Mitsubishi Heavy Industries BD2GII User manual

TRACTOR
BD2GR
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2B1 02467uP3S1 00060-up
2B2 00775-UP 3S5 00098-up
2B3 00295UP3S6 00061-up
2B5 00883-up
2B6 01125-up
287 00047-up
TRAcnrOR ~OiL.
BSSon
POWER TRA~N
CONTENS
SYSTEMS OPERAT~ON
TEST~NG AND ADJ.US11NG
D~SASSEMBLY AND
REASSEMBLY
t?~W ~ ~~VV ~ ~TI~:,
1

FOREWORD
This manual has instructions and procedures for the subject on the front cover. The information,
specification, and ifiustrations in this publication are on the basis of information that was current
at the time this issue was written.
Correct operation, maintenance, test and repair procedures will give this product a long service
life.. Before starting a test, repair orrebuildjob, the serviceman must read the respective sections
of this manual, and know all the components he will work on.
Safety precautions, skills and knowledge are listed in the descriptions of operations where hazards
exist. Warning labels have also put on the machine to provide instructions and identify specific
hazards which, if not heeded, could cause bodily injury or death to you or other persons. These
labels identify hazards which may not be apparent to a trained mechanic. There are many potential
hazards during repair for an untrained mechanic and there is no way to label the machine against
all such hazards. These warnings in this manual and on the machine are identified by this symbol:
This manual is divided in threeparts, SYSTEMS OPERATION, TESTING AND ADJUSTING
and DISASSEMBLy AND REASSEMBLY. In each part, however, a full explanation is not
given; the explanation is for the servicemen who have had a basic training or those with wide
experience.

INDEX
SYSTEMS OPERATION
General information 2
Direct drive (DD) 3
Direct power shift (DPS) 7
Flywheel clutch 11
Clutch hydraulic control 12
Direct drive (DD) transmission 13
Transmission control (DD) 15
Damper 16
Direct power shift (DPS) transmission 17
Transmission hydraulic control 20
Transmission control valve 22
Operation 23
Steering clutches, brakes and final drives 31
Steering clutch and brake controls 32
Steering clutch hydraulic control 33
Undercarriage 34
TESTING AND ADJUSTING
DPS transmission 38
Inching pedal 45
Transmission control lever 45
Steering clutches 46
Brake pedal 47
Clutch pedal 47
Clutch brake 48
Tracks 48
Troubleshooting 50

DISASSEMBLY AND REASSEMBLY
Engine removal and installation 66
Flywheel clutch 71
Direct drive (DD) transmission 81
Gear pump for transmission and steering clutches 89
DPS transmission 91
Transmission control valve 108
Transfer 110
Bevel gear 112
Damper 113
Steering clutches and brakes 115
Steering valve 126
Final drives 128
Undercarriage 132
Front idlers 133
Recoil cylinders and recoil springs 135
Track rollers 139
Tracks 142
Track carrier rollers 145
Special tools 148

SYSTEMS OPERAT~O~

SYSTEMS OPERATION
GENERAL 1NFORMATION
The BD2GII and BS3GII machines are either direct çlrive type or direct power shift type, the difference
being based on the type of a ~ansmission they use.’
Direct Drive Type Direct Power Shift Type
2

SYSTEMS OPERATION
Power from diesel engine 1 is sent to flywheel
clutch 2. The flywheel clutch is engaged and
disengaged manually. The output shaft of the
flywheel clutch drives the upper (input) shaft in
transmission 4 through a universal joint 3.
The transmission has three FORWARD and two
REVERSE speeds. The selection of these speeds
is done manually. The bevel pinion, at the rear of
the transmission, sends the power to bevel gear 5.
The power is then sent through steering clutches
6 into final drives 7, to the sprockets which drive
the tracks.
The engine and flywheel clutch are integrally
coupled and are mounted on the frame at four
places with cylindrical rubber mounts.
The transmission is housed in its own case which
is bolted to the front of the steering clutch cases.
Diiect Drive (DD)
1 Diesel engine
2 Flywheel clutch
3 Universal joint
4 Transmission
5 Bevel gear
6 Steering clutches
7 Final drives
8 Undercarriage
3

SYSTEMS OPERATION
Direct Power Shift (DPS)
Power from diesel engine 1 is sent through damper
2 to universal joint 3. The universal joint drives
the sun gears andplanet gears in the transmission.
Five planetary gear trains 4, each with its own
clutch, give the machine three speeds in either
forward or reverse. The selection of the desired
machine speed is done manually by the operator
but hydraulic oil, directed by the transmission
hydraulic control valve, engages the clutches in
the transmission.
The output shaft of the transmission drives the
input shaft of transfer 5. The bevel pinion in the
transfer sends power to bevel gear 6. The power
is then sent through steering clutches 7 into final
drives 8, to the sprockets which drive the tracks.
~ The engine and damper are integrally coupled
and are mounted on the frame at four places with
cylindrical rubber mounts.
The transmission planetary gears and transfer
are housed in their own cases. The transfer case
is bolted to the front of the steering clutch cases.
1 Diesel engine
2 Damper
3 Universal joint
4 Planetary gears
5 Transfer
6 Bevelgear
7 Steering clutches -
8 Final drives
9 Undercarriage
10 Hydraulic oil pump
11 Transmission gear pump
7

~1
10 Main shaft
SYSTEMS OPERATION
The flywheel clutch is a multiple-disc wet type
clutch (running in sprayed oil). This clutch is
operated manually and sends the torque from the
engine through the universal joint to the trans
mission.
Clutch discs (driven plates) 2, whose facings
ha~e•checkered oil grooves, are slightly “dished”
to facilitate smooth clutch engagement. Dishing
the clutch discs will permit a gradual engagement
of the clutch facings with the flywheel and
pressure plate. When in the engaged position,
the dished clutch discs are pressed flat between
the flywheel and pressure plate.
FLYWHEEL CLUTCH
1 Flywheel
2 Clutch discs
3 Mating )late
4 Pressure plate
5Clutch cover
6 Release lever
7 Release hub
8 Pressure spring
9 Fork
11 Gear pump
12 Oil strainer
13 Clutch (inertia) brake
Facing
Clutch disc
Splined hub
4-
Flywheel side
Clutch disc assembly
Amount of dishing
602183A I

SYSTEMS OPERATION
CLUTCH HYDRAULIC CONTROL
In the DD machine, oil for the lubrication and
cooling of the clutch disc friction surfaces is
from the supply used for the operation of the
steering clutches.
Oil is pulled from the reservoir through slrainer
1 by~earpump2and goes torelief valve 3. After
this relief valve, the oil flows to the steering
clutch valves. The remainder of the oil flows
through oil cooler 4 (built in the lower tank of the
radiator) to clutch main shaft 5 from which it is
sprayed on the clutch discs and pres sure plate for
lubrication and cooling.
The oil used for actuating the clutch valves is
returned to the top of the clutch case for lubri
cation.
1 Oil strainer 4 Oil cooler
2 Gear pump (for steering clutches) 5 Clutch main shaft
3 Relief valve 6 To steering clutch valves
12

SYSTEMS OPERATION
This transmission is a sliding gear type and has
three forward and two ~reverse speeds. The
selection of these speeds~is done manually.
For the selection of forward s’peed, sliding gear
on the bevel pinion shaft (3rd shaft) is slid into
mesh with gear on the cduntersha±t (2nd shaft).
For the selection of reverse speed, sliding gear is
slid into mesh with gear ~on the input shaft (1st
shaft).
DIRECT DRWE (DD) TRANSMISSION
1 Input shaft
2 1st-speed rev~rse gear
3 2nd-speed reverse gear
4 Input gear
5 2nd-speed drive gear
6 Countershaft
7 1st-speed drive gear
8 1st-speed sliding gear
9 2nd-speed sliding gear
10 Countergrear
11 3rd-speed sliding gear
12 Bevel pinion shaft..
13

SYSTEMS OPERATION
Power Flow
Forward 1st speed position
Forward 2nd speed position
Reverse iSt speed position
Reverse 2nd speed position V
Input 2nd-speed
reverse
gear 3
2nd-speed
sliding
gear 9
— 3— 9—12
602173
Forward 3rd speed position
Input shaft 1
1st-speed
reverse
gear 2
lst-speed
sliding
gear 8
Input shaft 1
V I — 2— 8—12
Bevel pinion
shaft 12
602172
1— 4—10— 6— 5— 9—12
602~l 70
Bevel pinion
shaft 12
-Input gear 4
- Countergear
10
3rd-speed
sliding gear
602 171
1 — 4—10—11—12
14

SYSTEMS OPERATION
The transmission control (gearshift mechanism)
consists of three shift rails, three shift forks,
spring-loaded detent balls and a shift lever. This
mechanism is designed so~that it is only possible
to engage one gear reduction at a time.
The interlock mechanism ~consjsts of a pin and
steel bails which fit into notches on the shift rails.
If 1st shift rail 7is moved for making a shift (the
shift lever is moved to forward 1st-speed posi
tion), for example, 2nd shift rail 8 and 3rd shift
rail 9 are locked by the steel balls. This holds the
transmission gears so that they will not slide out
of position.
TRANSMISSION CONTROL (DD)
1 1st shift fork 5 2nd-speed sliding gear 8 2nd shift rail
2 2nd shift fo± 6 3rd-speed sliding gear 9 3rd shift rail
3 3rd shift fork~ 7 1st shift rail 10 Steel balls
4 1st-speed sliding gear
15

SYSTEMS OPERATION
The damperconsistsessentially of six coil springs
1 and two friction plates 2. Its hub is splined to
the shaft and one of the friction plates is bolted to
flywheel 3.
The combination of coil springs and friction
plates absorbs power impulse from the engine
which would otherwise be transmitted directly to
the gears in the transmission as when the engine
is quickly accelerated or decelerated and shocks
from the ground through power train.
DAMPER
1 Coil spring 3 Flywheel
2 Friction plates
16

SYSTEMS OPERATION
DIRECT POWER SHIFT (DPS) TRANSMISSION
1
2
3
4
5
6
7
Reverse~clutch
Forward clutch
3rd-speed clutch
2nd-speed clutch
1st-speed clutch
Input shaft
Output shaft
8 Sun gear
9 Planet gear
10 Ring gear
11 Carrier
12 Piston housing
13 Piston
14 Mating plate
15 Friction plate
16 Return spring
17 Bevel pinion
18 Gear pump
19 Oil filter
17

SYSTEMS OPERATION
1 Reverse clutch
2 Forward clutch
3 3rd-speed clutch
4 2nd-speed clutch
5 1st-speed clutch
6 Input shaft
7 Output shaft
This transmission consists of five sets of plan
etary gear train, each having a hydraulically
controlled clutch pack, control valve, oil pump,
oil filter and their related parts.
The two planetary gear sets on the input side are
for directional control — forward or reverse
drive — and the remaining three sets on the
output side are for speed selection — 1st-speed,
2nd-speed or 3rd-speed drive.
Each planetary gear set comprises sun gear 8,
planet gears 9, carrier 11 and ring gear 10. The
sun gear rotates; the cat-rier revolves; and the
planet gears rotate on their own shafts or pins and
revolve with the carrier, on which they are
mounted.
19.
•1
602311
8 Sun gear
9 Planet gear
10 Ring gear
11 Carrier
12 Piston housing
13 Piston
‘14 Mating plate
15 Friction plate
16 Return spring
17 Bevel pinion
18 Gear pump
19 Oil filter
18