Bolens G152/G154/G172/G174 Diesel Tractors OEM Service & Repair Manual

BOLENS / ISEKI SERVICE AND REPAIR MANUAL G152 / TX1300 G154 / TX1300F G172 / TX1500 GI74 / TX1500F a barriosbooksale manual 1

a barriosbooksale reprint. CONTENTS SECTION I NAMES OF MAIN COMPONENTS . . . 5 SECTION II DIMENSIONS AND SPECIFICA- TIONS ....................................................... 7 SECTION III PERIODIC MAINTENANCE CHART . 9 Engine ............................................................................ 9 Tractor ............................................................................ 10 SECTION IV LUBRICATION ....................................... 11 1. Lubrication c h a r t .................................................. 11 SECTION V SERVICE D A T A .................................... 12 1. Service s t a n d a r d s ................... .. ............................... 12 2. Special t o o l s ............................................................ 12 3. Tightening torque c h a rt .......................................... 22 4. Stud bolt l i s t ............................................................ 23 5. List of parts requiring scaling a g e n t ..................... 24 SECTION VI POWER TRAIN DIAGRAM ................... 25 SECTION VII CONSTRUCTION AND SERVICE OF THE ENGINE .................................................... 27 1) Sectional view of engine ............................................ 27 2) Engine (1) Construction of cylinder head ........................ 29 (2) Disassembly, assembly and adjustment of cylinder h e a d ......................... 30 (3) Construction of crankcase ............................. 33 (4) Disassembly, assembly and adjustment of crankcase .......................................................... 34 3) Lubrication system (1) Construction of lubrication system ................. 41 4) Fuel system (1) Construction of fuel system .......................... 42 (2) Disassembly, assembly and adjustment of fuel system ............................................................... 45 5) Cooling system (1) Construction of cooling system ....................... 48 6) Electrical system (1) Construction of electrical system ................... 48 (2) Disassembly, assembly and adjustment of electrical system ................................................ 50 SECTION VIII DISASSEMBLY OF THE TRACTOR . 53 1. Bonnet and other components in the front section ....................................................................... 53 2. Driver’s scat and rear fenders ................................ 57 3. Radiator and air cleaner ........................................... 61 4. Muffler ....................................................................... 65 5. Fuel tank, battery, throttle lever, tank base and stop plate .................................................................. 66 6. Clutch system .......................................................... 69 7. Brake system ............................................................. 75 8. Steering system ........................................................ 79 9. Front axle .................................................................. 83 10. Front wheel drive s h a f t ........................................... 91 11. Hydraulic system ..................................................... 95 12. Transmission system ................................................ 96 SECTION IX ASSEMBLY AND ADJUSTMENT OF THE TRACTOR ..........................................117 1) Clutch ......................................................................... 117 2) Transmission ...............................................................120 3) Front drive ................................................................. 127 4) Brake ............................................................................ 130 5) Hydraulic system ....................................................... 131 6) Engine accessories....................................................... 132 7) Steering system .......................................................... 133 8) Tire tread adjustment ............................................... 134 9) Electric w iring ............................................................ 136 10) Standard accessory .................................................. 138 ROTARY HOE .................................................................. 139 a barriosbooksale manual 2

SECTION I NAMES OE THE MAIN COMCONENTS a barriosbooksale reprint. a barriosbooksale manual 3

a barriosbooksale reprint. - _____ Models Items - _ TX 1000 TX 1000F TX 1300 TX 1300F TX 1500 TX 1500F Dimensions and Specifications Overall length in (mm) 71.6S (1820) 74 .80 (1900) I 75.59 (1920) 77.95 (1980) | 78.74 (2000) Overall width in (mm) 35.63 (910) 38.58 (980) 40.16(1020) Overall height in (mm) 45 28(1150) 47.24 (1200) 48.43 (1230) Wheelbase in (mm) 46 46(1180) 48 02 (1220) 50.39 (1280) - Min. turning radius in (mm) — W. 69-29 (1760) 72.83 (1850) 69.69(1770) 77.95 (1980) 73.62 (1870) 78.74(2000) Ground clearance in (mm) 12 20 (310) 10.04 (255) 12 99 (330) 10.63 (270) 13.78 (350) 10.63 (270) Front wheel tread in (mm) 27.56 (700) 30.12 (765) 27.56 (700) 30.12 (765) 27.56 (700) 30.12 (765) Rear wheel tread in (mm) 27.56 • 31.50 (700 • 800) 29.13 • 33.07 (740 • 840) 30.71 • 34.65 (780 • 880) Total weight lbs (kg) 992 (450) 1,058 (480) 1,058 (480) 1,124 (510) 1,124 (510) 1,190 (540) Front wheel weight 471 (214) 531 (241) 502 (228) 568 (258) 515 (234) 477 (262) Rear wheel weight 520 (236) 527 (239) 555 (252) 555 (252) 608 (276) 613 (278) Engine Model name KE55 KE70 | KF.75 Type Water Cooled Four Cycle Diesel Engine Output PS 11 13 14.8 Maximum torque kg m/rpm 2.9/2300 3.5/2300 4.0/2300 Combustion chamber Swirl Chamber No. of cylinders 2 2 2 llnre x stroke in (mm) Total displacement ett-in (cc) 2.68 x 2.95 (68 x 75) 33.20 (544) 2 87 x 3.15 (73 x 80) 40.82 (669) 3.07 x 3.15 <7H x HO) 46.62 (764) Fuel Diesel Light Oil Fuel tank capacity Gallon (lit.) 2 64 (12) Starting method Starter Motor Hit tery NS60 (12V x 45A) Air cleaner type Dry Type SECTION II DIMENSIONS AND SPECIFICATIONS a barriosbooksale manual 4

barriosbooksale reprint. --------- Models Hems ~ — ---- _ __ TX 1000 TX 1000F TX 1300 TX 1300F TX 1500 TX 1500F Power Train Trtctor speeds tnph (km/h) 6 Forward speeds 2 reverse speeds 1st 0.62 (1.0) 1st 0.6R (1.1) 1st 0.75 (1.2) 2nd 0.93 (1.5) 2nd 1.06 (1.7) 2nd 1.12 (1.8) 3rd 1.57 (2.5) 3rd 1.74 (2.8) 3rd 1.66 (3.0) 4th 2.74 (4 4) 4th 3.11 (5.0) 4th 3.35 (5.4) 5th 4.22 (6 R) 5th 4 84 (7 8) 5th 5.15 (8 3) 6th 7.51(12 1) 6th 8.57(13.8) 6th 9.13 04.7) Rev. Ist0.81 (1.3) Rev. 1st 0.87 (1.4) Rev. 1st 0.93 (1.5) 2nd 3.60 (5 8) 2nd 4.10 (6.6) 2nd 4 35 (7.0) Front tire 400-9 5-12 4.50-10 5 00-12 4 00-12 | 5 00-12 Rear lire 7-14 (ML) 8-16 (HL) 8-18 (HL) Front axle type Center pin Lemoine Center pin joint Center pin Lemoine Center pin joint Center pin Lemoine Center pin joint Resr axle type Central Axle Differential lock Equipped Steering system Ball • screw type Brake system Mechanical, Internal Expansion type Powrr TakeOff Location At the rear end center P.T.O. speeds rpm/engine at 2700 1st 472 2nd 752 3rd 1177 StanJarJs JIS 35 Implement Mounting Device Tilling 2P (fixing with pins) Towing Trailer hitch (Fixing with pins) General Category 0 (3-point linkage, JIS) Option Implement Lift Typt Hydraulic Type Operating pressure PSMkg/cm1) 1565 (110 kg/cmJ ) 1707 (UOkg/cm1) Control system Others Model of rotary hoe SR1000CD SRI000N SR1100CD SR1100N SR1200CD SR1200N Drive type Side Center Side , Center Side Center No. of wheels driven 2 wheels 4 wheeb 2 wheels 4 wheels 2 wheels 4 wheels The specifications are subjected to change without notice. a barriosbooksale manual 5

a barriosbooksale reprint. SECTION III PERIODIC MAINTENANCE CHART ENGINE ■ SERVICE AT 0 Check, add & adjust A Clean • Change * Repair at service station ITEM >* < o © § o v» w* o o <N o *n <N § r*» O m § O m V o o w O v-t 1 INSPECTION THERAFTER CHECK STANDARDS ON DAILY INSPECTION Engine oil 0 • • • • • • Change every 100 hours. Must be in specified range on level gauge. Air cleaner A A A • A A Clean every 100 hours. Change every 400 hours. Radiator coolant o Change onoe a year. Filled to the mouth. Fud o Fuel filter o A o A • O A O A o • Clean every 100 hours. Change every J00 hours Cleaning inside fuel tank Clean once a year. Fan belt o o o Check every 200 hours. 10 mm (approx. 3/8") deflection when pushed by finger Battery electrolyte level O O 0 o o O Check every 100 hours. Oil filter • • • • • • Change every 100 hours. Damages & leaks 0 Change broker parts. Cracks and leaks should be repaired Lnoseness of bolt and nut 0 Should not be loose. Valve clearance ♦ Adjust every 400 hours 0.3S mm (.014 in) for both valves (when cooled) Engine idle speed Scarring pressure of nozzle injection Starting pressure 120 kg/cm’ (1707 psi) Injection no tile * ♦ * Check every 200 hours Starror motor, alternator & regulator * Adjust every 400 hours Glow plug * Check every 400 hours Check for broken wire Compression pressure Check every 800 hours 0 a barriosbooksale manual 6

a barriosbooksale reprint. TRACTOR DAILY SERVICE AT 0 Cheek, add & adjust A dean • Ciange ♦ Repair at service station ITEM o v» 8 O § N o s •A o W “» m 1 O *r» ♦ § Kb o wi o 2 INSPECTION THERAFTER CHECK STANDARDS ON DAILY INSPECTION Transmission oil • o o • o o Check every 100 hours. Change every 300 hours. Clutch pedal play O Brake pedal play O Briking effect o Function of levers O Suction filter A A dean every 300 hours. Sceerinf play o Tire sir pressure See "Service Dsta" Toe-in O 0 2-4 mm (0.08-0.16 in) Bevel case oil (4wbeel drive tractor) • • Gear case oil (4-wbeel drive tractor) • • Retightening of freer in g bill joint o o Retighten every 300 hours. Wheel set bolts o Function of electrical equipment and gauges o Assure chic they ire functioning properly. Throttle adjustment o o Adjust every 300 hours. Lubrication o o o o o o O oo 0 oo Apply grease every 50 hours (every day when puddling) Looseness of bolts and nuts o • Should not be loose. Oil leaks at clutch chamber Check once • year, removing cheek plug at clutch fchamber bottom. Check for presence of muddy water in front gear case After padding, check by removing check plug at front gear case. Packing of grease in front wheel hub (J-wheel drive) Pack every 900 hours. Retighten front wneel bearing (2-wheel drive) ♦ Pack every 900 hours. © a barriosbooksale manual 7

a barriosbooksale reprint. SECTION IV LUBRICATION 1. LUBRICATION CHART NO. LUBRICATION POINT TYPE OF LUBRICANT QUANTITY: liters (gal.) TX 1000 TX 1300 TX 1500 2-wheel 4-wheel 2-wheel 4-wheel j 2-wheel | 4-wheel j 1 Engine Diesel engine oil 2.0 (0.44) 2.6 (0.65) 2 Steering gear box Gear oil SAE 80 or SAE 90 Replenish ! Replenish (Grease) | 3 Transmission case Gear oil SAE 80 12.3 (2.71) 4 Bevel case Gear oil SAE 80 or SAE 90 0.7 (0.151 (4-whccl drive type only) 5 Front gear case 0.25 (0.06) 2 points ( 4 -wheel drive only) 6 ; Radiator (Coolant) 4.2 (0.92) 7 1 Fuel tank (Diesel light oil) (2.64) 8 ! Cenrer pivot Grease As required (2-wheel drive type only) 9 1 King pin As required 10 Tie rod end U Drug rod end 12 Brake pedal 13 Brake shaft 14 Clutch pedal 15 Knuckel arm As required (2-wheel drive type only) NOTE: To drain oil easily, drain the oil while the machine ts warm 0 a barriosbooksale manual 8

a barriosbooksale reprint. SECTION V ' SERVICE DA IA 1. SERVICE STANDARDS 1) CHASSIS _________________________________ _______________ ITEMS____________________ . _________ Free play of dutch pedi] ....................... — .................. Free play of brake pedal .................................................. Steering wheel play ...... - ................................................... Clutch--------------------------------------------------------------- Pawl height to release lever from flywheel mating face Difference in heights of three pawls ............................. Clearance between release lever and bearing ............. Clearance between safety switch and yoke ................. Backlash of drive pinion-to-ring gear ............................. Backlash of differential side gear-to-pinion ••—............. Pull-out force of shifters .................................................. Front wheel differential load ......................................... Front gear disengaging angle ......................................... Difference in lift arm ends ............................................... Thickness of radiator cushion rubber .......................... Fan belt tension ..... - ...... Engine idling speed ................. - ................................... — Front axle deflection ................................................... — Front axle oscillation .............................................. - ...... Water temperature lamp functioning temperature ----- ON .................................. ............................................... OFF ..... ................................... ......... ................................ Tire air pressure -------------------------------------------------- TX1000 front .......................... ........ ............... - ........ rear ............................ —- ................... • TX1000F front ................................. - ...... rear ............. - ....... * .................................... TX1300 front .............- ......................... ............... . rear ............. - ............................................. TX1300F front ................................ ........................... rear ............. *............................................. TX1J00 front •••• .................. - ................................— rear .................. - ................................... —■ TX1500F front .................................. ......................... St and ardIs __________________ Remarks_____ ... 0.59—0.79in (15—20mm) ■— 1.18—1.57in (30—40mm) .... 0.08—0.16in (2—4mm) ..... 1.18in (approx. 30mm) — ----- at outer circumference of steering wheel .... 1.79±0.03in (45.5±0.7mm) .... Less than 0.02 in (0.5mm) .... 0.06-0.lOin (1.5-2.5mm) — 0.08—0.16in (2-4mm) ..... 0.002—0.006in — — - ............ Assemble parts having (0.05—0.15mm) same punched number — 0.009—0.017in (0.22-0.42mm) — More than 48.5 lbs (22kg) ..... 17.7—26.5lbs (8-12kg) ----------- At knuckc arm top •— 45 degrees .... Less than 0.24 in (6mm) ............ At the position lowered by 8° from level position ..... Approx. 0.31in (8mm) ..— Approx. 0.39in (10mm) — 850—950rpm — 0—0.01 in (0—0.2mm) — 0.5 lin (13mm) ---------- — ....... To both sides — 226—237°F (108-114°C) 201—225*F (94—107#C) .... 23 psi (1.6kg/cm3) 14 psi (1.0kg/cm3) — 17 psi (1.2kg/cm3) ..... 14 psi (1.0kg/cm3) ..... 20 psi (1.4kg/cm3) ...- 17 psi (1.2kg/cm3) — 17 psi (1.2kg/cm3) — 17 psi (1.2kg/cm3) .... 20 psi (1.4kg/cm3) 17 psi (1.2kg/cm3) .... 17 psi (1.2kg/cm3) —. 17 psi (1.2kg/cm3) a barriosbooksale manual 9

a barriosbooksale reprint. 2) ENGINE Items Standards Correction Limit Compression pressure .................... Compression pressure difference between cylinders ......—......... —• Fuel injection order .................... Fuel injection timing .................... Cylinder Head ------------------------- 455 psi(32kg/cm*) at 2800 rpm 1-2 25 degrees BTDC 35 psi (2.5kg/cm2) Flatness (distortion) of lower face Inside diameter of valve guides (Intake & exhaust) KE55 ..................... ...... ......... ............. .................... KE70 & KE75 Valve seat angle (Intake & exhaust) ..... — Valve seat width (Intake St exhaust) ....... Valve scat sinkage (Intake & exhaust) .... Valve Timing Intake open ........ - ................... Intake close ............................. Exhaust open ......................... Exhaust close ......... — ........ - Valve clearance (Intake & exhaust) ----- Less than 0.002in (0.05mm) 0.2598—0.2 604in (6.6-6.615mm) 0.3149-0.3155in (8-8.015mm) 45 degrees 0.039-0.059in ..... (1—1.5mm) 18 degrees BTDC 46 degrees ABDC 46 degrees BBDC 18 degrees ATDC 0.014in (0.35mm) at cold engine — 0.004in (0.1mm) 0.079in (2mm) Intake Valve --------------- Valve dia. x total length KE55 .... ......—.......... KE70 and KE75 ..... Stem outside diameter KE55 ..... ............. .... KE70 & 75 Clearance between stem and guide KE55 --------------------------------- KE70& KE75 Seat face angle —........ Thickness of valve head KE55 ............ ............ KE70 & KE75 ......... 1.103x4.196in (28x106.5mm) 1.181x4.57in (30x116mm) 0.258-0.259in — (6.565—6.580mm) 0 .3 1 3 —0 . 3 14in ■••• (7.96—7.975mm) 0.0008-0.0019 ~ (0.020—0.050mm) 0.0009-0.0021 — (0.025—0.055 mm) 45 degrees 0.039in(lmm) — 0.059in (1.5mm)-— 0.004in (0.1mm) 0 004in (0.1mm) Usable Limit 313.0 psi(22kg/cmJ ) 0.039in (1mm) 0.004in (O lmni) 0.004in (0.1 nua) 0.0196in (0.5mm) 0.0196in (0.5mm) : 0 a barriosbooksale manual 10

Bolens G152/G154/G172/G174 Diesel Tractors OEM Service & Repair Manual

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