cleaner dust ejector Clean
● Air cleaner elements Inspect, clean or replace
● Fuel tank level Fill
● Fuel filter sediment bowl Inspect and clean
● Fuel filter element Replace and bleed
● Battery & cables Check, clean & tighten
● Battery electrolyte level Check and replenish
● Lights, flashers & horn Check and repair
● Clutch pedal free-play Check and adjust
● Brake adjustment & balance Check and adjust
● Tyre pressure & condition Check and adjust
● Wheel bolt torque Check and adjust
● Steering free-play Check and repair
● Front axle end-float Check and adjust
● Clutch housing leaks Remove plug & check
Items marked (*) indicate initial service interval only. Subsequent (later) intervals marked “●”. Intervals above are for normal usage. Severe
operating conditions (wet, dusty, etc.), or when previous servicing has indicated need for more frequent action, intervals may need to be
shortened.
131
4. SERVICE STANDARDS
(mm)
Part names and Tractor Standard value Usable Service instruction

inspection items type for reassembly limits and remarks
1. CLUTCH AND RELATED PARTS

Clutch disc
Thickness MT/HST 7.8±0.3 6.3 Replace.
Rivet depression 1.0 0.2 or more Replace.

Rotational play of hub spline 0.3 Replace.
Deviation Surface evenness 0.4 Replace.
Lateral run-out 1.0

Vertical run-out 1.0
Damper spring play 1.5
Clutch cover
Flatness of place surface less than 0.05 0.5
Diaphragm spring tension 415 kgf 340 kgf
Tightening torque of clutch cover 1.5 – 1.2 kgf·m

Clutch pedal play 20 – 30 Measure at pedal top.
Adjust with clutch wire.
2. BRAKE AND RELATED PARTS
Brake shoe thickness 2.2 Measure in the middle.
Brake drum abnormal wear

or cracks
Brake pedal play 30±5 Measure at pedal top.

Parking brake lever play one to two notches Adjust.
3. TRANSMISSION AND RELATED PARTS
Backlash between drive pinion 0.1 – 0.2 Adjust with 0.1 or 0.2 mm
and ring gear shim.
Backlash between dif-side gear

and dif-pinion
4. STEERING SYSTEM AND 4WD SYSTEM

Free play of steering wheel Manual 25 – 30 50 Adjust with adjusting bolt.
(on circumference)
Power-assisted 30 or less 50
Front wheel steering angles 55±1° (inner)

Toe-in 2–6 Adjust.
Fore-and-aft play of front axle 0 – 0.2 Adjust.
132
(mm)

Front axle bush play 0.2 Replace.

Final case bush play 0.2 Replace.
5. HYDRAULIC SYSTEM
Safety valve assembly 8.5 – 10.0 kfg·m

(Tightening torque) (61.5 – 72.3 ft·lbs))
Control valve bolts 1.3 – 1.8 kgf·m

(Tightening torque) (9.4 – 13.0 ft·lbs)
Relief set pressure Cracking pressure:

120 kgf/cm2
Lift capacity (at lower link end) 480 kgf
Lift arm top clearance 3–5
Position control lever stopper Set stopper just before relief valve works
in up position.
6. ENGINE ACCESSORIES
Antifreeze density of engine Should be determined in accordance with local

coolant conditions
Fan belt tension 8 – 10 Depress belt at a point

between fan pulley and
alternator pulley.
Operation force of throttle lever 6 – 8 kgf Adjust.
7. POWER-ASSISTED STEERING SYSTEM (INTEGRAL ORBIT ROLL)
Cylinder Dimension between Adjust

rod ends: 355±2
8. GEAR PUMP
Gear contacting trace Less than 1/2 of gear

around intake port housing bore diameter
Contact trace width 0.05 or less 0.1 Replace pump body.

Clearance between metal bore 0.07 – 0.08
and gear shaft
Clearance between metal shaft 0.015 – 0.025
diameter and metal bore
Clearance between metals 0.010 – 0.020
133
(mm)

Gear offset projection against 0.005 – 0.015

metal diameter
Pump cover tightening torque 3.0 – 3.5 kgf·m
Gear pump starting torque 0.3 kfg·m

9. MANUAL STEERING SYSTEM
Starting torque of ball/nut worm 0.5 kgf·m Replace.
Ball/nut thrust clearance 0.1 Replace.

Clearance between T-groove in 0.15 Replace.
sector shaft and shim
Steering shaft starting torque 1.5 – 8 kgf·m
Rear cover tightening torque 16 – 20 kgf·m
Side cover tightening torque 1.7 – 2.8 kgf·m

Pitman arm tightening torque 14 – 18 kgf·m
Pitman arm end play 0.5 or less Adjust.
Adjusting screw lock nut 2.0 – 3.0 kgf·m Adjust.

tightening torque
Sector shaft working angles 43° each

10. ELECTRICAL ACCESSORIES
Electrolyte capacity 1.240 – 1.260
(Specific gravity)
Terminal voltage 12V 10.8V Charge.
134
4. SPECIFIED TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS
Size 4T bolts and nuts 7T bolts and nuts 7/9 bolts and nuts
kgf·cm (N·m)
M5 2.9 – 3.9 4.9 – 5.9 5.9 – 6.9

(30 – 40) (50 – 60) (60 – 70)
M6 5.9 – 7.8 8.8 – 10.8 9.8 – 12.8

(60 – 80) (90 – 110) (100 – 130)
M8 12.8 – 17.7 19.6 – 26.5 24.5 – 34.3

(130 – 180) (200 – 270) (250 – 350)
M10 19.6 – 29.4 44 – 54 54 – 69

(200 – 300) (450 – 550) (550 – 700)
M12 49 – 59 74 – 88 88 – 108
(500 – 600) (750 – 900) (900 – 1100)
M14 69 – 78 98 – 118 128 – 147

(700 – 800) (1000 – 1200) (1300 – 1500)
M16 98 – 118 118 – 137 157 – 177

(1000 – 1200) (1200 – 1400) (1600 – 1800)
M18 118 – 137 157 – 177 196 – 235

(1200 – 1400) (1600 – 1800) (2000 – 2400)
M20 147 – 167 186 – 206 235 – 255

(1500 – 1700) (1900 – 2100) (2400 – 2600)
135
136
TM TRACTOR SERVICE MANUAL APPENDIX
APPENDIX
Install gears in correct direction, i.e. chamfered
sides facing rearward.
1. PRECAUTIONS FOR
Press in roll pin (6 x 16). After assembly, clearance between gear (17T–24T) and gear (15T–34T)
REASSEMBLY should be about 0.4 mm. They should not follow each other.
Install thrust collar
1.1. MECHANICAL with oil groove Apply adhesive to surface contacting change metal.
facing toward NRB. Apply adhesive to surface
TRANSMISSION Apply adhesive to contacting surfaces.
contacting cylinder case.
As drive pinion and ring gear make a pair,

they should have the same punched marking.
Apply grease to oil seals.
Install oil seals in correct direction.
Apply grease to O-ring.
It should not be damaged
when installed.
Apply grease.
Backlash:
Bac klash: 0.1 – 0.2 mm,
which is adjusted
by
y shimming dif-metal.
Apply adheseive to
surface contacting
oil seal.
Apply adhesive to contacting surfaces.

Install gear in correct direction, i.e. clutch claws facing forward.
Insatall gear in correct
direction. Install thrust collar with oil groove facing NRB.
137
1.3. FRONT AXLE AND DRIVE MECHANISM
Apply wear-proofing grease.
Apply adhesive. Apply grease to dust seal. Apply wear-proofing grease.

Apply grease.
Apply grease to bush.
Apply grease.
Be sure to install snap ring. Drive in roll pin in correct
Fore-and-aft play of front axle: 0 to 0.2 mm direction and retain it
After play has been set, axle should rock smoothly. with wire securely.
Drive in roll pin in correct direction and
retain it with wire securely.
Be sure to install
snap ring. Apply wear-proofing grease.
After assembly dif-pinions Be sure to install
Be sure to install snap ring.
snap ring. should turn smoothly.
Apply adhesive
to contacting surfaces.
Be sure to install
snap ring.
Apply grease to shaft seal,

which should securely be
driven in with a driving-in tool.
Apply grease.
Be sure to install Apply wear-proofing grease.

snap rings.
Apply adhesive
to blind plug.
141
2. WIRING DIAGRAM
Hazard Instrument panel lamp 3.5W

warning POWER SUPPLY
signal ACCESSORY
switch
EARTH
FUEL TEMP
Main beam
switch Front samll lamp
(Make COBO)
0.5 B 990C:0.5 B
Parking lamp 21W 5W
21W Stop lamp (RH)
Head lamp (RH) switch 0.5 RB 204B:0.5 LY
45/40 W 73B:0.5 GY
0.5 GB 73: 0.5 GY
(Make COBO) 204: 0.5 LY
LgW
Flasher unit
LgR
Tail lamp (LH)
GW
1.25 LW
GR
GB
GY
1.25 LB
RL
10W
Lg
210A: 0.5 RW
R
1.25 L
35: 0.5 YR
99D: 0.5 B 99B: 0.5 B (Make COBO)
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
99C: 0.5 B
214: 0.5 YR Fuel switch Front turn signal lamp (RH)
212: 0.5 LR
Rear turn signal
205: 0.5 GR
72A: 0.5 GB
73A: 0.5 GY
23: 0.5 LW
35: 0.5 YR
207: 0.5 RY
10A: 0.5 YB
0.5 YB
2A: 0.5 RL
0.5 YL
21W
99A: 0.5 B
lamp (RH)
1.25 LW
1.25 LB
1.25 L
Fuses
5:
1:
108A:0.5 RW
205: 0.5 GR
72B: 0.5 GB
73B: 0.5 GY
207: 0.5 RY
RB
RY
RY
206: 0.5 GL
GL
LR
RL
112: 0.5 LR 102: 0.5 LR
36: 0.5 G
G
G
G
70A: 0.5 R
99D: 0.5 B
5A
211: 0.5 RL 2: 0.5 RL
206: 0.5
36A: 0.5
36B: 0.5
36C: 0.5
102: 0.5
0.5
103: 0.5
0.5
99D: 0.5
5A
214: 0.5 YR 103: 0.5 YR
5A
213: 0.5 RY 5A
3: 0.5 RY
2:
3:
108B: 0.5 RW
205: 0.5 GR
72A: 0.5 GB
73A: 0.5 GY
23: 0.5 LW
10A: 0.5 RB
35: 0.5 YR
207: 0.5 RY
0.5 YB
2A: 0.5 RL
134: 0.5 YB
0.5 YL
99A: 0.5 B
0.5 Y
4: 0.5 GW Stop lamp Mid PTO 99: 0.85 B For opt (AC)
switch switch
5:
1:
34:
99A: 0.5 B 70: 1.25 R located under right fender
100W
Hor n
204C: 0.5 RY 0.5 RY Legistration

5W plate lamp
99E: 0.5 B 0.5 B
(Make Hella)
102: 0.5 LR 102: 0.5 LR
5:0.5 YL 2: 0.5 RL 2: 0.5 RL
301:0.5 LGB
210: 0.5 RW
10B: 0.5 RB
1: 0.5 YB 1: 0.5 YB 103: 0.5 YR 103: 0.5 RY
700:0.5 W
13: 0.5 RY 13: 0.5 RY
4: 0.5 GW 4: 0.5 GW
5: 0.5 YL 5: 0.5 YL
1: 0.5 YB 1: 0.5 YB
99B: 0.5 B 7: 0.85 P 7: 0.85 P 7: 0.85 P
16A: 0.85 BW
23: 0.5 LW 23: 0.5 LW

70: 1.25 R 70:1.25 R
10: 0.5 B 10: 0.5 B 210: 0.5 RW 210:0.85 RW
Engine stop
solenoide
204: 0.5 LY 204: 0.5 LY

203: 0.5 LB 203: 0.5 LB
73: 0.5 GY 73: 0.5 GY
Diode (3A) 72: 0.5 GB 72: 0.5 GB
99: 2 B 99: 1.25 B 99: 0.85 B 99: 0.85 B
13: 2 BY 13: 2 BY
46B24R
Battery
0.85 BW 16: 0.85 BW 16: 0.85 BW

15: 0.85 LR 15: 0.85 LR
11: 0.5 W 23: 0.5 LW

Diode (3A)
0.85 B
16B: 0.85 BW
302A: 0.5 LgR
99: 2 B
Slow blow fuse

(50A)(Red)
301:0.5 L&R 301:0.5 LgR
302:0.5 RW 302:0.5 LgR
Opt for trailer

Glow plugs 7-pole socket
6: 3 BW 6: 3 BW (Make COBO)
302: 0.5 LGB

25: 3 R 14: 3 R 14: 3 R
R
70B: 1.25 R
99F: 0.85 B
700: 0.5 W
202: 0.5 R
202: 0.5 R
302:3 LgR
99E:0.5 R
216: 3 R 216: 3 R 216: 3 R R
31:2 BY
13:2 BY
L 73A: 0.5 GY 0.5 GY L
72A: 0.5 GB 0.5 GB
210B: 0.5 RW 0.5 RW
54
B
108:1.25 WR
99F: 0.85 B 0.5 B
12V
209:0.5 RB
32:0.85 LR
73:0.5 GY
72:0.5 GB
33A:3 RW
203A: 0.5 LB 0.5 RB
4:0.5 GW
66A:3 BR
1.4 kW 31
36:0.5 G
66:3 BW
34:0.5 Y
B
31:3 BY
204A: 0.5 LY 0.5 RY
For opt (AC)
14:3 R
Slow blow switch 58L
12: 3 W
24: 3 W
58R
Alternator E S fuse (50A)
1.25 WR
0.85 BW
301: 0.5 LGB

10: 0.85 RB
0.85 YB
0.85 RL
0.85 RL
15: 0.85 LR
0.85 LR
12V 40A (Red)

1.25 R
0.85 B
0.85 P
0.5 LB
0.5 LY
2 RW
3 RW
215: 3 R
Starter
motor ND relay
30 B
99B:
204:
203:
108:
134:
16:
70:
32:
33:
33:
0.85 LR
0.85 RW
0.85 WB
0.85 RG
0.85 GB
0.85 RY
7:
8:
8:
0.5 GW
13: 2 BY
0.85 G
0.85 R
3 RW
3 BW
3 BR
3 BY
3R
Safety PTO
Head lamp (LH) switch switch
1.25 RW
0.85 RW
0.85 RG
1.25 RG
45/40 W
0.85 RB
215: 3 R
0.85 YB
0.85 LR
0.85 LR
Enginestop
0.85 R
0.5 LB
0.5 LY
(Make COBO)
2 RW
3 RW
Slow blow relay

fuse (50A) L T 50 19
212: 0.5 RL (Green) R H
204:
203:
108:
301:
134:
BR 17
70:
37:
10:
15:
32:
33:
33:
213: 0.5 RY
8:
99C: 0.5 B 5A B2 1
5A 30 AC
10A B1 2
20A 21W Stop lamp (LH)
5A
10A Front samll lamp
20A (Make COBO) 99A: 0.5 B
5A 210: 0.85 RW Tail lamp (LH)
5A 203: 0.5 LB 10W
0.5 GB 72B:0.5 GB 72: 0.5 GB (Make COBO)
0.5 RB 203B:0.5 LB
Ref. Circuit No. Amperage Functions OFF 0.5 B 990D:0.5 LB 21W Rear turn signal
1 1 5A PTO Light switch 1 21W 5W lamp (LH)
2 5A
2
3 Front turn signal lamp (LH)
3 3 10A Stop lamps R
4 4 20A Direction indicator & CAB(AC) Turn signal OFF 0
switch L
5 6 5A Engine stop relay
1
6 5 10A Spare (AC) Horn switch OFF
7 7 20A Warning flash lamps ON 2
8 10 5A Tail lamps (LH)
Main switch Main switch
9 11 5A Tail lamps (RH)
145

Tm215f-Tm217f-Iseki Manuel d'ATELIER PDF

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Tm215f-Tm217f-Iseki Manuel d'ATELIER PDF

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ISEKI TM TRACTOR SERVICE MANUAL

§1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS ......................................................................... 5

CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS ........................................................ 13

CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES .................................................................................... 19

5.1. REMOVAL AND RE-INSTALLATION ................................................................................................................. 23

CHAPTER 4. CLUTCH SYSTEM .................................................................................................................................. 27

CHAPTER 5. TRANSMISSION ...................................................................................................................................... 33

1. GEAR-TYPE TRANSMISSION ............................................................................................................................. 33

CHAPTER 6. REAR AXLE AND BRAKES ................................................................................................................... 43

1. GENERAL DESCRIPTION ................................................................................................................................ 43

CHAPTER 7. MANUAL STEERING SYSTEM .............................................................................................................. 51

§1. CONSTRUCTION .............................................................................................................................................. 51

CHAPTER 8. FRONT AXLE .......................................................................................................................................... 57

CHAPTER 9. HYDRAULIC SYSTEM ............................................................................................................................ 63

§1. GENERAL DESCRIPTION ................................................................................................................................ 63

CHAPTER 10. HYDROSTATIC TRANSMISSION ......................................................................................................... 85

1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS ......................................................................... 85

4.7. REASSEMBLY ................................................................................................................................................... 98

CHAPTER 11. POWER-ASSISTED STEERING SYSTEM ......................................................................................... 111

§1. CONSTRUCTION ............................................................................................................................................ 111

CHAPTER 12. ELECTRICAL SYSTEM ...................................................................................................................... 123

1. FUSES, FUSIBLE LINKS AND SLOW-BLOW FUSE ...................................................................................... 123

CHAPTER 13. SERVICING DATA ............................................................................................................................... 129

1. SPECIFICATIONS & CAPACITIES .................................................................................................................. 129

APPENDIX ................................................................................................................................................................. 137

1. PRECAUTIONS FOR REASSEMBLY ............................................................................................................. 137

CHAPTER 1. GENERAL INFORMATION

§1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS

1. MODEL NAME PLATE 2. CHASSIS PRODUCTION NUMBER

3. ENGINE MODEL AND SERIAL

(1) TM215 or TM217

(3) Production No. 2

Power take-off (PTO)

Models ...................................................................................................................................... TM215 .................................................. TM217

Steering system type ......................................................................................................................................... Manual/ Power-asisted (Option)

Maximum axle loading

Models .............................................................................................................................................. TM215 ................................................. TM217

Agricultural tyres/turf tyres

§ 4. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION

(1) Roller or ball bearings (3) O-rings

2) Installed O-rings should not be twisted or slack.

3) Installed O-rings should maintain proper air tight-

1) Snap ring installers should be designed so as not

(7) Bolts and nuts

Round edge side 1) Special bolts are installed at several locations, so

4) When locking bolts and nuts with an adhesive,

5) Apply an adhesive to parts through which there is

6) Each lock nut must be tightened securely.

7) When tightening bolts and nuts, refer to the tight-

(8) Grease fittings

1) After installation, each grease fitting should be

2) When installing grease fittings of types B and C,

(9) Other precautions

1) Be sure not to damage any finished surfaces or

2) Always refrain from forcing the installation.

3) Each lever knob should be coated with an adhe-

4) Each contact surface should be coated with an

5) Precautions for applying adhesives

– The surface or the thread where an adhesive is to

– The surface or the thread where an adhesive is to

CHAPTER 2. DISASSEMBLING INTO MAJOR

§1. OPERATION CHART FOR DISASSEMBLING AND RE-ASSEMBLING BY

HST model Gear transmission model