Iseki TM3160 TM3200 TM3240 4WD Tractor Complete Workshop Service Repair Manual
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TM3160
TM3200
TM3240
ISEKI TRACTORS
TM3160
TM3200
TM3240
ISEKI TRACTORS
TM3160
TM3200
TM3240
TABLE OF CONTENTS
1
CHAPTER 1. GENERAL INFORMATION .........................................................................................5
1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS............................................5
1.1. MODEL NAME PLATE ...................................................................................................5
1.2. CHASSIS PRODUCTION NUMBER ..............................................................................5
1.3. ENGINE MODEL AND SERIAL NUMBER .....................................................................5
2. SPECIFICATIONS ..................................................................................................................6
3. GENERAL PRECAUTIONS FOR SEPARATION AND RE-INSTALLATION .........................12
3.1. BEFORE OPERATION .................................................................................................12
3.2. PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING STANDARDIZED PARTS12
CHAPTER 2. DISASSEMBLING INTO MAJOR FUNCTIONAL COMPONENTS ..........................15
1. OPERATION CHART FOR DISASSEMBLING
AND RE-ASSEMBLING BY MAJOR BLOCKS .............................................................15
2. DISASSEMBLY OF FUNCTIONAL BLOCKS .......................................................................16
2.1. EXTERIOR PARTS ......................................................................................................16
2.2. SEPARATION OF THE ENGINE FROM THE CLUTCH HOUSING .............................17
2.3. REMOVAL OF THE ENGINE .......................................................................................18
2.4. SEPARATION OF THE CLUTCH HOUSING
FROM THE FRONT TRANSMISSION CASE .......................................................18
2.5. REMOVAL OF THE CYLINDER CASE ........................................................................18
2.6. REMOVAL OF THE CHANGE METAL (SUPPORT) ....................................................19
2.7. SEPARATION OF THE FRONT TRANSMISSION CASE
FROM THE REAR TRANSMISSION CASE..........................................................19
2.8. REMOVAL OF THE MID-PTO ......................................................................................19
2.9. SEPARATION OF THE REAR AXLE HOUSING
FROM THE REAR TRANSMISSION CASE..........................................................19
2.10. REMOVAL OF THE FRONT AXLE ...............................................................................19
2.11. REMOVAL OF THE RADIATOR ...................................................................................20
CHAPTER 3. ENGINE SERVICE DATA AND ACCESSORIES ......................................................21
1. SPECIFICATIONS ................................................................................................................21
2. TIGHTENING TORQUE OF MAJOR FASTENERS..............................................................22
3. RADIATOR ............................................................................................................................23
3.1. CONSTRUCTION ........................................................................................................23
3.2. REMOVALAND RE-INSTALLATION............................................................................23
3.3. INSPECTION ...............................................................................................................23
4. COOLING FAN AND BELT ...................................................................................................24
4.1. SPECIFICATIONS ........................................................................................................24
4.2. ADJUSTMENT OF BELT..............................................................................................24
5. AIR-CLEANER ......................................................................................................................25
5.1. REMOVALAND RE-INSTALLATION............................................................................25
5.2. INSPECTION ...............................................................................................................25
5.3. CLEANING THE ELEMENT .........................................................................................25
6. FUEL SYSTEM .....................................................................................................................25
TM TRACTOR SERVICE MANUAL
2
6.1. FUEL SYSTEM DIAGRAM ...........................................................................................25
6.2. INSPECTION ...............................................................................................................26
6.3. FUEL FILTER ...............................................................................................................26
6.4. AIR-BLEEDING ............................................................................................................26
7. TROUBLESHOOTING ..........................................................................................................27
CHAPTER 4. CLUTCH SYSTEM ....................................................................................................29
1. CONSTRUCTION .................................................................................................................29
2. DISASSEMBLY .....................................................................................................................29
3. INSPECTION ........................................................................................................................30
4. PRECAUTIONS FOR RE-ASSEMBLY .................................................................................31
5. TROUBLESHOOTING ..........................................................................................................33
CHAPTER 5. TRANSMISSION .......................................................................................................35
1. GEAR-TYPE TRANSMISSION .............................................................................................35
1.1. POWER TRAIN ............................................................................................................35
1.2. CONSTRUCTION ........................................................................................................37
1.3. DISASSEMBLY ............................................................................................................37
1.4. INSPECTION ...............................................................................................................38
1.5. PRECAUTIONS FOR RE-ASSEMBLY.........................................................................38
2. HST TRANSMISSION...........................................................................................................39
2.1. POWER TRAIN ............................................................................................................39
2.2. CONSTRUCTION ........................................................................................................40
2.3. DISASSEMBLY ............................................................................................................40
2.4. INSPECTION ...............................................................................................................41
2.5. PRECAUTIONS FOR RE-ASSEMBLY.........................................................................41
3. MID-PTO ...............................................................................................................................42
3.1. CONSTRUCTION ........................................................................................................42
3.2. INSPECTION ...............................................................................................................42
3.3. PRECAUTION FOR RE-ASSEMBLY ...........................................................................42
CHAPTER 6. REAR AXLE AND BRAKES .....................................................................................43
1. GENERAL DESCRIPTION ...................................................................................................43
2. REAR AXLE HOUSING AND DIFFERENTIAL GEARS ........................................................44
2.1. DISASSEMBLY ............................................................................................................44
2.2. INSPECTION ...............................................................................................................44
2.3. PRECAUTIONS FOR RE-ASSEMBLY AND ADJUSTENT ..........................................44
3. BRAKES ...............................................................................................................................46
3.1. CONSTRUCTION ........................................................................................................46
3.2. DISASSEMBLY ............................................................................................................47
3.3. INSPECTION ...............................................................................................................47
3.4. PRECAUTIONS FOR REASSEMBLY ..........................................................................47
3.5. BRAKE ADJUSTMENT ................................................................................................47
4. TROUBLESHOOTING ..........................................................................................................49
CHAPTER 7. MANUAL STEERING SYSTEM ................................................................................51
1. CONSTRUCTION .................................................................................................................51
3
2. DISASSEMBLY, INSPECTION, AND REASSEMBLY ...........................................................52
2.1. DISASSEMBLY ............................................................................................................52
2.2. INSPECTION ...............................................................................................................53
2.3. REASSEMBLY AND ADJUSTMENT ............................................................................54
2.4. TROUBLESHOOTING .................................................................................................56
CHAPTER 8. POWER-ASSISTED STEERING SYSTEM...............................................................57
1. CONSTROUCTION ..............................................................................................................57
2. MAJOR COMPONENT .........................................................................................................58
3. INTEGRAL ORBIT ROLL ......................................................................................................59
3.1. COMPONENT ..............................................................................................................59
3.2. DISASSEMBLY ............................................................................................................60
3.3. RE-ASSEMBLY ............................................................................................................62
4. TROUBLESHOOTING ..........................................................................................................66
CHAPTER 9. FRONT AXLE ............................................................................................................69
1. CONSTROUCTION ..............................................................................................................69
1.1. SECTIONAL VIEWS.....................................................................................................69
1.2. MAJOR COMPONENTS ..............................................................................................70
2. DISASSEMBLY .....................................................................................................................71
2.1. FRONT AXLE AND DIFFERENTIAL GEARS...............................................................71
2.2. FINAL CASE AND RELATED PARTS ..........................................................................72
DISASSEMBLY OF THE FINAL CASE ASSEMBLY .............................................................72
3. INSPECTION ........................................................................................................................72
4. PRECAUTIONS FOR RE-ASSEMBLY .................................................................................73
5. TROUBLESHOOTING ..........................................................................................................74
CHAPTER 10. HYDRAULIC SYSTEM............................................................................................75
1. GENERAL DESCTIPTION ....................................................................................................75
1.1. HYDRAULIC SYSTEM DIAGRAMS.............................................................................75
2. SPECIFICATIONS ................................................................................................................80
3. CONSTRUCTION, DISASSEMBLY AND INSPECTION OF MAJOR COMPONENTS ........81
3.1. SUCTION FILTER ........................................................................................................81
3.2. HYDRAULIC PUMP (GEAR PUMP) ............................................................................81
3.3. CYLINDER CASE ........................................................................................................82
3.3.1. CONSTRUCTION AND COMPONENTS....................................................................82
3.3.2. DISASSEMEBLY ........................................................................................................83
3.4. MAIN CONTROL VALVE ..............................................................................................84
4. REASSEMBLY OF MAJOR COMPONENTS........................................................................88
5. TROUBLESHOTING.............................................................................................................90
CHAPTER 11. HYDROSTATIC TRANSMISSION ...........................................................................93
1. CONSTRUCTION AND NAMES OF MAJOR COMPONENTS (TM3200FH / TM3240FH) ..93
2. OPERATING DIAGRAM OF HST .........................................................................................94
3. FUNCTION ...........................................................................................................................95
3.1. VARIABLE TYPE PUMP ..............................................................................................95
3.2. FIXED TYPE MOTOR ..................................................................................................96
TM TRACTOR SERVICE MANUAL
4
3.3. VALVES ........................................................................................................................96
4. DISASSEMBLY AND REASSEMBLY ...................................................................................99
4.1. REQUIRED TOOLS .....................................................................................................99
4.2. PRESS-IN JIGS .........................................................................................................100
4.3. PRECAUTIONS FOR DISASSEMBLY .......................................................................101
4.4. DISASSEMBLY ..........................................................................................................101
4.5. CRITERIA FOR REPLACING WORN PARTS ...........................................................104
4.6. PRECAUTION BEFORE REASSEMBLY ...................................................................104
4.7. REASSEMBLY ...........................................................................................................105
4.8. LIST OF MAJOR COMPONENTS OF HST................................................................112
5. HST CONTROL PEDALS ...................................................................................................113
5.1. DIMENSIONS OF PEDALS ........................................................................................113
5.2. NEUTRAL ADJUSTMENT ..........................................................................................114
5.3. CONFIRMATION ITEMS AFTER ADJUSTMENT.......................................................114
5.4. CRUISE CONTROL LEVER .......................................................................................115
6. TROUBLESHOOTING ........................................................................................................116
CHAPTER 12. ELECTRICAL SYSTEM ........................................................................................117
1. FUSES, FUSIBLE LINKS AND SLOW-BLOW FUSE..........................................................117
2. SAFETY SYSTEM WIRING DIAGRAM ..............................................................................118
3. TROUBLESHOOTING ........................................................................................................119
3.1. BATTERY ...................................................................................................................119
3.2. METERS, GAUGES, AND SWITCHES ......................................................................119
CHAPTER 13. SERVICING DATA ................................................................................................123
1. SPECIFICATIONS & CAPACITIES .....................................................................................123
2. LUBRICATION / FILL POINTS............................................................................................125
3. PERIODIC MAINTENANCE SCHEDULE ...........................................................................128
4. SERVICE STANDARDS .....................................................................................................129
5. SPECIFIED TIGHTENING TORQUES OF STANDARD BULTS AND NUTS .....................132
1.2. CHASSIS PRODUCTION NUMBER
TM3160 000001
Chassis production serial number
Manufacturer`s model name
1.3. ENGINE MODEL AND SERIAL
NUMBER
(1) Engine model
(2) Serial Number
Fig. 1-3
CHAPTER 1: GENERAL INFORMATION
5
Each tractor is identified by means of the
tractor model and serial numbers. As a fur-
ther identification, the engine and chassis
are also provided with identification num-
bers.
To ensure prompt, effcient service when
ordering parts or requesting repairs from
authorized ISEKI dealer, record these num-
bers in spaces provided.
CHAPTER 1. GENERAL INFORMATION
1. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS
(1) Model name plate
(2) Punched model name and serial num-
ber on the right side of the front frame
(3)Cast engine model name and
punched engine serial number on the
right side wall the cylinder block
1.1. MODEL NAME PLATE
(1) MODEL
(2) TYPE
R .....ROPS
H .....HST transmission
M .....Mid-PTO
U .....Power-assisted steering system
(3) Production No.
(4) Production year
The year of 1996 is allotted to "A" and
the following years are expressed alphabetically
except for "I".
Fig. 1-1
Fig. 1-2
TM TRACTOR SERVICE MANUAL
6
2. SPECIFICATIONS
Mechanical Transmission
MODEL: TM3160F TM3200 TM3240
Sub Models RE MRE ME URE MURE MUE URE MURE MUE
ENGINE:
Make Iseki Diesel
Model E393-B06 E3112-B14 E3112-B16
Type Indirect injection, overhead valve
Aspiration Natural
Displacement 928 cc 1123cc
Number of Cylinders 3
Bore 74.0 mm 78.2 mm
Stroke 72.0 mm 78.0 mm
Engine Horsepower (Net) 15.5 PS (11.4 kW) @ 2500 rpm 19.5 PS (14.3 kW) @ 2500 rpm 22.0 PS (16.1 kW) @ 2600 rpm
PTO Horsepower (Estimate) 13.5 HP 16.5 HP 18.5 HP
Firing Order 1-3-2
Compression Ratio 22.5 to 1
Low Idle Speed 950-1000 rpm 1250-1300 rpm 1250-1300 rpm
High Idle Speed 2650-2750 rpm 2650-2750 rpm 2760-2860 rpm
Valve Clearance (Clod); Intake 0.25 mm
Exhaust 0.25 mm
Air Cleaner single dry element
Engine Cooling Liquid, forced circulation
Cold Starting Aid Glow plugs (3)
TRANSMISSION:
Type; Primary F3 / R1
Range 2 speeds
Gear Speeds 6 gears forward, 2 reverse
Clutch Dry single disk
Brakes Mechanically actuated sealed wet disk
POWER TAKE-OFF (PTO):
Control
Rear PTO; Shaft
Lever
35 mm diameter, six spline
Output Clockwise rotation
PTO Speed @ engine rpm 540 @ 2308 rpm 540 @ 2475 rpm 540 @ 2476 rpm
Mid PTO; Shaft 25.4 mm diameter, fifteen spline
Output Clockwise rotation
Mid PTO Speed @ engine rpm - 2000 @ 2445 rpm - 2000 @ 2445 rpm - 2000 @ 2445 rpm
CHAPTER 1: GENERAL INFORMATION
7
Mechanical Transmission
MODEL: TM3160F TM3200 TM3240
Sub Models RE MRE ME URE MURE MUE URE MURE MUE
HYDRAULICS:
Steering System; Type Manual Hydrostatic (power)
Pump
-
(flow divider)
Maximum Output - 9.8 L / min at 2500 rpm 10.2 L / min at 2600 rpm
Presure - 10301 kPa (105 kgf / cm
2
)
Main Hydraulic System; Pump Engine-mounted gear pump
Maximum Output 9.8 l / min at 2500 rpm 19.8 l / min at 2500 rpm 20.6 l / min at 2600 rpm
Pressure Relief valve setting 13740 kPa (140 kgf / cm
2
)
Rear Linkage; Type Three-point hitch
Size Category 0 Category 1
Control Position
Lift Capacity 480 kg measured at ball ends 540 kg measured at ball ends
ELECTRIAL SYSTEM:
System Voltage 12 volt, negative (-) ground
Battery cca @ 0 F (-18) 325 cca 435 cca
Charging
8.5 amp alternator with
internal regulator / rectifier
40 amp alternator with internal regulator / rectifier
CAPACITIES:
Engine Creankcase with Filter 2.6 liters 2.7 liters
Transmission 13.5 liters 13.5 liters
Fuel Tank 13.5 liters 25 liters
Cooling system 5.0 liters 7.1 liters
Front Drive Axle 2.7 liters
TREAD WIDTH SETTINGS:
Front 4WD
Ag. Tires
Turf Tires
Rear 4WD
Ag. Tires
Turf Tires
MAXIMUM AXLE LOADING:
Front Axle
Rear Axle
755 mm 750 mm
857 mm 870 mm 900 mm
790 mm, 962 mm 820 mm, 930 mm 820 mm, 940 mm
870 mm 920 mm 910 mm
400 kg 650 kg
750 kg
TM TRACTOR SERVICE MANUAL
8
GENERAL DIMENSIONS
Tire size
TM3160 TM3200 TM3240
Agri. Tire Turf Tire Agri. Tire Turf Tire Agri. Tire Turf Tire
Front 5-12 4PR 20 x 8.00 -10 4PR 5-12 4PR 20.5 x 8.00 -10 4PR 5-12 4PR 23 x 10.50 -12 4PR
Rear 8-16 4PR 212 / 80D -15 4PR 8-18 4PR 29 x 12.00-15 4PR 9.5-16 4PR 315 / 75 D -15 4PR
Model
Transmission
Sub-models
Tire
TM3160 TM3200 TM3240
mech. mech. mech.
RE MRE ME URE MURE MUE URE MURE MUE
Agri Turf Agri Turf Agri Turf Agri Turf Agri Turf Agri Turf Agri Turf Agri Turf Agri Turf
A Overall Height 2245 mm 2220 mm 2245 mm 2220 mm 1280 mm 1255 mm 2315 mm 2280 mm 2315 mm 2280 mm 1300 mm 1270 mm 2320 mm 2325 mm 2320 mm 2325 mm 1330 mm 1340 mm
B Overall Width 1068 mm 1096 mm 1068 mm 1096 mm 1280 mm 1255 mm 1070 mm 1210 mm 1070 mm 1210 mm 1070 mm 1210 mm 1070 mm 1230 mm 1070 mm 1230 mm 1070 mm 1230 mm
C1
C2
Overall Length
(including front hitch)
Overall Length
2585 mm
-
-
2485 mm
2860 mm
-
-
2760 mm
2860 mm
-
-
2760 mm
D Wheelbase 1345 mm 1520 mm
E
Min. Ground
Clearance 215 mm 190 mm 215 mm 190 mm 265 mm 240 mm 235 mm 200 mm 235 mm 200 mm 285 mm 245 mm 240 mm 245 mm 240 mm 245 mm 290 mm 295 mm
-
Turning radius
with brake 2000 mm 2400 mm 2600 mm 2400 mm 2600 mm 2400 mm 2600 mm 2400 mm 2600 mm 2400 mm 2600 mm 2400 mm 2600 mm
-
Turning radius
without brake 2300 mm 2700 mm 2900 mm 2700 mm 2900 mm 2700 mm 2600 mm 2400 mm 2600 mm 2400 mm 2600 mm 2400 mm 2600 mm
- Weight 600 kg 590 kg 605 kg 595 kg 570 kg 560 kg 655 kg 645 kg 660 kg 650 kg 630 kg 620 kg 670 kg 685 kg 675 kg 690 kg 645 kg 660 kg
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This Complete Workshop Service Repair Manual for the Iseki TM3160, TM3200, TM3240 4WD Tractor is an invaluable resource for both professional mechanics and DIY enthusiasts.
DESCRIPTION:
- This comprehensive manual covers every Service & Repair Procedure with easy-to-follow step-by-step instructions and pictures for all areas of servicing & repairs.
- It enables significant cost savings by empowering users to perform their own repairs.
- Once downloaded, the manual is accessible for printing or viewing on a tablet or smartphone.
MODELS COVERED:
- All Models/Engines/Trim/Transmissions Types Are Covered.
CONTENTS:
- This high-quality manual covers all repair procedures A-Z, ensuring that every repair and service procedure is comprehensively addressed.
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