TYM

WORKSHOP MANUAL
FOR
TRACTORS
(T394 HST)

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

T394HST
WORKSHOP MANUAL

Chapter 1. Introduction ------------------------------------ 01

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

INTRODUCTION-------------------------------------------------------------- 1-1
SAFETY INTRODUCTION------------------------------------------------- 1-2
WARNING SIGNS IN THIS MANUAL---------------------------------- 1-5
SAFETY SIGNS---------------------------------------------------------------- 1-6
SAFETY DECALS----------------------------------------------------------- 1-11
UNIVERSAL SYMBOLS--------------------------------------------------- 1-14
SECTION 1. TRACTOR TYPES AND PUNCHED
IDENTIFICATION MARKS ----------------------------- 1-15
SECTION 2. SPECIFICATIONS------------------------------------------ 1-17
SECTION 3. GEAR TRAIN DIAGRAMS------------------------------- 1-20
SECTION 4. PRECAUTIONS FOR TRACTOR OPERATIONS--- 1-21
1. INSTRUMENTS ------------------------------------------------------- 1-21
2. CONTROLS ----------------------------------------------------------- 1-22
3. FILLING DIAGRAM AND CAPACITY TABLE--------------- 1-24
4. MAINTENANCE CHART ------------------------------------------- 1-25
 Chapter 1 .Introduction

This tractor Workshop manual is for qualified service personnel engaged in

servicing and overhauling T394HST tractor. Use of this publication is not
recommended for field operators since they usually do not have access to special
tools and shop equipment essential for most servicing.

Servicing procedures outlined herein contain sufficient information to return all

component parts of a tractor to new condition. In discussion of each component
parts, it is assumed that a complete overhaul is been performed, consequently,
complete disassembly and reassembly are outlined. The mechanic is relied upon to
decide how far disassembly must be carried when complete overhaul is not required.

Study unfamiliar service procedures thoroughly and clearly understood before

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

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

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

1-1
SAFETY INSTRUCTION
ALWAYS PRACTICE SAFETY BY THINKING BEFORE ACTION
AVOID FIRE HAZARDS.
-Keep fire extinguishers easily available and in good operating condition.
All relevant personnel should know how to operate fire fighting equipment.
-Keep a first aid kit in an easily accessible location.
-Do not smoke while handling fuel,or other highly flammable material.
-Do not use an open pail for transporting fuel.
-Use of an approved fuel container.
-Dispose of all fuel-soaked rags in covered containers where cigarettes cannot be dropped
carelessly.
-Do not smoke and avoid open flame when charging,jumping,or boosting batteries.
-Batteries give off gas which is flammable and explosive.
-Do not charge batteries in a closed area. Provide proper ventilation to avoid explosion of
accumulated gases.
Avoid acid burns.
-Wear safety goggles when handling battery electrolyte.It contains sulfuric acid which is a poison
and can cause blindness.Avoid it contacting eyes,skin,or clothing. sulfuric acid will eat through
clothing and can cause severe burns to skin.
AVOID HIGH-PRESSURE FLUIDS
1) Before beginning work on hydraulic system components,turn off engine and operate hydraulic
control levers to relieve internal hydraulic pressure.
2) Oil under pressure can penetrate skin and lead to personal injury.Treat sources of oil pressure
with extreme care,wearing safety goggles.
3) If hydraulic leak develops,correct immediately.Escaping hydraulic oil can have extremely high
pressure. A stream of high pressure oil may easily penetrate skin just like modern needless
vaccination equipment,but with the exception that hydraulic fluid may cause blood poisoning.
It is imperative that connections are tight and that all lines and pipes should be in good condition.
If injured by escaping hydraulic fluid,see a doctor at once.

1-2
STAY CLEAR OF PTO

1) Entanglement in rotating drive line can cause serious injury or death.

2) Keep tractor master shield and drive line shield in place at all times except for special applications
as directed in the implement operator's manual.
3) Wear fairly tight tight fitting clothing.Stop the engine and be sure PTO driveline is stopped before
making adjustment,connections,or cleaning out PTO drive equipment.

SERVICE TIRES SAFELY

-Tire changing can be dangerous and should be done by trained personnel using proper tools and
equipment.
-Do not re-inflate a tire that has been run flat or seriously under-inflated.Have it checked by qualified
personnel.
-Use wheel handling equipment adequate for weight involved when removing and installing wheels.

1-3
WARNING SIGNS IN THIS MANUAL
The following warning symbols in this manual draw additional attention to items of importance
for the safe and correct operation of the tractor.

SIGN MEANING OF SIGN

Serious hazard with a very high level of risk of

either serious injury or death
DANGER

Hazard or unsafe practice that can lead to severe

injury or death.
WARNING

Hazard or unsafe practice that can lead in injury

or death.

CAUTION

Instructions for the correct operation of the

machine which, if followed, will ensure that it
performs at it’s best
IMPORTANT

1-4
SAFETY SIGNS

RECOGNIZE SAFETY INFORMATION

This symbol, Safety-Alert Symbol, means ATTENTION! YOUR
SAFETY IS INVOLVED.
The message that follows the symbol contains important information
about safety. Carefully read the message

SIGNAL WORDS.
A signal word―DANGER, WARNING OR CAUTION―is used DANGER
with safety alert symbol. DANGER identifies the most serious
hazards. Safety signs with signal Word ―DANGER OR WARNING
WARNING―are typically near specific hazards. General
precautions are listed on CAUTION safety signs.
CAUTION

READ SAFETY INSTRUCTION

Carefully read all safety instructions given in this manual for your
safety. Tempering with any of the safety devices can cause serious
injuries or death. Keep all safety signs in good condition. Replace
missing or damaged safety signs.
Keep your tractor in proper condition and do not allow any
unauthorized modifications to be carried out on the Tractor, which
may impair the function/safety and affect Tractor life.

PROTECTION CHILDREN
Keep children and others away from the Tractor while operating.
BEFORE YOU REVERSE
- Look behind Tractor for children.
- Do not let children to ride on Tractor or any implement.

1-5
USE OF ROPS AND SEAT BELT
The Roll over Protection Structure (ROPS) has been certified to industry
and/or government standards. Any damage or alternation to the ROPS,
mounting hardware, or seat belt voids the certification and will reduce or
eliminate protection for the operator in the event of a roll-over. The ROPS,
mounting hardware, and seat belt should be checked every service for any
evidence of damage, wear or cracks. In the event of damage or alteration,
the ROPS must be replaced prior to further operation of the Tractor.
The seat belt must be worn during machine operation when the machine is
equipped with a certified ROPS.
Failure to do so will reduce or eliminate protection for the operator in
the event of a roll-over.

PRECAUTION TO AVOID TIPPING

Do not drive where the Tractor could slip or tip.
Stay alert for holes and rocks in the terrain, and other hidden hazards.
Slow down before you make a sharp turn.
Driving forward out of a ditch or mired condition could cause Tractor to
tip over backward. Back out of these situations if possible

PARK TRACTOR SAFELY

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

KEEP RIDERS OFF TRACTOR

Do not allow riders on the Tractor.
Riders on Tractor are subject to injury such as being stuck by foreign
objects and being thrown off of the Tractor

1-6
 HANDLE FUEL SAFELY-AVOID FIRES
Handle fuel with care; it is highly flammable. Do not refuel the
Tractor while smoking or near open flame or sparks.
Always stop engine before refueling Tractors.
Always keep your tractor clean of accumulated grease, and
debris. Always clean up spilled fuel.

STAY CLEAR OF ROTATING SHAFTS

Entanglement in rotating shaft can cause serious injury or death.
Keep PTO shield in place at all times.
Wear close fitting clothing. Stop the engine and be sure PTO drive is
stopped before making adjustments, connections, or cleaning out
PTO driven equipment.

ALWAYS USE SAFETY LIGHTS AND DEVICES

Use of hazard warning lights and turn signals are recommended
when towing equipment on public roads unless prohibited by state or
local regulations.
Use slow moving vehicle (SMV) sign when driving on public road
during both day & night time, unless prohibited by law

PRACTICE SAFE MAINTENANCE

Understand service procedure before doing work.
Keep the surrounding area of the Tractor clean and dry.
Do not attempt to service Tractor when it is in motion.
Keep body and clothing away from rotating shafts.
Always lower equipment to the ground. Stop the engine.
Remove the key. Allow Tractor to cool before any work repair is
caused on it.
Securely support any Tractor elements that must be raised for service
work.
Keep all parts in good condition and properly installed.
Replace worn or broken parts. Replace damage/missing decals.
Remove any buildup of grease or oil from the Tractor.
Disconnect battery ground cable() before making adjustments on
electrical systems or welding on Tractor

1-7
AVOID HIGH-PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the skin causing serious
injury. Keep hands and body away from pinholes and nozzles, which
eject fluids under high pressure. If ANY fluid is injected into the skin.
Consult your doctor immediately.

PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and open flame away from the top of the
battery. Battery gas can explode.
Never check battery charge level by placing a metal object across
the poles.

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to
burn skin, cause holes in clothing and cause blindness if found entry
into eyes.
For adequate safety always;
1.Fill batteries in a well-ventilated area.
2.Wear eye protection and acid proof hand gloves
3. Avoid breathing direct fumes when electrolyte is added.
4. Do not add water to electrolyte as it may splash off causing severe
burns.
If you spill acid on yourself;
1.Flush your skin with water.
2.Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.

SERVICE TRACTOR SAFELY

Do not wear a necktie, scarf or loose clothing when you work near
moving parts. If these items were to get caught, severe injury could
result.
Remove rings and other jeweler to prevent electrical shorts and
entanglement in moving parts.

1-8
WORK IN VENTILATED AREA
Do not start the Tractor in an enclosed building unless the doors &
windows are open for proper ventilation, as tractor fumes can cause
sickness or death. If it is necessary to run an engine in an enclosed area
remove the exhaust fumes by connecting an exhaust pipe extension
which vents the fumes outside the enclosed area.

Using external control

Stand well clear of the rear linkage and implements when
using the hitch remote switches or injury can result from
moving parts.

TRACTOR RUNAWAY

1 .The Tractor can start even if the transmission is in the engaged position causing the Tractor
to runaway and cause serious injury to the people standing nearby the tractor.
2 .For additional safety keep the pull to stop knob (were fitted)(fuel shut off control) in fully
pulled out position. Transmission in neutral position Foot brake engaged and PTO lever in
disengaged position while attending to the Safety Starter Switch or any other work on
Tractor.

SAFETY STARTER SWITCH

1. Clutch operated safety switch is provided on all Tractors which allow the starting system to
become operational only when the Clutch pedal is fully pressed.
2. Do not By-pass this safety starter switch or work on it. Only Authorized Dealers are
recommended to work on safety starter switch.
3. On some models Safety Starter switch is provided on transmission High-low shifter lever
and in PTO shifter lever.The tractor can be started only if High-low shifter lever is in
neutral position.

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

1-9
 SAFETY DECALS

The following safety decals ARE INSTALLED ON THE MACHINE.

If a decal become damaged, illegible or is on the machine, replace it. The decal part number is listed
in the parts lists (Refer to Fig 903 in the parts catalogue)

DECALS ON THE DASH COVER

1-10
DECALS ON THE CHASSIS

1-11
DECALS AROUND THE SEAT

1-12
 UNIVERSAL SYMBOLS
Some of the universal symbols have been shown below with an indication of their meaning

Engine speed Pressured- Corrosive

rev/minX100) open slowly substance

”Tortoise”
Hours, Continuous
Slow or
recorded variable
minimum Setting

Engine ”Hare” fast or

coolant Warning maximum
temperature setting
Hazard
Transmission
Fuel level warning
oil pressure

Engine
Stop Neutral Turn signal
control

Transmission
Lights Fan
oil temperature

Power take
Horn Parking brake
off engaged

Power
Engine oil
take off Work lamps
pressure
disengaged

Differential
Air filter
Lift arm/raise lock

See
Battery charge Lift arm/lower operator’s
manual

Regen Request Exhaust Temp

Lamp Lamp

1-13
SECTION 1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS
The tractor serial number is shown on the left hand side of the tractor as shown in the picture.

The engine number is stamped on the top of the engine block.

Stamped position of the

Engine type or Number

Manufacturer’s tractor Sr. No.

stamped on plate on the L.H.S of Axle bracket

1.MODEL NAME PLATE

The plate indicates the model and type of the tractor.
① Model name
② Production I.D No.
The production I.D reference number is as shown
below
39NH K 00001
39SH K 00001

Production serial No
Production year
Production Model

1-14
2. Engine Model Identification and serial number location.
1) Engine identification location (1) 3) Description of engine model number

Ex) 3 TNV 88 C - DKTF

2) Engine EPA decal (2) Note : When ordering parts or making an inquiry
about the engine you are working on, be sure to
include the complete model and serial numbers as
shown on the engine nameplate.

This decal represents that this engine is in compliance

with the U.S.EPA and California (CARB) exhaust
Emission regulation.

Note : The engine number is necessary information

that is requisite for the warranty registration form.
Engine number assignment standard

E YDX L 1.64 M 3 N

1-15
SECTION 2. SPECIFICATIONS

MODEL T394

Maker YANMAR

Model 3TNV88-CR

Type Water cooled 4 cycle 4 cylinder diesel

Out put (Kw(ps)/rpm) T394 – 27.5 (37.4) / 3,000rpm

Number of Cylinder 3

Displacement (cu-in/cc) 100.2 / 1,642

Bore and Stroke T394 - 88 mm X 90mm

Compression ratio T394 – 19.1

Engine
Firing order 1-3-2-1

Injection pump CRDI

Lubrication type Forced circulation

Cooling system Water cooled, Forced circulation

Coolant capacity 4.8ℓ(1.27 US gal)

Air cleaner Dry dual Element

Muffler Horizontal

Fuel Diesel fuel

Fuel Tank capacity 33ℓ(8.7 US gal)

Battery 12V80AH (Option)

Starting system Starter motor with pre-heater

Electrical
Starter Capacity 1.4KW

Alternator 12V 55A

Hydraulic, + Mechanical
Transmission
3 range gear with constant-mesh

Drive Train MFWD(4WD) Standard

Differential lock Bevel gears with diff-Lock

Brakes Wet disc brake, mechanical

Steering hydraulic

1-16
 MODEL T394
Clutch Main Dry single disc, mechanic
PTO Multiple wet disk
Dimensions Overall length(mm) 3,200 (126”)
Overall width (mm) 1,360 (53.5”)
Overall Height (mm) 2400 (94.5”)
Wheel base (mm)
1,680 (66.1”)
(Distance between shafts)
Min. Ground Clearance (mm) 325 (12.8”)
Front 8-16, 4PR
R1
Rear 12.4-24, 6PR
Front 27X10, 50-15, 8PR
R4
Rear 12.5-20 R4, 12PR
Front 27X10, 50LL-15, 6PR
R3
Rear 41X14, 00-20- RL
Front Center pin
Axle type
Rear Central axle

Implement Operation Hydraulic

Mounting method 3-Point hitch

Drawing method Trailer hitch

3-Point hitch category Category 1

Hydraulic-control Position, Remote control, Joystick

Traveling speeds : Km/h (Mile/h)

Engine rpm @3,000

Range shift Forward Reverse
L ~8.08 (~5.02) ~8.46 (~5.26)
M ~15.46 (~9.61) ~16.2(~10.07)
H ~28.96 (~18.00) ~30.34(~18.86)

1-17
SECTION 3. GEAR TRAIN DIAGRAMS

FIG.1-3 GEAR TRAIN DIAGRAM

1-18
 SECTION 4. PRECAUTION FOR TRACTOR OPERATION
1. INSTRUMENTS

Left turn Indicator lamp Tachometer

Right turn Indicator lamp
Fuel Gauge
Hazard Warning Signal S/W
Throttle Lever

Regen Disable Lamp

and Regen Disable S/W PTO ON/OFF S/W

Regen ACK Lamp Key S/W

and RegenDisable S/W
PTO Control S/W
Cruise control S/W
Turn Signal S/W
Parking Brake Lever
Horn S/W
Head Lamp S/W
ECU
Tilt Lever

Note;
Oil pressure warning light and charge light on the monitor array will light when the main switch is
turned from OFF to ON
- All lights on the panel go out automatically when the engine is started and its speed is increased to
a specific level.
- Do not panic if some lights on the monitor light array do not go out while the engine is at idle speed
just after its starting.They will go out automatically when the engine speed reaches as a specific level.

1-19
 MONITOR LIGHT ARRAY

High beam lamp Low beam lamp PTO monitor Lamp Fuel 4WD drive lamp

Charge Glow signal Oil pressure Parking brake Check lamp Cruise Control
lamp Lamp lamp lamp Lamp

Air cleaner filter

contamination indicator Regen Request Lamp Exhaust Temp Lamp

2. CONTROLS

1-20
3. FILLING DIAGRAM & CAPACITY TABLE

TABLE 1-7
No. Filling point Fillings Quantity Liter (gal)
MODEL T394HST
1 RADIATOR 50/50 : Ethylene Glycol/Water (L.L.C)
7ℓ(1.85 US gal)
ASTM D4985 / D6210
2 ENGINE API : CJ-4 grades
Above:25°C(77°F)… SAE30 or 15W/40
0°C to 25°C(32°F to 77°F)… 5 ℓ (1.32 US gal)
SAE20 or 10W30
Below 0°C(32°F)… SAE 10W or 10W-30
3 TRANSMISSION CASE 35ℓ(9.25 US gal)
4 FRONT AXLE THF 500 (API GL-4 Grades) Gear oil #80 or #90
8.2ℓ(2.166US gal)
5 FINAL DRIVE CASE(B)
6 Clutch pedal shaft Grease As required
7 BALL JOINT Grease As required
8 FUEL TANK Diesel fuel 34ℓ(9 US gal)

Tire size and inflation TABLE 1-8

Tire DIVISION SIZE Air pressure Mpa (PSI) MODEL
Front 8-16, 4PR 0.176 Mpa (25.53 PSI)
R1 (Ag)
Rear 12.4-24, 6PR 0.176 Mpa (25.53 PSI)
Front 27X10, 50-15, 8PR 0.380 Mpa (55.11 PSI)
R4 (Ind) T394HST
Rear 12.5-20 R4, 12PR 0.340 Mpa (49.31 PSI)
Front 27X10, 50LL-15, 6PR 0.220 Mpa (31.91 PSI)
R3 (Turf)
Rear 41X14, 00-20- RL 0.170 Mpa (24.66 PSI)

1-21
 4. MAINTENANCE CHART
○ inspection,replenish,and adjustment
● Replacement △ Cleaning and/or washing
☞ ENGINE ★ Consult your Dealer

Inspection and servicing intervals

Daily

Hour of operation
Inspection Judgment
(X10 on hour meter)
items Intervals after that criteria
5 1 1 2 2 3 3 4 4 5 5 6 mm(in)
0 5 0 5 0 5 0 5 0 5 0

Level is between
Engine oil ○ ● ● ● Every 250 hours or upper and lower
12months after first 50 limits
hours
Oil filter ● ● ●
Clean after every
100hrs.Replace element
Air cleaner △ △ △ △ △ ● that has been washed
more than 5 times

Replace every year.

Radiator Fill coolant up to
coolant
○ Check daily top up if radiator throat
required
Check daily for
Radiator ○ damages leakage

Radiator fin Clean cooling fins

& screen
○ △ △ △ and cores

Everyday and
Fuel ○ Tank should be full
before work
Wash after every
Fuel filter ○ △ △ △ △ ● 100hrs.and replace after
500 hrs or 12months

Check daily
About 5(0.20in)
Fan belt ○ deflection pushed
with a finger

Hose clamps ○

Check after every

Electrolyte 100hrs.and replenish if
level
○ ○ ○ ○ ○ ○ ○ necessary

1-25
 ○ inspection,replenish,and adjustment
● Replacement △ Cleaning and/or washing

☞ TRANSMISSION ★ Consult your Dealer

Inspection and servicing intervals

Daily

Hour of operation
Inspection Judgeement
(X10 on hour meter) criteria
items Intervals after that
mm(in)
5 1 1 2 2 3 3 4 4 5 5 6
0 5 0 5 0 5 0 5 0 5 0

Clean hydraulic
Transmission
oil
○ ● ★ ● suction filter at the
same time.
Every 500 hours or
HST oil Filter ● ● ● 12months
after first 50 hours
Front axle oil
● ★ ●
(4WD)

Free play:
Brake pedal ○
1.18~1.57 in

Replenish after every 50

Greasing up
each part
○ hrs(every time after
pudding)

Steering
wheel free
play ○

Toe-in ★ ★ Check every 300 hrs 0.08~0.24 in

Front wheel Inject grease after every

hub greasing 300 hrs

Retightening
ball joints of
steering ○ Check after every 300 hrs
system
All should be
Wheel tighten (kgf.cm)
tightening ○ Front : 1600~1800
bolts Rear : 1600~1800

Replenish every 50 hrs

Greasing each
nipple
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ (Everyday in dusty
condition)

Loose bolts
and nuts
○

Electric
wiring
○ ○ ○ Check every year

1-26
 ○ inspection, replenish, and adjustment
● Replacement △ Cleaning and/or washing
★ Consult your Dealer

Daily Inspection and servicing intervals

Hour of operation
Inspection Judgment criteria
(X10 on hour meter)
items Intervals after that mm(in)
5 1 1 2 2 3 3 4 4 5 5 6
0 5 0 5 0 5 0 5 0 5 0

Electric All should work

Parentheses properly

Adjusting
accelerator Check after 300
pedal and
★ ★
hours
throttle lever
Check every year by
Oil leaks in removing the plug
clutch installed in the front
housing bottom of clutch
chamber
Strainer Clean at first 50 hrs.
(Hydraulic △ ★ ● Replace every 500 hrs.
fluid filter ) Check every 250 hrs

Check after every 100

Rubber pipes ○ ○ ○ ○ ○ ○ hrs.

1) Every terminal should be connected securely

2) Wiring should not interfere with other parts.
3) Fatigued wiring should be replaced.
4) Wiring should be held in each clamp properly.

1-27
 Chapter 2
Disassembly and reassembly of major components

SECTION 1. GENERAL PRECAUTIONS AND SEPARATION

AND REINSTALLATION --------------------------------- 2-1
1. Before operation ------------------------------------------------- 2-1
2. Precautions to be followed when installing standardized parts.
----------------------------- 2-1

SECTION 2. OPERATION CHART FOR DISASSEMBLY

AND REASSEMBLY BY MAJOR BLOCKS------------ 2-4

SECTION 3. SEPARATION OF MAJOR COMPONENTS -------- 2-5

1. Separation of the front axle and axle bracket --------------------------- 2-5
2. Separation of the engine and front axle bracket -------------------------- 2-6
3. Separation of the engine and front transmission --------------------------- 2-7
4. Separation of the mid transmission and rear trans mission------------------ 2-12
5. Separation of the rear transmission and rear axle housing ------------------ 2-16
6. Separation of the rear transmission and Cylinder case ---------------------- 2-18
 Chapter 2
Disassembly and reassembly of major components

SECTION 1. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION

1.BEFORE OPERATION 2. PRECAUTIONS TO BE FOLLOWED

WHEN INSTALLING STANDARDIZED
PARTS.
1) Always be safety-conscious in selecting
(1) Roller or Ball bearings
clothes to wear and suitable tools to use.
1) When a bearing is fitted in by the outer race,
use an installer which is an specially
2) Before disassembly, be sure that you
designed to push only the outer race and vice
familiarize yourself with the assembled
versa.
condition for subsequence in reassembly.
2) The installer must be designed to install the
3) Keep parts and tools in proper order
bearing on the shaft in a parallel position.
during operations.
3) When installing a bearing which appears the
4) When servicing electrically charged
same on both sides, install it so that the face
parts,be sure to disconnect the negative
which has the identification number faces
battery terminal.
in a direction for easy visual identification. All
the bearings which are to be installed in the
5) To prevent oil or water leaks,use the
transmission case should be placed so that
liquid gasket as required.
their identification number faces outward.
6) When lifting up only the front or rear part
4) If a shaft or hole where a bearing is to be
of the tractor,be sure to wedge the
installed has a stopper, the bearing should be
grounded wheels.
pushed in completely until it is seated against
the stopper.
8) When the tractor is jacked up, be sure to
support the entire tractor with something
5) Installed bearings should turn smoothly.
like a stand.Lifting it up with a jack only
is dangerously unstable procedure.
(2) Oil seals
1) Oil seals installer should be designed so as
9) When replacing parts,use authorized,
not to deform the oil seals.
genuine TYM parts only.TYM assumes no
2) During installation, be careful not to damage
responsibility for accidents,operating
the lips, and assure that it is pushed in parallel
problems or damage caused by the use of
to the shaft or hole.
imitation parts.
3) When oil seals are installed, there should be
no turnover of the lips nor dislocation of the
Also,the use of unauthorized parts will
springs.
result in relatively poor machine
4) When a multi-lip seal is installed, the grooves
performance.
between lips should be filed with grease, not
adhesive.

2-1
(3) O-rings 3) The roll pins installed in the transmission or
1) O-rings should be coated with grease other parts where much force is applied
before installing. should be retained with the wire.
2) Installed O-rings should have no slack or
(6) Cotter pins
twist.
When installed, cotter pins should be bent
3) Installed O-rings should maintain proper
securely at the ends as shown in the figure
air tightness.
(4) Snap rings
1) Snap ring installers should be designed so
as not to permanently deform the snap
rings.
2) Installed snap rings should be seated
securely in the groove. Fig.2-3
3) Be careful not to overload the snap ring
to the extent that it is permanently (7) Bolts and nuts
deformed. 1)Special bolts are installed at several locations,
4) How to install the snap ring: so be sure not to interchange them other bolts.
When installing a snap ring,install it as 2) Bolts and nuts should be tightened to their
shown in the figure with its round edge specified torque wrench.
side turned toward the part to be 3) When locking the bolts or nuts with wire or
retained.This round edge is formed when a lock washer, Be sure to wind the wire paying
the snap ring is pressed out. sufficient attention to its winding direction and
bend the lock washer for secure looking.
4) When locking bolts and nuts with an adhesive,
apply the adhesive on the thread and tighten
securely.
5) Apply an adhesive(THREE BOND TB1104)
to parts through which there is any possibility
of oil leaks,such as stud bolts and tapped-
through parts.
Fig.2-1 6) Each lock nut must be tightened securely.
7) When tightening bolts and nuts, refer to the
(5) Spring(roll) pins
tightening torque table.
1) Spring pins should be driven in properly as
tightly.
(8) After installation, each grease fitting
2) Spring pins should be installed so that their
should be filled with grease.
seams should face the direction from which
1) When installing grease fittings of type B and
the
C, be sure to turn the fitting tips in a direction
load is applied.
that will provide easy access for a grease gun.

(9) Other precautions.

1) Be sure not to damage any finished surfaces
or parts.
2) Always refrain from forcing installation.
3) Each lever knob should be installed coated
with an adhesive
(SUPER THREE CEMENT TB1702)

Fig.2-2 2-2
4) Each contact surface should be coated with an 5) Precautions for applying adhesives.
adhesive(THREE BOND TB 1215) and tightened The surface or the thread where and adhesive
evenly with bolts. Adhesive coated surfaces should is to applied should be completely free of chips.
be installed within 30 minutes after application of The surface or the thread where an adhesive is
the adhesive. The contact surfaces should be flawless to be applied should be completely free of oil-
and free from foreign matter, and especially from ness.
grease before application of the adhesive.
Bolt Tightening Torque (kgf.m)
4T 7T 9T
Spec
Coarse Fine Coarse Fine Coarse Fine
M3 0.07~0.09 - - - - -
M5 0.35~0.45 - 0.5~0.7 - - -
M6 0.50~0.70 - 1.1~1.4 - 1.25~1.45 -
M8 1.3~1.7 - 2.3~3.0 - 3.0~3.5 -
M10 2.5~3.5 2.0~2.8 4.5~6.0 3.6~4.8 6.5~7.2 5.2~5.76
M12 4.5~6.0 3.6~4.8 8.0~10 6.4~8.0 10.5~12 8.4~9.6
M14 7.0~8.5 5.6~6.8 12~15 9.2~12 17~20 13.6~16.0
M16 11~14 8.8~11.2 17~21 13.6~16.8 20.5~31 16.4~24.8
M18 16~19 12.8~15.2 24~29 19.2~23.2 35~41 28~32.8
M20 22~27 17.6~21.6 33~41 25.4~32.8 50~58 40~46.4
* In case of nut torque, 80% torque of above table respectively

Air-conditioner (kgf.m)
Coupling-Hydraulic (Kgf-m)
Without With O-
R-12 (R-134a) Pipe Diam.
O-ring ring
7/16-20UNF ( - ) 1/4”,D6 1-1.5 - ¼” 2.5
9/16-18UNF (M16xP1.5) 5/6”,D8 2-3 1-2 3/8” 5
5/8-18UNF (M18xP1.5) 3/8”,D9.52 2-3 1-2 ½” 6
3/4-16UNF (M20xP1.5) 1/2”, D12.7 3-4 1.5-2.5 ¾” 12
7/8-14UNF (M22xP1.5) 5/8”,D15.8 4-5 2-3 1” 14
11/16-14UNF ( - ) 3/4”,D18.9 5-6 2.5-3.5 1-1/4” 17
11/14-12UNF ( - ) 7/8”,D22.2 6-7.5 3-4 1-1/2” 21

Nut-Bearing (kgf.m) (Calking Nut only)

AN02 AN03 AN04 AN05 AN06 AN07 AN08 AN09 AN10 AN11 AN12
M 1 5 M17 M20 M25 M30 M35 M 4 0 M45 M50 M55 M 6 0
2 - 4 2 - 4 3 - 5 3 - 5 3 - 5 6 - 8 6 - 8 6 - 8 8-10 8-10 8 -1 0

2-3
SECTION 2. OPERATION CHART FOR DISASSEMBLY AND
REASSEMBLY BY MAJOR BLOCKS

•Power steering •Center pivot

•Air cleaner Axle Bracket Front Axle •Final case
•Radiator •Differential gear
•Oil cooler

•Engine front parts Engine •Muffler

•HST UNIT
Front
Transmission

Space
transmission
•Flow-Divider
•PTO Clutch
•HST control linkage

•Speed range gears

•Drive pinion
•Mid PTO gears
Rear
transmission

•Ring gear
Cylinder case •Differential gear Brake case Rear Axle Housing
•Valve system •Rear PTO gear
•Brake
•Control linkage •Diff-Lock (RH) •Final gear
•Piston and Arm •Wheel shaft

2-4
 SECTION 3. SEPARATION OF MAJOR COMPONENTS
1.SEPARATION OF THE FRONT Note:
AXLE AND AXLE BRACKET When working on the 4WD version, the drive shaft
should be removed ahead of time.

Parts which can be inspected during This

operation
-Center pivot
-Final case
-Differential gear

(1) Removal
1) Hold the front hitch or the front bracket
securely with a crane or stands.
2) Support the front axle with a jack
3) Remove the power steering hoses to the
power steering cylinder.
4) Remove the pivot metal bolts.
5) Remove the front axle assembly forward.

FIG.2-5 Drive shaft

(2) Installation
1) Install the front axle assembly.
2) Install both pivot metals(supports)

Power Steering Hoses

pivot metal (R)

FIG.2-6 Front axle

Note:
pivot metal (F)
Apply grease to the bushing and fill the oil seal with
grease ahead of time.Install the oil seal carefully not
FIG.2-4 Front axle to allow its lips to turn over.
3) install both of the right and left tie rod.
2-5
2.SEPARATION OF THE ENGINE AND THE FRONT AXLE BRACKET
5) Remove the other wiring and clamp.
Parts which can be inspected during This
6) Remove the fuel hoses.
operation
7) Remove the upper hose, lower hose and
-Air cleaner
drain hose from the radiator.
-Radiator
8) Remove the steering hoses.
-Power steering system
9) Remove oil cooler pipes in the middle of them
-Oil cooler
from the axle bracket.
-Engine front part.

(1) Removal Fuel Feed Pump

Fuel Cock Water separator
1) Hold or support the engine with a crane or
stands.
2) Hold or support the front bracket or the axle Fuel Filter Element
bracket in a manner that the part other than
the engine can be removed if required.
3) Open the Engine hood.

Fuel filter

Fig.2-9 Fuel filter

FIG.2-7 Hood and damper

Fig.2-10 Oil cooler
4) Disconnect the positive and negative battery
cables.

FIG.2-8 Battery

2-6
 3.SEPARATION OF THE ENGINE
AND THE FRONT TRANSMISSION.

Parts which can be inspected during this

operation.
-Fly wheel
-HST unit

(1) Removal
1) Drain the transmission of the oil if needed.
Remove the front wheel drive shaft.
Disconnect the battery cables.
Wedge both sides of the front axle to prevent
the engine from tilting.
Fig.2-11 Oil cooler
10) Remove the mounting bolts (LH / RH).

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

(2) installation
Reassemble in reverse order of removal.
1) Install the axle bracket on the engine.
2) Retighten the mounting bolts.
3) Connect the piping of the power steering
system.
4) Install the battery cables, other wiring and clamp.
5) Install the pipes of the oil cooler.
6) Connect the upper, lower and drain radiator hoses.
7) Install the fuel hoses.
8) Fill the radiator with coolant.

FIG.2-12

2-7
2) Support the engine on the bottom with a jack 6) Disconnect the pipes for the oil cooler.
or stands. Remove the fuel hoses.
3) Hold the transmission with a garage jack or a
crane so that the transmission side can be
moved when needed.

FIG.2-13

4) Disconnect the hydraulic hoses for power steering.

FIG.2-16

FIG.2-14

5) Disconnect the rubber hose from the suction pipe.

Disconnect the pipe from gear pump.

FIG.2-15
2-8
7) Detach the wiring harness.

FIG.2-17

8) Remove the mounting bolts and nuts.

FIG.2-18

2-9
(2) Engine separation from the chassis.
When separating the engine from the chassis, the following steps are required as well as the ones
mentioned above.

FIG.2-19 suction pipe.

1) Lift the engine with the hoist and hold the front axle bracket with a stands or the like.
2) Disconnect the upper, Lower and drain hoses from the radiator.
3) Disconnect the air cleaner assembly.

FIG.2-20 Line up

4) Remove the fuel hose.

5) Disconnect the hydraulic pipes(If needed).
6) Loosen the tightening bolts on the front
axle bracket.
7) Separate the engine from the front axle
bracket.

2-10
(3) INSTALLATION
REASSEMBLY IN REVERSE ORDER OF REMOVAL.
1) Install the engine on the front axle bracket.
2) Retightening the tightening bolts on the front axle bracket.
3) Connect the fuel hoses.
4) Connect the radiator hoses.
5) Install the air cleaner assembly.
6) Assemble the engine and the front transmission.
Note:
- Apply small mount of grease to each of the sliding parts.
Be careful not to apply excessive amount of grease as this could cause clutch slipping.
- During operation, be sure to avoid any of the reassembly operations that may place load
upon the input gear.
7) Install the hydraulic pipes.
8) Install the steering pipes.
9) Install the wirings and clamp.
10) Connect the battery terminals.

2-11
4.SEPARATION OF THE MID TRANSMISSION AND REAR TRANSMISSION
Parts which can be inspected during This 7) Remove the slow-return check valve knob.
operation Remove the diff-lock pedal.
-HST unit -PTO clutch -Range gears

1) Removal
A:Removal of the whole floor.
1) Disconnect the negative battery cable.
2) Detach all the wiring relevant to the removal of
the floor.

FIG.2-23 Slow return check valve

8) Remove the knob of remote control lever.
When the tractor is equipped with an optional
remote control valve, remove the remote control
valve link.
Remove the knob of the position control lever.
Remove the knob of Rage gear lever.
Remove the 4WD shifting lever.
Remove the knob of the PTO lever.

FIG.2-22
3) Remove the steering pipes from hydraulic cylinder.
Disconnect the fuel hoses.
4) Disconnect the oil cooler pipes in the middle.
5) Disconnect the hydraulic pipes at the hydraulic pump.
Remove the front end loader valve from the bracket.
6) Remove the Forward and Reverse pedals in the middle. FIG.2-24 remote control valve lever
Remove the pins which is connected between the brake rod
and the linkage.

2-12
9) Remove the parking brake (If equipped).
10) Remove four rubber mounts.

FIG.2-28 Rubber mounting

11) Lift up the floor slightly with a hoist.

12) Disconnect the clamp which is tied.

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

2-13
B: Division of the chassis.
1) Drain the transmission of oil
2) Remove the front wheel drive shaft

FIG.2-33 Front wheel drive

3) Disconnect the brake rods.

Slow return check valve

Brake rod.
FIG.2-34 Brake rod.
4) When the tractor is equipped with an
optional remote control valve ,remove the
remote control piping.

FIG.2-35 Optional remote control valve

2-14
5) Remove the suction and delivery pipes.
6) Remove the delivery pipe for the PTO clutch.
7) Remove the 4WD shift metal

FIG.2-37 PTO Clutch

Note : Position the floor taking care not to allow
wiring or other parts to be pinched under it
(7) With the floor lifted up a little, install the fuel
FIG.2-36 4WD shift metal hoses.
(8) Fix the floor at the four rubber mounts.
8) Hold the space and rear transmission case with (9) Install all levers, knobs, and Rods.
a crane or jack. (10) Install the wirings and clamp.
9) Remove the bolts which tighten the front (11) Connect the negative battery cable.
transmission and spacer transmission cases. (12) Fill the transmission case with oil
Remove the rod for HST unit control. T394HST: 35ℓ
10) Remove the front transmission case and
the HST unit
11) The spacer and rear transmission assembly
will be separated.
Note:
When moving the rear part of the tractor.
be careful not to allow the garage jack to shift
from the spacer transmission case.

2.installation
Reassemble in reverse order of disassembly.
FIG.2-39 forward and Reverse arm
(1) Assemble the spacer transmission on the rear.
Install the HST unit on the spacer transmission case.
Install the front transmission case.

Note : Make sure that the turning lock of the PTO

clutch is securely seated in the groove in the
spacer transmission case.

(3) Install the PTO clutch and HST unit delivery piping.
(4) Install the 4WD shift metal and the brake rods.
(5) Install the hydraulic pipes.
(6) Install the front wheel drive shaft.

2-15
 5.SEPARATION OF THE REAR TRANSMISSION AND REAR AXLE HOUSING

Parts which can be inspected during This operation

- Diff Lock
- Brakes
-Final gears

1) Removal (6) Detach the brake assembly from the rear

As both sides can be disassembled in the same transmission case after removing the rear
way, only side with the diff-lock installed will be axle housing tightening bolts.
explained here.
(1) Drain the transmission case of oil.
(2) Support the rear transmission with a jack or stands.
(3) Hold the floor frame assembly with a crane.
(4) Remove the tire.
(5) Remove the mounting bolt along with rubber bracket.
Loosen the three other points slightly.

FIG.2-40

(6) Remove the 3-point linkage and related parts.

FIG.2-41

2-16
2) Installation

Reassemble in reverse order of disassembly.

(1) Join the rear axle housing and rear transmission

Note:
Make sure that the diff-lock shifter is fitted into the groove in the dif-lock metal

(2) Reinstall the other removed parts.

(3) Mount the rear tire.
(4) Refill the transmission with oil up to the specified level.

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

FIG.2-42

2-17
6.SEPARATION OF THE REAR TRANSMISSION AND CYLINDER CASE
Parts which can be inspected during This
operation
- Control valve
- Control linkage
- Piston and lift crank linkage
- PTO change gears.

Inspection and service of the rear transmission (10) Detach the delivery pipe from the cylinder
should be performed following the instructions case.
in the paragraph : 5 SEPARATION OF THE (12) Remove the slow-return check valve along
REAR TRANSMISSION AND FRONT with the shaft.
TRANSMISSION (13) Remove the 3-point lift link and related
parts from the lift arm.
1)Removal (14) Remove the Cylinder case tightening bolts.
(1) Remove the operator’s seat(If required). (15) Detach the cylinder case assembly from
the rear transmission

FIG.2-30 operator’s seat

(2) Remove the position lever
(3) Remove the lever guide(RH)
(4) When the tractor is equipped with an
optional remote control valve, remove the
remote control lever and related parts from FIG.2-31 cylinder case
the bracket.
(5) Remove the back panel(If needed).
(6) Remove the tank cover(If needed). 2) Installation
(7) Remove the wiring for the rear combination Reassemble the reverse order of disassemble.
lamps and trailer socket coupler(If needed). (1) Tighten the cylinder case on the rear
(8) Drain the fuel of fuel tank(If needed). transmission case to the specified torque.
(9) Remove the fuel tank and tank stay bracket Tightening torque 550∼700 kgf-Cm
(If needed).
(39.8~50.6lb.fts)

(2) After reassembly, make sure that the system

functions properly.

2-18
 Chapter 3
ENGINE ACCESSORIES

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

1. General description ------------------------------------------------------ 3-1
2. Radiator -------------------------------------------------------------------------------------------- 3-2
3. Specifications ------------------------------------------------------------------------------------ 3-3
4. Removal of the radiator -------------------------------------------------------------------3-3
5. Inspection of each part -------------------------------------------------------------------- 3-3
6. Radiator reassembly ------------------------------------------------------3-5
7. Daily inspection ----------------------------------------------------------- 3-5
8. Trouble shooting ---------------------------------------------------------- 3-6
SECTION 2. AIR CLEANER SYSTEM---------------------------------- 3-7
1. General description ------------------------------------------------------ 3-7
2. Double elementary air-cleaner ---------------------------------------- 3-8
3. Inspection of each part-------------------------------------------------- 3-9
4. Cleaning of the air cleaner---------------------------------------------- 3-9
5. Element installation ------------------------------------------------------ 3-10
 Chapter 3.Engine accessories

SECTION 1. RADIATOR
1.General description
The pressure cooling system includes mainly the
radiator,water pump,multi-blade fan, and
the thermostat.During the warm-up period,the
thermostat remains closed and coolant is directed
through by-pass to the suction side of the water
pump.
Coolant then circulates through the cylinder block
and water pump only to provide a uniform and fast
warm-up period. Once the engine has reached
operating temperature,the thermostat opens and
coolant is pumped from the bottom of the radiator
via the lower hose into the cylinder block. Here it
circulates through the block and around the
cylinders.
FIG.3-1
From the cylinder block,coolant is directed through
the cylinder head and into the thermostat
housing.With the thermostat open,coolant passes
through the housing and upper radiator hose into
the top of the radiator where it is circulated to
dissipate heat.

FIG.3-2

3-1
 2. Radiator
The radiator consists of radiator cores, a tank to Flow coolant, side plates to install the radiator,
and a fan guide. Fin-tube type cores are used and the cores and tank is made of anti corrosive aluminum
and aluminum alloy.

1. RADIATOR SET 2. SHROUD 4. SPONGE, UNDER 5. BOLT , C/R HEX/SP

6. HOSE , RADIATOR INLET 7. CLIP , 45 8. HOSE . RADIATOR OUTLET 9. SPONGE , FRONT 430
10. SPONGE , SIDE(430) 11. BRACKET COMP , FIX RADIATOR RH 12. BOLT . HEX /SP
13. BRACKET COMP , FIX RADIATOR LH 14. BOLT , C/R HEX/SP 15. NET COMP
16. BRACKET COMP, TANK 17. BOLT , HEX/SP 18. HOLDER COMP , TANK/RESERVE
19. BOLT , HEX/SP 20. TANK ASSY , RESERVE 21. HOSE . 500 22. CLIP , HOSE D=12.5
23. CAP , RADIATOR 24. BAND , HOSE 25. CLAMP , 40 26. INSULATOR , RADIATOR
27. CUSHION RUBBER , RADIATOR
FIG.3-3
3-2
 3. SPECIFICATIONS

Description T394HST
Radiator core type Flat water tube with corrugate fins
Core train number 4 trains
Radiator fin pitch 4.2 mm
Thermal radiator area 9.3044㎡
Pressure valve opening pressure 0.9±0.15Kgf/ ㎠
Coolant capacity 7 ℓ(contains in cylinder block)
Test pressure 0.9±0.15 Kgf/㎠

4. REMOVAL OF THE RADIATOR Excessively compressed air may damage the cores,
1) Release the clamp and remove the upper hose. so perform the air delivery carefully,watching the
pressure gauge. Water leaks are inspected by
2) Release the clamp and remove the lower hose. watching for rising air bubbles.
3) Release the hose clamp and remove the water
drain hose.

Note:
- Refer to the paragraph”SEPARATION OF THE
ENGINE AND THE FRONT AXLE BRACKET
in chapter 2 for operation up to this step.

-When removing the radiator,take care not to

damage the radiator cores and oil cooler.
5. INSPECTION OF EACH PART FIG.3-4
(1) Inspection for radiator water leaks.

Water leaks are liable to occur at the fitting

portion between the upper tank and the core b.Leak test with a radiator cap tester
section or between the lower tank and the core
section. With the inlet and outlet pipes plugged up and the
If any water leak should occur there,repair the leak radiator filled with water,replace radiator cap with
by soldering.Besides making a visual check,a more a radiator cap tester as shown in the figure.
complete inspection should be accomplished as Pump up the pressure in the radiator to the specified
follows: value and check to see if there are any leaks in the
radiator.
a. Leak test with compressed air. When the radiator is water-tight,the pressure
Place the radiator as shown in the figure. Close indicated on the pressure gauge does not
the openings for water inlet and with something increase,but if there are leaks,the pressure
like a rubber plug and apply compressed air decreases.This tester is also applicable for leak tests
(1㎏f/㎠ or 14.2psi) through the drain pipe for the whole cooling system,not only for the
into the radiator. radiator.The test method is the same as mentioned
above.
3-3
 -Clean with a detergent
When cleaning the radiator with a detergent,
follow the instructions given by its manufacturer.
Different detergents have different characteristics.

b. Cleaning the radiator exterior

- Cleaning the net (wire mesh)

After the tractor has been operated in dusty
FIG.3-5 conditions,check the net daily and clean it if
necessary.
Testing Pressure 1.8Kgf/ /㎠
-Cleaning the radiator cores
2) Inspection for radiator clogging
Clean the radiator cores by applying water spray
To inspect the radiator cores to see if they are or compressed air so as to for a right angle with
clogged with fur or rust,remove the radiator cap and the radiator cores,moving water application in
check for transparency of the coolant,and for rust or parallel.
fur formation around the radiator throat inside the
radiator. Note:
If some rust or fur has formed or the coolant When cleaning the radiator cores with pressurized
transparency is very poor,the radiator should be water,be sure to apply it at a right angle to the
cleaned. cores. Slanted application might deform their
cooling fins.
a. Cleaning the radiator inside.
-Place the radiator upside down and supply 3) Visual inspection of the exterior parts
pressurized water from a faucet to the lower tank,
draining through the upper tank,as shown in the When the radiator exterior is corroded,cracked,or
figure to wash out accumulated deposits. badly damaged,replace the radiator.Also replace
damaged or fatigued water hoses.
Retighten loose hose clamps securely if water is
leaking through the hose clamps securely ,or
replace them if necessary.

4) Inspection of the radiator cap.

Check the radiator cap to see if it functions

normally,using a radiator cap tester as following.

FIG.3-6
FIG.3-7
3-4
 Pressure valve 0.9 Kgf/ ㎠ 6. RADIATOR REASSEMBLY
Reassemble the radiator in the reverse order of
Opening pressure (12.79 psi)
disassembly.
Vacuum valve 0.04-0.05 Kgf/ ㎠
Opening pressure (0.57-0.71psi) Note:
- The rubber hoses should be clamped securely
-Function test: and must not interfere with the cooling fan.
- The radiator cores must not interfere with the
The pressure type radiator cap has a pressure valve cooling fan.
and a vacuum as shown in the figure.
Both valves are held against there seats by springs 7. DAILY INSPECTION
while the pressure in the cooling system remains 1) Coolant level inspection and coolant
within a specified range,thus keeping the cooling replacement
system air-tight. When the radiator is hot after operation,be sure
to wait until the coolant cools down sufficiently
When the pressure in the radiator rises higher than
before removing the radiator cap.
the specified valves,it overcomes the force of the
If this is not done,heated vapor might burst out
pressure valve spring and open the pressure valve
and cause burns.Use fresh water from a faucet
to release excess pressure through the overflow
as the coolant. When the coolant is replenished
pipe as shown in the figure.
or changed,let the engine idle for a while for the
coolant to circulate sufficiently in the cooling
system and replenish if necessary after stopping
the engine.
2)Antifreeze
When The weather is cold,use an antifreeze to
prevent the engine from freezing.The freezing
point differs according to the mixture ration of
water and antifreeze.Therefore,prepare an
antifreeze solution which will have a freezing
point 5℃ lower than the estimated lowest
atmospheric temperature in your environment.
FIG.3-8
Precaution for filling antifreeze.
When the coolant temperature falls enough to - The radiator interior should be washed clean
cause the vapor to condense in the cooling system ahead of time.
and decrease the coolant volume,the radiator - As concerns of mixing ratio of an antifreeze,
pressure becomes negative.When this occurs,the follow its manufacture's instructions.
vacuum valve opens to let outside air into the - Antifreeze should be blended well with water
radiator as shown in the figure, before filling.
- When the coolant level is lowered due to
thus preventing the radiator from being deformed. evaporation,maintain the level by adding water,
not by using an antifreeze solution.
- When the coolant level is lowered due to leaks,
maintain the level by adding an antifreeze solution
of the same mixing ratio.
- As antifreeze corrodes point,take care not to
spill it on painted parts.
-The tractor is filled with a permanent type
antifreeze (Mobile Long Life Coolant)
when shipping(mixing ratio:50%)

FIG.3-9 3- 5
8. TROUBLE SHOOTING TABLE 3-1
Problems Causes Countermeasures
1) Overheating (1) Low coolant level (1)Replenish coolant and inspect
water leaks.
(2) Fatigued pressure valve spring (2)Replace radiator cap.
(3) Loose or broken fan belt (3)Adjust belt tension or replace.
(4) Oily fan belt (4)Replace.
(5) Poor thermostat (5)Replace.
(6) Poor water pump or water leaks (6)Repair or replace.
(7) Clogged water passages (7)Clean radiator and water
passages.
(8) Improper injection timing (8) Adjust injection timing.
(9) Clogged air ways (9) Clean radiator exterior.
(10) Fuel gas enters water jacket due (10) Inspect cylinder head and
to broken cylinder gasket replace cylinder gasket
2) Overcooling (1) Poor thermostat (1)Replace
(2) Excessive low atmospheric (2) Decrease radiator working area
temperature by radiator masking.
3)Lose of coolant (1) Leaking radiator (1)Repair or replace
(2) Loosely clamped or broken water (2)Retighten or replace
hose
(3) Fatigued pressure valve spring (3)Replace radiator cap
(4) Leaking water pump (4)Repair or replace
(5) Water leakage through cylinder (5) Inspect cylinder head and
head gasket Replace gasket
(6) Cracked cylinder head or body (6)Replace
4) Noisy cooling (1) Poor water pump bearing (1)Replace
fan (2) Loose or bent fan (2)Retighten or replace
(3) Unbalanced fan (3)Replace.
(4) Poor fan belt (4)Replace.

3- 6
SECTION 2. AIR CLEANING SYSTEM

1.GENERAL DESCRIPTION
Unfiltered air contains many particles harmful to the engine such as dust ,sand,or other foreign matter.
When such foreign matter have entered in to the engine,They have mixed into the lubricant and promote
wear of lubrication parts in addition to damaging the piston cylinders.To eliminate these harmful
particles,an air cleaner has been installed.The air cleaner Which is installed on the T series tractor is a
dry,cyclone type and is constructed as shown in the figure.

Under the influence of suction generated by the engine,unfiltered air flows through air inlet tube and is
forced into a high-speed centrifugal motion.By this circulating action most of the dust and dirt particles
are separated from the air and collected in the dust unloading valve(4).The remaining dust is removed as
the air flows through the paper element(2) before being drawn into the engine.

① Body ② Paper element outer ③ Cover assy ④ Dust unloading valve

FIG.3-10 Air Cleaner

3-7
2.ELEMENT AIR CLEANER
(1) SPECIFICATIONS.

Model T394HST

Type Dry, paper element filtering type

Rated intake air volume(㎥/min .(cu.ft/min) 4.25(150)

Air venting resistance (㎜Aq) 120 or less

Cyclone efficiency (%) 45 or over

Total filtering efficiency(%) 99.9 or over

Dust holding capacity (gr) 700

Filtering area (㎡)(sq.in) 1.89±4%

Filter material FPG 057512

Temperature -30~80°C

(2) DISASSEMBLY
1) Element removal

Remove the wing bolt which clamps the paper

element and take out the element.

1.Air cleaner Sub assembly

1-01.Body assy
1-02.Body
1-03.Cover
1-04 Cover assy
2.Bracket comp ,guide
3.Hose,air inlet
4.Hose,air outlet
5.Clip,64
6.clip,60
7.Bolt
8.Plate ,stay

FIG.3-11

3-8
3. INSPECTION OF EACH PART Note:
1) Inspection of the cleaner body Especially note the glue portions of the paper and
(1) Check the cleaner exterior for cracks, metal parts.
deformation,or damage and repair or replace
if necessary. 4. CLEANING THE AIR CLEANER
(2) Check each packing for fatigue or damage Clean the air cleaner after 100 hours of operation or
and replace if necessary. less depending on conditions in the following manner.
1) When the air cleaner is cleaned or the element is
replaced,dust accumulated inside the air cleaner body
should be removed with a cloth.As inhaled dust causes
engine wear,remove a dust accumulated inside the inlet
pipe,the rubber hose which connects in the inlet pipe
and the air cleaner,the inlet manifold,and inlet port.
(1)When accumulated dust is dry.
-When removing the dust in the element,hold the
element by a hand and pat the side wall with other
hand. Never hit the element against a stone or a
concrete wall because that might cause its side wall
to peel off.
-apply compressed air from inside of the element to
blow dust off while turning the element by hand.
2) Inspection of rubber hoses
Check the rubber hoses for fatigue or damage
and replace if necessary.
3) Inspection of the paper element to check
the element for damage,Dry it sufficiently
after washing and put an electric bulb in to
the element and look for damage.

FIG.3-13 Element

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

(2)When accumulated dust is oily.

-Use a solution of TC 101 element detergent
or the quality household neutral detergent.
Leave the element in the solution for
approximately 30 minutes and then wash it by
dipping it in and out of the solution.
FIG.3-12 Element check 3-9
5.ELEMENT INSTALLATION
Install the element in the reverse order of
disassembly, but follow these instructions.

1) Each tightening clamp must be secured and

care must be taken not to miss the packing
and washers.
2) Before installing the element, clean the
rubber packing on the top of the element.

Note:
The clamp retaining the element should be
tightened sufficiently so that it will not become
loose during operation

3-10
 Chapter 4
HST SYSTEM

SECTION 1. INTRODUCTION ------------------------------------------------------ 4-1

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

SECTION 3. COMPONENT LOCATION ------------------------------------------ 4-3

SECTION 4. TROUBLESHOOTING ------------------------------------------------ 4-6

SECTION 5. DIAGNOSTICS ---------------------------------------------------------- 4-8

SECTION 6. THEORY OF OPERATION ------------------------------------------ 4-9

SECTION 7. TESTS AND ADJUSTMENT ---------------------------------------- 4-15

SECTION 8. REPAIR ---------------------------------------------------------------- 4-19

SECTION 1. INTRODUCTION

1. Introduction
This Manual describes the specifications, structure, mechanism, and handling about a two-shaft
HST used as a continuously variable transmission for road vehicles in order to prevent any
nonconformity of handling and keep its good performance for the long run.

<WORD MESSAGE>
Each Word Message of ‘DANGER’, ‘WARNING’, ‘CAUTION’ in this Manual is defined as follows.
It is needless to say that the marking of Word Messages is so important for a safe work and handling
of machine/equipment in the field that everyone should understand the messages fully and comply to
them.

It marks an imminent danger resulting to death or serious injury if handling

DANGER
wrongly.

WARNING It marks an imminent danger resulting to death or serious injury if handling

wrongly.

CAUTION It marks any possibility resulting to a slight or moderate injury or to

physical damage if handling wrongly .

4-1
 SECTION 2. GENERAL SPECIFICATIONS

< HST for road Vehicles >

Item SPECs

PUMP 0~37cc/rev
HST Capacity
MOTOR 37cc/rev

PUMP SWASH PLATE ANGLE 0~±18˚

From the position of clockwise input shaft

DIRECTION OF INPUT ROTATION
( Marked with asterisk* )

CHARGE RELIEF SET PRESSURE 4.0-6.0Kg/㎠ VG46, 50˚C, 15L/min

SPECs
Basic

DRAIN PRESSURE Within 1Kg/㎠

FILTER 10Иm

STRAINER 150Иm

OIL POLLUTION DEGREE Within NAS 9 Level

ENGINE HP 37.4Hp/2400rpm

INPUT ROTATION 1000~2600

PRESSURE DIFFERENCE BETWEEN

350±5Kg/㎠ at 15L/min
HIGH AND LOW SIDE
Conditions of Use
for Customers

CRACKING PRESSURE Over 320Kg/㎠ at 2L/min

TEMPERATUE RANGE Common Temp.:+10~+80˚C

OF HYDRAULIC OIL Limit:-20~+90˚C

MAX. VIBRATION Within 9G

Input shaft: Direct coupling

DRIVING METHOD
Output shaft: Direct coupling

Input=2600rpm
Performance

TRUNNION SHAFT OPERATING △50~220Kg/㎠

-1.5≤ T≤ 2.5Kgf.m
General

TORQUE Θ=0˚~18˚
VG46,50˚C

INPUT/OUTPUT ROTATION RATIO 1±0.03 For no-load

4-2
 SECTION 3. COMPONENT LOCATION

1. Hydraulic oil filter 2. Suction pipe 3. Gear pump

1. Hydraulic Hoses and lines. 4. Delivery pipe A 5. PTO Sol valve 6. Delivery pipe B
7. Drain pipe 8. Charge pipe 9. Drain pipe
10. Power steering pipe (LH, RH) 11. HST UNIT

10 7 5
8

4 1

3
2

11
Fig.4-1

2. Hydrostatic Transmission

Fig.4-2
4-3
3. Hydrostatic control linkage

8
7

5
3

2
1

1. Holder comp 2. Control rod assembly 3. Forward arm comp. 4. HST Pedal Bracket comp.
5. Forward pedal comp 6. CAM comp 7. Reverse pedal comp 8. Damper , oil

Fig. 4-3

4-4
4. Hydrostatic system schematic

Fig. 4-4
4-5
 SECTION 4. TROUBLESHOOTING

1. Troubleshooting
In case that HST shows troubles, it is as a general rule to replace the Assy. For a more clear-cut
explanation and understanding, here is a detailed outline of troubles, causes, checking points,
and actions.

TROUBLE CAUSE CHECK LIST ACTION

Measure the pressure of Charge Replace with a new
1. A set value of Low Pressure
Circuit and check that it reaches its component if failing to go
Relief Valve drops.
set value. up to a specified pressure.
Measure the pressure of High Replace with a new
2. A set value of High Pressure
Pressure Circuit and check that it component if failing to go
Relief Valve drops.
reaches its specified value. up to its specified pressure.
3. The Seat of Check Valve Measure the pressure of Charge Replace with a new
(HST) is defective. Circuit and Low Pressure Circuit, component if failing to go
(Low/high pressure state of HST and check that it reaches its specified up to its specified pressure.
1. Even when is out of normality) value.
turning an Measure the pressure of Charge Replace with a new
operating 4. Gear Pump gets damaged.
Circuit and check that it reaches its component if failing to go
lever, Output Flow rate drops.
specified pressure. up to its specified pressure.
Shaft does not
rotate. - Let the air out of HST.
- Replenish a hydraulic oil
- Check the flow rate of tank.
(operating oil).
5. Air comes into HST. -Check if pipe is out of order
- Repair the pipe.
(ex: suction of air caused by
defective seal).
6. Main parts of HST - Replace with a new
malfunction because of being - Check that output rotation number Coupling.
damaged. of HST goes up to its specified value. - Clean the Hydraulic
Input/output shaft or coupling - Check if Spline of Coupling is Circuit in Main Body and
shows problem. worn out. replace with a new HST
ASSY.
- Measure the pressure of High
Pressure Circuit.
After going through
Check Valve malfunctions. - Check the conversion state of high
disassembly and washing
(ex: Hole is clogged) and low pressure when moving it
process, reassemble it.
backward/forward.
2. Even when
placing a Adjust the Pedal slightly from its Replace with a new
Pedal in its 2. A Moving Swash Plate is neutral position and check that there component if there is no
neutral worn out. is any point where its output rotation point where its output
position, stops. rotation stops.
rotation does
not stop. 3. An operating torque of Lever
increases.
Replace with a new Swash
The force of Return Spring, at - Measure an operating torque at the
Plate Bush.
the end of Main Body Link, end of Trunnion Shaft.
Replace with a new Link
deteriorates, which makes the - Check the force of Return Spring.
Part.
return force of Pedal poor.

4-6
 TROUBLE CAUSE CHECK LIST ACTION

1. The flow rate of Charge is short Measure the pressure of Charge

Wash the Filter/Strainer, or
because of having Filter or Strainer Circuit and check that it reaches its
replace with a new one.
(Main Body) clogged. specified pressure.

Discharge HST Air, and check the

state of tank flow rate. Repair the pipe of supplying a
2. Air is flowed into HST.
Check if pipe is out of order (ex: Air hydraulic oil (operating oil).
3. HST output suction caused by seal defect)
and rotation are Measure the pressure of Charge
insufficient. Circuit and check that it reaches its
Replace with a new Gear Pump
3. The flow rate of Charge is short. specified pressure. If it fails to reach
Assy.
its specified pressure, check if Gear
Pump is out of order.

4. A high rate of hydraulic oil runs Clean the Hydraulic Circuit in

Check that HST Output Rotation
because of having the vibration part Main Body, and replace with a
goes up to its specified value.
of HST pump or motor worn. new HST Assy.

-Let the air out of HST, and

- Check the flow rate of tank. supply a hydraulic oil
1. Air comes into HST. - Check if pipe is out of order (ex: (operating oil).
Air suction caused by seal defect) - Repair the pipe.

2. The flow rate of Charge is Measure the pressure of Charge

Wash the Filter/Strainer, and
insufficient because of having Circuit and check that it reaches its
replace with a new one.
Filter/Strainer of Main Body clogged. specified pressure.
4. HST makes a
noise 3. Link part of Main Body is loose or Check that noise decreases when
Adjust and repair the Link part.
worn. covering the Link part with hands.

4. The clearance of Input/Output Check if Input/Output Shaft and

Replace with a new Coupling.
Shaft and Coupling gets wider. Coupling gets loose or worn.

Check that output rotation of HST

5. The internal components of HST reaches its specified value when
Replace with a new HST Assy.
are defective, worn, or damaged. jacking up vehicle and idling
engine. .

-Repair the pipe if finding no

1. Abnormal rise of oil temperature problem in Hydraulic Circuit
Check if oil temperature rises over
damages Oil Seal, O-ring, and (Oil Cooler).
its specified value.
5. Oil flows out Gasket, etc. - Replace with a new Seal
of Shaft and Seal Component.
Part. 2. Oil outflows because of damage in Repair the pipe and replace with a
Oil Seal, O-ring and Gasket (caused Check if the pressure of pipe rises new Seal
by an excessive internal pressure over its specified value. Component if fining any problem
inside the case of HST) in pipe.

1. Operating torque of HST Lever Measure the torque at the end of Replace with a new Swash Plate
6. The return of increases (Hysteresis UP) Trunnion Shaft. and Bush.
Pedal is slow, or
it is difficult to do 2. The force of Link Return Spring
Change the Link Part.
it. deteriorates. Check the state of Return Spring.
Adjust the force of Spring.
Free cushion of spring part increases.

4-7
 SECTION 5. DIAGNOSTICS

Test conditions by bench test.

- Operator in seat
- Key switch in RUN position

Test/Check point Normal If Not normal

1. Control pedals Pedal should move freely Check linkage from pedals to pump

Test conditions:
- Start engine and run at slow idle

Test/Check point Normal If Not normal

2. Directional pedals are Machine should not creep Adjust centering of pump control
in neutral position forward or backward pedals

3. Move forwards or Machine should accelerate Check fluid reservoir for proper fluid
reverse pedal slowly smoothly forward or level.
from neutral to backwards. Check hydraulic pipe and connections
maximum travel speed for leaks.
position Perform system flow and pressure
checks to verify proper operation of
charge pump and hydrostatic pump
4. Control pedal in full Machine should move forward Check pedals and forward/reverse
forward position linkage for damage.
Check forward drive pressure relief
valve
5. Control pedal in full Machine should move Check pedals and forward/reverse
reverse position backward linkage for damage.
Check reverse drive pressure relief
valve.

4-8
 SECTION 6. THEORY OF OPERATION

HYDROSTATIC SYSTEM
The hydrostatic system provides a means to transfer. Power from the engine to the final drive to the
wheels. It also provides infinitely variable speed control, forward or reverse, by foot pedal operation.

1. Operation
※ Each operation drawing is a schematic diagram, so there may be slightly differences in real product,
size and shape.
1) PUMP, MOTOR CIRCUIT (Variable Pump)
<Figure-1(a)> shows a rotation part of axial piston pump (Swash plate type), with 9 pistons inserted to
cylinder block. Shaft is not connected into driving source (ex: Engine or motor). When shaft rotates, so
does cylinder block together (Swash plate does not rotate).
If Shaft Center and Swash Plate are connected with each other vertically, as shown in <Figure-1(a)>,
Space ‘A’ and ‘B’ (Cylindrical space of Cylinder Block) have the same volume so that they do not work
suction and discharge, not to mention pumping.
If rotating the Swash Plate askew as much as ‘a’, as shown in <Figrue-1(b)>, each volume of Space ‘A’
and ‘B’ is changed as shown in the drawing (A>B). In this condition, if rotating the shaft in the direction of
φ, oil is sucked between s180˚where piston moves from B to A.
So, if connecting suction and discharge pipe to two crescent ports, as shown in <Figure-1(c)>, it becomes
one pump.
In this case, Ps becomes a suction port and Pd becomes a discharge port. On the contrary, if rotating the
Shaft towards ω, Ps becomes a discharge port and Pd becomes a suction port.
The next is about discharge capacity. As described above, in case of ‘a=0˚’, there is no suction and
discharge. The bigger the volumetric difference between Space ‘A’ and ‘B’ is (that is to say, as much as its
slant angle), the bigger its flow rate is.
In this case, discharge capacity of pump is calculated as follows:

Q = D PMAXㆍtan a ㆍN inㆍη vp / tan(a Max) = (㎤/min)

D PMAX : Max. Capacity of PUMP(㎤/rev)

a : Swivel Angle of Swash Plate (deg)
a MaX : Max. Inclination Angle of Swash Plate (Swivel angle) (deg)
N in : Pump Input Rotation (rpm)
η vp : Pump Volume Efficiency

4-9
 Figure-1(a)

Figure-1(b)

(MOTOR)
<Figure-2> shows a rotation part (Shaft and Cylinder Block) in Axial Piston Pump, and 9 pistons are
inserted to Cylinder Block. At the end of Cylinder Block, there is Valve Plate with two crescent
passages (Ps and Pd), and the two crescent passages are connected to inlet pipe and discharge pipe,
respectively.
In this condition, if having high pressure oil delivered from Ps Port, piston will be pressed and Swash
Plate will be affected by Force (F). The force component (Ft) of this Force’s rotation direction rotates
Cylinder Block, which makes its Spline get in and generates torque in the Shaft towards ε and finally
works Motor.
Output torque of Motor is calculated as follows:
T = ( PㆍDмㆍηm ) / (2π ) = N.m
Dм : Motor Capacity (㎤/rev)
P : Working Pressure MPa
ηm : Torque Efficiency
The number of rotation is changed by flow pressure, and it is calculated as follows:
N = ( Q.η vm ) / Dм
Q : Inflow Quantity (㎤/min)
η vm : Motor Volume Efficiency
At this time, hydraulic oil (operating oil) is discharged from Pd Port. Reversely, if drawing pressure oil
from Pd Port, it rotates contrary to the above expression.

4-10
 Figure-2(a) Figure-2(b)
2) CHARGE CIRCUIT
HST Circuit has an internal gap, so it is equipped with Charge Circuit to compensate the weak point.
Oil discharged from Charge Pump is to be supplied to Pump and Motor through Check Valve. The
remaining oil goes inside the Case through low-pressure Relief Valve and cools down Pump and
Motor, from which it goes back to Tank.
3) H S T Operation
(a) NEUTRAL (TRUNNION BAR : Neutral Position)---------------------------------------Figure-1(a)
A variable pump does not work even if rotating the input shaft of HST. Oil is not supplied from pump
to motor, and output shaft does not rotate. Two(2) high-pressure passages linking pump and motor are
connected to Charge Circuit.
The remaining oil that is supplied to main circuit via Check Valve, discharged from Gear Pump
(Charge Pump), flows into the case through low-pressure Relief Valve and comes back to tank.
(b) FORWARD (TRUNNION BAR : α side )------------------------------------------------- Figure-2(a)
In case of rotating the input shaft of HST to the right and tilting TRUNNION BAR from its neutral
position to the direction of ‘a’: When the Lever is at a minimum inclination angle, pump does not
work and output shaft does not rotate not to make a volumetric difference of inner Cylinder by the
taper angle of moving Swash Plate. If tilting the Lever above the taper angle of moving Swash Plate,
pump starts to run and supply motor with oil, and output shaft rotates. Output rotation is directed to
the right when seeing it from the position of output shaft.
And Relief Valve is usually closed. If the output shaft of motor is overloaded and pressure inside the
HST Circuit is over 340kgf/㎤, Relieve Valve works to prevent the damage of each equipment.
In this case, energy is all transformed to heat and oil temperature inside the HST Circuit rises sharply.
So, operation of Relief Valve has to last just for as a short time as possible (Within 30 seconds). Oil
that has already passed through Relief Valve is flowed into low-pressure circuit.
(c) BACKWARD (TRUNNION BAR :β side)-------------------------------------------------Figure-2(b)
The operation principle is the same as the above FORWARD operation.
In case of tilting the TRUNNION BAR to the direction of ‘β’ and tilting the Lever above the taper
angle of moving Swash Plate, pump starts to discharge oil and supply motor with oil, and output shaft
rotates. Output rotation is directed to the left when seeing it from the position of output shaft.

4-11
4) Handling Precautions
4-1 Storage CAUTION
In case of keeping it over one(1) month, a clean hydraulic oil (operating oil) has to be injected to the
inner case of HST to prevent any possible corrosion of HST inside, and it has to be kept in a dry and
clean place.

4-2 Operating Oil (Hydraulic Oil) WARNING

Oil for operating a hydraulic system affects the performance and service of machinery as to what to
choose and handle the oil. In general, an operating oil has to be a quality hydraulic oil and it has to be
excellent in its lubrication, oil resistance, oxidative stability, and anti-corrosion. And it has to have
properties not to give damage to packing and seal. For this HST, an operating oil of ISO VG46 is highly
recommended. In case of mixing with other kind of oil, it has to use a new oil.

4-3 Pollution Management WARNING

1) HST is to be delivered in a fully washed condition to protect the Main Body of HST. In case of
feeding the hydraulic oil (operating oil) into a tank or while using it, you make sure to take a special
care not to have any pollution molecules come into the HST. The pollution level of hydraulic oil has to
be maintained within NAS9 Level. Pollution molecules of over 100μm can be a main factor that can
give a severe damage to the HST for a short time.

4-4 Shaft Coupling WARNING

1) A special carefulness will be taken when taking out HST Input/Output Shaft and
Driving M/C Shaft/Core. The stagger (deflection) of core shall be set within 0.05mm.
2) When attaching/detaching HST to Main Body, an excessive load shall not be given to the end of
Output/Input Shaft.

4-5 Defect of Trunnion Part WARNING

1) If Trunnion Shaft of HST has an excessive torque beyond its specified value, it is highly likely to be
broken. So, Stopper shall be operated less than its maximum inclination angle that HST allows, and a
special care is taken not to apply an excessive torque, beyond its specified value, to Trunnion Shaft.
2)A special care is needed not to have rain or water drops fall towards the Trunnion Shaft or Oil Seal;
otherwise, Trunnion Shaft gets rusted and oil leakage may happen.

4-12
 4-6 Starting WARNING
1)Fill a hydraulic oil (operating oil) in HST Case.
2) After mounting HST, start to idle the engine, work the pedal of vehicle slowly, and move it
forward/backward repeatedly. In this way, air has to be let out of HST.
Failure to let the air out of HST fully results to noise caused by aeration, not by HST. So, you shall
continue the above operation procedure until the noise is completely gone.
If there is an excessive inflow or mix of air, Output Shaft of HST may not work its rotation. In this case,
place the Lever at its maximum inclination angle from idling rotation of engine temporarily, and it
starts to rotate. (In this case, it is safe to jack up a vehicle because a sudden acceleration of vehicle can
occur)
3) At first, you shall drive it at a low rotation state. After checking that there is nothing abnormal, such
as noise or vibration, you can go up to its specified rotation.
4-7 Oil Temperature Management CAUTION
As for hydraulic unit, the most important thing is to how extent a driving temperature is maintained. If
it is too high, oxidative resistance of hydraulic oil (operating oil) deteriorates, which leads to the
shortening of its service life. On the contrary, if it is too low, its density gets high, which leads to the
deterioration of HST’s mechanical efficiency. So, users should comply to the following precautions.
1) Starting Temperature
In case that a driving temperature is less than +10˚C, you turn up a heater over +10˚C and start to drive
the Main Body.
2) Common Driving Temperature
It is optimal to maintain it within +20˚C~ +60˚C
3) Max. Limit of High Temperature for Driving
Max. limit of driving temperature is 90˚C. This max. limit value is determined by the aging effects of
hydraulic oil’s density, oxidative resistance, O-ring, and Oil Seal, etc. So, driving at over +90˚C can
deteriorate the service life of HST, not to mention the life of oil.
4-8 Piping WARNING
1) As for drain pipe of HST, you shall set the size, length and bending of pipe so that internal pressure
of HST Case can be less than its value specified in SPECs.
2) Be sure to wash the pipe before assembly, and eliminate scales in the pipe safely.
3) A special care is needed not to have dirty or foreign materials comes into the pipe from inlets of each
HST while laying pipe.

4-13
5. Regular Check & Replacement Cycle of Hydraulic Oil CAUTION

Even at the first washing, there may be sedimentation (ex: sludge) in circuit tank while doing a long
drive. It can lead to damage of HST, deterioration of hydraulic oil, and malfunction of it.
To prevent these conditions, it is requisite to perform a regular inspection on hydraulic oil and replace
with a new one if necessary. It is difficult to indicate the pollution state or deterioration of oil in a
quantitative way, but there is an effective method of judging the state by naked eyes. You should refer
to the following visual inspection.

But if fifty(50) hours or more pass after factory shipment, it shall be replaced with a new one upon the
earlier of once a year (after starting to use it that year) or 200Hrs.

When replacing with a new hydraulic oil, there is mixture of deteriorated oil, sludge, and water, etc in
the tank, which may result in poor performance of HST and shorten its service life. So, it is requisite to
flush the internal of machine before making replacement of oil.

※ Visual Inspection & Judgment

(Take the sample of oil from HST Case, put it in a test tube, and compare it with a new hydraulic oil)

Appearance Smell Condition Action

Normal
Transparent, and no discoloration Good Usable
(Good)

Normal Foreign materials are Filter out the foreign

Transparent, and small black spots
(Good) contained. materials, and use it.

Normal Moisture (water) is

It is discoloring into milk-white color Replace with a new oil
(Good) contained
It has been discolored into black. Stink Oxidized and aged Replace with a new oil

4-14
 SECTION 7. TESTS AND ADJUSTMENT

1. HYDROSTATIC PEDAL AND NEUTRAL ADJUSTMENT

Reason:
To ensure that tractor does not move unless the forward or the reverse pedal is depressed.

Procedure:
1.Operate the hydrostatic control pedals. They should return by themselves to the neutral position.
If pedals do not operate properly, check pedals and linkage for damage or wear.
2.Start engine and run at low idle.
3.Place range shift lever in LOW gear. Tractor should not move. If tractor moves, note direction and
adjust neutral return linkage as follows:

4.Shut engine OFF, engage the park brake.

5.On the right side of the tractor, next to the forward and reverse control pedals, loosen the turnbuckle
in the control rod assembly. The turnbuckle must be turned to perform the neutral adjustment.
6.Start engine and run at low idle and disengage the park brake.
7.If fastening or loosening the turnbuckle, it can be set up to the neutral position.
8.Place range shift lever in LOW gear. Tractor should not move. If tractor moves, repeat step 4 through
9 until the movement is eliminated.
8
7

5 3
2

Fig. 4-5
1. Holder comp 2. Control rod assembly 3. Forward arm comp. 4. HST Pedal Bracket comp.
5. Forward pedal comp 6. CAM comp 7. Reverse pedal comp 8. Damper , oil
4-15
2. HYDROSTATIC PUMP 4.Start engine and run until hydraulic oil is
PRESSURE TEST warm.
5.Stop engine.
Reason:
6.Cycle all controls to relieve any pressure
To ensure that internal parts of the hydrostatic
that may be in the hydraulic system
pump are not worn excessively, and the relief
valves are operating properly.

Equipment:

①Gauge spec. : Over 500 kgf/cm2 (6,610 psi)

②Coupler spec. : 3/8”(Hose with quick coupler) PF3/8”
③Adaptor spec. : PF3/8”
④Gauge
⑤Adaptor

④ 7.Locate test ports on hydrostatic transmission

inside tunnel opening.
② 8.Remove test port plugs.
9.Install ⑤adaptor male into each test port.
10.Attach ④gauge and hose assembly as shown
③ each test port adapter.

IMPORTANT : Make sure that the hydraulic fluid

is visible in sight glass. Insufficient hydraulic
fluid could cause system to run dry and
damage pump and motor.
IMPORTANT : Do not allow valves to relieve for
more than 10 seconds or hydraulic oil may
11.Position gauges so they can be read from
overheat.
tractor’s side.
Procedure: 12.Perform test from tractor’s side.
1.Park tractor on a level surface Make sure park brake in engaged and press right
2.Turn key switch to OFF position. and left brake pedals. Place range transmission
3.Make sure range transmission shift lever is in shift lever in neutral position.
neutral position. Start engine and run at full throttle.

4-16
13.Slowly depress forward directional pedal and Procedure:
observe gauge. Gauge should slowly rise to 1.Park tractor on a level surface and set park brake.
approximately 350kgf/cm2 and relief valve 2.Turn key switch to OFF position.
will open with an audible squealing noise if there 3.Shift transmission to NEUTRAL.
is a filter plugging or an insufficient supply of oil.
(at the Pb port : Forward ) IMPORTANT : Make sure to relieve system pressure
14.Repeat same procedure with reverse pedal. before loosening any system lines or hoses.
(at the Pa port : Backward ) 4. Cycle all controls to relieve any pressure that
Specifications : Pump pressure should reach may be in the hydraulic system.
approximately 350kgf/cm2 in either
direction and then relieve.

Results:
-If pressure will not reach 350kgf/cm2
in either direction, check charge. PF3/8”
Pressure.
(SEE ”CHARGE PUMP PRESSURE TEST)
-If charge pressure is good and hydrostatic pump
pressure will not get up to relief pressure
hydrostatic pump is worn or damaged.
-If pressure reaches 250~280kgf/cm2 in one
direction and not the other, one of the relief
Note : Be careful not to use plugs on the Top.
valves is defective or the seat is leaking.
It is possible to test the pressure for F and R
on the bottom of HST unit.
It is possible to test the pressure for N on the
outside pipe.
3.CHARGE PUMP PRESSURE TEST 5.Underneath the tractor, at the front of the tunnel,
locate the hydrostatic transmission,
Reason: Remove the plug in the charge pressure test port.
To ensure that charge pump is operating at 6.Assembled test equipment as shown and install
specified pressure to supply oil to hydrostatic to test port.
pump. 7.Start engine and run at high idle (2400rpm)
Equipment : 8.Check pressure reading gauge.

Specifications : at the Pc port

Charge Pressure : 4~6kgf/cm2, at neutral position
or reverse position with 350 kgf/cm2.

Results : Charge pressure should reach 4~6kgf/cm2

(57~85psi). Can not be obtained ; the mesh
inlet filter may be restricted, the suction line
may be restricted or leaking air, or front hydraulic
pump may be defective.

4-17
4. HYDRAULIC SYSTEM BLEED PROCEDURE

Reason:
To remove air trapped in the hydraulic system which will prevent proper operation.

Procedure:
IMPORTANT : If contamination is found in hydraulic system filter or inside reservoir, flush entire
hydraulic system.
NOTE : Fill the hydraulic oil filter with new oil before installing.

1.Install a new hydraulic oil filter.

2.Fill the transaxle with specified and recommended transmission oil to the proper level in sight glass.
3.Turn the key to the glow position for 10 seconds to heat the combustion chamber in the engine.
4.Turn the key to START. And turn the key to OFF.
5.Raise tractor front end and support on suitable stands.
6.Start the engine and run at low idle.

IMPORTANT :
If steering fails to respond, or pump pressure is not being delivered to steering control unit (SCU),
shut engine off and check to see that steering hoses are connected to the correct SCU ports.

7.Slowly turn the steering wheel left and right until wheels turn smoothly indicating that any trapped air
has been bled back to the reservoir.

IMPORTANT :
If rock shaft fails to react to lift control lever movement, shut engine off and check hose clamps on
suction tube elbow and manifold to ensure that they are properly tightened.

8.Operate rockshaft several times until it operates smoothly.

9.Stop the engine and check the hydraulic reservoir oil level. Fill as needed. Check all line
connections for leaks; tighten if necessary.
10.Lower the tractor to the ground.
11.Drive tractor in forward and reverse several times until transmission operates smoothly.

4-18
 SECTION 8. REPAIR

1. HYDROSTATIC SPLITTING.
Prepare the Tractor:
1. Park tractor on a level surface.
2. Shut off engine.
Release hydraulic pressure by operating all controls.
3. Remove the transmission assembly from the chassis.
4. Detach the HST control rod.
5. Remove the hydraulic pipes and related parts

Fig. 4-9
Separation point
Note : Oil may drain from the HST unit
after it is removed.
Have a suitable container ready to catch
excess oil.

Note : Be careful not to damage the filter and

O-rings and lock pin.
Fig. 4-6
Note : Hydraulic transmission weights
approximately 20 Kg.
Attach a suitable lifting device to
transmission before removing screws.
Installation :
Install the reverse order of disassembly.

1) Clean the surface of front transmission before

installing the O-Rings.
Fig. 4-7 2) Apply grease or gear oil to O-rings.
3) Tighten the screws attaching hydrostatic unit
to the mid transmission.
6. Remove the mounting bolts.
Separate between the front and mid transmission. Note : If neutral adjustment locking screws were
loosened, neutral adjustment procedure
must be performed.
See “HYDROSTATIC PEDAL AND
NEUTRAL ADJUSTMENT”

Fig. 4-8
4-19
 2. HYDROSTATIC OVERHAUL.
1. Tools
No. Tool Name Size & Set Value
1 Plastic hammer Light alloy core 0.3kgf
2 Driver(-) 150mm
3 Snap ring plier (For inner hole) H-3, H-5
4 Snap ring plier (For shaft) S-1, S-2, S-3
Torque set value
5 Torque wrench 51.N.m
25.N.m
2-side width 4mm
2-side width 5mm
6 Hexagonal wrench
2-side width 6mm
2-side width 10mm

2. Pre-Disassembly Precautions
a. Make sure to remove dirt or foreign materials from the outside surface.
(Make sure to wash the outside surface fully. When doing this job, it is important to close lids
so that dirt or foreign materials cannot comes into each port).
b. Discharge a hydraulic oil (Operating oil) out of its case.
c. Keep working site clean and tidy, and be fully careful not to have any dirt or foreign materials
come into each part.
d. Take a special care to prevent any possible falling of parts and puncture damage caused by contact.
e. For each Part Number stated in Assembly Manual, see the assembly drawing attached at the end.

4-20
3. Disassembly Procedure

Process Drawing Description

1. Take off FRONT COVER ASS’Y.

a.Take off WRENCH BOLT [M12x45L] 8pcs

(47)

29 b.Take off FRONT COVER (ASSY) (29)

29

! Be careful not to drop VALVE PLATE

! Be careful not to lift it with CYLINDER

BLOCK.

In case that CYLINDER BLOCK is not

separated, tap on FRONT COVER lightly with
plastic hammer, and it will be separated.

45 27

(FRONT COVER ASS’Y)

4-21
 Process Drawing Description

2. Disassemble FRONT COVER ASS’Y

a. Separate VALVE PLATE(27) and (45).

45 27

b. Separate PLUG (34)of RELIEF VALVE

by L-wrench or Torque wrench.

c. Separate SPRING(33)and RELIEF VALVE

ASS’Y(32)

34

33 32

4-22
Process Drawing Description

d. Take off WRENCH BOLT [M6x10L] 2pcs

(40) by L-wrench or Torque wrench.

40

e. Separate SPRING HOLDER(39)and

SPRING(38), CHECK(37)
39

38

37

3. Take off GASKET(28).

28

4-23
Process Drawing Description

4. Take off CYLINDER BLOCK(PUMP)

23

12 5. Separate Snap Ring(12) using Pliers.

▶SNAP RING(12) and SET PLATE((11), PISTON

ASS’Y(10), CYLINDER BLOCK(23)

12 11

10 23

4-24
 Process Drawing Description

6. Take off CYLINDER BLOCK ASS’Y(MOTOR)

CYLINDER BLOCK ASS’Y ▶ Disassemble SWASH PLATE(21),

HOLDER(22),CYLINDER BLOCK(10),
SET PLATE(11), PISTON ASS’Y (22),
into CYLINDER BLOCK ASS’Y.

22

21 11

10 23

4-25
Process Drawing Description

7. Take off SHAFT(17) from BODY(1).

17

8. Take off SHOE PLATE(9) from

SWASH PLATE(PUMP)

9. Turn the contrary BODY,

Separate Snap Ring(16) using Pliers.

16

4-26
Process Drawing Description

10. Take off OIL SEAL COVER(54) ASS’Y.

54

11. Separate Snap Ring(16) using Pliers.

13 12. Take off SHAFT(13) from BODY(1).

4-27
 Process Drawing Description

13. Take off FLUSH M/C SCREW [M6x15L] 3pcs

(7) by L-wrench or Torque wrench.

14.The other side in the same way ,

7 Take off FLUSH M/C SCREW [M6x15L] 3pcs
(7) by L-wrench or Torque wrench.

3 8 15. Take off SWASH COVER(3,8) Of both.

4-28
Process Drawing Description

16. Take off SWASH PLATE(13) from

BODY(1).
1
13

4-29
4. Pre-Assembly Precautions

a) Wash each part with a cleaning (washing) oil and dry it with a clean air.

b) Take a special care in handling each part to prevent stain by dirt or foreign materials, and any
possible puncture, traces of holes or any other physical damage.

c) Replace seals with new ones.

d) Use a specified fastening torque when tightening each part.

e) Spread Lithium Grease on oil seal and O-ring beforehand.

Process Drawing Description

5. Assembly Procedure
1. Assembly of SWASH PLATE

a. Assemble SWASH PLATE(2) in

BODY(1).
13

8 2. Assemble SWASH COVER(3,8) in

3
both of BODY(1) .

4-30
Process Drawing Description

3. Assemble FLUSH M/C SCREW [M6x15L]

3pcs (7) by L-wrench or Torque wrench.

4.The other side in the same way ,

7 Assemble FLUSH M/C SCREW [M6x15L]
3pcs (7) by L-wrench or Torque wrench.

5. The ball bearing assembly is assembled to

the SHAFT(13) in the body(1).

13

4-31
Process Drawing Description

6. Assemble Snap Ring(16) using Pliers.

16

7. Assemble OIL SEAL COVER(54) ASS’Y.

54

8. Assemble Snap Ring(16) using Pliers.

16

4-32
Process Drawing Description
9. Turn the contrary BODY,
Assemble SHOE PLATE(9) in SWASH
PLATE(PUMP)

10. The ball bearing assembly is assembled to

the SHAFT(17) in the body(1).

17
1

4-33
 Process Drawing Description

CYLINDER BLOCK ASS’Y ▶ Assemble SWASH PLATE(21),

HOLDER(22),CYLINDER BLOCK(10),
SET PLATE(11), PISTON ASS’Y (22),
in turn.

22

21 11

10 23

11. After assemble CYLINDER BLOCK

ASS’Y.
Assemble CYLINDER BLOCK ASS’Y
in BODY.

4-34
Process Drawing Description

11. Assemble the PISTON ASS'Y(10) on

SET PLATE(11).

10 11

12 12. After assemble the PISTON ASS'Y(10) +

SET PLATE(11) in SWASH PLATE.
Assemble Snap Ring(12) using Pliers.

13. Assemble CYLINDER BLOCK(PUMP).

23

4-35
Process Drawing Description

14. Assemble GASKET(28).

28

15. Assemble NEEDLE BEARING(30) 2pcs

on FRONT COVER.

4-36
 Process Drawing Description

16. Assemble CHECK(37), SPRING(38),

39
SPRING HOLDER(39) on FRONT COVER.

38

37

17. Assemble WRENCH BOLT [M6x10L] 2pcs

(40) by L-wrench or Torque wrench.

40

18. Assemble RELIEF ASS’Y(32), SPRING(33),

PLUG(34) on FRONT COVER.

34

33 32

4-37
Process Drawing Description

19. Assemble PLUG (34) of RELIEF VALVE

by L-wrench or Torque wrench.

20. Assemble VALVE PLATE(27) and (45).

45 27

21. Assemble FRONT COVER ASS’Y(29).

29

4-38
Process Drawing Description

21.Assemble FRONT COVER(29) into

BODY(1) and then tighten the Wrench
Bolt[M12x45L] 8pcs (47) using torque
wrench.

29

▶Assembled Products

4-39
 PRESS

Press-fit BEARING using a jig, as

shown in the left figure.

Press-fit SHAFT up to its protrusion.

Figure-30. Press-Fitting of SHAFT BEARING

4-40
(Figure-35) Assembly drawing

4-41
 CHAPTER 5
Transmission

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

1.Wheel driving system--------------------------------------------------------- 5-1
2.PTO drive system ------------------------------------------------------------- 5-1
3.Power train diagrams -------------------------------------------------------- 5-1

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

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

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

1. HST system and change gear(front transmission)---------------------- 5-3
2.Mid transmission case--------------------------------------------------------- 5-6
1) PTO Input gear-------------------------------------------------------------- 5-6
2) PTO counter shaft---------------------------------------------------------- 5-6
3) PTO clutch ------------------------------------------------------------------ 5-7
4) HST Unit ------------------------------------------------------------------- 5-10
5)MID PTO Stopper--------------------------------------------------------- 5-13
6)MID PTO Stopper operation-------------------------------------------- 5-14
3.Rear transmission ----------------------------------------------------------- 5-15
4.Shifter and related parts.--------------------------------------------------- 5-24

SECTION 4.TROUBLE SHOOTING--------------------------------------- 5-36

1. Wheel drive system---------------------------------------------------------- 5-36
2. PTO drive system ----------------------------------------------------------- 5-37
3. Power train diagrams------------------------------------------------------- 5-38
 Chapter 5 .Transmission

SECTION 1.GENERAL DESCRIPTION

1. WHEEL DRIVE SYSTEM
The wheel driving system is composed of the following major components:

Damper
Front transmission
HST

Transmission

Change gears
Mid transmission Front drive change gears
PTO Clutch

Rear transmission MID PTO change gears

REAR PTO change gears

Fig.5-1 Wheel drive system

1) The standard transmission produces the hydraulic static transmission and 3 speeds forward and
reverse by Forward/Reverse control pedal and sub-change gears.
2) All of shifting system have the HST unit and sub-change gears with constant-mesh and sliding-mesh.
Therefore, between these stages, gear shifting must be surely stopped traveling.

2. PTO DRIVE SYSTEM

(1) PTO drive system is composed of the hydraulic clutch and the PTO change gears.

(2) PTO drive system is composed of MID PTO and REAR PTO, which is referred
POWER TRAIN DIAGRAMS.

3. POWER TRAIN DIAGRAMS

Refer to the end page at the end of this chapter.

5-1
SECTION 2. SPECIFICATIONS
1. WHEEL DRIVE SYSTEM
2538HST
Speed shift range Engine rated rpm: 2,400 rpm
Main speed shift HST
Speed range shift L(Low) 0.453 (22/21*16/37)
Reduction
M(Mid) 0.867 (22/21*24/29)
ratio
H(High) 1.624 (22/21*31/20)
Drive pinion-Wheel gear 0.032 ( 9/52*10/54)
Operation Main speed shift Pedal - RH
methods
Speed range shift Side shift - LH
Oil capacity Transmission case Recommended Oil Mahindra hyd. oil
Capacity 35 ℓ

2) PTO DRIVE SYSTEM

MODEL 2538HST
TYPE INDEPENDANT
CLUTCH Multiple Wet Disk
Speed shift range 1
Rear PTO Reduction ratio 0.226 (12/53)
PTO shaft speed 540 @ Engine 2,385rpm
PTO shaft size Φ35 mm, 6 straight splines
Rotation direction CW viewed from the rear
Mid PTO Speed shift range 1

Reduction ratio 0.844 (12/53*41/11)

PTO shaft speed 2000 @ Engine 2,369 rpm
PTO shaft size Φ25 mm, 15 straight splines
Rotation direction CW viewed from the rear
PTO clutch Type Wet, multi-disc, hydraulic-operated clutch
Number of clutch plates 6
Used oil Mahindra hyd. oil

5-2
SECTION 3. DISASSEMBLY, INSPECTION, AND REASSEMBLY

1.HST system and change gears (Front transmission).

2
1

1. Input shaft From engine 2. HST unit

Fig.5-2

5-3
 1.1 Disassembly.
(1) Removal of HST system and related parts.
Separate the engine from the front transmission after removing the tightening bolts and nuts.

1. Bolts (10xM12-40) 2. Nuts (2xM12) 3. Washer (2xM12)

Fig.5-3

(2) Remove the HST unit after removing the tightening bolts.

Note : Be careful not to damage O-rings.

1. HST unit (37cc) 2. Pin (D8-20) 3. Bolt(2xM12-85)

4. Bolt(4xM10-55) 5. O-ring(2xP14) 7. O-ring(2xG80)

Fig.5-4

5-4
1-2. REASSEMBLY
Reassemble them in reverse order of disassembly in accordance with the following instruction.
- Installation of clutch damper and related parts.
(1) When installing the clutch damper on the flywheel, be sure to install the cotter pin to flywheel.
(2) Apply a thin coat of molybdenum disulfide-based grease(Three bond TB1901 or equivalent) to
revolving or sliding parts prior to reassembly.
(3) When installing the clutch damper on the flywheel, take care not to damage this clutch damper.
(4) Apply an ANTI RUST 720S or equivalent after installing clutch damper in order to prevent from rust.

Fig.5-5

5-5
2. MID TRANSMISSION
1) Separation between the mid transmission and rear transmission.
(1) Remove the mounting bolts.
Separate the mid transmission from the rear transmission.

1. Pin(D10-22) 2. Stud bolts(4xM12-40) 3. Bolts(8xM12x40) 4. Washer(4xM12) 5. Nuts(4xM12)

Fig.5-6

(2) Remove the PTO input shaft and the bearings.

Pull out the PTO clutch assembly and shaft.
Remove the bearing metal and the input gears.

1. SHAFT ,PTO INPUT

2. BEARING,
BALL6005
3. WASHER, 3. CLUTCH ASSY , PTO
15.2X21X2 CLUTCH
4. BEARING, 4. SHAFT , PTO
NEEDLE141813 CLUTCH
5. GEAR, INPUT 22T 5. BEARING ,
6. BEARING, BALL6204
BALL6205 6. COLLAR , 40X46X08
7. COUPLING 19. C-RING , HOLE Ø 47
8. METAL, BEARING

Fig.5-7

5-6
(3) Remove the 4WD Drive Gear and shaft.
Remove the Sub change gears and shaft.
Remove the Pinion gears

Note : Be careful not to damage the needle bearing and shims.

Pinion Gear
1. C-RING , SHAFTØ 20 2. WASHER , 20X30X1.0 3. BEARING , BALL/6304HL1 4.
WASHER , 20X34X3
5. GEAR COMP , HELICAL 20T 6. BEARING , NEEDLE CAGED KT222613 7. C-RING ,
SHAFTØ 28
8. HUB , 28X51X59 9. GEAR , SPUR 29T 10. GEAR , SPUR 37T
11. BEARING , NEEDLE CAGED KT283327 12. WASHER , 28X46X3
13. GEAR , SPUR 25T 14. C-RING , SHAFT Ø 30
15. NUT , M33X1.5 16. C-RING , HOLE Ø 72
17. SHIM , P/3.0 D=73 18. SHIM , P/0.1
19. BEARING , TAPER-ROLLER30207J
20. SPACER , BEARING
21. BEARING , TAPER-ROLLER 32207J
23. SHIM , P/0.2 T=0.2

Sub Change Gear

1. PIN ,
PARALLEL/A10X22
2. BOLT , HEXM12X60
3. BEARING , BALL6306
4. GEAR , HELICAL 31T 4WD Drive Gear
5. GEAR , 24-16T 1. SEAL , OIL/D25478
6. GEAR , SPUR 29-28T 2. C-RING , HOLE 47
ASSY 3. BEARING , BALL6005
6-1. GEAR , SPUR 29-28T 4. SHAFT , 4WD DRIVE
6-2. BUSH , 30X32X21 5. BALL , STEEL 5/16
7. BEARING , BALL6305 6. 4WD GEAR , SPUR 28T
8. WASHER, SPRINGM12 7. C-RING , SHAFT Ø 28
9. C-RING,Fig.5-7
SJAFT30 8. BEARING , BALL6204
10. GEAR , SPUR 21T 9. SPRING , SHIFTER
11. BEARING , BALL6204

5-7
3) PTO CLUTCH

(3-1) DISASSEMBLY
1. GEAR , HUB PTO
2. BEARING , BALL6005
3. CLUTCH ASSY , PTO
CLUTCH
4. SHAFT , PTO CLUTCH
5. BEARING , BALL6204
6. COLLAR , 40X46X08
7. C-RING , HOLE Ø 95
8. PLATE ASSY
9. SPRING
10. CLUTCH , PLATE
11. CLUTCH , DISK
12. PLATE , RETURN
13. DISC
14. SEAL , C
15. PISTON
16. RING , PISTON
17. CASE
18. SEAL , B Fig.5-8
19. C-RING , HOLE Ø 47
Note:
Disassembly of the PTO clutch assembly should be done in a clean, dust-free place. Exercise special
attention to avoid damage of the seal rings, etc

a. Pull out PTO drive shaft forwards. e. Disassemble into separate parts; piston, return
b. Pull out PTO drive bearing forwards. sparing, brake disc, and cover assembly.
c. Remove snap ring (D95 for hole),and take
bake-up plate, disc assembly, and driving (3.2) INSPECTION
plates.
d. While holding return spring(43) compressed a. Cover assembly
with a special tool, remove snap ring. -Replace a cover assembly which has a damaged
or worn sliding surface.
-If there is any damage to the cover assembly
and the piston seal ring, these parts should also
be replaced.
b. Disc assembly
- If the thickness of a disc assembly exceeds the
usable limit mentioned below or combined width
of the disc assembly and driven plate is less than
23.8mm(0.937 in), replace both the disc
assembly and driven plate.
Fig.5-9

5-8
 -Inspection for disc thickness and serration
wear.

Inspection Items Specified values Usable limit

Disc thickness 2.2±0.1mm 1.9mm
(0.087 in) (0.075 in)
Surface flatness - 0.2mm
(0.008 in)

Fig.5-11
e. If the combined thickness of the return
plate and brake disc deviates from the
specified value, replace both parts.

Inspection Items Specified values Usable limit

Combined 5.5 ±0.18 5mm
thickness of (0.217 in) (0.2 in)
return plate and
brake disc

Fig.5-10
c. Driven plate
-Inspection for deformation and burning.
-A seriously damaged or worn disc should
be replaced.

Inspection Items Specified values Usable limit

Surface flatness - 0.2mm
(0.008 in)
d. Brake disc
-Inspection for deformation and burning.
-A seriously damaged or worn disc should
be replaced.
Fig.5-12
Inspection Items Specified values Usable limit
f. Also inspect other parts for wear and
Disc thickness 3±0.1mm 2.5 mm deformation and replace them if
(0.118 in) (0.098 in) necessary
Surface flatness - 0.2mm Note:
(0.008 in) Seal ring and the two seal rings should be
replaced as a pair
5-9
 (3-3) REASSEMBLY

Reassemble the parts in reverse order of

disassembly, following these instructions.

Note:
-Each parts should be washed clean before
reassembly.
-Apply multi-purpose, quality grease to
needle bearings in advance.
-Each bolt and nut should be tightened to
the respective specified torque table.
-Every time a gear is installed, its smooth
rotation should be checked.
-Every snap ring should be seated securely
in its groove.

a. When installing seal rings, apply fresh

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

b. Install the return plate with the

press-processed side turn towards the brake
disc.

Fig.5-14
① Return plate ②Brake Disc

c. When installing the return spring, use a

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

d. Install washer in correct direction.

e. After reassembly, check to see that gear
turns smoothly by locking the PTO clutch.

5-10
4) HST REASSEMBLY

Fig.5-16

Reassemble them in reverse order of disassembly in accordance with the following instruction.
- Installation of clutch damper and related parts.
(1) When installing the clutch damper on the flywheel ,be sure to install the cotter pin to flywheel.
(2) Apply a thin coat of molybdenum disulfide-based grease(Three bond TB1901 or equivalent) to
revolving or sliding parts prior to reassembly.
(3) When installing the clutch damper on the flywheel, take care not to damage this clutch damper.
(4) Apply an ANTI RUST 720S or equivalent after installing clutch damper in order to prevent
from rust.

5-11
(4-1). Forward and reverse
1) HST holder comp
(1) When reassembling holder comp, take care directions.
(2) After installing holder comp, be sure not to skip the parts.

Fig.5-17 HST holder comp and Rod assembly

5-12
3. Rear transmission case

Fig.5-23

5-13
 3-1. DISASSEMBLY
Separate the spacer transmission and the rear transmission from each other and then remove the hydraulic
cylinder case.

1. PEDAL COMP , DIFF LOCK

(1) Ring gear, Drive pinion, and related parts. 2. PIN , SPRING6X32
3. O-RING , P16
4. SHAFT , DIFF LOCK
5. PIN , SPRING8X60
6. BEARING , BALL/6011HL1
7. HUB , DIFFLOCK
8. FORK , DIFF LOCK
9. WASHER , PLAINM20
10. SPRING
11. BOLT , HEX/SM8X16
12. PLATE , STOP
13. RING , C TYPEØ 75
14. SHIM , O/0.5
15. SHIM , O/0.2
16. SHIM , O/0.1
17. DIFF ASSY , RR
18. CASE , DIFF
19. GEAR , BEVEL 20T(RH)
20. GEAR , BEVEL 20T(LH)
21. PINION , DIFF 12
22. WASHER , THRUST
23. COLLAR , PINION THRUST
24. SHAFT , DIFF PINION
25. PIN , SPRING5X36
26. GEAR , BEVEL 52
27. BOLT , HEX/SM8X20
28. CLUTCH COMP , DIFF LOCK
29. BEARING , BALL/6009HL1
30. PINION , DRIVE 9
31. SHIM , O/0.1
32. SHIM , O/0.2
33. METAL , DIFF CASE R
34. BOLT , HEX/S M10X25

Fig.5-24

Fig.5-24

5-14
a. Disconnect Mid PTO case by loosening bolts f. Pull out diff pinion shaft(24) and take out dif-
as shown. pinions(21) and dif-side gears(19).
g. Remove the pinion metal(support) tightening
bolts and take put drive pinion and related
parts as an assembly. The number of installed
shims should be written down or memorized
for later reference.

Fig. 5-25 MID PTO Case

b. Disconnect Case Brake LH and Case Brake

RH by loosening bolts as shown in Fig.
plate brake Metal brake Fig.5-27

h. Release the lock of nut and remove the nut

Fig. 5-26
c. Remove metal brake and plate brake as a set
d. Remove the ring gear(17) as a set.
e. When disassembling the ring gear set further, Fig.5-28
remove the diff-metal.
i.Push out drive pinion from the rear transmission.
j.Remove the bearing from the drive pinion with
a special tool.
5-15
 (2) PTO shaft and related parts.

Fig.5-29

a.Remove the rear hitch and the trailer hitch.

b.Extract PTO shaft stay(8) rearwards and take out shifter(8).
c.Be alert to the steel ball which may spring out of the shifter. Extract PTO shaft(21) rearwards
and remove the change gears and related parts.
d.Remove gear,spur (21).

Fig.5-30 Rear hitch and trailer hitch

5-16
 3-2. INSPECTION

Before and after disassembly, inspect each part

for the items mentioned below. Parts which
deviate from the specified values should be
replaced.

-Wash clean all disassembled parts and check them for

wear, damage, deformation, Burning ,etc. Defective parts
should be corrected or replaced.
Fig.5-31-1
-As the drive pinion and the ring gear make a pair, they (1) Drive pinion
should be replaced together even if only one is found to (2) Tapered roller bearing
be defective. (3) Drive pinion metal
(4) Tapered roller bearing
-Backlash between the drive pinion and the ring gear (5) Nut (M33X1.5)
(6) Gear
Backlash 0.1-0.2 mm
(0.004-0.008 in) b.Be sure that the starting torque of the drive
pinion meets the specified level.
-Backlash between the diff-pinion and the dif-side gear.
Starting torque 8-11 Kgf.m
Backlash 0.1-0.2 mm
(0.004-0.008 in)

-When the backlash exceeds 0.5mm,also inspect the

thrust collar for wear,defective collars should be
replaced.

-Disengaging the resistance of PTO shifters.

Standard Value 18-22Kgf (40-49lbs) Fig.5-31-2

Usable limit 17 Kgf (38 lbs) c.After the starting torque has been
adjusted to the specified level,crimp the
* Measured at the shifter lock of the nut at one point as illustrated.

3-3. REASSEMBLY

Reassemble the parts in reverse order of disassembly,

following these instructions.

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

a. Apply oil to the drive pinion and related parts
ahead of time. Then install them and tighten the
Fig.5-32
assembly to the specified torque.

Tightening torque 1.4Kgf.m (9.36 ft.lbs) d. Tighten the drive pinion metal(support)
by providing it with the same shimming
thickness that it had when it was
disassembled.
5-17
 When the drive pinion or the ring gear has been
replaced, the proper number of shims to be Ring gear tightening 9.0-11 Kgf.m
installed should be determined based upon the torque (39.8-69 ft.lbs)
following procedure:
Note:
- Apply multi-purpose, quality grease to the
parts mentioned below:
3
• Tooth surfaces of dif-pinions and dif-side
5 4 gears
7
• Friction surfaces of dif-pinion shafts and
dif-pinions.

f.Backlash between dif-pinion and dif-side

gear should be within as range of 0.1 to
0.2mm(0.004-0.008 in) and these parts
should turn smoothly.
1, 6
2
1. Shim (2x0.1t) 2. Shim (2x0.2t) 3.Shim (2x0.2t)
3
4. Shim (2x0.1t) 5. Shim (3.0t) 6. Bolt(4xM10-25)
7. C-Ring (72) 5 4
7
Fig.5-33
Note:
When assembling without replacing the pinion
gear and ring gear with new ones, provide the
same shimming thickness as that provided before
disassembly.
e. Install the differential gears.
1, 6
2
Fig.5-35

g. Install the differential gear assembly.

Diff-case metal 5.5-7 Kgf.m

tightening torque. (39.8-69 ft.lbs)

Fig.5-34

5-18
Note:
When reassembling the used pinion and ring gear,reinstall the same thickness of shims as was installed
before disassembly in each shimming position.
h.Backlash adjustment between the drive pinion and the ring pair(Fig5-35)

i.As the drive pinion and the ring gear make a pair,be sure not to mate them with other parts from
differential tractors.
ⅱAdjust the shimming to backlash of 0.1-0.2 mm
(0.004-0.008 in). The standard shimming is 0.4mm
(0.016 in) on both sides.

Fig.5-36

5-19
Note:
Strike the circumference of the ring gear both sides with a copper hammer by turning the ring gear
manually,and check to see that the backlash remains unchanged.The backlash should be checked at
four points 90 degrees apart to each other.
ⅲ.inspection of the tooth bearing
Apply an even coat of oil-dissolved minium on the drive pinion teeth and turn the drive pinion on the
ring gear to check the tooth bearing by observing the bearing traces on the ring gear.

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

Tip contact Excessive backlash.Move differential case and shims

from right side to left side.See”Assembly and
installation”.

Root contact Inadequate backlash.Move differential case shims from

left side to right side.See”Assembly and installation”.

Toe contact Too little engagement.Remove some drive pinion support

shims.See Transmission:REAR TRANSMISSION
ASSEMBLY-Setting cone center.

Heel contact Too much engagement.Add some drive pinion support

shims.See TRANSMISSION:”REAR TRANSMISSION
ASSEMBLY-Setting cone center.”

INSTALLATION OF A NEW PAIR OR RING GEAR AND DRIVE PINION

1.use a new pair of ring gear and drive pinion delivered from the manufacturer. Never mix its
components with those of other pairs.
Note:
Every ring gear-dive pinion pairs is adjusted and inspected for tooth contact individually at factory.

2.Adjust the backlash between the ring gear and drive pinion to be 0.1-0.2mm(0.004-0.008 in) by
shimming the drive pinion metal and right and left dif-case metal and make sure that their tooth
contact is proper
5-20
(2) PTO shaft and related parts.

a.Pushing the PTO counter gear end into the bearing until the stop on the gear is securely seated
against the bearing. The seal should be coated with an adhesive (THREE BOND TB1215) on the
circumference before installing.
b.Install the oil seal on the PTO shaft, paying attention to its installed direction.
c.After installation, the slide coupling should smoothly slide and mesh with the designated gears.

Fig.5-37

(3) MID PTO shaft and related parts.

Fig.5-38

5-21
4. SHIFTERS AND RELATED PARTS.

4.1. CONSTRUCTION
(1) Forward and reverse control linkage mechanism.

8
7

6
4

5 3
2
1

1. Holder comp 2. Control rod assembly 3. Forward arm comp. 4. HST Pedal Bracket comp.
5. Forward pedal comp 6. CAM comp 7. Reverse pedal comp 8. Damper , oil

Fig.5-39

5-22
(2) range shifter (Speed range shift) mechanism

Fig.5-40

1. ARM SET, RANGE 2. HOOK COMP , RANGE 3. ARM COMP , RANGE 4. PIN , TAPER SPLIT6X36
5. ROD , RANGE 275 6. PIN , SNAP8 7. WASHER , PLAINM8 8. WASHER , SPRINGM12
9. BOLT , HEX 10. HIB(13*17*61) 11. WASHER , PLAINM12 12. LEVER COMP , RANGE
13. NUT , HEX FINE/2 M10 14. GRIP COMP , SUB SHIFT GRIP 15. BALL , STEEL5/16
16. SPRING , SHIFTER 17. FORK , RANGE 18. E-RINGØ 10 19. STAY , RANGE SHIFT
20. BOLT , HEX/SM8X16 21. PLATE 22. WASHER , PLAINM10 23. O-RING , P12

5-23
(3) Front drive change (4 WD shaft) mechanism

1. SEAL , OIL/D25478
2. C-RING , HOLE47
3. BEARING , BALL6005
4. SHAFT , 4WD DRIVE
5. BALL , STEEL5/16
6. 4WD GEAR , SPUR 28T
7. C-RING , SHAFTØ 28
8. BEARING , BALL6204
9. SPRING , SHIFTER

Fig.5-43

1. ARM COMP , 4WD

2. O-RING , P12
3. ARM COMP , 4WD
4. PLATE
5. BOLT , HEX/S M8X16
6. PIN , SPRING 6X25
7. WASHER , PLAIN M8
8. PIN , SNAP 8
9. LEVER , 4WD
10. GRIP , 4WD
11. NUT , HEX FINE/2 M10
12. WASHER , PLAIN M10

Fig.5-44
5-24
(4) Rear PTO mechanism

Counter shaft

1. COUPLING
2. BEARING , BALL6305
Fig.5-45 3. GEAR , SPUR PTO 12T
PTO shaft 4. BEARING , BALL6306
5. CAP , 72
6. E-RINGØ 10
7. BOLT , SET M8X16
8. STAY , PTO SHIFT
9. FORK , PTO
10. BALL , STEEL5/16
11. SPRING , SHIFTER
12. O-RING , P10
13. BEARING , BALL 6205
14. GEAR ,SPUR PTO 53T
15. C-RING , SHAFTØ 35
16. COLLAR , 35X50X2
17. BEARING , BALL6207
20. C-RING , HOLEØ 72
21. SHAFT , PTO
22. SEAL ASSY , OIL
23. HOOK SET , RR PTO
24. HOOK COMP , RR PTO
25. ARM COMP , RANGE
26. PIN , SPRING6X25
27. O-RING , P12
28. PLATE
29. BOLT , HEX/SM8X16
30. HUB(13X17X61)
31. LEVER COMP , PTO/DOWN
32. WASHER , PLAIN
33. WASHER , SPRINGM12
34. BOLT , HEXM12X85
35. LEVER COMP ,PTO(UP)
36. GRIP , LEVER 12
37. BOLT , HEXM8X35
38. NUT , HEX/2 M8
39. WASHER , PLAIN
40. PIN , SNAP8
41. ROD , 236
42. GEAR , SPUR 41T
Fig.5-46 43. WASHER , 35X55X3
44. BEARING , NEEDLE
45. HUB, 35X62X20
46. WASHER , 25X40X26

5-25
(5) MID PTO
(5-1) MID PTO CASE ASSY

1. COVER, MID PTO

2. BOLT, HEX/SM10X25
3. PIN , PARALLEL/A10X20
4. CASE, MID PTO
5. SHAFT, MID PTO COUNT
6. GEAR, SPUR 35T
7. BEARING , BALL6304
8. C-RING, HOLE
10. C-RING, SHAFT
11. CAP, MID PTO
12. BOLT, HEX/SM6X12
13. SEAL OIL/D255210
15. BEARING , BALL6205
16. SHAFT, MID PTO
19. PLUG, MAGNET

Fig.5-47

5-26
 5. PRECAUTIONS FOR DISASSEMBLY,
INSPECTION,AND ASSEMBLY
(1) Disassembly
When drawing a shifter stay from its shifter,be careful not to lose the steel ball.It can jump out of the shifter.

(2) Inspection
-Shifter –disengaging load:
Sub change:18-22 Kgf (40-49lbs)
4WD change:25-29 kgf (55-64 lbs)

-Usable limit of shifter-disengaging load:

Main change & Sub-change:17 Kgf (38lbs)
4WD change: 24Kgf( 53lbs)
-Wearing limit of each shifter: 0.5 mm (0.02 in)

(3) Reassembly
a.lubricate the grooves in the shifters.
b.Each shifter should be installed in the correct direction.
c. When installing the shifter on the shifter stay, Use the special tool as shown below

Fig.5-48

5-27
SECTION 4. TROUBLESHOOTING
1. WHEEL DRIVE SYSTEM
Problems Causes Countermeasures
Transmission makes Insufficient or improper lubricant Replenish or replace
noise in neutral
Excessive splines of change shaft,spline hub,etc Replace
Worn or broken bearings Replace
Slide couplings interfering with the gears due to worn Replace
or deformed shifters

Gears make a noise Improperly disengaged clutch Repair or replace

when shifted. (Clutch pedal play)
Wear in width of gears,splined hubs,collars,etc Replace
Defective Change shift fork Replace
Gears disengage by Broken shifter springs Replace
themselves
Wear in width of gears,splined hubs,collars,etc Replace
Worn shifters Replace

Gears do not engage or Improper disengaged shift lever Repair or replace

disengage
Gears are locked due to foreign matter between them Remove the foreign
matter

5-28
 2. PTO DRIVE SYSTEM

problem Causes Counter measures

PTO does not spin with PTO PTO shift lever is in neutral Shift lever positively to
shifted to ON ON
Defective PTO switch replace
Clogged PTO valve Wash clean
Poor Pump Replace
Defective solenoid valve Replace
PTO spins but does not Worn clutch disc Replace
produce sufficient torque.
Broken or fatigues seal ring at clutch sleeve Replace
Loose joint or broken O-ring of delivery Retighten or replace
valve
Poor pump Replace
Clogged PTO valve Wash clean
PTO does not stop when PTO Defective PTO valve solenoid Replace
switch is shifted to OFF
Poor PTO valve (contamination) Wash clean
Broken clutch piston return spring Replace
Poor switch Replace
PTO follows too much when Improper oil Replace
PTO switch is shifted to OFF
Insufficient warming up Let tractor warm up
sufficiently
Poor PTO clutch brake Replace
Weak or broken piston return spring Replace
Poor PTO valve( contamination) Wash clean
Deflected clutch plate Replace

5-29
Fig.5-49

5-30
 CHAPTER 6
FRONT AXLE

CHAPTER 6. FRONT AXLE(4WD)----------------------------------------- 6-1

SECTION 1.GENERAL DESCRIPTION----------------------------------- 6-1

SECTION 2. SPECIFICATIONS--------------------------------------------- 6-2

SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY-- 6-3

1. Center pivot ----------------------------------------------------------------- 6-3

1-1. Disassembly -------------------------------------------------------------- 6-4
1-2. Inspection ---------------------------------------------------------------- 6-4
1-3. Reassembly -------------------------------------------------------------- 6-4

2. Front differential ---------------------------------------------------------- 6-6

2-1. Disassembly -------------------------------------------------------------- 6-7
2-2. Inspection ---------------------------------------------------------------- 6-7
2-3. Reassembly -------------------------------------------------------------- 6-8

3. Final case -------------------------------------------------------------------- 6-10

3-1. Disassembly -------------------------------------------------------------- 6-11
3-2. Inspection ---------------------------------------------------------------- 6-12
3-3. Reassembly -------------------------------------------------------------- 6-13

SECTION 4.TROUBLE SHOOTING -------------------------------------- 6-15

 Chapter 6 Front axle(4WD)

SECTION 1.GENERAL DESCRIPTION

The 4WD front axle is a center pivot type.The front wheel drive mechanism is incorporated as a part
of the axle.
The front wheel drive power is taken off the rear transmission and transmitted to the differential in
the front axle where the power is divided into right and left and to the respective final cases.
In the final cases,the transmitted revolution is reduced by the bevel gears to drive the front wheel.
The 4WD mechanism with bevel gears provides wider steering angle and greater durability.

그림

Fig 6-1

6-1
 SECTION 2. SPECIFICATIONS

2538 HST

Wheel alignment Toe-in (mm) 2~6

Camber 3°± 1°
Caster 1°± 1°
Front axle Pivot metal (F) bore (mm) Φ55
Pivot metal (R) bore (mm) Φ80

Pivot metal (F) bush (mm) 50X55X20

Pivot metal (R) bush (mm) 75X80X30
Housing (F) Diameter (mm) Φ50
Housing (R) Diameter (mm) Φ75
Front wheel steering angles 52˚

Fig.6-2

6-2
 SECTION 3. DISASSEMBLY,INSPECTION,AND REASSEMBLY

1. CENTER PIVOT

Fig.6-3

1.Housing,front axle 10.Bolt (M16X40) 19.O-ring(G 55)

2.Oil cap 11.Washer,spring(M16) 20.Bolt
3.Plug 12.O-ring(P) 21.Nut
4.connector 13.O-ring 22.Seal washer
5.Hose(820) 14.Spacer (R) 23.Bolt(M12X40)
6.Clamp,(worm/14.5) 16.Metal pivot(F) 24.Washer spring
8.Metal,pivot(R) 17.Bush(50X55X20) 25.Washer
9.Bush(75X80X30) 18.Spacer (F)

6-3
 2) FRONT AXLE BUSH BORE DIAMETER
1.1.DISASSEMBLY
1) Dismount the front wheel drive shaft, Measure the bore diameter of the roll
referring to the pertinent paragraph in chapter 2. bush in the pivot metal(F).If the measured value
2) Remove the right and left tie rods. exceeds the usable limit,replace the bush.
3) Suspend the front axle bracket with a chain.
4) Remove the front metal clamping bolts.The Front rear
front axle can then be separated from the axle Standard value as assembled Ø 50 Ø 75
bracket.
5) Remove the front and rear pivot metals. Usable limit Ø 50.35 Ø 75.35

Fig.6-4

1.2.INSPECTION
1) FRONT AXLE SHAFT DIAMETER
Measure the diameter at a roll bush contact point
with a micro-meter or vernier calipers.If the
measured value is less than usable limit, replace the
housing front axle or bush in Metal pivot (F)or
Metal pivot (R) . Fig.6-6
3) Worn or damaged oil seals,O-rings,
Front rear bearings,etc.should be replaced.
Standard value as assembled Ø 50 Ø 75
1.3 REASSEMBLY
Usable limit Ø 49.9 Ø 74.9 Reassemble the parts in reverse order of
disassembly,following these instructions.

1) Lips of the oil seals,bush contact surfaces,

and O-rings should be coated with grease
in advance.
2) When installing the roll bushes,abide by
the following precautions.

-Use an installer and press in the bush on a press.

-The bore surface should be coated with grease
in advance.
-The shim of the roll bush should reach position
as shown Fig.6-7.In other words the seam
should be in a position which is free from any
Fig.6-5 load.

6-4
 Fig.6-9
Fig.6-7
Note:
Slanted or forced installation of the bush should be
avoided,and the bore surface of the bush should not
damaged.
3) Pay particular attention to the installed direction
of thrust collar,that is,with the sharply-edged
face turned towards the bevel gear case.
4) When the thrust collar has been replaced or the
fore-and aft play of the front axle exceeds the
usable limit,correct play by screwing in the
adjust bolt on the top of the pivot metal(F).

Note:
After correcting the pivot metal play,tighten the
lock nut of the adjusting bolt to a torque of
11.7~13.7KN-cm(1200~1400 kgf-cm)

5) The reassembled front axle should rock

smoothly while pivoting.
6) When the tie-rods are reinstalled,the toe-in
should be adjusted.At the same time,the steering
angles of the both wheels should also be adjusted.
7) Be sure the dimension C and D is same size and
Adjust E and F as same dimension.

Fig.6-8

6-5
2. FRONT DIFFERENTIAL

Fig.6-10

1.Oil seal 3.Pinion bevel 8T 4.Gear bevel 35T 5.Case front Diff 6.Pinion Diff (12)
7.Thrust collar 8.Gear diff side (20) 9.Washer thrust 10.Pin spring 11.Shaft diff pinion
12. Pin spring 13.Bearing Ball(6212) 14.Snap ring 15.Snap ring( hole) 16.Shim(A)
17.Shim(B) 18.Bearing taper roller 19.collar 20.Nut(M30) 21.Bearing ball(6211)
22.Shim

6-6
 2.1 DISASSEMBLY
1) As concerns operation prior to removal of 6) Remove the bearings from the Axle housing
the front axle,refer to the paragraph covering And the ring gear,and then the ring gear can
disassembly of the center pivot be separated from the Axle housing.
2) Remove both wheels 7) Remove the straight pin(4) which retains the
3) Remove the drain plug from the final case and axle housing.
drain oil from the final case.
4) remove both final case assembly (A and B) Note: Discard the removed straight pin and oil
from the front axle( Fig.6-11) seal and install a new pin and Oil seal
when reassembled,because this pin and oil
seal is apt to be damaged when removed.
8) Remove the snap ring and the bevel pinion
can then be removed together with the
TRB’s (Fig.6-11)
Diff case 9) When separating the TRB’s from the bevel
pinion,release the calking of the lock nut and
remove the bearings.

Lock Nut
Snap ring

Snap ring
Oil seal
Fig.6-13
Bevel pinion
Note:
Fig.6-11 The lock nut should be calked at a point
completely apart from the threads may damage
5) Remove the oil seal,assuring parallelism of the threads of the bevel pinion.
the ring gear and bearing
2.2 INSPECTION
Note:
The number of shims(1) installed and the the 1) visually check the bearing surfaces of the
shimming thickness should be noted for later bevel pinion and ring gear teeth.
reference.
Note:
The bevel pinion and the ring gear should be
replaced as a pair.

2) seriously worn or damaged parts should be

replaced.

Fig.6-12
6-7
 2-3.REASSEMBLY Specified thrust play 0.1-0.3
Reassembly the parts in reverse order of mm(in) (0.004-0.011 in)
disassembly,following these instructions.

1)Each friction surface should be coated Note:

with grease in advance.
TRB and collar should be replaced as a pair.
2)The bevel pinion and the ring gear make
a distinct pair after a mesh adjustment
performed at the factory. Consequently, (1) Bevel pinion (8)
when reassembling the pair,be sure to Lock Nut
pair parts with a same reference number.

-Tighten the lock nut to the specified

starting torque of the single unit of the
bevel pinion.
Fig.6-15

(2) FRONT DIFF CASE

a.When installing washer and thrust washer,apply

fresh Molybdenum grease ahead of time.
b.Apply fresh Molibdenium grease to teeth of diff-
pinion and dif-side gear.
c.Each parts should be washed clean,and There
should be no sharp edge to the surface of thrust
washer.
Fig.6-14 d.When assemble the spring pin,Be sure the spring
pin should be different direction (Ø 5 and Ø 3)
e. When any of the bevel pinion,ring gear,TRB,
collar,etc.has been replaced,inspect the bevel
Note:
pinion assembly for thrust play in the front axle
As a general rule,a disassembled lock nut
housing.
should be replaced and a new one should
be installed.However,when there is no
Specified thrust play 0.1-0.3
alternative but to reuse the disassembled
lock nut assure that it can lock securely. mm(in) (0.004-0.011 in)

Note:
Measure the starting torque a manner as
shown in the figure 6-14.

Specified starting 6 -7 Kgf-cm

torque (0.43-0.51 ft.lbs)

-When any of the bevel pinion,ring

gear,TRB, collar,etc.has been replaced,
inspect the bevel pinion assembly for
thrust play in the front axle housing.

6-8
 Fig.6-16

3) DIF CASE AND BEVEL PINION

1.shim
2.shim
3.shim
4.Parallel pin

Fig.6-17 Note: Discard the removed straight pin and oil

seal and install a new pin and Oil seal
when reassembled,because this pin and oil
1) Each friction surface should be coated seal is apt to be damaged when removed.
with grease in advance. 5) Install the bearings from the Axle housing
2) The bevel pinion and the ring gear make And the ring gear,and then the ring gear can
a distinct pair after a mesh adjustment be assembled from the Axle housing.
performed at the factory. Consequently, 6) Install the straight pin(4) which retains the
when reassembling the pair,be sure to axle housing.
pair parts with a same reference number. 7) When any of the bevel pinion,ring gear,TRB,
3) When installing the TRB’s from the collar,etc.has been replaced,inspect the bevel
bevel pinion,Be sure the calking of the pinion assembly for thrust play in the front
lock nut and the bearings. axle housing through drain plug hole.
4) Install the snap ring and the bevel pinion
can then be installed together with the
TRB’s (Fig.6-17) Specified thrust play 0.1-0.2
mm(in) (0.004-0.008 in)
6-9
 3. FINAL CASE

3-1. Front gear case 1.

Fig.6-18

1.Final drive case(A) 2.Gear bevel(9) 3.RBB(6208) 4.Pin,parallel 5.Bolt(fine) 6.Washer spring
7.Gear bevel(16) 8.RBB(6207) 11.Final drive case(B)(L) 13.Final drive case(B)(R)
14. Housing seal 15.Seal 16.RBB(6014) 17.shaft 18.Gear bevel(12)
19.RBB(6308) 20.O-ring 23.Cap 90 25.Shaft RH(296) 26. shaft LH(480)
30.C-ring 31.collar(68X80X2) 35.Space(47.5) 40.Snap ring
41.RBB(6012) 42.Snap ring 43.Plug 45.shim
46 Snap ring 48.Bolt 49.Nut

6-10
 3-2. Front gear case 2.
10.Bolt
11.Nut.
12.Gear,Bevel 41
13.C-ring
14. Seal
15.Bearing,Ball/HL1
16.Bearing,Ball
17.Cover wheel shaft
18.O-ring
19.Bolt
20.Shaft,wheel
21.Washer,50X60X2

1.Case,LH Final Drive 8.

2 Case RH Final Drive (B)
3.Shaft
4.Gear Bevel 11
5.Bearing Ball
6.Cap 90
7. Plug square
Fig.6-19
8.Shim,75X90X2
3.1 Disassembly 9.C-ring

1) Drain oil from the final case by removing the

drain plug.
2) Remove the tie rod or the tie rod end.
3) Remove the final drive case clamping bolts and
take out the assembly of the wheel shaft,
4) Remove the wheel shaft cover clamping bolts
and cap (90)

Note:
Discard the removed Cap(90) and install a
new cap(90) when reassembled,because this
cap is apt to be damaged when removed.
5) Detach the snap ring C from the bevel gear.
6) Extract the wheel shaft bearing together with
the bevel gear,using a bearing puller Fig.6-20

6-11
 Note:
The removed cap(90) (black plug) should be
discarded and replaced when reassembled.

3.2 INSPECTION

1) Wheel shaft cover

- Inspect mechanical oil seal, O-rings, Gears,
cases, etc and replace them if worn or damaged.
-Measure the diameter the part which makes
Fig.6-21 contact with the wheel shaft, with a micro-meter
or vernier-calipers. When the measured value
7) Remove the stop ring and the wheel shaft can less than the usable limit, replace the wheel shaft
be extracted. cover.

Standard value 62
Usable limit 61.9

Fig.6-22
8) Remove the seal from the the wheel shaft cover
Fig.6-24
2) Final Drive case (B)
-Measure the diameter the part which makes
contact with the Final drive case (A),with a
micro-meter or vernier-calipers.When the
measured value less than the usable limit,
replace the wheel shaft cover.

Standard value 110

Usable limit 110.1

Fig.6-23

9) Remove the cap (11) from the bottom of the

final case B and detach the snap ring(hole).
Then the counter shaft(8) and RBB can be
removed. Fig.6-25

6-12
 -Wheel shaft cover
3.3 REASSEMBLY
1) Every snap ring(5) should be seated securely
Reassemble the parts in reverse order of
in its groove.
disassembly, following these instructions.
2) Be sure the numbers of Bevel gear is correct
1) Apply an adhesive (THREE BOND TB1215)
(teeth numbers are 41)
to the following parts.
a.Contact surfaces between the final case B
and wheel shaft cover.
b.Contact surfaces between the final case A
and front axle.
2) The installed wheel shaft should turn smoothly.
3) When installing unitized seals on the wheel
shaft cover and the rotating part between the
final cases (A and B),apply force only to the
outer circumference of the seal as shown in Fig.6-27
Fig.6-26 to avoid deformation.
-Final drive case A

1) Each parts should be washed clean before

reassembly.
2) Apply multi-purpose,quality grease to
Take care not bearings in advance
to deform 3) Every time a gear and bearings are installed,
these portions its smooth rotation should be checked
4) Adjust Back lash between bevel gear 9 (2) and
bevel gear 16 (3) with collar(4) .

Back lash 0.1-0.2

Fig.6-26 mm(in) (0.004-0.008 in)

4) The oil seal should be coated with grease in 5) Apply oil to the housing ahead of time to
advance. Then install them carefully, assuring install the mechanical seal.
that their lips are not turned over. 6) Be sure that the length of shaft (8) is 192 mm.
5) The reassembled final case (B) should turn 7) Tighten the bolts to the specified torque.
smoothly until it makes contact the stopper.
6) When the wheel(tire) is reinstalled, Turn it by Tightening torque 130-180Kgf.cm
hand to make sure that all the mechanism
turns smoothly without making any noise. 8) Adjust backlash between gear bevel 38 and
7) After adjustment of the toe-in,perform road gear bevel 11(9) with collar(10)
tests. There should be no abnormalities such
as vibration, abnormal noises, defected Back lash 0.1-0.2
steering wheel operation, etc. mm(in) (0.004-0.008 in)

9) Apply an adhesive to the Cap (90),and be sure

not to deform when installing.

Note: Refer to Fig.6-23

6-13
- FINAL DRIVE CASE AND HOUSING - STEERING CYLINDER

Fig.6-28

1) When installing the shaft,Be sure that the

gears are not damaged.

2) Be sure the differences between the LH and

RH shaft.

LH RH Fig.6-30
Specified length 479mm 295mm
1) When installing the steering cylinder,Be sure
that the rods are not damaged.
2) Install the pin(2) before assembling the
cylinder.
3) Apply an adhesive Locktite and tighten
the bolts to specified torque

Fig.6-29 Tightening torque 900-1100 Kgf.cm

3) Tighten the bolts to specified torque. 4) Apply an adhesive locktite to the ball joint (7)
and tighten the ball joint to specified torque
Tightening torque 1300-1500 Kgf.cm Tightening torque 1600-1800 Kgf.cm

5) Be sure to bend the split pin (5) after installing

the ball joint

6-14
 SECTION 4. TROUBLE SHOOTING
PROBLEMS AND PROBABLE CAUSES COUNTERMEASURES

● Steering wheel hard to turn

1)Too low tire inflation Inflate to specified value
2)Broken thrust bearing Replace
3)Stuck or broken ball joint of tire-rod end Grease or replace
4)Seizure or poor lubrication of axle end bush Grease or replace

● Vibrating or pulling steering wheel

1)Unbalanced wheels Adjust balance
2)Wheel deflation Repair or replace
3)Unequal diameter of both tires Adjust inflation or replace
4)Loose,worn,or damaged wheel axle bearing Repair or replace
5)Loose,worn,or damaged wheel steering wheel shaft Retighten or replace
6)Worn final case bush Replace
7)Loose final case-front axle tightening bolt Retighten
8)Loose front wheel(tire)tightening nuts1) Retighten

● Steering wheel tends to turn to the right or left while traveling on straight paved road.
1) Deflected wear of tire Replace
2)Different tire diameters Adjust inflation or replace
3)Damaged final case bearing Replace

● Excessive or eccentric wear of tire

1)Improper tire inflation Adjust
2)Worn front wheel shaft bearing Replace
3)Poorly adjusted toe-in Readjust correctly:2-6mm
(0.08-0.24 in)
4)Front wheel drive is always engaged Engage FWD 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

6-15
 CHAPTER 7
Rear axle and brakes

SECTION 1.GENERAL DESCRIPTION----------------------------------- 7-1

SECTION 2. SPECIFICATIONS--------------------------------------------- 7-2

SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY-- 7-3

1.Rear axle housing and brake system--------------------------------------7-3
1.1. Disassembly -----------------------------------------------------------------7-4
1.2. Inspection -------------------------------------------------------------------7-4
1.3. Reassembly ----------------------------------------------------------------- 7-5
SECTION 4.TROUBLE SHOOTING--------------------------------------- 7-7
 Chapter 7. Rear axle and brakes
SECTION 1. GENERAL DESCRIPTION
The rear axle system is of the central axle type, which contains the final reduction gears, differential
gears with diff-lock, and brakes. The power from the engine is transmitted to the right and left wheel
pinions through the differential gears, and reduced in the revolution to the rear wheels by the wheel
gears. A wet, multi-Disc, mechanical operated brake system is employed. Each of the brakes has 2
friction plates and can produce significant braking force with excellent durability. The two actuators
work to push their friction plates in opposite directions, that is, outward, so that stable braking force can
be realized in both forward and reverse movements of the tractor. A dif-lock mechanism which is
housed in the right-hand rear axle housing is employed to lock the differential gears and is activated by
depressing the dif-lock pedal, resulting in the same rotary speeds of both wheels.

Fig.7-1

7-1
 SECTION 2. SPECIFICATIONS

MODEL 2538HST

Type Spur Gear

Final reduction gears
Reduction ratio 5.4

Friction Type Wet,multi-disc,Mechanically operated

Plate
Outer diameter Φ153mm(Φ 6.02 in)

Thickness 3.4±0.1 mm(0.134 in)

Lining material Paper base

Brake system
Number of plates 4 on each side

Outer diameter Φ158mm(Φ 6.22 in)

Separator Thickness 2.5±0.09 mm(0.098 in)
Plate
Number of plates 4 on each side

7-2
SECTION 3.DISASSEMBLY,INSPECTION,AND REASSEMBLY
Separate the rear axle housing from the rear transmission referring to paragraph 6.(1) of SECTION 4.
SEPARATION OF MAJOR BLOCKS in Chapter 2
1) REAR AXLE HOUSING AND BRAKE SYSTEM

Fig.7-2

1.Housing,rear axle 2.C-ring 80 3.Bearing,Ball/6208HL1 4.C-ring shaft 40

5.Pinion LH, shaft 6.Gear(spur/54) 7.Bearing,ball/6209HL1 8.Stop ring
9.C-RING, HOLE 10.Seal shaft 12.Shaft wheel 14.Bearing,Ball/6210
30.Pinion,RH wheel 33. Collar(56X60X238)

7-3
1.1 Disassembly
1) Release the bolt and nut and remove them. 1.2. INSPECTION
2) Extract the bearing with a puller and remove 1) Friction plates.
wheel gear Replace the plates whose surfaces have been
become glossy by carbonization or whose
thickness exceeds the usable limit.

Fig.7-4
3) Remove the collar and pull out wheel shaft(3)
Note:
Removed oil seal should be replaced with a
new one when reassembled Fig.7-7

Standard thickness:mm(in) 3.4±0.1(0.134)

Usable limit:mm (in) 3.0 (0.118)

snap ring Actuator brake cam

Note:
Also replace those whose grooves have been
oil seal worn out completely even if only on one side

Fig.7-5
4) Detach the brake rod from actuator
5) Remove plate and the rubber boot
6) Remove the brake metal tightening bolts and
remove brake metal with wheel pinion and the
disc brake assembly on it
7)Remove the snap ring of wheel pinion
(Fig.7-5) And individually separate the friction
plates,actuator and separator plates from each other.
6) The actuator can be disassembled by removing
Spring

Note:
Be careful to keep the friction surfaces of the linings,
Actuators and separator plates free from damage and
foreign matter.
7-4
 2) Metal brake 4) Wheel shaft

Check the pressure plate,and brake rod for Check the shaft for abnormalities like wear,
abnormality.Replace defective parts.Replace the damage,etc,and replace a defective one.
metal brake whose thickness exceeds the usable
limit. 5) Bearings
Check them for abnormalities like hitching,
irregularity,etc.in rotation after being washed
clean.Replace defective ones.

6) Oil seals
Removed oil seal should be replaced with a new
one when reassembled.

1.3 REASSEMBLY.
Fig.7-8
Reassemble the parts in reverse order of
disassembly ,follow these precautions.
Standard thickness:mm(in) 15(0.590)
Usable limit:mm (in) 14.5((0.571) 1) Make sure that oil grooves,friction surfaces,etc
of the brakes are free from matter such as dust,
iron powder,etc.to avoid brake lining damage.
Note: 2) When installing the brake unit on the wheel
Slight scratches on the friction surface can be pinion,friction plates and separator plates
corrected with sandpaper(#1000) should be arranged in correct order and never
forget to retain the unit with the snap ring.
3) Separator plate. 3) Brake metal tightening bolts should be
Measure the thickness and replace the plate whose tightened to the specified torque with a torque
thickness exceeds the usable limit or whose wrench.
surfaces are damaged (Fig.7-9)

3
2

wheel pinion

L/H: 72.9 mm
R/H: 101 mm

Fig.7-9 (Fig.7-10)

Standard thickness:mm(in) 2.50.09 Tightening torque 5.5-7 Kgf.m

(0.098) (39.8-50.6ft-lbs)

Usable limit:mm (in) 2.2(0.087)

7-5
 4) Replace the oil seal.

Install the bearing,snap ring,and collar into the axle

housing,and then press in the oil seal by applying
force only to the circumference as shown in the
figure( Fig.7-11)

Apply force only to the shaded parts

Take care not to deform these portions

Take care not

to deform
these portions

Fig.7-11

5) press in the wheel shaft.

6) Install the wheel gear and bearing on the
wheel shaft and retain them with nut.
7) Apply adhesive (THREE BOND 1215) to the
contact surfaces of the brake metal and housing
and then retain the plates by tightening the nuts
to the specified torque.

Tightening torque 0.6-0.8 Kgf.m

(4.3-5.8ft-lbs)

snap ring Actuator brake cam

oil seal
Fig.7-13 Wheel shaft metal

Apply adhesive

7-6
 SECTION 4. TROUBLESHOOTING

Problem Cause Countermeasures

1) Rear Axle

Noises •Worn or damaged bearing Replace

•Worn gear or wheel shaft Replace
2) Brake system

(1) Insufficient braking •Insufficient depressing of brake pedals Depress pedals positively.
force •Improper pedal free play Adjust
•Worn friction plates Replace
(2) Brake Noise •Insufficient brake oil Replenish
•Broken actuator spring Replace
•Eccentric wear of actuator Replace
(3) Brake overheating •Insufficient oil Replenish
•Excessive pedal free play Adjust
•Improper operation Operate brakes properly
(4) Brake cannot be •Improper brake pedal free play Adjust
disengaged completely •Broken actuator spring Replace
•Broken pedal spring Replace
(5) Not uniform braking •Improper free play adjustment Adjust
•Worn actuator ball Replace
(6) Excessive pedal play •Improper adjustment of brake rod Adjust
•Worn actuator-fork tightening bolt Replace
•Worn brake shaft of brake arm Replace

7-7
 Chapter 8. Power assisted steering system.
SECTION 1. GENERAL DESCRIPTION
The hydraulics of this power-assisted steering system are actuated by a specially designed steering
valve system.
Non Load reaction valve blocks the L,R cylinder ports in neutral condition and does not transmits the
reaction load of the tire to the steering wheel in neutral. Generally the system is used for the vehicles
that treat heavy equipment or low speed traveling.
Hydraulic circuit consists of Independent system.
The oil from tank flows into gear pump of orbitrol via filter and the quantity of oil in the proportion
to the rotations of steering wheel flows into steering Cylinder Via "R"-port at right turn and via "L"-
port at left turn.
As follow figure shows components composition of power steering system on the vehicle with the
Orbitrol

Fig.8-1

8-1
SECTION 2. SPECIFICATIONS
1) GEAR PUMP

MODEL T394HST
Delivery (cc/rev) 6.5
Maximum pressure (kgf/㎤) 180
Rated operation speed (rpm) 500~3500

Rotation direction C.C.W as viewed from shaft

2. Power steering valve Unit(orbitrol)

MODEL T394HST
Model number OSPM 80 ON
Displacement (cc/rev) 80
Rated flow (ℓ/min) 7~20
Maximum system pressure (kgf/㎤) 180
Max. back pressure (kgf/㎤) 20
Max. temperature(℃) 90
Input torque (N.m) 0.8~1.5

Inlet relief pressure setting (kgf/㎤) 110~115

Recommended filtration (ISO4406) 22/20/17

Weight (kgf) 2.7

3. OIL TANK

MODEL T394HST
TANK TRANS MISSION
Fluid volume (ℓ) 35
Fluid THF500

8-2
SECTION 3. FUNCTION
OSPM is a hydrostatic steering unit which can be used with an add-on steering column,
OTPM/OTPM-T or with the steering column integrated with the unit.
The steering unit consists of a rotary valve and a rotary meter.
Via a steering column the steering unit is connected to the steering wheel of the vehicle.
When the steering wheel is turned, oil is directed from the steering system pump via the
rotary valve and rotary meter to the cylinder ports L or R, depending on the direction of
turn. The rotary meter meters the oil flow to the steering cylinder in proportion to the
angular rotation of the steering wheel.
If the oil supply from the steering system pump fails or is too small, the steering unit is
able to work as a manual steering pump.

OSPM-ON
Open center steering units have open connection between pump and tank in the neutral position.

8-3
 3.1 TECHNICAL DATA OSPM

Max. input flow 20 l/min [5.28 US gal/min]

Ambient temperature Min. –30°C [–22°F]
Max. +60°C [140°F]
Surface treatment Permissible temperature assuming 120°C [248°F] for 20 minutes
non-activated steering unit
Oil temperature Min. -30 °C [-27°F]
Max. +90 °C [194°F]
Oil viscosity Min. 4 mm2/s [40 SUS]
Max. 1000 mm2/s [4629 SUS]
Filtration Max. degree of ON 22 / 20 / 17
contamination ISO 4406
PB 22 / 20 / 17
Steering torque Normal steering 0.8-1.5 Nm [7.08-13.3 lbf·in]
Manual steering Max. 80 Nm [708 lbf·in]
Momentary load Max. 160 Nm [1416 lbf·in]

MANUAL STEERING PRESSURE

Under normal operating where the steering pumps supplies an adequate oil flow at the required
pressure, the maximum torque on the steering wheel will not exceed 2 Nm[17.7 lbf·in]. If the oil
flow from the steering system pump fails or is too small, the steering unit functions automatically as
a manual steering pump. Manual steering can only be used for a limited control of the vehicle if a
sudden drop of pump pressure occurs.The Pm 50bar[725 psi] shows the manual steering pressure
(Pm) for all sizes of Sauer-Danfos steering units type OSPM at a steering wheel torque of 80 Nm
[708 lbf·in].The values apply only if the suction conditions on the steering unit T port are adequate.

PRESSURE RELIEF VALVE

The pressure relief valve protects the pump
and steering unit against excess pressure
and limits the system pressure while
steering.
The pressure relief valve in the steering unit
will limit the maximum pressure drop from
P to T. The pressure relief valve is set at 12
l/min[3.17 US gal/min] flow.

8-4
SHOCK VALVES
The shock valves protect the steering unit against shocks from external forces on the steering cylinder.
The shock valves in the steering unit limit the max pressure drop from L to T and from R to T. The
shock valves are set at 1 l/min [0.27 US gal/min]. They are of the direct type and therefore have a very
quick reaction. The setting tolerance is +20 bar [+290 psi].

CHECK VALVE
The check valve protects the driver against kickbacks in the steering wheel. It prevents the oil from
flowing back into the pump line during steering under high pressure on the cylinder side. The check
valve is mounted in the P-connection of the steering unit.

PRESSURE DROP IN NEUTRAL

The pressure drop is measured with the steering
unit in neutral position.On the OSPM ON the
pressure drop is measured from P to T. The values
are valid at an oil temperature of 50°C [122°F] and
a viscosity of 21 cSt [100 SUS].

8-5
 SECTION 4. Disassembly,Inspection,And Reassembly
1. Major component of steering valve (orbitrol)

Fig.8-2

1.Dust seal ring 2. Housing spool and sleeve 3.Ball 4. Ball stop 5.Shaft seal 7.Bearing 10.Ring
11. Cross pin 12.Set of springs 13.Cardan shaft 14.Spacer 15.O-ring 16. Distributor plate
17.Gear wheel set 18.O-ring 19.End cover 20.O-ring 22.Special screw 23. Special screw
24. Name plate 30.Complete relief valve.

8-6
2.SPECIAL TOOLS
F. Fork for fitting cardan shaft (OMM)
A.Holding tool, code no. SJ150L9001-01
SJ 151G9000 -1

G .Ordinary hand tools.

Socket spanner (5/8 in)
B .Assembly tool for shaft seal ø17.5, Ratchet spanner, 1/2”
code no. code no. SJ150L4011 - 01 Torque wrench: 0-70 Nm (0-7 da Nm)
Allen keys: 5 & 8 mm a/flats
Small screwdriver, ground sharp.
Pincers

3. Disassembly
C. Assembly tool for shaft seal ø19,2, Separate the orbitrol referring to Fig.8-2 of
code no. SJ150L4012 - 01 SECTION .Disassembly,Inspection,And
Reassembly 1.Major component of steering
valve (orbitrol)
STEP 1.
- Column
If there is a steering column on OSPM, place the
unit in the holding tool, on the four locating
D .Assembly tool for dust seal ring, pins with steering column upwards. Dismantle
code no. SJ150L0396 -01 the steering column.
STEP 2.
-Pressure relief valve (30, 31)
If there is a pressure relief valve in OSPM,
remove the plastic plug from the adjusting screw
and unscrew with the 5 mm a/flats Allen key.
Remove the spring and use special pliers-lift the
E. Pliers for piston in pressure relief valve,
valve cone out of the housing.
code no. SJ150-9000 -25

Lift OPSM clear of the holding tool, turn it so

that the output shaft points downwards and place
it in the holding tool again.
Note, the locating pin in the tool must engage
with the OSPM housing.

8-7
STEP 3. STEP 9.
-Cross pin(11)
-Special. Screws (22, 23) Press the pin out of the spool set.
Remove the screws with a 16 mm a/flats Carefully press the spool out of the sleeve.
(5/8”) spanner.
-Springs (12)
-End cover (19) Press the neutral position springs out of the
Remove end cover sideways. spool.

STEP 4. -Dust seal (1)

-Gear wheel set (17, 18) Remove the dust seal ring (with a “sharp”
Hold a hand under the gearwheel set to keep screwdriver).
the gearwheel from falling out.
Remove O-rings. -Shaft seal (5)
Remove the shaft seal
STEP 5. (with a “sharp” screwdriver if necessary).
-Distributor plate (16)
Remove distributor plate.
4. Cleaning, inspection,replacement
-Cardan shaft (13) and lubrication
Remove cardan shaft.
Note:
STEP 6. a.Clean all parts carefully.
-O-ring (15) b.Carefully check all parts and replace
Remove O-ring from housing. imperfect parts, if any.
c.Always replace all sealing parts during a
-Balls and ball stop (3, 4, 37) repair.
Shake out check valve ball (not in all units), d.Before assembly, lubricate all parts with
ball stop and emergency steering ball. Use hydraulic oil and grease rubber parts with
pincers if necessary. Vaseline.

STEP 7. 5.REASSEMBLY
Place the OSPM in the tool again. Lift up
steering unit and fixture in one piece and turn it STEP 1.
90° to horizontal. -Housing (2)
Place the OSPM housing horizontally in the
-Housing/spool/sleeve (2) holding tool, with the hole for the output shaft
Turn the spool set so that the pin in spool facing the tool.
and sleeve is horizontal and push it out
Note: the locating pin in the tool must engage
STEP 8. with in the OSPM housing.
-Bearing (7)
Remove bearing from shaft end.
The outer washer may sometimes adhere to the
housing. If the washer does not come out with
the shaft, it will come out when shaft seal item
5 is being pressed out.

-Ring(10)
Remove retaining ring for the neutral position
springs.

8-8
STEP 2. Note: The ring must be able to rotate unimpeded
-Shaft seal (5) by the springs.

With the assembly tool the shaft seal must STEP 6

into the housing.
Note that the small guide piece at the front of -Cross pin (11)
the tool must remain in the hole for the output Fit the cross pin in the spool set.
shaft when the tool itself is drawn out of the
housing. -Thrust bearing (7)
Fit the thick race, needle cage and thin
Note: there are two different tools: race.Lubricate the output shaft on the inner
One for housings for steering column mounting spool with Molykote PG plastslip 75,on the
(SJ150L4011-01) surface in contact with the shaft seal.
One for housings with integrated steering
column (SJ150L4012-01).

STEP 3 STEP 7
-Spool/sleeve (2) -Housing /spool/sleeve (2)
Guide spool and sleeve together, turn the spools
so that the key slots are opposite each other. a.With the housing still horizontal in the holding
tool - secure it with one hand. With the other
hand take the assembled spool/sleeve set,
STEP 4.
making sure two fingers hold the cross pin (11)
-Springs (12)
in position. Guide the spool set into the housing
Insert the curved springs between the flat with the cross pin (11) horizontal.
springs and push them into place (see sketch).
Note:
Be careful with the small guide piece from
mounting of the shaft seal.
With it is pressed out by the shaft rotary.

b. With housing and spool set remaining in the

tool,lift the whole unit into vertical position.
The pin in the spool set must now point
towards port P in the housing, either at 6
o’clock or 12 o’clock.
STEP 5.
Spring retaining ring (10)
Center the springs in the spool/sleeve set and guide
the ring down over the sleeve.

8-9
STEP 8. STEP 12
-O-rings (18)
-Ball (3) Place the O-rings in the grooves on each side
Place the emergency steering ball in port P. of the gearwheel rim.
-Ball stop (4) -Gear ring ( 17 )
Place the ball stop in port P. Place the gearwheel rim over the distributor
plate so that all holes are in line with each
-Ball (37) other.
Place the check valve ball (if required) in port P
STEP 13.
STEP 9. -Spacer ( 14 )
Place the spacer over the cardan shaft.
-O-ring (15)
Fit the O-ring in the housing. -End cover (19)
Place the cover so that the hole marked “P”
-Distributor plate (16) lines up with port P in the housing(“6 o’clock
Place the distributor plate on the housing. ” or “12 o’clock”).
Turn it so that the holes line up.
STEP 14.
STEP 10 -Special screws (20, 22,23)
-Cardan shaft(13) Fit screws (with O-rings). Remove the
Fit the cardan shaft into the inner spool and retainer fork. Tighten all five screws
allow it to engage with the pin. (cross pattern) with 30 ± 3 Nm (3 daNm).

If so required use fork SJ 151G9000-1to retain

the cardan shaft. Note:
With open center units, the screw with no oil
STEP 11 flow connection must be fitted in port E.
17 Gear wheel
When fitting the gearwheel, it must be oriented If the OSPM must be mounted with a
correctly so that it engages with the cardan shaft. Pressure relief valve, lift it out of the tool
and place it on the four pins with the axle
The cross pin (11) in the spool set must line up journals upwards.
with the bottom of the teeth in the star
(see sketch). STEP 15.
-Piston (30)
Fit the piston.
-Spring (31)
Fit the spring.

STEP 16.
-Adjustment (30)
Screw in the adjusting screw.

8-10
STEP 17. (Test)

a.Lift OSPM out of the tool and prepare it for

testing.
The pressure relief valve can be set either on a
test panel or in a system with pressure-gauge
read-off.
b.Insert plastic plug.

STEP 18.
Dust seal (1)
Guide the dust seal ring down over the shaft
end press into place in the housing with
assembly tool. SJ 150L0396 - 01.

Note: The dust seal must be fitted after testing

so that any leakage from the shaft seal can be
detected.

8-11
SECTION 5. TROUBLESHOOTING

Problems and probable causes Counter measures

1. Steering wheel is very heavy to turn

1) Poor assemble between steering column and

unit.
(1)Spline of column and unit are assembled -Replace column spline
tightly.
(2)Spool of unit is seized by spline of column -Check column assembly face and spline
. length (MAX 6.5㎜)
(3)Poor rotation of column -Replenish oil or Exchange
2) Insufficient pump pressure or fluid volume
(1)Check pump delivery -Exchange pump
(Unit volume×120 rpm×1.15)
(2)Check oil tank fluid volume -Replenish oil
(3)Check pump pressure -Adjust relief pressure
3)Trouble internal steering unit valve
(1)Low setting pressure of relief valve -Adjust fluid level properly
(2)Ball-nut heavy to work -Wash clean or replace
4)Trouble machine mechanism.
(1)Poor link work -Wash and replenish oil
(2)Excessive sector gear pre-load -Adjust backlash

2. Return to neutral is too slow

1)Poor assemble steering column and unit
(1)Poor assemble to center between -Loosen the bolt and fix again with center
column and unit
(2)Column assembly face depressed unit -Replace column or repair
bushing
2)Depressed control set (spool+sleeve)
(1)Excessive fluid volume
(2)Excessive pressure -Adjust fluid level properly
(3)Dust -Adjust pressure
-Wash
3) High pressure ratio of "T" port (tank port)
(1) Tank port hall is small -MAX. Pressure ratio 20 bar
(2) Tank port pipe is linked to other lines -Wash and clean pipe line
-Separate unit pipe line and reinstall

8-12
 Problems and probable causes Counter measures

3. Free play of steering wheel

1)Too low elastic of centering spring

( Remove P port pipe line and check left and
right turning) -Replace spring
(1)Damaged spring or poor elastic
2) Depressed control set
(1) Excessive fluid and pressure -Adjust fluid level and pressure properly
(2) Depressed by foreign material -Wash
(3) Depressed from external when assemble -Check column and adjust
with column

4. Steering wheel resistance with turning

(1)Worn of spline gear column -Replace column
(2)Depressed control set -Wash,and Adjust fluid level and pressure
properly
(3)Air trapped in cylinder and pipe line -Deflate the air
(4)Excessive backlash column -Adjust column
(5)Poor turning of column,or wear of bearing . -Replace column and replenish oil

5.Too much free play of steering wheel(Rough touching on tire causes vibration)

(1)Air trapped in steering cylinder and pipe line. -Deflate the air
(2)Worn ball bearing -Replace

6.Free play steering wheel

(1)Insufficient oil in the tank -Replenish oil

(2)Worn,damage steering cylinder -Replace oil seal and cylinder
(3)Loose spacer in unit -assemble spacer parts.

7.Kick-back of steering wheel

(1)Loose check valve in "P" port or don't -Adjust check valve

operate
(2) Trouble in system -consult workshop

8-13
 Problems and probable causes Counter measures

8.Serious kick-back each side

(1)Poor assemble the gyrotor lower the unit -Reassemble

9. Steering wheel is very heavy to begin turning

(1)Oil density is too high or cool -Replace oil

10. External Oil leakage

(1)column -Replace oil seal,slide ring
(2)End cap gyrotor -Replace o-ring
(3)Tightening Bolt -Replace copper washer
(Torque 1st:175 ㎏f·㎝. 2nd:280 ㎏f·㎝)

8-14
 Chapter 9
Hydraulic system

SECTION 1. GENERAL DESCRIPTION ------------------------------ 9-1

SECTION 2. SPECIFICATIONS ----------------------------------------- 9-2

SECTION 3. MAJOR COMPONENT OF THE HYDRAULIC

SYSTEM ------------------------------------------------------- 9-3
1.Hydraulic system ------------------------------------------------------- 9-3
2.Flow-divider -------------------------------------------------------------- 9-4
3.Flow-control valve(Slow-return check valve) ---------------------- 9-7
4.Safety valve(main relief valve)---------------------------------------- 9-9
5.Gear pump --------------------------------------------------------------- 9-10
6.Filter----------------------------------------------------------------------- 9-15

SECTION 4. REMOTE HYDRAULIC CONTROL------------------ 9-16

1.Remote hydraulic control valve (optional)------------------------- 9-16

SECTION 5.HYDRAULIC SYSTEM ----------------------------------- 9-17

1.Hydraulic cylinder ------------------------------------------------------ 9-17

2.Linkage(Internal)-------------------------------------------------------- 9-19
3.Linkage(External) ------------------------------------------------------ 9-20
4.main control valve------------------------------------------------------- 9-21
4.1.General description------------------------------------------------- 9-21
4.2.Specifications -------------------------------------------------------- 9-21
4.3.Construction --------------------------------------------------------- 9-22
4.4.Operation ------------------------------------------------------------ 9-22

SECTION 5. SERVICE INSTRUCTION------------------------------- 9-25

SECTION 6. TROUBLESHOOTING ---------------------------------- 9-27

 Chapter 9 Hydraulic system

SECTION 1. GENERAL DESCRIPTION

The hydraulic system is composed of a gear pump,valves,oil filter,cylinder(actuator),piping,etc.The
implement lift is operated by a control valve which is actuated by the control lever through a link
mechanism.
ON and OFF of the PTO is controlled by a hydraulic,wet,multi-disc clutch whose circuit is opened and
closed by an electromagnetic valve in the flow-divider.
The construction and circuit of the hydraulic system are shown in Fig.9-1 and 9-2

Fig.9-1 hydraulic system construction

9-1
SECTION 2.SPECIFICATIONS

T394HST
Piston and cylinder Lift (㎏f)
(At lower link top end / 24in behind) 1200 / 800
Cylinder port leaks (cc/min.) 10
Control Valve (Under a pressure of 9800kpa(100 ㎏f/㎠) (0.610 cu in)
With gear oil SAE 80W

Cracking pressure (㎏f/ ㎠) 135

Main relief valve Relief pressure (㎏f/㎠) 160
Delivery(91% efficiency): litre (cu.in) mm
Gear Pump At 3000rpm (3000x0.91x9x0.903) 22.2
Fluid TDH oil or Donax TD
Rated flow (ℓ/min) 35
Suction filter Filtration density (mesh) 150
Filtration area (㎠) 450
Rated flow (ℓ/min) 32
Line filter Filtration density (mesh) 80
Filtration area (㎠ 31

NOTE: Recommendable Transmission oil

Manufacturer :Product
CALTEX :Textran TDH Premium
Texaco :TDH oil
Chevron :Chevron 1000THF
ESSO :Torque Fluid 56
MOBIL :Mobil fluid 423
SHELL :Donax TD
CASTROL :CASTROL AGRI MULTITRANS
TOTAL :Transmission MP

9-2
SECTION 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM

1.HYDRAULIC SYSTEM

Fig.9-2

1.Case, Cylinder 2.Main control valve 3. Cover,Main control valve 4.Lift arm
5.Lift shaft 6.Relief valve 7.Rod,piston 8.Piston,hyd.
9,10.O-ring P 11. Cylinder 12.Lift crank 13.Link,crank lift
14. Arm link 15.Link valve 16.Knob,slow return 17.Screw
18.Washer spring 19.Nut 20.Shaft 21.Clevis

9-3
2.FLOW-DIVIDER
GENERAL DESCRIPTION
This valve is installed to bypass working fluid of a specified pressure from the main circuit into the
PTO circuit through a fixed orifice. It includes a changeover valve for engaging and disengage the
PTO clutch by means of a solenoid and a sequential valve for PTO circuit's over the main circuit.

Fig.9-3

9-4
(1) Solenoid
This solenoid is switched on or off by operating the PTO switch.With this lever operation,the solenoid
shifts the changeover valve to the left or the right to bypass or block the flow to port B.

(2) PTO changeover valve

This valve is composed of the spool and spring. When the solenoid is switched on,the spool is moved
to the left by overcoming the spring force and allows the fluid from the pump to flow from port P to
port B through the fixed orifice.

-When the solenoid is switched 「ON」

The fluid from the pump flows to port B through port P,the pressure-reducing valve,and the
changeover valve.
The pressure of the PTO clutch circuit and that of passage(2) are the same and will be set as P₂.The
pressurized fluid acts on the left-hand side of the valve,passing through port ; its pressure will be set as
P₁.
As passage (1) and passage (2) are interconnected,then P₁=P₂.
The force imposed upon the left-hand side of the valve is P1 whereas the force imposed upon the right
side of the valve is P1 plus the spring force.Consequently the spool is pushed leftwards.
Here port A is blocked, so the fluid from the pump is branched off to the PTO clutch.

(1) Passage 1
(2) passage 2
(3) Pressure-reducing valve
(4) Changeover valve
(5) PTO clutch
(6) To control valve.

Fig.9-4

9-5
-When the solenoid is switched 「OFF」:
The fluid in the PTO clutch is unloaded to the bank through port B.Consequently pressure P2
at passage(2) becomes zero,whereas the pressure at passage (1) is P1.Then the force imposed upon the
left side of spool (P1)overcomes the force imposed upon the right side
(P2+spring force),so that the spool is pushed rightwards to connect port P and part A. Therefore no fluid
from the pump is branched off to the PTO clutch; that is,all fluid flows to the control valve.

(1) Passage (1)

(2) Passage (2)
(3) Pressure-reducing valve
(4) Changeover valve
(5) PTO clutch
(6) To control valve

Fig. 9-5 PTO solenoid switch 「OFF」position

(1) Pressure-reducing valve.

This valve is composed of the spool,spring,and piston and bleeds off the surplus fluid from the pump
into the tank by actuating the spool when the fluid pressure exceeds the regulated pressure at port B
(2) Fixed orifice
This orifice controls the fluid flow at B in accordance with the pressure differential between the
secondary pressure of the pressure reducing valve and the PTO clutch actuating pressure.

9-6
3.FLOW-CONTROL VALVE (SLOW-RETURN CHECK VALVE)
3.1. GENERAL DESCRIPTION
This valve regulates the lowering speed of the lift by controlling the unloading flow from the lift
cylinder to the tank.

①Dust seal
②Snap ring
③Collar
④Body
⑤0-ring
⑥Adjust screw
⑦Back-up ring
⑧0-ring
⑨Stop ring
⑩Poppet
⑪Spring
⑫0-ring

9-7
3.2 OPERATIONS
2) Up position
1) Down position
The flow port A,overcoming the force of
The fluid from port B pushes up stop ring (9) spring(11),pushes up poppet (10) and
of poppet(10) until the ring comes into choke(C)is fully opened regardless of the
contact with adjust screw(6),as it reaches position of adjust screw(6).Thus the fluid
chamber(R). Consequently, the extent flows to port B and the cylinder,which
choke (C) is opened is determined by the results in raising the lift arm.
positioning of adjust screw (6):that is,when
adjust screw(6) is screwed in clockwise,the
opening of chock(C) decreases and the
lowering speed of the lift arm slows
down;whereas the opening of choke(C)
increases and the lowering speed of the lift
is accelerated when the adjust screw is
unscrewed counterclockwise.When the
adjust screw screwed in completely,the
poppet comes into contact with body seat(S)
and the choke is closed completely,so the
lift arm stops.

Fig. 9-8 Up position

Fig. 9-7 Down position

9-8
 4. SAFETY VALVE (MAIN RELIEF VALVE) 2) PRECAUTIONS FOR DISASSEMBLY
1)GENERAL DESCRIPTION AND REASSEMBLY
This valve regulates the maximum pressure in (1)Tightening torque of lock nut (9)5.0∼6.0
the whole hydraulic circuit. The regulated
㎏f·㎠(36.2∼43.4 ft.lbs)
pressure can be set with the adjust screw.
(2)Install seat(2)and then tap ball(3)(5/16)
lightly so as to provide tight seating.
(3)Wrap the valve threads with sealing tape
and tighten the valve up to a specified
torque of 5-6Kgf.m(36-43 ft.lbs)
(4)Before disassembly, the current
screwing-in depth of the adjust screw
should be written down or memorized for
later reference.

3) MEASUREMENT OF THE RELIEF

Fig. 9-9 Main Relief valve PRESSURE
(1) 3 POINT TO TEST RELIEF PRESSURE
①Remove the plug in the delivery pipe on
the right-hand side of the transmission
case and install a compression gauge to
measure the pressure.
Keep the engine speed at 2600 rpm and
shift the position control lever at the
highest position.
②Control valve coupler.
③Remove the plug in the hyd. pump flange
and engage the pressure gauge and
Fig 9-10 relief valve circuit.
measure it.
Measurement the Pressure must be done 3
times and should be set within specified
pressure.

Specified relief pressure 160 +5 ㎏f·㎠

9-9
5.GEAR PUMP
1) GENERAL DESCRIPTION
This pump induces fluid from one side and delivers it from the other side by rotating two gears
meshed with each other. The actual delivery is as mentioned below, considering the consequences of
fluid temperature and volume efficiency in accordance with revolution speed. That is dual pump
system.
2) Gear pump

Fig. 9-12 Gear pump

3) OPERATIONS.
This pump induces fluid from one side and
delivers it from the other side,by rotating
two gears meshed with each other. The
actual delivery is as mentioned Fig.9-13,
Considering the consequences of fluid
Temperature and volume efficiency in
accordance with revolution speed.

Fig. 9-13 Gear pump

9-10
 6. FILTER

Fig. 9-30 Filter

1)GENERAL DESCRIPTION
The tractor is equipped with oil filters:
suction filter(1) for better filtration.

2)SPECIFICATIONS

-Suction filter

Applicable oil Mahindra hyd. oil

Rated flow rate(ℓ/min.) 45
Filtration density (mesh) 150 mesh
Filtration area(㎠) 790
Working oil temperature (℃) -30 ∼130℃

3) REPLACEMENT
Check the O-rings for damage or deformation
and replace defective ones. When installing the
filters, be sure to install the O-rings properly
with grease applied.

9-11
SECTION 4. REMOTE HYDRAULIC CONTROL (If equipment)

Maximum flow (ℓ/min) 26

Maximum pressure (kgf/㎠) 400
System pressure (kgf/㎠)(at 26 ℓ/min) 160
A and B port leak(cc/min) Less than 9
①under a load of 100kgf/㎠
② Oil temperature:50 ºC
Recommended fluid Mahindra hyd. oil
Operating temperature range( ºC) -30 ∼130℃

1.Remote hydraulic control valve

1.Grip , Lever/red
2. Lever,Aux1
3.Valve assy,Aux.Exterior 2P
4. Elbow,PF3/8 PF ½
5. Coupling
6.Union,1/2
7.Washer spring
8.Nut
9.Lever,Aux.
11.Stud
13.Valve,Aux Exterior spring
14.Cover
15.Bolt

Fig. 9-32 Remote hydraulic pump

9-12
SECTION 5. HYDRAULIC SYSTEM
1.HYDRAULIC CYLINDER
1) Hydraulic system must be washed clean and care must be taken not to let any foreign substances.

2) The O-ring and back-up ring should be coated with grease ahead of time. Install with care so as not
to damage them.

3) Install the Piston from the cylinder head side.

4) The lift arms should be assembled mutually by reference to their matching marks.

5) When installing the control valve,apply grease to the O-rings and avoid their dislocation or binding
during tightening the valve to the specified torque 130 ∼180㎏f-㎝

6) The safety valve should be installed levelly,and make sure there is no oil leak through the filter seal
. Tightening torque is 900∼1100 ㎏f-㎝

7) The spool should move smoothly after assemble the control valve.

8) The lift crank should be installed levelly,and make sure there is no interference through the pipe.

Lift crank
Spring O-ring

Apply Adhesive
(Loctite)

Safety valve
Tightening torque :
900∼1100 ㎏f-㎝

Apply grease
(O-ring,Back up ring)

Bush

Lift shaft

Fig.9-33. Hydraulic cylinder.

9-13
 Apply grease

Lift arm Apply oil

Fig.9-34.Lift arm

9)Adjust the angle of the roll bush from horizontal is 30°

10)Apply grease to the roll bush.
11)Apply grease to the cylinder case and lift arm face Which touched with each other.
12) When assemble the lift crank on the lift shaft, mesh their splines using the alignment marks
which were put there before disassembly.
13) Be sure the lift shaft should be moved smoothly after installation.
14) The clearance of lift arm should be less than 3 mm

Tight torque 1000∼1200 ㎏f-㎝

Tight torque 130∼180kg.cm

Fig. 9-35 Slow return check valve.

16)Tighten the slow return valve to the specified torque 1000∼1200 ㎏f-㎝ and be sure
not to damage the O-ring.

9-14
2. LINKAGE (INTERNAL)
1)Before installing the linkage,apply grease to relayed drive parts.
2)Be sure not to over operate within specified spool stroke(24mm between valve and clevis)

Main control valve

Apply locktite

Roller

Clevis Nut
Apply locktite
(Take care not to protrude the edge of Bolt)

24mm

1 2 3 4 6 7
1.Link valve
2.Roller
5
3.E type-stop ring
4.Shift( Position)
5. E type-stop ring
6.Link B
1 7. Link
0 8.Arm Link
8 9.Shift(draft)
10. E type-stop ring
1 11.Link( crank lift)
1 12. Pin(link)
1 9 13.O-ring
1
3 2
Fig.9-36 Linkage (internal)

9-15
 3.LINKAGE (EXTERNAL)

8 7 6 3 1

1.Spring washer
2.Bolt,support 2
3. Bolt,support 1
4.Friction plate
5.Arm position
6.Plate A
4 7.C-type stop ring
8.Spring
5
9.Nut
10.Plate D

1 9 2
0
3 4 5
1.Pin,parallel
2.Hydraulic cylinder
3.Bolt
4.Hose(500)
5.Band(20)
6.Hose(1400)

2
Tightening torque:
550~700Kgf-cm

Apply adhesive

Fig. 9-37 Linkage(external)

9-16
4.DISASSEMBLY
1)Remove the cylinder case assembly,referring
to relevant paragraph in Chapter 2.

Fig.9-41
4) Applying aligning marks on the Lift shaft
and right hand lift arm ,Then remove the arm

Fig.9-38
Note:
Put the cylinder case on a wooden plank to
prevent the surface from damage.

2) Remove the link pin and extract the related

Lift link .
4 3 2 1
aligning marks
Fig.9-42

5) Applying aligning marks on the Draft shaft

And Draft arm ,Then remove the shaft

Fig.9-39
6 5
3) Remove the cylinder head and extract the
cylinder.Then remove the piston from the
cylinder.
Fig.9-43
6) Applying aligning marks on the Lift crank
And Bar ,Then remove Bar

Fig.9-40 Fig.9-44

9-17
7) Remove the set bolt for the lift crank and 10) Remove the bolt and extract the main
remove the assembly of the lift shaft and lift control valve
arm.

Fig.9-45
8) Remove the assembly of the lift crank Fig.9-48
and piston rod.
9) Unhook the each link parts and remove 11) Remove the following linkages:
the cover main control valve a.Each linkage
b.position control linkage
c.Draft control linkage

5.REASSEMBLY

Reassemble in reverse order of disassembly.

5.1 GENERAL PRECAUTIONS

1) Hydraulic system parts should completely

be free from dust before reassembly.
Fig.9-46
2) All O-rings should be replaced with new
ones,which should be lubricated with grease
before installation.
3) When the lift shaft is removed,the oil seal
cover main control valve should also be replaced with a new one.
4) Install the piston from the cylinder bottom
side.The O-ring and and back up ring should
be coated with grease ahead of time.Install
with care so as not to damage them.

Apply
Molybdenum
grease

Fig.9-47 Apply grease Fig.9-49

9-18
 5) When assembling the lift crank on the lift 7) When installing the control valve,apply grease
lift shaft,mesh their splines using the to the o-rings and avoid their dislocation or
alignment marks which were put their binding during tightening the valve to the
before disassembly specified torque

8) Tighten the slow return check valve to the

specified torque

Tightening torque 1000~1200 Kg.cm

Fig.9-50

Fig.9-54
9) Tighten the Exterior valve(remote control valve)
to the specified torque
Fig.9-51

Tightening torque 550~700 Kg.cm

Tightening torque 550~700 Kg.cm

3
2
Fig.9-52 6
6) Tighten the Main valve securely to the
specified torque 1

Tightening torque 130~180 Kg.cm

Fig.9-55
Fig.9-53
9-19
 4) Install the lift crank temporarily along with the
feed back link.Install the piston on the lift crank.

Fig.9-56
3.2 REASSEMBLY STEPS.
Fig.9-59
1) Install the main control valve
5) Install the lift shaft and lift crank together in
accordance with the aligning marks on them.
2) Install the clevis comp.
(Fig.9-23).Apply grease to the roll bush.

Main control valve

Apply locktite

Fig.9-60

Roller 6) Drive the oil seal onto the lift shaft and install
the lift arm.
Clevis Nut
Note:
When installing the oil seal,take care not to allow
Fig.9-57 the oil seal lips to be damaged by the splines of
Note: the lift shaft.
After installing the clevis to main control
valve ,make the installed length of the set the 7) Install the cover main control valve and Then
body and plate to be 10mm(Fig.9-57) install the remote control valve.(If equipment)

3) Install the each link parts. remote control valve.

cover main control valve

Fig.9-58 Fig.9-61
9-20
 6. ADJUSTMENT OF THE LINK MECHANISM.

Fig.9-62
1) Adjustment of the position control link Point 2. Fix the clearance between the body and
mechanism plate on the control valve and the casing
spool to be 24 mm (Fig.9-64),while the
Place the cylinder case assembly upside so that the main spool is set in the neutral position.
lift arm can be moved freely
Main control valve
Point 1.Set the lift crank to the top position.Adjust
Apply locktite
the top position installed length of the body
and plate is about 10mm or determine the
position where the angle of the lift arm
from horizontal is 60~ 61.5°.

Roller

Clevis Nut

24mm

Fig.9-63 Fig.9-64
9-21
Point 3.Set the feed back link so that there is no
play by the adjusting nut.
Point 4. Apply an locktite to adjusting Nut.

Fig.9-65
Thus the adjustment of the position control
linkage is completed.

2) Adjustment of the draft-control link

mechanism

Point 1.Shift the draft-control lever to the top

position and the position-control lever to
the bottom position.

Fig.9-66

Point 2. With position (A) is 90° together in

accordance with Shifting the draft-control
lever to the top position and the position-
control lever to the bottom position.
Adjust by loosening the lock nut.
Thus the adjustment of the draft-control link
mechanism is completed.

9-22
7. MAIN CONTROL VALVE
7.1 GENERAL DESCRIPTION
This valve controls the lifting and lowering operation of the hydraulic cylinder.It has especially been
developed to control the working height of the implement.It consists of a feed back valve;direction
control valve,flow-control unloading valve,and holding check valve.

7.2 SPECIFICATIONS

Maximum operating pressure 165 Kgf. /㎠

Maximum flow 45 liters /min
C-port leaks 5 cc/min below
(Fluid temp : 50℃: Pressure :140 Kgf/㎠)

7.3.CONSTRUCTION
1) Main spool
it consists of a spool,spool head,and snap ring E and has three functions.
a. It opens and closes passages P to C and C to T and controls the passage wall area successively.
b. It converts unloading pilot pressure to C-port pressure or tank pressure
c. It turns the pilot pressure of the pilot spool on or off.
Lowering

Load of main spool 8 Neutral tolerance

(10 Kg below) 8
24 (0.3~0.6mm)
Lifting
P
C

24mm
Fig.9-67

9-23
7.4 OPERATION

Port p means “pump port”, and is connected to the pump, while port C means “Cylinder port”, and is
connected to the cylinder. Drain ports T1 to T4 are connected to the tank.

1) Neutral position
In the NEUTRAL position, Spring chamber of
unloading valve connected to TANK(T2),
Therefore the force imposed upon the right hand
side of the unloading valve, then the fluid from the
pump flows into TANK(T1).
The pressure in chamber becomes equal to the tank
pressure. Consequently the fluid in the C port
becomes high, then the check valve and main check
valve completely closes the cylinder circuit enough
to hold the piston steady. Fig.9-35

2) Lifting position
When the main spool is shifted to the lifting position,
Passages to the Tank(T2) are closed with unloading
spring and the Fluid from the pump flows into
unloading valve spring., therefore the force imposed
up the left-hand side of the unloading check valve,
Consequently the fluid in the T1 port becomes to
close the unloading.
The pump delivery fluid pressure open the loading
check valve, then through C port the pump pressure
flows into hydraulic cylinder to lift up the lift arm. Fig.9-36

3) Lowering position
When Main spool is shifted to the lowering position,
Unloading spring is connected to the Tank(T2),and
the force imposed up the right hand side of the
unloading check, therefore the fluid from the pump
flows into the Tank(T1).
Consequently the force imposed up the left hand
side of the main check valve, which is connected
with Plate-B to open the T3 port.
By this action, the fluid from the cylinder flows out
and into the tank through chamber, so the piston is
released
Fig.9-37

9-24
 SECTION 6. TROUBLESHOOTING
Problems Causes Countermeasures
1.Lift does 1) Insufficient engine speed Raise engine speed slightly
not rise 2) Insufficient transmission oil Maintain oil level by replenishing with the
same kind of oil
3) Air taken in through suction Tighten securely or replace broken parts.

4) Clogged suction filter Clean.

5) Broken or poor hydraulic pump Inspection pump and repair or replace if
necessary.Pay particular attention to shaft
seal because a broken seal sometimes
intakes air.
6) Poor link mechanism Inspect,adjust,repair,or replace if
necessary.(Refer to section 3)
7) Excessive load on lift Decrease load
8) Broken cylinder Replace
9) Too low viscosity of As it will cause oil leaks or internal
transmission oil wear,replace with gear oil of SAE80

10)Maladjusted relief valve Readjust.

(Cracking:refer to the specifications)
11)Excessive internal leaks Inspect cylinder and valves.Replace
damaged seals,and repair.
(Check each part systematically)
12)Broken flow divider Disassemble and wash spool clean.
(Stuck sequential valve spool) If it is damaged seriously,replace it as an
assembly.If damage is minor,correct surface
with oil stone and finish by lapping.
13)Broken control valve
(Even when spool is shifted to up position,lift does not rise)
①Stuck compensator plunger Lap after repairing flaws with oil stone
(unloading valve 1)
②Clogged orifices or slanted Clean them with compressed air or a sharp
orifices in pilot passage. point.

③Stuck poppet(unloading valve 2) Correct minor flaws with oil stone

④Bitten or stuck check valve Lap after repairing flaws with oil stone
plunger
14)Broken slow-return check valve
①Stuck poppet Lap after disassembling,cleaning, and
repairing flaws with oil stone

9-28
 Problems Causes Countermeasures
2.Too low 1)Above causes can also be Repair according to above instructions.
rising speed of possible
lift 2) Too small a spool stroke in Inspect,readjust,or replace link mechanism
control valve if necessary.

3)Broken compensator spring Replace spring.

(unloading valve 1) in control
valve
4)Stuck poppet Correct minor flaws with an oil stone
(unloading valve 2)
3.Lift lowers even 1)Stuck poppet Lap after disassembling,cleaning,repairing
when adjust knob flaws with oil stone
is closed fully with
2)Poor valve seat Replace valve
adjust Handle
(While engine is 3)Poor 0-ring Replace
stopped)
4.Lift does not 1)Slow-return-check valve Turn knob to fast position
lower knob is turned to the lock
position
2)Stuck poppet of slow- Lap after disassembling, cleaning,repairing
Return-check valve flaws with oil stone
3)Seized lift shaft Apply grease and repair or replace bushings
or shaft if necessary.
4)Stuck main spool Lap lightly after disassembling, cleaning,
and repairing flaws with oil stone or replace
as an assembly.
5.Too slow lift 1)Above mentioned causes Repair or adjust according to instructions
lowering speed can also be possible. mentioned above.
2)Insufficiently lowered Lower lever sufficiently
control lever
3)Excessively closed slow- Open valve sufficiently
return check valve
6.When hydraulic 1) Maladjusted lever stopper Readjust lever stopper guide position
control lever is check valve
raised,relief,valve
2) Poor link mechanism Inspect,readjust,repair,or replace link
beeps.
mechanism if necessary.
7.Fluid 1)Excessively high working Inspect and adjust
overheating pressure
2)Too high or low viscosity Replace with fluid of adequate viscosity.
of working fluid.
3)Insufficient fluid Maintain specified level by replenishing
9-29
 Problems Causes Countermeasures
8.Pump noise 1) Partially clogged suction filter or Clean.
suction piping.
2) Air inhaled through suction Inspect and retighten.
piping and intake pipe connections
for pump
3) Loosened pump cover tightening Inspect and retighten
bolts.
4) Too rich oil viscosity Replace with fluid of adequate
viscosity.
5) Broken or worn pump parts Inspect and replace defective parts.
9.Excessive 1) Dirty fluid Eliminate foreign matter and inspect
wear,deflection or filters.
damage of pump 2) Circuit pressure exceeds pump Adjust relief valve or replace if
capacity necessary
3) Oil-less operation due to Inspect transmission oil level and
Insufficient oil quantity maintain specified oil level by
replenishing.In either case,clean, and
repair pump parts and replace
damaged ones if necessary.
10.Oil leaks Broken or fatigues oil seal or Replace
outside pump O-ring
11.Oil leaks from Poorly connected piping Inspect,clean,and eliminate dust.
piping or joints Repair flaws with oil stone if
necessary. Retighten.
Poor O-ring Replace
Broken piping Replace with a new one after washing
clean related parts.
12.Oil leaks Poor oil seals Replace oil seal or bushing if
around lift arm necessary

13.Independent 1) Clogged fixed orifice of Flow Disassemble and wash clean.

PTO clutch slips or divider
is too slow in
engaging 2) Port B regulated pressure is too Inspect and reset pressure
slow
3) Clogged PTO pressure control Disassemble and wash clean.
valve or stuck Repair flaws with oil stone if
necessary or replace with a new one.
4) Poor flow divider solenoid Disassemble and repair or replace
valve with new one if necessary .

9-30
 Problems Causes Countermeasures
14.Independent 1) Stuck pressure-reducing valve Lap after correcting flaws with oil
PTO clutch is too spool stone
quick in engaging 2) Fatigued or broken pressure- Replace.
reducing valve spring
3) Worn or broken sealing of PTO Replace
clutch
4) Worn friction plates or driven Replace
plates
5) Overheated fluid Refer to paragraph for "fluid
overheating"
6) Port B regulated pressure is too Inspect and reset pressure
high of Flow-divider
7) Stuck pressure-reducing valve Lap after correcting flaws with oil
spool stone
8) Clogged orifice in pressure- Clear clogged with compressed air or
reducing valve spool with a sharp point.

9-31
 Chapter 10
Electrical accessory and instruments

SECTION 1. GENERAL DESCRIPTION ----------------------------- 10-1

SECTION 2. SPECIFICATIONS --------------------------------------- 10-1

SECTION 3. BATTERY---------------------------------------------------- 10-2

1.1. Inspection -------------------------------------------------------------- 10-2
1.2. Inspection of electrolyte level---------------------------------------- 10-2
1.3. Inspection of electrolyte specific gravity-------------------------- 10-2
1.4. Battery testing chart-------------------------------------------------- 10-3
SECTION 4. Meters and switches---------------------------------------- 10-5
1. Meters --------------------------------------------------------------------- 10-5
1.1 Removal ------------------------------------------------------------------ 10-5
1.2 Tacho/Hour meter----------------------------------------------------- 10-5
1.3 Fuel gauge and fuel gauge sensor----------------------------------- 10-5
1.4 Thermometer ----------------------------------------------------------- 10-6
2. Starter switch ------------------------------------------------------------ 10-6
3.Combination switch ----------------------------------------------------- 10-7
4.Stop light switch---------------------------------------------------------- 10-8
5.Relay unit ----------------------------------------------------------------- 10-8
6.Fuse ------------------------------------------------------------------------- 10-8
7.Controller Unit ---------------------------------------------------------- 10-9
8.Trailer socket(7P) ------------------------------------------------------ 10-11

SECTION 5. EARTHING POINT -------------------------------------- 10-12

SECTION 6. WIRING DIAGRAM ------------------------------------- 10-15

SECTION 7. TROUBLESHOOTING ---------------------------------- 10-17

 Chapter 10 Electrical accessory and instruments

SECTION 1. GENERAL DESCRIPTION

The basic electrical system of tractors consists of the engine cranking system ,battery charging
system,lighting system,meters,switches,etc.
For further information concerning the engine cranking equipment and battery charging equipment,
please refer to the engine manual.
The battery is a power source to activate the engine cranking system,lighting system,and other
electrical equipment.The lighting system is used to activate the illumination lights,indicators,and
signal lights.The meter is a device that enables the operator to be aware of the present operating
conditions;oil pressure gauge,water temperature gauge(thermometer),fuel gauge,etc.are installed.
All the controls,meters, and indicators are arranged around the operator’s seat for easy
Maneuverability readability,and convenience.

SECTION 2. SPECIFICATIONS

MODEL T394HST
PART NAME Specification(w) Quantity
1.lighting Head lights 50/40 2
system
Front combination Turn signal lights 21 2
lights Small lights 5 2
Rear combination Turn signal lights 21 2
lights Stop lights 21 2
Tail light 5 2
2. Monitoring Meter assembly Hour meter - 1
system Fuel gauge - -
Thermometer - -
Pilot light (3.4) 15
Horn - 1
3.Fuses Fuses(A) In main fuse box 15 5(2)
(with spare fuse) 10 9(2)
Fusible links Main Fuse 50A 1
Glow Fuse 60A 1
Charge Fuse 60A 1
4.Battery 12V80AH 1

10-1
 Note:
SECTION 3. BATTERY
When the distilled water is added,charge the
battery to mix it well into the electrolyte before
1.INSPECTION
measuring the specific gravity.
1.1 INSPECTION OF ELECTROLYTE LEVEL
a.Temperature correction of the hydrometer
As the battery repeats charging and
reading
discharging during operation.The water
The specific gravity of the battery
content in the electrolyte gradually evaporates,
electrolyte(diluted sulfuric acid) varies with the
and as a result,the level should be inspected at
temperature of the electrolyte at a rate 0.0007
the specific level;replenish with distilled water.
specific gravity point for each 1℃ change in
temperature.Therefore, when the specific gravity
of the electrolyte in the battery is measured with
a suction type hydrometer,a temperature
correction should be made,using the following
formula to permit the direct comparison of the
measured valve with the standard specific gravity
at 20 ℃.
S20 :St+0.0007(t-20)
S20 :Specific gravity at standard
temperature of 20 ℃.
t : Temperature of the electrolyte
Fig.10-1 electrolyte level at the time of measurement
St : Specific gravity of the
electrolyte measured at t ℃.

1.2 INSPECTION OF ELECTROLYTE 1.3 BATTERY CHARGING

SPECIFIC GRAVITY
If the specified gravity of the battery electrolyte
The specific gravity of the electrolyte lowers in lower than 1.220 (at 20 ℃),the battery should
as the battery discharges,so the battery be recharged,because leaving an undercharged
condition can be determined by measuring the battery without recharging it will lead to
specific gravity.The specific gravity can be permanent battery damage.The battery is subject
measured generally with a suction type to self-discharge at a rate as shown in the table
hydrometer which must be read properly as below.Therefore it should be recharged from
shown in Fig. 10-2 time to time when storing the battery unused for
a long period of time.
When recharging the battery,wash clean the
outside of the battery case and the battery
posts.Check the level of the electrolyte in each
cell and replenish with distilled water as
necessary.

Temperature Self-discharge Decrease in

rate per day specific gravity
(%) per day

30 ℃ 1 0.002
20 ℃ 0.15 0.001
Fig.10-2 electrolyte gravity
5℃ 0.025 0.005
10-2
 1.4 BATTERY TESTING CHARTS

Step 1.
VISUAL INSPECTION

Check for obvious damage such as cracked or

broken case that shows loss of electrolyte,thermal
damage,etc.

Obvious damage No obvious damage

Replace battery Check electrolyte level

Electrolyte level is below top of Electrolyte level is above top of

plates in one or more cells plates in all cells
-proceed to step 2

Add water up to just above separators.

Charge for 15min.with 15.25 amp

Hydrometer test
Step 2

50 points or more variation Less than 50 points variation

between highest and lowest cell between highest and lowest cell

Recharge battery and if 50 points

variation persists,replace battery

Specific gravity:Below 1.225

Charge until all cells are at least

1.225
Specific gravity 1.225 or above
Turn on head lamps (or 15-A
load)for 15seconds
Proceed to step 3

Proceed to step 3

10-3
 Step 3
Load test

1.Connect voltmeter and ampere load equal to ½ the cold cranking

amperes(18℃) rating of the battery for 15 seconds.
2. Observe voltage at 15 seconds with load on.Disconnect load
3.Place thermometer in one cell to take temperature of electrolyte.
4.Refer to voltage table

Voltage below table value Voltage equal to or above table

value-return to service

Replace

Voltage table

Estimated electrolyte temperature Minimum required voltage under 15 sec.load

(Use ½ these values for 6-V batteries)
70 ℉ (21 ℃) and above 9.6
60 ℉ (16 ℃) 9.5
50 ℉ (10 ℃) 9.4
40 ℉ (4 ℃) 9.3
30 ℉ (-1 ℃) 9.1
20 ℉ (-7 ℃) 8.9
10 ℉ (-12 ℃) 8.7
0 ℉ (-18 ℃) 8.3

10-4
 SECTION 4. METERS AND SWITCHES
1.METERS The generated pulses are converted into voltage
1.1 Removal output through a converter.Then the voltage is
divided into three different phase coils through a
a. Disconnect the cable from the negative post. IC circuit.The tachometer pointer is swung by
b. Remove the philips screw which hold the the compound magnetic field generated by the
meter panel and lift up the panel assembly a three point.
little
b. Inspection

-Tachometer
The allowable error of a tachometer reading is
specified as shown on the table below.If the
reading deviates from the specified value.replace
the meter assembly.

Engine speed(rpm) 1000 2500

Allowable error(rpm) ±150 ±150

1.3 Fuel gauge and Fuel gauge sensor

Fig.10-3 Meter panel
a.Construction
c. Then the meter panel can be detached by
When the fuel tank is full,the float is at the top
removing the wire harness couplings.
and has moved the variable resister to a position
of least resistance.This feeds maximum current
into the meter circuit and the pointer swings
fully to the F position.Consequently when the
fuel level in the tank is low,everything acts in
reverse.

Fig.10-4 Wire harness

1.2 Tacho/hour meter and sensor

a.Construction
An electric tachometer is employed along with a
Tachosensor.The tach/hour meter converts
Fig.10-5 Fuel gauge sensor
engine revolutions to electric signals,which is
sent to the tachometer.The tachometer displays
the engine revolutions visually.The tachosensor
generates 14 pulses per one engine revolution.
10-5
b.Inspection

-Fuel meter
Note:
Connect the fuel gauge to form a circuit with the
1) Figures in parentheses are reference value
resisters as shown Fig.10-6 and check to see if
2) Inspect each position in order F to E
the gauge pointer swings to each position: F.1/2
3) Read values in three minutes.
and E by changing the resistance value.
If it does not,change the gauge assembly.
1.4.Thermometer

a. Construction
This is the same moving magnet type meters as
the fuel gauge.As the coolant temperature
becomes higher,the resistance in the thermo
unit(sensor) become lower,which results in
more current to the meter circuit and swinging
the meter pointer to the high temperature side
on the scale.Of course,as the coolant
temperature become lower,everything acts in
reverse.
Fig.10-6
b. Inspection
Normally the thermometer resisters higher
values as the coolant temperature rises after the
-Fuel gauge sensor(variable resistor)
engine is running.If it does not,check the wiring
Check each resistance value with a tester at each
float position as shown in Fig.10-7.if the first.If the wiring is normal.Replace assembly.
measured values are deviated from respective
2. STARTER SWITCH
specified values,replace the sensor assembly.
(1) Removal
a. Remove the dash cover(Upper)
b. Remove the ring nut holding the starter switch
using a conventional screw driver.
c. Pull out the key switch as shown in Fig.10-8

Fig.10-7

Standard pointer position F (1/2) E

Regulated resistance( Ω) 3 32.5 110
Fig.10-8
Allowable error(Ω) ±2 (±4) ±7

10-6
(2) Inspection

a.The main switch circuit,switching positions,

and terminals are as shown in the figures.
Check the continuity across respective
terminals referring to the switch circuit
diagram. Replace a defective switch as an
assembly

Fig.10-12

(3) Release the ring nut with a conventional

screw drive(-) and remove the combination
switch.

2) Inspection
Each switch circuit is as shown,so check each
Fig.10-9 switch for a continuity across respective
terminals with a tester.Replace a defective
switch as an assembly.

Fig.10-10

3. COMBINATION SWITCH Fig.10-13 combination switch

1) Removal

(1) Remove the meter panel

(2) Remove the light switch knob and turn
signal switch lever.

Fig.10-14 Harness socket

10-7
-Lighting 4. STOP LIGHT SWITCH

Color RY Y BR O
code

B1*1 T 1 2
OFF
**2
1 ● ● ●
2 ● ● ●

Fig.10-15 Stop light switch

*1 :Terminals
**2: Switching positions
Capacity 15 A (DC12V)
-Flasher
Stroke to ON 2 ±0.8mm
Color G WG GB Total stroke 5mm
code (Green) (White/ (Green/
Green) Black) 5.RELAY UNIT

B2*1 R L
1**2 ● ●
OFF
2 ● ●

*1 :Terminals
**2: Switching positions Fig.10-16 Relay unit
6. FUSE
-Horn switch Fuses are installed in the main fuse box and one
for the headlights.Three fusible links are
Color code B LW installed to prevent the wiring from burning
due to a short circuit.
B1*1 H
Free**2
Push ● ●

*1 :Terminals
**2: Switching positions

Fig.10-17 Fuse box

10-8
Each fuse is connected as follows 7. CONTROLLER

Fig.10-18 Fig.10-20

Capacity DC12V
1 Panel 10A
Operating range DC10~16V
2 Head Light / Horn 15A
Operating temperature -15~80ºC
3 Working Lamp 10A
1.Function
4 Stop / Tail Lamp 10A
a. Engine stop
5 Turn Signal Lamp 10A When below condition is performed,Engine
will be stopped within 10±3 sec.( 1st )
6 Self Leveling 10A
No Seat S/W Brake S/W PTO S/W HST S/W
7 Over run 10A
1 OFF ON ON ON
8 Monitor 15A
2 OFF ON ON OFF
9 Engine Stop Sol 10A 3 OFF OFF ON ON

10 Fuel Filter Pump 10A 4 OFF OFF OFF ON

5 OFF OFF ON OFF
11 External Power 15A
6 OFF OFF OFF OFF
The circuit has 8 blade type fuses in its
Note:
wiring circuit.When a fuse has blown
When the seat S/W is Off position,engine will
replace it with one of the same value.
stop after 3 seconds.

b. Engine Start control

Engine can be started on the condition of
Brake S/W ON ,HST S/W,and PTO S/W OFF
Position

Fig.10-19 c. Cruise control

When Cruise momentary S/W is operated as
Note:
Procedure OFF→ON→OFF.it will change the
Using a large capacity fuse or wire burn out output of Cruise magnetic.And ON output
the wiring system. relay will operate to light the cruise lamp.
Use fuse tongs to replace fuses
10-9
2. CIRCUIT DIAGRAM

Fig.10-21 controller

Fig.10-22 connector

1.Battery(+12V) 11.GND
2.Battery(+12V) 12.HST S/W
3.Hey(+12V) 13.Seat S/W
4.Generator charger signal 14.N.C
5.Brake S/W 15.PTO S/W
6.Parking brake S/W 16.N.C
7.Cruise S/W 17.Cruise lamp
8.Check valve 18.Cruise magnetic
9.Starter S/W 19.Starter relay
10.Engine stop solenoid 20.Engine stop solenoid

10-10
8.Trailer socket
A hella’s 7-pin trailer socket is equipped as a standard equipment.Lamp on a trailer can be
operated through the socket.

A type

B type
Fig.10-23

Wire Description Color Specification

Hous
ing A type B type A type B type A type B type

1 Turn signal (LH) Earth G/B W AV 0.85 AV 1.25

2 Reserve light (Fog light) Small light(Tail light) R/W B AV 0.85 AV 1.25
3 Earth Turn signal (LH) B Y AV 2.0 AV 1.25
4 Turn signal (RH) Stop Light G/Y R AV 0.85 AV 1.25
5 Parking light (RH) Turn signal (RH) Y/W G AV 0.85 AV 1.25
6 Stop Light Rear Light W/L Br AV 0.85 AV 1.25
7 Parking light (LH) Reserve light Y L AV 0.85 AV 1.25

Note:
Lamp on the trailer should be of the same size or smaller than those on the trailer.
10-11
 SECTION 5. EARTHING POINT

2 3

Fig.10-24 2) Contact surfaces of the Hood frame and

1) Fuel tank guard (RH) bracket where they tightened together
Earthed at tapped hole in the lower the working lamp

Fig.10-25 A

10-12 Fig.10-26 Hood frame

3) Right surface of the frame comp.Where the
battery cable is to be installed.

Fig.10-27 Battery cable

10-13
SECTION 6. WIRING DIAGRAM

10-14
SECTION 6. WIRING DIAGRAM

10-14
SECTION 7. TROUBLESHOOTING
Important: Whenever effecting a repair the reason for the cause of the problem must be investigated
and corrected to avoid repeating failure.
The following table lists problems and their possible causes with the recommended remedial action

1. LIGHTING SYSTEM

Problems Causes Countermeasures

Discharged battery Check battery and charge or renew

Loose or defective battery cable Inspect,clean,and tighten connection

connection

Loose wire harness connectors Check and ensure connectors securely

engaged
Several or all
lights do not Burnt out fuse or fusible link Inspect and renew.Check circuit before re-
illuminate connecting power
Faulty wiring Check lighting Circuit wiring and repair or
renew
Defective light switch Check and renew
Several light bulbs burnt out due Check and renew voltage regulator
to defective voltage regulation (Alternator)
Individual Burnt out bulb Check and renew
lights do not
Defective or corroded bulb contact Inspect,clean or renew
illuminate
Burnt out fuse Inspect and renew.Check circuit before
reconnecting power
Loose or broken wires Inspect ,secure,repair,or renew wiring
Poor ground connection Inspect,clean, and tighten ground connection
Lights burnt Faulty voltage regulator Check and renew voltage regulator
out repeatedly (Alternator)
Turn signal Blown fuse Inspect and renew.Check circuit before re-
lights do not connecting power
illuminate
Inoperative flasher unit Check and renew
Inoperative turn signal switch Check and renew
Defective wiring or connections Inspect circuit,clean,and tighten connection.
Repair or renew wiring if necessary

10-15
 Problems Causes Countermeasures
Individual Burnt out bulb Check and renew
turn signal
Corroded or loose bulb contacts Inspect,clean,and renew
light does not
illuminate Poor ground connection or damage Inspect,clean,and tighten connections or
wiring renew wiring
Turn signal Faulty bulb Check and renew
pilot light is
Defective flasher unit Check and renew
inoperative
Faulty wiring or connections Inspect,clean,and tighten connections or
renew wiring
Stop lights Inoperative stop light switch Check and renew
does not
See “Individual lights do not See “Individual lights do not illuminate
illuminate
illuminate”
Inoperative Work light switch is not turned on Ensure work light illuminates
work light
See “Individual lights do not See “Individual lights do not illuminate
illuminate

2. INSTRUMENTATION

Problems Causes Countermeasures

Inoperative or Loose or broken wiring Inspect Circuit, tighten connections or renew
erratic meters wiring
Defective meters Inspect and renew
Defective sensors Check and renew
Defective Voltage regulator Check and renew voltage regulator
(Alternator)
Monitor light Loose or broken wiring Inspect circuit,tighten connections or renew
does not wiring
illuminate
Faulty main switch Check and renew
Burnt out bulb Check and renew
Burnt out fuse Check and renew
Defective switch Check and renew
Loose or broken wiring Check and renew
PTO does not Burnt out fuse Inspect and renew.Check circuit
operate
Loose or broken wires or Inspect circuit,tighten connections,or renew
connections wiring
Defective PTO switch Check and renew
Defective PTO solenoid Check and renew
10-16
 Problems Causes Countermeasures
Inoperative Burnt out fuse Inspect and renew.Check circuit before re-
horn connecting power
Loose or broken wires of Inspect circuit,tighten connections,or renew
connections wiring
Defective horn switch Check and renew
Defective horn Check and renew
Cruise does Burnt out fuse Inspect and renew.Check circuit before re-
not operate connecting power
Loose or broken wire Inspect circuit,tighten connections,or renew
wiring
Loose the magnetic assembly Inspect circuit,tighten connections

3.GLOW SYSTEM

Problems Causes Countermeasures

All glow Discharged Battery Check battery and charge or renew
plugs do not
Loose or defective battery cable Inspect,clean,and tighten connections
heat red
connections
Loose wire harness connections Check and ensure connectors securely
engaged
Burnt out fusible link Inspect and renew.Check circuit before re-
connecting power
Faulty wiring Check glow plug circuit wiring and repair
or renew
Defective main switch Check and renew
Individual Defective glow plug Check and renew
glow plug
Defective or corroded glow plug Inspect,Clean,or renew
does not glow
contacts
Loose or broken wires Inspect,secure,repair,or renew wiring
Glow monitor Defective glow timer Check and renew
light does not
Defective glow monitor light or See”Light system troubleshooting”
illuminate
monitor and warning check unit

10-17
 4. STARTING SYSTEM

Problems Causes Countermeasures

Starter motor Discharged battery Check battery and charge or renew
does not spin
Defective stop light switch Check and renew
Defective key switch Check and renew
Defective starter motor connections Check,clean and tighten connections
or loose battery connections

Faulty starter motor Inspect,repair,or renew

Defective master brake pedal Inspect and try to push brake pedal
Faulty reverse or forward pedal Inspect ,adjust neutral
Defective push switch Check and renew
Defective controller Check and renew
Engine cranks Discharged battery Check battery and charge or renew
slowly
Excessive resistance in starter Check circuit connections and repair or
circuit renew faulty wiring
Defective starter motor Refer to the engine manual
Tight engine Refer to the engine manual

5. CHARGING SYSTEM

Problems Causes Countermeasures

Battery is low Loose or worn alternator drive belt Check and adjust belt tension or renew
in charge or
Defective battery:It will not accept Check condition of battery and renew
discharge
or hold charge.Electrolyte level is
low
Excessive resistance due to loose Check,clean,and tighten circuit
charging system connections connections
Defective alternator Check and repair or renew
Alternator is Defective battery Check condition of battery and renew
charging at
Defective Alternator Check and repair or renew
high rate
(Battery is
overheating)
No output Alternator drive belt is broken Renew and tension correctly
from alternator
Loose connection or broken cable in Inspect system,tighten connections and
charge system repair or renew faulty wiring
Defective voltage regulator Check and renew
Defective alternator Check and repair or renew

10-18
 Problems Causes Countermeasures
Intermittent Alternator drive belt is slipping Check and adjust belt tension or renew
or low
Loose connection or broken cable in Inspect system,tighten connections and
alternator
charge system repair or renew faulty wiring
output
Defective alternator Check and repair or renew
Warning light Faulty external charging circuit Inspect system,clean and tighten
dims connections connections
Faulty rotor slip rings or brushes Inspect and repair or renew
Defective monitor and warning unit Check and renew
Faulty rectifier or rectifying diodes Check and renew
Warning light Defective voltage regulator Check and renew
is normal but
Faulty starter Check and renew
battery is
discharged Faulty rectifier or rectifying diodes Check and renew
Warning light Loose or worn alternator drive belt Check and adjust tension or renew
is lit during
Defective diodes Check and renew
operation
Faulty rotor,slip rings,or brushes Inspect,repair,or renew
Defective starter Check and renew
Defective rectifier or rectifying Check and renew
diodes
Warning light Faulty external charging circuit Inspect circuit,clean,and tighten
flashes connections.Repair or renew faulty wiring
intermittently
Alternator’s internal connections Inspect and test circuitry,Repair or renew

10-19
CONVERSION TABLES

M illimeters to inches Inches to millimeters

mm in mm in mm in mm in in mm in mm in mm
1 0.0394 26 1.0236 51 2.0079 76 2.9921 1/64 0.3969 25/64 9.9219 13/16 20.6375
2 0.0787 27 1.0630 52 2.0472 77 3.0315 1/32 0.7938 13/32 10.3188 53/64 21.0344
3 0.1181 28 1.1024 53 2.0866 78 3.0709 3/64 1.1906 27/64 10.7156 27/32 21.4313
4 0.1575 29 1.1417 54 2.1260 79 3.1102 1/16 1.5875 7/16 11.1125 55/64 21.8281
5 0.1969 30 1.1811 55 2.1654 80 3.1496 5/64 1.9844 29/64 11.5094 7/8 22.2250
6 0.2362 31 1.2205 56 2.2047 81 3.1890 3/32 2.3813 15/32 11.9063 57/64 22.6219
7 0.2756 32 1.2598 57 2.2441 82 3.2283 7/64 2.7781 31/64 12.3031 29/32 23.0188
8 0.3150 33 1.2992 58 2.2835 83 3.2677 1/8 3.1750 1/2 12.7000 59/64 23.4156
9 0.3543 34 1.3386 59 2.3228 84 3.3071 9/64 3.5719 33/64 13.0969 15/16 23.8125
10 0.3937 35 1.3780 60 2.3622 85 3.3465 5/32 3.9688 17/32 13.4938 61/64 24.2094
11 0.4331 36 1.4173 61 2.4016 86 3.3858 11/64 4.3656 35/64 13.8906 31/32 24.6063
12 0.4724 37 1.4567 62 2.4409 87 3.4252 3/16 4.7625 9/16 14.2875 63/64 25.0031
13 0.5118 38 1.4961 63 2.4803 88 3.4646 13/64 5.1594 37/64 14.6844
14 0.5512 39 1.5354 64 2.5197 89 3.5039 7/32 5.5563 19/32 15.0813
15 0.5906 40 1.5748 65 2.5591 90 3.5433 15/64 5.9531 39/64 15.4781
16 0.6299 41 1.6142 66 2.5984 91 3.5827 1/4 6.3500 5/8 15.8750
17 0.6693 42 1.6535 67 2.6378 92 3.6220 17/64 6.7469 41/64 16.2719
18 0.7087 43 1.6929 68 2.6772 93 3.6614 9/32 7.1438 21/32 16.6688
19 0.7480 44 1.7323 69 2.7165 94 3.7008 19/64 7.5406 43/64 17.0656
20 0.7874 45 1.7717 70 2.7559 95 3.7402 5/16 7.9375 11/16 17.4625
21 0.8268 46 1.8110 71 2.7953 96 3.7795 21/64 8.3344 45/64 17.8594
22 0.8661 47 1.8504 72 2.8346 97 3.8189 11/32 8.7313 23/32 18.2563
23 0.9055 48 1.8898 73 2.8740 98 3.8583 23/64 9.1281 47/64 18.6531
24 0.9449 49 1.9291 74 2.9134 99 3.8976 3/8 9.5250 3/4 19.0500
25 0.9843 50 1.9685 75 2.9528 100 3.9370 49/64 19.4469
25/32 19.8438
51/64 20.2406

11-11
 L e ngth Fe e t to M e te rs
ft 0 1 2 3 4 5 6 7 8 9 ft
m m m m m m m m m m
0 0.0000 0.3050 0.6100 0.9150 1.2200 1.5250 1.8300 2.1350 2.4400 2.7450 0
10 8.0532 3.3550 3.6600 3.9650 4.2700 4.5750 4.8800 5.1850 5.4900 5.7950 10
20 21.1097 6.4050 6.7100 7.0150 7.3200 7.6250 7.9300 8.2350 8.5400 8.8450 20
30 34.1661 9.4550 9.7600 10.0650 10.3700 10.6750 10.9800 11.2850 11.5900 11.8950 30
40 47.2225 12.5050 12.8100 13.1150 13.4200 13.7250 14.0300 14.3350 14.6400 14.9450 40
50 60.2790 15.5550 15.8600 16.1650 16.4700 16.7750 17.0800 17.3850 17.6900 17.9950 50
60 73.3354 18.6050 18.9100 19.2150 19.5200 19.8250 20.1300 20.4350 20.7400 21.0450 60
70 86.3919 21.6550 21.9600 22.2650 22.5700 22.8750 23.1800 23.4850 23.7900 24.0950 70
80 99.4483 24.7050 25.0100 25.3150 25.6200 25.9250 26.2300 26.5350 26.8400 27.1450 80
90 112.5047 27.7550 28.0600 28.3650 28.6700 28.9750 29.2800 29.5850 29.8900 30.1950 90
100 125.5612 30.8050 31.1100 31.4150 31.7200 32.0250 32.3300 32.6350 32.9400 33.2450 100

M e te rs to Fe e t
m 0 1 2 3 4 5 6 7 8 9 m
ft ft ft ft ft ft ft ft ft ft
0 0.0000 3.2808 6.5616 9.8424 13.1232 16.4040 19.6848 22.9656 26.2464 29.5272 0
10 32.8080 36.0888 39.3696 42.6504 45.9312 49.2120 52.4928 55.7736 59.0544 62.3352 10
20 65.6160 68.8968 72.1776 75.4584 78.7392 82.0200 85.3008 88.5816 91.8624 95.1432 20
30 98.4240 101.7048 104.9856 108.2664 111.5472 114.8280 118.1088 121.3896 124.6704 127.9512 30
40 131.2320 134.5128 137.7936 141.0744 144.3552 147.6360 150.9168 154.1976 157.4784 160.7592 40
50 164.0400 167.3208 170.6016 173.8824 177.1632 180.4440 183.7248 187.0056 190.2864 193.5672 50
60 196.8480 200.1288 203.4096 206.6904 209.9712 213.2520 216.5328 219.8136 223.0944 226.3752 60
70 229.6560 232.9368 236.2176 239.4984 242.7792 246.0600 249.3408 252.6216 255.9024 259.1832 70
80 262.4640 265.7448 269.0256 272.3064 275.5872 278.8680 282.1488 285.4296 288.7104 291.9912 80
90 295.2720 298.5528 301.8336 305.1144 308.3952 311.6760 314.9568 318.2376 321.5184 324.7992 90
100 328.0800 331.3608 334.6416 337.9224 341.2032 344.4840 347.7648 351.0456 354.3264 357.6072 100

M i l e to ki l ome te rs
miles 0 1 2 3 4 5 6 7 8 9 miles
Km Km Km Km Km Km Km Km Km Km
0 0.000 1.609 3.218 4.827 6.436 8.045 9.654 11.263 12.872 14.481 0
10 16.090 17.699 19.308 20.917 22.526 24.135 25.744 27.353 28.962 30.571 10
20 32.180 33.789 35.398 37.007 38.616 40.225 41.834 43.443 45.052 46.661 20
30 48.270 49.879 51.488 53.097 54.706 56.315 57.924 59.533 61.142 62.751 30
40 64.360 65.969 67.578 69.187 70.796 72.405 74.014 75.623 77.232 78.841 40
50 80.450 82.059 83.668 85.277 86.886 88.495 90.104 91.713 93.322 94.931 50
60 96.540 98.149 99.758 101.367 102.976 104.585 106.194 107.803 109.412 111.021 60
70 112.630 114.239 115.848 117.457 119.066 120.675 122.284 123.893 125.502 127.111 70
80 128.720 130.329 131.938 133.547 135.156 136.765 138.374 139.983 141.592 143.201 80
90 144.810 146.419 148.028 149.637 151.246 152.855 154.464 156.073 157.682 159.291 90
100 160.900 162.509 164.118 165.727 167.336 168.945 170.554 172.163 173.772 175.381 100

ki l ome te rs to M i l e s
Km 0 1 2 3 4 5 6 7 8 9 Km
M iles M iles M iles M iles M iles M iles M iles M iles M iles M iles
0 0.000 0.621 1.242 1.863 2.484 3.105 3.726 4.347 4.968 5.589 0
10 6.210 6.831 7.452 8.073 8.694 9.315 9.936 10.557 11.178 11.799 10
20 12.420 13.041 13.662 14.283 14.904 15.525 16.146 16.767 17.388 18.009 20
30 18.630 19.251 19.872 20.493 21.114 21.735 22.356 22.977 23.598 24.219 30
40 24.840 25.461 26.082 26.703 27.324 27.945 28.566 29.187 29.808 30.429 40
50 31.050 31.671 32.292 32.913 33.534 34.155 34.776 35.397 36.018 36.639 50
60 37.260 37.881 38.502 39.123 39.744 40.365 40.986 41.607 42.228 42.849 60
70 43.470 44.091 44.712 45.333 45.954 46.575 47.196 47.817 48.438 49.059 70
80 49.680 50.301 50.922 51.543 52.164 52.785 53.406 54.027 54.648 55.269 80
90 55.890 56.511 57.132 57.753 58.374 58.995 59.616 60.237 60.858 61.479 90
100 62.100 62.721 63.342 63.963 64.584 65.205 65.826 66.447 67.068 67.689 100

11-12
 Are a S qu are i nc h e s to s qu are c e nti me te rs
in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
0 0.000 6.462 12.924 19.386 25.848 32.310 38.772 45.234 51.696 58.158 0
10 64.620 71.082 77.544 84.006 90.468 96.930 103.392 109.854 116.316 122.778 10
20 129.240 135.702 142.164 148.626 155.088 161.550 168.012 174.474 180.936 187.398 20
30 193.860 200.322 206.784 213.246 219.708 226.170 232.632 239.094 245.556 252.018 30
40 258.480 264.942 271.404 277.866 284.328 290.790 297.252 303.714 310.176 316.638 40
50 323.100 329.562 336.024 342.486 348.948 355.410 361.872 368.334 374.796 381.258 50
60 387.720 394.182 400.644 407.106 413.568 420.030 426.492 432.954 439.416 445.878 60
70 452.340 458.802 465.264 471.726 478.188 484.650 491.112 497.574 504.036 510.498 70
80 516.960 523.422 529.884 536.346 542.808 549.270 555.732 562.194 568.656 575.118 80
90 581.580 588.042 594.504 600.966 607.428 613.890 620.352 626.814 633.276 639.738 90
100 646.200 652.662 659.124 665.586 672.048 678.510 684.972 691.434 697.896 704.358 100

S qu are c e nti me te rs to S qu are i nc h e s

cm2 0 1 2 3 4 5 6 7 8 9 cm2
in2 in2 in2 in2 in2 in2 in2 in2 in2 in2
0 0.000 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 0
10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100

C u bi c i nc h e s to C u bi c C e nti me te rs
in3 0 1 2 3 4 5 6 7 8 9 in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc)
0 0.000 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.096 147.483 0
10 163.870 180.257 196.644 213.031 229.418 245.805 262.192 278.579 294.966 311.353 10
20 327.740 344.127 360.514 376.901 393.288 409.675 426.062 442.449 458.836 475.223 20
30 491.610 507.997 524.384 540.771 557.158 573.545 589.932 606.319 622.706 639.093 30
40 655.480 671.867 688.254 704.641 721.028 737.415 753.802 770.189 786.576 802.963 40
50 819.350 835.737 852.124 868.511 884.898 901.285 917.672 934.059 950.446 966.833 50
60 983.220 999.607 1015.994 1032.381 1048.768 1065.155 1081.542 1097.929 1114.316 1130.703 60
70 1147.090 1163.477 1179.864 1196.251 1212.638 1229.025 1245.412 1261.799 1278.186 1294.573 70
80 1310.960 1327.347 1343.734 1360.121 1376.508 1392.895 1409.282 1425.669 1442.056 1458.443 80
90 1474.830 1491.217 1507.604 1523.991 1540.378 1556.765 1573.152 1589.539 1605.926 1622.313 90
100 1638.700 1655.087 1671.474 1687.861 1704.248 1720.635 1737.022 1753.409 1769.796 1786.183 100

C u bi c C e nti me te rs to c u bi c i nc h e s
cm3(cc) 0 1 2 3 4 5 6 7 8 9 cm3(cc)
in3 in3 in3 in3 in3 in3 in3 in3 in3 in3
0 0.0000 0.0610 0.1221 0.1831 0.2441 0.3051 0.3662 0.4272 0.4882 0.5492 0
10 0.6103 0.6713 0.7323 0.7933 0.8544 0.9154 0.9764 1.0374 1.0985 1.1595 10
20 1.2205 1.2815 1.3426 1.4036 1.4646 1.5256 1.5867 1.6477 1.7087 1.7697 20
30 1.8308 1.8918 1.9528 2.0138 2.0749 2.1359 2.1969 2.2579 2.3190 2.3800 30
40 2.4410 2.5020 2.5631 2.6241 2.6851 2.7461 2.8072 2.8682 2.9292 2.9902 40
50 3.0513 3.1123 3.1733 3.2343 3.2954 3.3564 3.4174 3.4784 3.5395 3.6005 50
60 3.6615 3.7225 3.7836 3.8446 3.9056 3.9666 4.0277 4.0887 4.1497 4.2107 60
70 4.2718 4.3328 4.3938 4.4548 4.5159 4.5769 4.6379 4.6989 4.7600 4.8210 70
80 4.8820 4.9430 5.0041 5.0651 5.1261 5.1871 5.2482 5.3092 5.3702 5.4312 80
90 5.4923 5.5533 5.6143 5.6753 5.7364 5.7974 5.8584 5.9194 5.9805 6.0415 90
100 6.1025 6.1635 6.2246 6.2856 6.3466 6.4076 6.4687 6.5297 6.5907 6.6517 100

11-13
 V ol u me Gal l ons ( U.S ) to L i te rs
US gal 0 1 2 3 4 5 6 7 8 9 US gal
Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters
0 0.000 3.785 7.571 11.356 15.142 18.927 22.712 26.498 30.283 34.069 0
10 37.854 41.639 45.425 49.210 52.996 56.781 60.566 64.352 68.137 71.923 10
20 75.708 79.493 83.279 87.064 90.850 94.635 98.420 102.206 105.991 109.777 20
30 113.562 117.347 121.133 124.918 128.704 132.489 136.274 140.060 143.845 147.631 30
40 151.416 155.201 158.987 162.772 166.558 170.343 174.128 177.914 181.699 185.485 40
50 189.270 193.055 196.841 200.626 204.412 208.197 211.982 215.768 219.553 223.339 50
60 227.124 230.909 234.695 238.480 242.266 246.051 249.836 253.622 257.407 261.193 60
70 264.978 268.763 272.549 276.334 280.120 283.905 287.690 291.476 295.261 299.047 70
80 302.832 306.617 310.403 314.188 317.974 321.759 325.544 329.330 333.115 336.901 80
90 340.686 344.471 348.257 352.042 355.828 359.613 363.398 367.184 370.969 374.755 90
100 378.540 382.325 386.111 389.896 393.682 397.467 401.252 405.038 408.823 412.609 100

L i te rs to Gal l ons ( U.S )

Liters 0 1 2 3 4 5 6 7 8 9 Liters
US gal US gal US gal US gal US gal US gal US gal US gal US gal US gal
0 0.000 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.114 2.378 0
10 2.642 2.906 3.170 3.435 3.699 3.963 4.227 4.491 4.756 5.020 10
20 5.284 5.548 5.812 6.077 6.341 6.605 6.869 7.133 7.398 7.662 20
30 7.926 8.190 8.454 8.719 8.983 9.247 9.511 9.775 10.040 10.304 30
40 10.568 10.832 11.096 11.361 11.625 11.889 12.153 12.417 12.682 12.946 40
50 13.210 13.474 13.738 14.003 14.267 14.531 14.795 15.059 15.324 15.588 50
60 15.852 16.116 16.380 16.645 16.909 17.173 17.437 17.701 17.966 18.230 60
70 18.494 18.758 19.022 19.287 19.551 19.815 20.079 20.343 20.608 20.872 70
80 21.136 21.400 21.664 21.929 22.193 22.457 22.721 22.985 23.250 23.514 80
90 23.778 24.042 24.306 24.571 24.835 25.099 25.363 25.627 25.892 26.156 90
100 26.420 26.684 26.948 27.213 27.477 27.741 28.005 28.269 28.534 28.798 100

Gal l ons ( IM P .) to L i te rs
Imp. gal 0 1 2 3 4 5 6 7 8 9 Imp. gal
Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters
0 0.0000 4.5460 9.0920 13.6380 18.1840 22.7300 27.2760 31.8220 36.3680 40.9140 0
10 45.4600 50.0060 54.5520 59.0980 63.6440 68.1900 72.7360 77.2820 81.8280 86.3740 10
20 90.9200 95.4660 100.0120 104.5580 109.1040 113.6500 118.1960 122.7420 127.2880 131.8340 20
30 136.3800 140.9260 145.4720 150.0180 154.5640 159.1100 163.6560 168.2020 172.7480 177.2940 30
40 181.8400 186.3860 190.9320 195.4780 200.0240 204.5700 209.1160 213.6620 218.2080 222.7540 40
50 227.3000 231.8460 236.3920 240.9380 245.4840 250.0300 254.5760 259.1220 263.6680 268.2140 50
60 272.7600 277.3060 281.8520 286.3980 290.9440 295.4900 300.0360 304.5820 309.1280 313.6740 60
70 318.2200 322.7660 327.3120 331.8580 336.4040 340.9500 345.4960 350.0420 354.5880 359.1340 70
80 363.6800 368.2260 372.7720 377.3180 381.8640 386.4100 390.9560 395.5020 400.0480 404.5940 80
90 409.1400 413.6860 418.2320 422.7780 427.3240 431.8700 436.4160 440.9620 445.5080 450.0540 90
100 454.6000 459.1460 463.6920 468.2380 472.7840 477.3300 481.8760 486.4220 490.9680 495.5140 100

L i te rs to Gal l ons ( IM P )
Liters 0 1 2 3 4 5 6 7 8 9 Liters
gal gal gal gal gal gal gal gal gal gal
0 0.0000 0.2200 0.4400 0.6600 0.8800 1.1000 1.3200 1.5400 1.7600 1.9800 0
10 2.2000 2.4200 2.6400 2.8600 3.0800 3.3000 3.5200 3.7400 3.9600 4.1800 10
20 4.4000 4.6200 4.8400 5.0600 5.2800 5.5000 5.7200 5.9400 6.1600 6.3800 20
30 6.6000 6.8200 7.0400 7.2600 7.4800 7.7000 7.9200 8.1400 8.3600 8.5800 30
40 8.8000 9.0200 9.2400 9.4600 9.6800 9.9000 10.1200 10.3400 10.5600 10.7800 40
50 11.0000 11.2200 11.4400 11.6600 11.8800 12.1000 12.3200 12.5400 12.7600 12.9800 50
60 13.2000 13.4200 13.6400 13.8600 14.0800 14.3000 14.5200 14.7400 14.9600 15.1800 60
70 15.4000 15.6200 15.8400 16.0600 16.2800 16.5000 16.7200 16.9400 17.1600 17.3800 70
80 17.6000 17.8200 18.0400 18.2600 18.4800 18.7000 18.9200 19.1400 19.3600 19.5800 80
90 19.8000 20.0200 20.2400 20.4600 20.6800 20.9000 21.1200 21.3400 21.5600 21.7800 90
100 22.0000 22.2200 22.4400 22.6600 22.8800 23.1000 23.3200 23.5400 23.7600 23.9800 100

11-14
 M AS S P ou nds to Ki l ograms
lbs 0 1 2 3 4 5 6 7 8 9 lbs
Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg
0 0.000 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 0
10 4.536 4.990 5.443 5.897 6.350 6.804 7.258 7.711 8.165 8.618 10
20 9.072 9.526 9.979 10.433 10.886 11.340 11.794 12.247 12.701 13.154 20
30 13.608 14.062 14.515 14.969 15.422 15.876 16.330 16.783 17.237 17.690 30
40 18.144 18.598 19.051 19.505 19.958 20.412 20.866 21.319 21.773 22.226 40
50 22.680 23.134 23.587 24.041 24.494 24.948 25.402 25.855 26.309 26.762 50
60 27.216 27.670 28.123 28.577 29.030 29.484 29.938 30.391 30.845 31.298 60
70 31.752 32.206 32.659 33.113 33.566 34.020 34.474 34.927 35.381 35.834 70
80 36.288 36.742 37.195 37.649 38.102 38.556 39.010 39.463 39.917 40.370 80
90 40.824 41.278 41.731 42.185 42.638 43.092 43.546 43.999 44.453 44.906 90
100 45.360 45.814 46.267 46.721 47.174 47.628 48.082 48.535 48.989 49.442 100

Ki l ograms to pou nd
Kg 0 1 2 3 4 5 6 7 8 9 Kg
lbs lbs lbs lbs lbs lbs lbs lbs lbs lbs
0 0.000 2.205 4.409 6.614 8.818 11.023 13.228 15.432 17.637 19.841 0
10 22.046 24.251 26.455 28.660 30.864 33.069 35.274 37.478 39.683 41.887 10
20 44.092 46.297 48.501 50.706 52.910 55.115 57.320 59.524 61.729 63.933 20
30 66.138 68.343 70.547 72.752 74.956 77.161 79.366 81.570 83.775 85.979 30
40 88.184 90.389 92.593 94.798 97.002 99.207 101.412 103.616 105.821 108.025 40
50 110.230 112.435 114.639 116.844 119.048 121.253 123.458 125.662 127.867 130.071 50
60 132.276 134.481 136.685 138.890 141.094 143.299 145.504 147.708 149.913 152.117 60
70 154.322 156.527 158.731 160.936 163.140 165.345 167.550 169.754 171.959 174.163 70
80 176.368 178.573 180.777 182.982 185.186 187.391 189.596 191.800 194.005 196.209 80
90 198.414 200.619 202.823 205.028 207.232 209.437 211.642 213.846 216.051 218.255 90
100 220.460 222.665 224.869 227.074 229.278 231.483 233.688 235.892 238.097 240.301 100

Ki l ograms to Ne w ton
Kg 0 1 2 3 4 5 6 7 8 9 Kg
N N N N N N N N N N
0 0.000 9.807 19.614 29.421 39.228 49.035 58.842 68.649 78.456 88.263 0
10 98.070 107.877 117.684 127.491 137.298 147.105 156.912 166.719 176.526 186.333 10
20 196.140 205.947 215.754 225.561 235.368 245.175 254.982 264.789 274.596 284.403 20
30 294.210 304.017 313.824 323.631 333.438 343.245 353.052 362.859 372.666 382.473 30
40 392.280 402.087 411.894 421.701 431.508 441.315 451.122 460.929 470.736 480.543 40
50 490.350 500.157 509.964 519.771 529.578 539.385 549.192 558.999 568.806 578.613 50
60 588.420 598.227 608.034 617.841 627.648 637.455 647.262 657.069 666.876 676.683 60
70 686.490 696.297 706.104 715.911 725.718 735.525 745.332 755.139 764.946 774.753 70
80 784.560 794.367 804.174 813.981 823.788 833.595 843.402 853.209 863.016 872.823 80
90 882.630 892.437 902.244 912.051 921.858 931.665 941.472 951.279 961.086 970.893 90
100 980.700 990.507 1000.314 1010.121 1019.928 1029.735 1039.542 1049.349 1059.156 1068.963 100

Ne w ton to Ki l ograms
N 0 1 2 3 4 5 6 7 8 9 N
Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg
0 0.000 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 0
10 10.197 11.217 12.236 13.256 14.276 15.296 16.315 17.335 18.355 19.374 10
20 20.394 21.414 22.433 23.453 24.473 25.493 26.512 27.532 28.552 29.571 20
30 30.591 31.611 32.630 33.650 34.670 35.690 36.709 37.729 38.749 39.768 30
40 40.788 41.808 42.827 43.847 44.867 45.887 46.906 47.926 48.946 49.965 40
50 50.985 52.005 53.024 54.044 55.064 56.084 57.103 58.123 59.143 60.162 50
60 61.182 62.202 63.221 64.241 65.261 66.281 67.300 68.320 69.340 70.359 60
70 71.379 72.399 73.418 74.438 75.458 76.478 77.497 78.517 79.537 80.556 70
80 81.576 82.596 83.615 84.635 85.655 86.675 87.694 88.714 89.734 90.753 80
90 91.773 92.793 93.812 94.832 95.852 96.872 97.891 98.911 99.931 100.950 90
100 101.970 102.990 104.009 105.029 106.049 107.069 108.088 109.108 110.128 111.147 100

11-15
 P re s s u re P ou nds pe r s qu are i nc h e s to Ki l ograms pe r s qu are c e nti me te rs
lb/in2(PSI) 0 1 2 3 4 5 6 7 8 9 lb/in2(PSI)
Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2
0 0.0000 0.0703 0.1406 0.2109 0.2812 0.3516 0.4219 0.4922 0.5625 0.6328 0
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0547 1.1250 1.1953 1.2656 1.3359 10
20 1.4062 1.4765 1.5468 1.6171 1.6874 1.7578 1.8281 1.8984 1.9687 2.0390 20
30 2.1093 2.1796 2.2499 2.3202 2.3905 2.4609 2.5312 2.6015 2.6718 2.7421 30
40 2.8124 2.8827 2.9530 3.0233 3.0936 3.1640 3.2343 3.3046 3.3749 3.4452 40
50 3.5155 3.5858 3.6561 3.7264 3.7967 3.8671 3.9374 4.0077 4.0780 4.1483 50
60 4.2186 4.2889 4.3592 4.4295 4.4998 4.5702 4.6405 4.7108 4.7811 4.8514 60
70 4.9217 4.9920 5.0623 5.1326 5.2029 5.2733 5.3436 5.4139 5.4842 5.5545 70
80 5.6248 5.6951 5.7654 5.8357 5.9060 5.9764 6.0467 6.1170 6.1873 6.2576 80
90 6.3279 6.3982 6.4685 6.5388 6.6091 6.6795 6.7498 6.8201 6.8904 6.9607 90
100 7.0310 7.1013 7.1716 7.2419 7.3122 7.3826 7.4529 7.5232 7.5935 7.6638 100

Ki l ograms pe r s qu are c e nti me te rs to P ou nds pe r s qu are i nc h e s

Kg/cm2 0 1 2 3 4 5 6 7 8 9 Kg/cm2
lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi)
0 0.00 14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.01 0
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
30 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39 60
70 995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100

Ki l ograms pe r s qu are c e nti me te rs to Ki l o pas c al

Kg/cm2 0 1 2 3 4 5 6 7 8 9 Kg/cm2
Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa
0 0.0 98.1 196.1 294.2 392.3 490.4 588.4 686.5 784.6 882.6 0
10 980.7 1078.8 1176.8 1274.9 1373.0 1471.1 1569.1 1667.2 1765.3 1863.3 10
20 1961.4 2059.5 2157.5 2255.6 2353.7 2451.8 2549.8 2647.9 2746.0 2844.0 20
30 2942.1 3040.2 3138.2 3236.3 3334.4 3432.5 3530.5 3628.6 3726.7 3824.7 30
40 3922.8 4020.9 4118.9 4217.0 4315.1 4413.2 4511.2 4609.3 4707.4 4805.4 40
50 4903.5 5001.6 5099.6 5197.7 5295.8 5393.9 5491.9 5590.0 5688.1 5786.1 50
60 5884.2 5982.3 6080.3 6178.4 6276.5 6374.6 6472.6 6570.7 6668.8 6766.8 60
70 6864.9 6963.0 7061.0 7159.1 7257.2 7355.3 7453.3 7551.4 7649.5 7747.5 70
80 7845.6 7943.7 8041.7 8139.8 8237.9 8336.0 8434.0 8532.1 8630.2 8728.2 80
90 8826.3 8924.4 9022.4 9120.5 9218.6 9316.7 9414.7 9512.8 9610.9 9708.9 90
100 9807.0 9905.1 10003.1 10101.2 10199.3 10297.4 10395.4 10493.5 10591.6 10689.6 100

Ki l o pas c al to ki l ogram pe r s qu are c e nti me te rs

Kpa 0 100 200 300 400 500 600 700 800 900 Kpa
Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2
0 0.000 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 0
1000 10.197 11.217 12.236 13.256 14.276 15.296 16.315 17.335 18.355 19.374 1000
2000 20.394 21.414 22.433 23.453 24.473 25.493 26.512 27.532 28.552 29.571 2000
3000 30.591 31.611 32.630 33.650 34.670 35.690 36.709 37.729 38.749 39.768 3000
4000 40.788 41.808 42.827 43.847 44.867 45.887 46.906 47.926 48.946 49.965 4000
5000 50.985 52.005 53.024 54.044 55.064 56.084 57.103 58.123 59.143 60.162 5000
6000 61.182 62.202 63.221 64.241 65.261 66.281 67.300 68.320 69.340 70.359 6000
7000 71.379 72.399 73.418 74.438 75.458 76.478 77.497 78.517 79.537 80.556 7000
8000 81.576 82.596 83.615 84.635 85.655 86.675 87.694 88.714 89.734 90.753 8000
9000 91.773 92.793 93.812 94.832 95.852 96.872 97.891 98.911 99.931 100.950 9000
10000 101.970 102.990 104.009 105.029 106.049 107.069 108.088 109.108 110.128 111.147 10000

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 Torqu e Foot pou nds to Ki l ogram me te rs
0 1 2 3 4 5 6 7 8 9 ft lbs
Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m
0.138 0.276 0.414 0.552 0.690 0.828 0.966 1.104 1.242
10 1.380 1.518 1.656 1.794 1.932 2.070 2.208 2.346 2.484 2.622 10
20 2.760 2.898 3.036 3.174 3.312 3.450 3.588 3.726 3.864 4.002 20
30 4.140 4.278 4.416 4.554 4.692 4.830 4.968 5.106 5.244 5.382 30
40 5.520 5.658 5.796 5.934 6.072 6.210 6.348 6.486 6.624 6.762 40
50 6.900 7.038 7.176 7.314 7.452 7.590 7.728 7.866 8.004 8.142 50
60 8.280 8.418 8.556 8.694 8.832 8.970 9.108 9.246 9.384 9.522 60
70 9.660 9.798 9.936 10.074 10.212 10.350 10.488 10.626 10.764 10.902 70
80 11.040 11.178 11.316 11.454 11.592 11.730 11.868 12.006 12.144 12.282 80
90 12.420 12.558 12.696 12.834 12.972 13.110 13.248 13.386 13.524 13.662 90
100 13.800 13.938 14.076 14.214 14.352 14.490 14.628 14.766 14.904 15.042 100

Ki l ogram me te rs to Foot pou nds

0 1 2 3 4 5 6 7 8 9 Kg-m
ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs ft-lbs
7.230 14.470 21.690 28.930 36.170 43.400 50.630 57.870 65.100
10 72.300 79.530 86.770 93.990 101.230 108.470 115.700 122.930 130.170 137.400 10
20 144.600 151.830 159.070 166.290 173.530 180.770 188.000 195.230 202.470 209.700 20
30 216.900 224.130 231.370 238.590 245.830 253.070 260.300 267.530 274.770 282.000 30
40 289.200 296.430 303.670 310.890 318.130 325.370 332.600 339.830 347.070 354.300 40
50 361.500 368.730 375.970 383.190 390.430 397.670 404.900 412.130 419.370 426.600 50
60 433.800 441.030 448.270 455.490 462.730 469.970 477.200 484.430 491.670 498.900 60
70 506.100 513.330 520.570 527.790 535.030 542.270 549.500 556.730 563.970 571.200 70
80 578.400 585.630 592.870 600.090 607.330 614.570 621.800 629.030 636.270 643.500 80
90 650.700 657.930 665.170 672.390 679.630 686.870 694.100 701.330 708.570 715.800 90
100 723.000 730.230 737.470 744.690 751.930 759.170 766.400 773.630 780.870 788.100 100

Ki l ogram me te rs to ne w tonme te rs
0 1 2 3 4 5 6 7 8 9 Kg-m
N-m N-m N-m N-m N-m N-m N-m N-m N-m N-m
9.810 19.610 29.420 39.230 49.030 58.810 68.650 78.450 88.260
10 98.100 107.910 117.710 127.520 137.330 147.130 156.910 166.750 176.550 186.360 10
20 196.200 206.010 215.810 225.620 235.430 245.230 255.010 264.850 274.650 284.460 20
30 294.300 304.110 313.910 323.720 333.530 343.330 353.110 362.950 372.750 382.560 30
40 392.400 402.210 412.010 421.820 431.630 441.430 451.210 461.050 470.850 480.660 40
50 490.500 500.310 510.110 519.920 529.730 539.530 549.310 559.150 568.950 578.760 50
60 588.600 598.410 608.210 618.020 627.830 637.630 647.410 657.250 667.050 676.860 60
70 686.700 696.510 706.310 716.120 725.930 735.730 745.510 755.350 765.150 774.960 70
80 784.800 794.610 804.410 814.220 824.030 833.830 843.610 853.450 863.250 873.060 80
90 882.900 892.710 902.510 912.320 922.130 931.930 941.710 951.550 961.350 971.160 90
100 981.000 990.810 1000.610 1010.420 1020.230 1030.030 1039.810 1049.650 1059.450 1069.260 100

Ne w tonme te rs to Ki l ogramme te rs
0 10 20 30 40 50 60 70 80 90 N-m
Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m
0 0.000 1.020 2.040 3.060 4.080 5.100 6.120 7.140 8.160 9.180 0
100 10.200 11.220 12.240 13.260 14.280 15.300 16.320 17.340 18.360 19.380 100
200 20.400 21.420 22.440 23.460 24.480 25.500 26.520 27.540 28.560 29.580 200
300 30.600 31.620 32.640 33.660 34.680 35.700 36.720 37.740 38.760 39.780 300
400 40.800 41.820 42.840 43.860 44.880 45.900 46.920 47.940 48.960 49.980 400
500 51.000 52.020 53.040 54.060 55.080 56.100 57.120 58.140 59.160 60.180 500
600 61.200 62.220 63.240 64.260 65.280 66.300 67.320 68.340 69.360 70.380 600
700 71.400 72.420 73.440 74.460 75.480 76.500 77.520 78.540 79.560 80.580 700
800 81.600 82.620 83.640 84.660 85.680 86.700 87.720 88.740 89.760 90.780 800
900 91.800 92.820 93.840 94.860 95.880 96.900 97.920 98.940 99.960 100.980 900
1000 102.000 103.020 104.040 105.060 106.080 107.100 108.120 109.140 110.160 111.180 1000

11-17
Temperature Fahrenheit to Centigrade Centigrade to Fahrenheit
˚F ˚C ˚F ˚C ˚C ˚F ˚C ˚F
-20 -28.9 95 35.0 -30 -22.0 36 96.8
-15 -26.1 100 37.8 -28 -18.4 38 100.4
-10 -23.3 105 40.6 -26 -14.8 40 104.0
-5 -20.6 110 43.3 -24 -11.2 42 107.6
0 -17.8 115 46.1 -22 -7.6 44 111.2
1 -17.2 120 48.9 -20 -4.0 46 114.8
2 -16.7 125 51.7 -18 -0.4 48 118.4
3 -16.1 130 54.4 -16 3.2 50 122.0
4 -15.6 135 57.2 -14 6.8 52 125.6
5 -15.0 140 60.0 -12 10.4 54 129.2
10 -12.2 145 62.8 -10 14.0 56 132.8
15 -9.4 150 65.6 -8 17.6 58 136.4
20 -6.7 155 68.3 -6 21.2 60 140.0
25 -3.9 160 71.1 -4 24.8 62 143.6
30 -1.1 165 73.9 -2 28.4 64 147.2
35 1.7 170 76.7 0 32.0 66 150.8
40 4.4 175 79.4 2 35.6 68 154.4
45 7.2 180 82.2 4 39.2 70 158.0
50 10.0 185 85.0 6 42.8 72 161.6
55 12.8 190 87.8 8 46.4 74 165.2
60 15.6 195 90.6 10 50.0 76 168.8
65 18.3 200 93.3 12 53.6 78 172.4
70 21.1 205 96.1 14 57.2 80 176.0
75 23.9 210 98.9 16 60.8 82 179.6
80 26.7 212 100.0 18 64.4 84 183.2
85 29.4 20 68.0 86 186.8
90 32.2 22 71.6 88 190.4
24 75.2 90 194.0
26 78.8 92 197.6
28 82.4 94 201.2
30 86.0 96 204.8
32 89.6 98 208.4
34 93.2 100 212.0

11-18
 T394HST
Workshop manual FOR TRACTORS
CODE NO. 17419600010
Printed on March 2015
1st EDITION
Edited by overseas service team