Service manual

ManualsBrandsCub Cadet ManualsLawn Mower8404

MTD Products, LLC Product Training and Education Department

www.mymowerparts.com

K&T Saw Shop 606-678-9623 or 606-561-4983

FORM NUMBER 769-00902

Summary of content (289 pages)

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www.mymowerparts.com CONTENTS CHAPTER 1 GENERAL INFORMATION .......................................................................................... 1-1 1. TRACTOR VIEW ............................................................................................................................................... 1-3 2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS ................................................................. 1-4 2.1 TIGHTENING TORQUE ...................................................
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www.mymowerparts.com 2. CLUTCH ............................................................................................................................................................ 3-8 2.1 CHARACTERISTICS ............................................................................................................................... 3-8 2.2 LINK STRUCTURE AND CONTROL ..................................................................................................... 3-9 2.3 TROUBLESHOOTING ...........
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www.mymowerparts.com 10.3 THIRD STAGE (DISASSEMBLY OF 25 GEAR SHAFT AND PROPULSION SHAFT 1) ........................... 4-30 10.4 FOURTH STAGE (DISASSEMBLY OF BEARING COVER ASSEMBLY) .......................................... 4-30 10.5 FIFTH STAGE (DISCONNECTION OF TRANSMISSION FORK) ..................................................... 4-31 10.6 SIXTH STAGE (DISASSEMBLY OF 22 GEAR SHAFT) ...................................................................... 4-32 10.
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www.mymowerparts.com 5. TIGHTENING TORQUE .................................................................................................................................. 7-7 6. DISASSEMBLY, MAINTENANCE ................................................................................................................... 7-8 6.1 STRUCTURE ............................................................................................................................................ 7-8 7.
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www.mymowerparts.com 6. OIL FLOW ......................................................................................................................................................... 8-9 6.1 IN NEUTRAL ........................................................................................................................................... 8-9 6.2 TURNING TO THE RIGHT .................................................................................................................... 8-9 6.
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www.mymowerparts.com 14.TIGHTENING TORQUE ................................................................................................................................ 9-24 15.DISASSEMBLY, ASSEMBLY ......................................................................................................................... 9-25 15.1 GEAR PUMP ........................................................................................................................................... 9-25 15.2 MAINTENANCE .......
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www.mymowerparts.com GENERAL INFORMATION 1.
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www.mymowerparts.com CHAPTER 1 8354/8404 2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS 2.1 TIGHTENING TORQUE Screws, bolts and nuts whose tightening torques are not specified in this workshop manual should be tightened according to the table below. A. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS Grade No grade 4T Unit Nominal Diameter M6 (6 mm, 0.24 in.) M8 (8 mm, 0.31 in.) M 10 (10 mm, 0.39 in.) M 12 (12 mm, 0.47 in.) M 14 (14 mm, 0.55 in.) M 16 (16 mm, 0.63 in.) M 18 (18 mm, 0.71 in.
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www.mymowerparts.com GENERAL INFORMATION B. TIGHTENING TORQUE FOR STUDS M8 11.7 ~ 15.7 N·m 1.2 ~ 1.6 kgf·m 8.6 ~ 11.5 lbf·ft M10 24.5 ~ 31.4 N·m 2.5 ~ 3.2 kgf·m 18.0 ~ 23.1 lbf·ft M12 34.3 ~ 49.0 N·m 3.4 ~ 5.0 kgf·m 25.3 ~ 36.1 lbf·ft C. TIGHTENING TORQUE FOR HIGH PRESSURE HOSE UNION NUTS Hose Size (Inside Diameter: Inches) 1/8″ 3/16″ 1/4″ 5/16″ 3/8″ 1/2″ 5/8″, 3/4″ 1″ Screw Size (PF) 1/8″ 1/4″ 1/4″ 3/8″ 3/8″ 1/2″ 3/4″ 1″ Tightening (N·m) 9.8 24.5 24.5 49.0 49.0 58.
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www.mymowerparts.com CHAPTER 1 8354/8404 3. SPECIFICATIONS 8354 Model 8404 Maximum PTO power 28.3 HP 33.4 HP Engine GROSS power 33.5 HP 40.4 HP 3A165D 4A200 Engine Model Type Indirect injection, vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke 3 4 87 × 92.4 mm 83 × 92.4 mm (3.425 × 3.637 in.) (3.268 × 3.637 in.) 1,647 1,999 Total displacement Rated revolution 2,700 rpm Injection timing 18° before T.D.C.
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www.mymowerparts.com GENERAL INFORMATION Model Traveling system 8404 8354 Synchronized shuttle and transmission Transmission 8 forward and 8 reverse speeds (CR: 16 forward and 16 reverse speeds) Brake Traveling Parking Wet disc type Connected with the traveling brake Differential Hydraulic system Bevel gear Hydraulic lift control system Pump capacity Position, Draft and Mixed control Main pump 29.7 /min (7.8 U.S.gal.) Power steering pump 17.8 /min (4.7 U.S.gal.
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www.mymowerparts.com CHAPTER 1 8354/8404 4. IDENTIFICATION 4.1 ENGINE NUMBER The engine serial number is stamped on the left side of the cylinder block as shown in the figure. Engine serial number provides important information. 615W102A (1) Engine Serial Number 4.2 CHASSIS NUMBER OF THE TRACTOR (CHASSIS NUMBER OF THE MACHINE) The chassis serial number of the tractor is stamped on the left side of the front axle frame as shown in the figure.
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www.mymowerparts.com GENERAL INFORMATION 5. CAUTION BEFORE REPAIR 5.1 BEFORE REPAIR OR INSPECTION 1. In case of repair or inspection, locate the tractor on the flat ground and pull the parking brake on. 2. Except for the items to be checked while the engine is running, be sure to stop the engine prior to the work. 7. Finish assembly within 20 minutes after applying sealant, after that, wait approx. 30 minutes later before filling with oil. 5.3 PARTS TO BE REPLACED 3.
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www.mymowerparts.com CHAPTER 1 8354/8404 5.5 ASBESTOS PARTS Since dust out of asbestos fibrous parts is extremely dangerous to your health, be sure to clean such parts carefully, do not use compressed air. 5.6 ELECTRICAL SYSTEM 1. Check electrical wiring every year for any damage or short circuit at the connections. In addition, have your dealer inspection the electric system regularly. 2. Do not modify or reorganize the wiring of the electric field parts. 3.
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www.mymowerparts.com GENERAL INFORMATION 5.7 TUBES AND RUBBERS 5.8 LUBRICANT 615W111A Be cautious of oil or other petroleum products on the hoses and rubber parts, this may cause damage. 615W112A When assembling and fixing, apply designated lubricant where specified in accordance with this repair manual.
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www.mymowerparts.com CHAPTER 1 8354/8404 6.
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www.mymowerparts.com GENERAL INFORMATION 7. OIL & WATER SUPPLY LIST Supply Items Fuel Capacity 40 (42.3 U.S.gal.) Recommended Spec. No. 2 - D diesel fuel No. 1 - D diesel fuel if temperature is below - 10 °C (14 °F) Coolant Engine Oil 3A165D 7.0 (1.85 U.S.gal.) 4A200B 8.9 (2.35 U.S.gal.) 3A165D 5.5 (1.45 U.S.gal.) 4A200B Fresh clean water with antifreeze SAE 15 W - 40 7.0 (1.85 U.S.gal.) Transmission Oil 44 (11.6 U.S.gal.) Universal tractor/transmission Front Axle Section 7.8 (2.
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www.mymowerparts.com ENGINE SYSTEM 1. GENERAL 1.1 APPEARANCE 615W201A The DAEDONG A series engines are vertical, watercooled, 4-cycle, three or four cylinders diesel engines, they concentrate DAEDONG’s foremost technologies. With swirl combustion chamber, bosch K type fuel injection pump, well-balanced designs, they feature greater power, low fuel consumption, less vibration and noise, and low emission.
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www.mymowerparts.com CHAPTER 2 8354/8404 1.2 SPECIFICATIONS Model Type Number of cylinder Bore and stroke Total Displacement 3A165D 4A200B Vertical, water-cooled, Vertical, water-cooled, 4-cycle diesel engine 4-cycle diesel engine 3 4 87 x 92.4 mm 83 x 92.4 mm 3.43 x 3.64 in. 3.27 x 3.64 in. 1,647 cc 1,999 cc 3 122.0 in3 100.5 in Combustion Spherical type Spherical type 33.5/2,700 HP/rpm 40.4/2,700 HP/rpm 30.0/2,700 kW/rpm 36.
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www.mymowerparts.com ENGINE SYSTEM 1.
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www.mymowerparts.com CHAPTER 2 8354/8404 1.4 DIMENSIONS 615W206A 3A165D (mm) (in.) 4A200B (mm) (in.) A B C D E F G H I J 602.3 722.3 280.0 400.0 488.1 251.6 729.9 259.7 240.0 315.0 95.0 23.71 28.44 11.02 15.75 19.22 9.91 28.74 10.00 9.45 12.40 3.74 697.3 817.3 280.0 400.0 488.1 251.6 735.8 259.7 240.0 321.0 92.0 27.45 32.18 11.02 15.75 19.22 9.91 28.97 10.22 9.45 12.64 3.62 K 1.5.
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www.mymowerparts.com ENGINE SYSTEM 2. STRUCTURE AND FUNCTION 2.1 BODY A. CYLINDER HEAD The cylinder head is made of special alloy cast iron which can resist high temperature and pressure caused by combustion. The inlet and exhaust ports are arranged cross-flow type to get high combustion efficiency by protecting the suction air from being heated and expanded by heated exhaust air. The DAEDONG vortex type combustion chamber is designed for high combustion efficiency and reducing fuel consumption.
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www.mymowerparts.com CHAPTER 2 8354/8404 C. CRANKSHAFT The crankshaft is made of forged steel and the journals, the crankpins and the bearing surface for the oil seal are induction-hardened to increase wear resistance. Each crankshaft journal is supported by the main bearing case (3) having a bearing inside. The front bearingcrankshaft bearing (2) is a solid type bushing and rear and intermediate bearings are a split type. The crankshaft, crankshaft bearings have oil holes for lubricant flow.
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www.mymowerparts.com ENGINE SYSTEM F. CAMSHAFT The camshaft (3) is made of forged steel and its journal and cams are hardened to increase wear resistance. The cams on the camshaft open and close the inlet and exhaust valves with the push rods and rocker arms. The journals and their bearings are forcelubricated. 615W213A (1) Cam Gear (3) Camshaft (2) Camshaft Stopper G. FUEL CAMSHAFT This fuel camshaft is made of forged steel and its cams are hardened and tempered to increase wear resistance.
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www.mymowerparts.com CHAPTER 2 8354/8404 I. INLET AND EXHAUST VALVES The valve and its guide of the inlet are different from those for the exhaust. Other parts, such as the spring, spring retainers, valve spring collets, valve stem seals are the same for both the inlet and the exhaust. All contact or sliding surfaces are hardened to increase wear resistance. 615W216A (1) Valve Spring Collet (4) Valve Stem Seal (2) Valve Spring Retainer (5) Exhaust Valve (3) Valve Spring (6) Inlet Valve J.
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www.mymowerparts.com ENGINE SYSTEM 2.2 LUBRICATING SYSTEM A. FLOW OF LUBRICATING OIL The lubricating oil is forced to each journal through the oil passages of the cylinder block, cylinder head and shafts. The oil, splashed by the crankshaft or thrown off from the bearings, lubricates other engine parts such as the push rods (11), tappets (12), camshaft (14), and crankshaft (15).
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www.mymowerparts.com CHAPTER 2 8354/8404 C. OIL FILTER AND RELIEF VALVE The lubricating oil force-fed by the pump is filtered by the filter cartridge, passing through the filter element from the outside to the inside. When the filter element accumulates dirt and the pressure difference between the inside and the outside rises more than 98 kPa (1.0 kgf/cm², 14 psi), the bypass valve (1) opens to allow the oil to flow from the inlet line to outlet line, bypassing the filter element.
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www.mymowerparts.com ENGINE SYSTEM 2.3 COOLING SYSTEM A. FLOW OF COOLING WATER The cooling system consists of a radiator (5), a centrifugal water pump (7), a cooling fan (6) and a thermostat (2). The water is cooled as it flows through the radiator core, and the fan behind the radiator pulls the cooling air through the radiator core. The water pump receives water from the radiator or from the cylinder head and forces it into cylinder block. The thermostat open or closes according to the water temperature.
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www.mymowerparts.com CHAPTER 2 8354/8404 C. THERMOSTAT The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet. The pellet is charged with wax. (A) At Low Temperature (Lower than 71 °C (160 °F)).
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www.mymowerparts.com ENGINE SYSTEM 2.4 FUEL SYSTEM A. FLOW OF FUEL The fuel is fed from the fuel tank (1) through the fuel feed pump (7) to the injection pump (3) by the fuel filter (2). The injection pump force-feds the fuel through the injection nozzles (5), which inject the fuel into the cylinders for combustion. The excessive fuel from the injection pump to the injection nozzles (5), which inject the fuel into the cylinders for combustion.
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www.mymowerparts.com CHAPTER 2 8354/8404 C. FUEL FEED PUMP The diaphragm (6) is linked to the tappet (3) with the push rod (2). The tappet is reciprocated by the eccentric cam on the fuel camshaft (7). (A) Inlet Stroke When the diaphragm is pulled down by the spring, vacuum in the chamber (5) causes the outlet valve (4) to close and the atmospheric pressure in the fuel tank to force the fuel into the chamber, opening the inlet valve (1).
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www.mymowerparts.com ENGINE SYSTEM a . Pump Element The pump element (1) consists of a plunger (3) and cylinder (2), their sliding surfaces are precision machined to maintain fuel tightness. The plunger (3) fits in the control sleeve (5) at the driving surface (7). The sleeve is engaged with the control rack, which rotate the plunger in the cylinder to control the amount of fuel delivery.
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www.mymowerparts.com CHAPTER 2 8354/8404 c. Amount of Fuel Delivery (A) No Fuel Delivery At the engine stop position of the control rack (3), the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The delivery chamber (4) is led to the feed hole during the entire stroke of the plunger. The pressure in the delivery chamber does not build up and no fuel is forced to the injection nozzle.
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www.mymowerparts.com ENGINE SYSTEM E. FUEL INJECTION NOZZLE The nozzle is a throttle-type one. It features low fuel consumption and works well with DAEDONG combustion chamber. The nozzle valve opening pressure is about 13.7 to 14.7 MPa (140 to 150 kgf/cm², 1991 to 2134 psi), the pressure overcomes the counterforce of nozzle valve spring, and push the valve up instantly, the fuel is then injected in a proper quantity into the swirling air in the combustion chamber for combustion.
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www.mymowerparts.com CHAPTER 2 8354/8404 b. Operation of Governor 1) At start The steel ball (13) has no centrifugal force. As the fork lever 1 (4) is pulled by the start spring (1), the control rack (14) moves to the maximum injection position. At start, the sufficient injection of the fuel enables easy starting. 615W247A 2) At idling At the idling position of the speed control lever (15), the governor spring 1 (2) is free and the governor spring 2 (3) does only act slightly.
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www.mymowerparts.com ENGINE SYSTEM 3) At high speed running with overload When an overload is applied to the engine running at a high speed, the centrifugal force of steel ball (13) becomes small as the engine speed is dropped, and fork lever 2 (5) is pulled to the right by the governor spring 1 (2) and 2 (3), increasing fuel injection. Though, fork lever 2 becomes ineffective in increasing fuel injection when it is stopped by the adjusting bolt (17).
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www.mymowerparts.com CHAPTER 2 8354/8404 A. FLOW OF INTAKE AIR AND EXHAUST GAS (a) Intake Air (b) Exhaust Gas (1) Intake Manifold (2) Air Cleaner (3) Cylinder Head (4) Muffler (5) Exhaust Manifold 615W251A B. AIR CLEANER The air cleaner is dry-cyclone type and easy to maintain. The air from the inlet port (2) circulates along the fin (3) and around the air cleaner element (4) and the heavier dust is carried to the evacuator (6), to the dust exhaust port.
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www.mymowerparts.com ENGINE SYSTEM 3. DISASSEMBLING AND SERVICING 3.
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www.mymowerparts.com CHAPTER 2 8354/8404 3.2 SERVICING SPECIFICATIONS A. ENGINE BODY a . Cylinder Head Item Factory Specification Allowable Limit 0.05 mm / 100 mm Cylinder Head Surface Flatness 0.002 in. / 3.94 in. 0.75 ~ 0.9 mm Top Clearance - 0.0295 ~ 0.0354 in. Cylinder Head Gasket Thickness Free 1.3 ~ 1.5 mm - 0.0512 ~ 0.0591 in. Tightened 1.15 ~ 1.25 mm - 0.0453 ~ 0.0492 in. Compression Pressure (When cranking with starting motor) 3.24 ~ 3.73 MPa 2.
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www.mymowerparts.com ENGINE SYSTEM d. Cylinder Bore Item Cylinder bore inner diameter Factory Specification Allowable Limit 3A165D 87.000 ~ 87.022 mm 3.4252 ~ 3.4261 in. 0.15 mm 4A200B 83.000 ~ 83.022 mm 0.0059 in. 3.2677 ~ 3.2690 in. e . Valve Spring Item Free length Assembling load / assembling length Squareness Factory Specification Allowable Limit 41.7 ~ 42.2 mm 41.2 mm 1.6417 ~ 1.6614 in. 1.6220 in. 12.0 kgf / 35.15 mm 10.2 kgf / 35.15 mm 26.46 lbs / 1.3839 in. 22.49 lbs / 1.
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www.mymowerparts.com CHAPTER 2 8354/8404 I. Timing Gear Item Timing gear backlash Idle gear side clearance Clearance between Factory Specification Allowable Limit 0.04 ~ 0.11 mm 0.15 mm 0.0016 ~ 0.0043 in. 0.0059 in. 0.20 ~ 0.51 mm 0.9 mm 0.0079 ~ 0.0201 in. 0.035 in. Idle gear shaft and idle gear bushing 0.025 ~ 0.066 mm 0.1 mm 0.00098 ~ 0.00260 in. 0.0039 in. Idle gear shaft O.D 37.959 ~ 37.975 mm - 1.49445 ~ 1.49508 in. Idle gear bushing I.D 38.000 ~ 38.025 mm - 1.49606 ~ 1.
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www.mymowerparts.com ENGINE SYSTEM l. Crankshaft Item Factory Specification Crankshaft Misalignment Clearance between Allowable Limit 0.08 mm - 0.0031 in. Crankshaft and crankshaft bearing 1 0.040 ~ 0.118 mm 0.20 mm 0.00157 ~ 0.00465 in. 0.0079 in. Crankshaft O.D 51.921 ~ 51.940 mm - 2.04414 ~ 2.04489 in. Crankshaft bearing 1 I.D 51.980 ~ 52.039 mm - 2.04646 ~ 2.04878 in. Clearance between Crankshaft and crankshaft bearing 2 Crankshaft O.D 0.040 ~ 0.104 mm 0.20 mm 0.00157 ~ 0.00409 in.
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www.mymowerparts.com CHAPTER 2 8354/8404 C. COOLING SYSTEM a . Thermostat Valve opening temperature at beginning Opened completely (height 8 mm 0.315 in.) 69.5 ~ 72.5 °C (157.1 ~ 162.5 °F) 85 °C (185 °F) b. Radiator No leak at 137 kPa, 1.4 kgf/cm2, 20 psi Radiator tightness 10 seconds or more for pressure falling from 88 ~ 59 kPa Radiator cap tightness from 0.9 ~ 0.6 kgf/cm2 from 13 ~ 9 psi Fan belt tension 7 ~ 9 mm [deflection at 98 N (10 kgf, 22 lbs) of force] 0.28 ~ 0.35 in. D.
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www.mymowerparts.com ENGINE SYSTEM E. TIGHTENING TORQUES Size x Pitch N•m kgf•m lbf·ft Cylinder head screws M11 x 1.25 103.0 ~ 107.9 10.5 ~ 11.0 75.9 ~ 79.6 Head cover nuts M10 x 1.25 8.8 ~ 10.8 0.9 ~ 1.1 6.5 ~ 8.0 * Bearing case screw 1 M9 x 1.25 46.1 ~ 51.0 4.7 ~ 5.2 34.0 ~ 37.6 * Bearing case screw 2 M10 x 1.25 68.6 ~ 73.6 7.0 ~ 7.5 50.6 ~ 54.2 * Flywheel screw M12 x 1.25 98.1 ~ 107.9 10.0 ~ 11.0 72.3 ~ 79.6 * Connecting rod screws M8 x 1.0 46.1 ~ 51.0 4.5 ~ 5.0 34.
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ENGINE SYSTEM 3.3 CHECKING, DISASSEMBLING AND SERVICING A. ENGINE DISASSEMBLED VIEW www.mymowerparts.
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www.mymowerparts.com ENGINE SYSTEM B. EXTERNAL COMPONENTS a . Checking and Adjusting 1) Fan belt Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. If the belt is damaged or worn (see figure), replace the belt. Belt tension (deflection) Factory spec 7 ~ 9 mm 615W258A 0.28 ~ 0.35 in. b.
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www.mymowerparts.com CHAPTER 2 8354/8404 2) Solenoid 1. Disconnect the stop lever 1 (5) from the engine stop lever (2). 2. Remove the screw (3) and (4). 3. Remove the solenoid (7) with its support. (When reassembling) • Loosen the solenoid mounting screws. • Install the support and complete the linkage between the solenoid (7) and the engine stop lever (2).
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www.mymowerparts.com ENGINE SYSTEM C. ENGINE BODY a . Checking and Adjusting 1) Compression pressure 1. Run the engine until warmed up. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 3. Connect a compression tester to the nozzle holder hole. 4. Pull the stop lever to cut the fuel and run the engine with the starter at 250 ~ 350 rpm for 5 ~ 10 seconds. 5. Measure the maximum pressure while running, several times. 615W262A 6.
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www.mymowerparts.com CHAPTER 2 8354/8404 2) Valve clearance 1. Remove the cylinder head cover and the timing window cover on the flywheel housing and all glow plugs. 2. Turn the flywheel and align the 1 TC or 1.4 TC mark mark with the timing mark of window on the flywheel housing to position the 1st cylinder valves at the top head center during compression. 3. Measure the clearance at the valves marked with in the table below with a feeler gauge. 4.
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www.mymowerparts.com ENGINE SYSTEM (B) Heat seal removal procedure 1. Drive screw driver lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3. While turning the screw driver, slowly pull the heat seal put together with the injection nozzle gasket. If the heat seal drops, repeat the above procedure. 4. Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service.
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www.mymowerparts.com CHAPTER 2 8354/8404 (D) Cylinder head 1. Remove the screw in the specified sequence shown in the figure and remove the cylinder head (1) and head gasket. 2. Remove the water flange (2). 3. Take out the tappets from the cylinder block. NOTE: • Mark the cylinder number to the tappets to prevent interchanging. (When reassembling) • Apply liquid gasket (Three bond 1215 or equivalent) on the both sides of water flange gasket.
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www.mymowerparts.com ENGINE SYSTEM 1) Timing Gears and Camshafts (A) Injection pump 1. Remove the injection pump cover (3) with the engine stop lever (2). 2. Remove the injection pump. (When reassembling) • Apply liquid gasket to the both sides of injection pump cover gasket and install it. • Install the injection pump so that its control rack pin (4) engages with the groove (5) of fork lever 1 (1).
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www.mymowerparts.com CHAPTER 2 8354/8404 (C) Start spring 1. Remove the start spring (1) from the fork lever 1 (2). (When reassembling) • Be careful not to drop the start spring into the gear case. • Hook the start spring so that the longer hook is on the fork lever side. 615W276A (1) Start Spring (2) Fork Lever 1 (D) Fan drive pulley 1. Install the stopper to the flywheel so that the crankshaft may not turn. 2. Flatten the metal lock and loosen the crankshaft nut (2). 3.
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www.mymowerparts.com ENGINE SYSTEM (F) Water pump and relief valve 1. Remove the water pump body (1). 2. Remove the relief valve cover (2) and take out the ball, spring and seat. (When reassembling) • Install the relief valve cover (2) with its mark up. Tightening Relief valve torque cover screw 32.4 ~ 36.3 N·m 3.3 ~ 3.7 kgf·m 23.9 ~ 26.8 lbf·ft 615W279A (1) Water Pump Body (G) (2) Relief Valve Cover Idle gear and crank gear 1.
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www.mymowerparts.com CHAPTER 2 8354/8404 (H)Camshaft 1. Align the holes on the cam gear (2) with the crews to loosen them through the holes with a T handle wrench. 2. Draw out the camshaft (1). 3. Remove the cam gear (2). (When reassembling) • Heat the cam gear to approx. 80 °C (176 °F) and insert the camshaft (1). 615W282A (1) Camshaft (2) Cam Gear (I) Fuel camshaft 1. Remove the fuel camshaft stopper. 2.
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www.mymowerparts.com ENGINE SYSTEM (B) Piston and connecting rod 1. Remove the screws and the connecting rod cap. 2. Push out the rod and piston assembly. (When reassembling) • Apply oil to the crankpin bearing, cylinder wall and connecting rod cap screw. • Insert the connecting rod and piston assembly with the mark on the rod facing the injection pump, using a piston ring compressor. IMPORTANT: • Mark the cylinder number on the piston and connecting rod to prevent interchanging.
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www.mymowerparts.com CHAPTER 2 8354/8404 (C)Piston ring and piston pin 1. Remove the piston rings with a piston ring replacing tool. 2. Remove the piston pin. (When reassembling) • Clean all the parts before assembling. • Heat the piston in approx. 80 °C (176 °F) of oil for 10 ~ 15 minutes, when inserting the piston pin into the piston. • Install the piston and connecting rod with the mark FW on the piston to the flywheel and the mark on connecting rod to the injection pump.
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www.mymowerparts.com ENGINE SYSTEM (B) Bearing case cover Loosen the screw first inside and next outside, and lift the cover (1) by screwing two screws gradually and evenly, referring to the photo. (When reassembling) • Apply grease to the oil seal lip and take care that it is not rolled when installing. Tightening torque Bearing case cover screw 23.5 ~ 27.5 N·m 2.4 ~ 2.8 kgf·m 17.4 ~ 20.3 lbf·ft 615W291A (1) Bearing Case Cover (C)Crankshaft 1. Remove the bearing case screw 2. 2.
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www.mymowerparts.com CHAPTER 2 8354/8404 IMPORTANT: • Mark the location line to the bearing case, to prevent interchanging. (When reassembling) • Clean the parts and the oil passage of the bearing case. • Apply oil to the journal, bearing inserts and the bearing case screws. • Place the thrust bearings on the bearing case with their oil groove outside. • Install the main bearing case with the mark “FLY WHEEL” toward the flywheel. Tightening torque Bearing case screw 1 46.1 ~ 51.
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www.mymowerparts.com ENGINE SYSTEM (C)Valve stem clearance 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of cylinder head, and calculate the clearance. 4. If the measurement exceeds the allowable limit, replace the valve guide of the valve. Valve stem clearance Factory spec. 0.040 ~ 0.070 mm 0.00157 ~ 0.00276 in. Allowable limit Valve guide bore I.D. Factory spec. Valve stem O.D. Factory spec. 0.1 mm 0.004 in.
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www.mymowerparts.com CHAPTER 2 8354/8404 (F) Valve spring 1. Measure the free length of the spring with venire calipers. 2. Place the spring on a spring compression tester and compress to the specified length, and get the tension. 3. If the measurement is less than the allowable limit, replace the valve spring. Tension Factory spec. 117 N / 35.15 mm 12.0 kgf / 35.15 mm 26.5 lbs / 1.3839 in. Allowable limit 100 N / 35.15 mm 615W2A0A 10.2 kgf / 35.15 mm 22.5 lbs / 1.3839 in. Free length Factory spec.
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www.mymowerparts.com ENGINE SYSTEM 2) Timing gears and camshafts (A) Timing gear backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. 4. If the oil clearance is improper, replace the gear. Clearance Factory spec. Allowable limit 0.04 ~ 0.11 mm 0.0016 ~ 0.004 in. 0.15 mm 615W2A3A 0.0059 in.
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www.mymowerparts.com CHAPTER 2 8354/8404 (D)Injection pump gear side clearance 1. Pull the fuel camshaft and pull the injection pump gear (1) to each end. A 2. Measure the clearance A between the injection pump gear (1) and the snap ring (2) on the fuel camshaft. 3. If the clearance exceeds the allowable limit, check the gear, the bearing and the key. Side clearance Factory spec. 0.15 ~ 0.57 mm 0.0059 ~ 0.0224 in. 0.9 mm Allowable limit 0.035 in.
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www.mymowerparts.com ENGINE SYSTEM (G)Camshaft oil clearance 1. Measure the I.D. of the camshaft bore on the crankcase with an inside micrometer. 2. Measure the O.D. of the camshaft journal with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft. Factory spec. Oil clearance 0.050 ~ 0.091mm 0.00197 ~ 0.00358 in. 0.15 mm Allowable limit Journal O.D. Factory spec. Bore I.D. Factory spec. 0.0059 in. 39.934 ~ 39.950 mm 615W2A9A 1.57221 ~ 1.57284 in. 40.000 ~ 40.
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www.mymowerparts.com CHAPTER 2 8354/8404 3) Connecting rod and piston (A) Piston pin bore 1. Measure the I.D. of piston pin bore in piston (lengthwise and widthwise of the piston) with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston. Piston Pin bore I.D. Factory spec. 25.000 ~ 25.006 mm Allowable limit 25.03 mm 0.9843 ~ 0.9845 in. 0.9854 in. 615W2B2A (B) Piston pin and brushing clearance 1. Measure the piston pin O.D. with an outside micrometer. 2.
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www.mymowerparts.com ENGINE SYSTEM (D)Piston ring end gap 1. Push down the ring into the cylinder to the lower limit of ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceed the allowable limit, replace the piston ring. Piston ring end gap 2nd ring Factory spec. Allowable limit Top ring, oil ring 0.55 ~ 0.70 mm 0.0217 ~ 0.0276 in. 1.25 mm 0.0492 in. 0.25 ~ 0.40 mm Factory spec. 0.0098 ~ 0.0157 in. Allowable limit 0.0492 in. 615W2B5A 1.
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www.mymowerparts.com CHAPTER 2 8354/8404 (F) Connecting rod alignment 1. Remove the connecting rod bearing and install the bearing cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool. 4. Put a gauge over the piston pin and move it against the face plate. 5. If the gauge does not fit squarely against the face plate, measure the space between the pin of the gauge and the face plate. 6.
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www.mymowerparts.com ENGINE SYSTEM (B) Crankshaft alignment 1. Support the crankshaft with V blocks on the surface plate at its front and rear journals and set a dial indicator with its tip on the intermediate journal. 2. Rotate the crankshaft in the V blocks and get the misalignment (half of the measurement). 3. If the misalignment exceeds the allowable limit, replace the crankshaft. Misalignment Allowable limit 0.08 mm 0.0031 in. 615W2B9A (C)Crankshaft journal and bearing 1 oil clearance 1.
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www.mymowerparts.com CHAPTER 2 8354/8404 (E) Crankshaft journal and bearing 2 oil clearance 1. Put plastic gauge lengthwise in the center of the journal. 2. Install the bearing cap and tighten the screw to the specified torque once, and remove the cap again. 3. Measure the amount of the flattening with the scale and get the oil clearance. 4. If the clearance exceeds the allowable limit, replace replace the bearing. Oil clearance Factory spec. Allowable limit Journal O.D. Bearing 2 I.D.
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www.mymowerparts.com ENGINE SYSTEM 5) Cylinder bore (A) Cylinder bore diameter 1. Measure the cylinder liner I.D. at sit positions shown in the figure to find the maximum wear. 4A200B 83.000 ~ 83.022 mm 3.2677 ~ 3.269 in. 3A165D 87.000 ~ 87.022 mm 3.425 ~ 3.4261 in.
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www.mymowerparts.com CHAPTER 2 8354/8404 D. LUBRICATING SYSTEM a . Checking (A) Engine oil pressure 1. Remove the oil pressure switch and install adaptors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed. 3. If the oil pressure is less than the allowable limit, check the amount of oil, oil filter, oil pump relief valve, oil passages and oil clearance. Engine oil pressure At idle speed Factory spec.
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www.mymowerparts.com ENGINE SYSTEM b. Servicing (A) Rotor and lobe clearance of oil pump 1. Measure the clearance between the outer and inner rotor with a feeler gauge. 2. Measure the clearance between the outer and the housing with a feeler gauge. 3. If the clearance exceeds the allowable limit, replace the pump. Outer and inner rotor clearance Factory spec. Allowable limit Outer and inner housing clearance Factory spec. Allowable limit 0.10 ~ 0.16 mm 0.0039 ~ 0.0063 in. 0.20 mm 0.0079 in.
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www.mymowerparts.com CHAPTER 2 8354/8404 E. COOLING SYSTEM a . Checking Adjusting (A) Fan belt 1. Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force. 2. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. 3. If the belt is damaged or worn (See figure), replace the belt. Belt tension (direction) 7 ~ 9mm Factory spec 615W2D0A 0.28 ~ 0.35 in.
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www.mymowerparts.com ENGINE SYSTEM b. Disassembling and Assembling (A) Thermostat 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) • Apply liquid gasket (Three Bond 1215 or equivalent) to the gasket. 615W2D3A (1) Thermostat (2) Thermostat Cover (B) Water pump 1. Remove the fan and fan pulley. 2. Remove the water pump body from the gear case cover. 3. Remove the water pump flange (1). 4. Remove the impeller and water pump shaft (3). 5.
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www.mymowerparts.com CHAPTER 2 8354/8404 F. FUEL SYSTEM a . Checking and Adjusting 1) Injection pump (A) Injection term (Injection timing) 1. Remove the injection pipes. 2. Set the speed control lever to the maximum fuel discharge position. 3. Turn the flywheel counterclockwise (facing the flywheel) until the fuel flow through to the hole of the delivery valve holder (1). 4. Turn the flywheel further and stop turning when the fuel stop to flow, to check the injection timing. 5.
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www.mymowerparts.com ENGINE SYSTEM b. Injection nozzle • Never contact with spraying diesel fuel under pressure, pressure, which can have sufficient force to penetrate the skin, causing serious personal injury. • Be sure nobody is in direction of the spray. CAUTION (A) Fuel injection pressure 1. Set the injection nozzle to the nozzle tester. 2. Measure the injection pressure. 3. If the measurement is not within the factory specifications, adjust with the adjustment washer (1) inside the nozzle holder.
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www.mymowerparts.com CHAPTER 2 8354/8404 c. Disassembling and Assembling 1) Injection pump IMPORTANT: • If replacing the pump element, the amount of fuel injection should be adjusted on specified bench. 615W2E0A (1) Pump Body (5) Delivery Valve (2) Control Rack (6) Tappet Roller (3) Delivery Valve Holder (7) Cylinder (4) Delivery Valve Spring (8) Plunger 2) Injection nozzle (A) Nozzle holder 1. Secure the nozzle retaining nut (7) with a vise. 2.
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www.mymowerparts.com CLUTCH 1. DISASSEMBLY AND ASSEMBLY 1.1 DISASSEMBLY OF PANEL FRAME A. FIRST STAGE 615W301A (1) Side Cover (Left, Right) (3) Front Grill Assembly (2) Bonnet (4) Cover-Low (Left, Right) 1. Disassemble side cover (1), bonnet (2), front grill assembly (3) and cover-low (4).
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www.mymowerparts.com CHAPTER 3 8354/8404 B. SECOND STAGE 615W302A 615W303A 615W304A (1) Steering Hose Assembly T (7) Accelerator Cable (2) Steering Hose Assembly P (8) Indicator Cable (3) Steering Hose Assembly L (9) Panel Wiring Harness Assembly (4) Steering Hose Assembly R (10) Fender Wiring Harness Assembly (5) Frame Cover (11) Clutch Rod (6) Parallel Pin 1. Disassemble power steering unit connection hoses (1), (2), (3) and (4). 2.
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www.mymowerparts.com CLUTCH C. THIRD STAGE 1. Disengage attaching bolt (2) of frame assembly (1). 2. Disassembly frame assembly. 615W306A (1) Frame Assembly (2) Bolt (When reassembling) • • When connecting with power steering unit hoses (1), (2), (3) and (4) make sure hose color and connecting port to be assembled properly.
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www.mymowerparts.com CHAPTER 3 8354/8404 1.2 DISASSEMBLY OF FENDER AND STEPLADDER ASSEMBLY A.
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www.mymowerparts.com CLUTCH 1. Disconnect ROPS (1). 2. Disconnect seat assembly (2). 3. Disconnect knobs (3), (4), (5), (6) and (7) of each transmission shift lever. 4. Disconnect transmission shift lever guide (8) and hydraulic lever guide (9). 5. Disconnect differential clamping rod (11) and the spring (12) from lower seat assembly (10). (When reassembling) Sect. Stepladder assembly and seat lower assembly locking nut Spec. Tightening Torque M16 196 ~ 225 N·m 20.0 ~ 23.
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www.mymowerparts.com CHAPTER 3 8354/8404 2. CLUTCH 2.1 CHARACTERISTICS 615W310A (1) Clutch Disc Assembly (5) Clutch Release Fork (2) Clutch Cover Assembly (6) Propulsion Shaft Case (3) Release Bearing (7) Main Clutch Lever (4) Clutch Release Hub • Independent PTO method clutch are adapted enable to control the power of Running and the PTO system independently. • Running Clutch: Is a dry single plate clutch. Depress clutch pedal to disconnect power of running system.
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www.mymowerparts.com CLUTCH 2.2 LINK STRUCTURE AND CONTROL • If working clutch pedal, clutch rod (2) is pulled in the direction of arrow and release hub (5) moves to the direction of arrow through release fork (4). • Release bearing (6) of release hub pushes diaphragm spring (8) of clutch cover assembly (7), releases clutch disc (10) between clutch pressure plate (9) and flywheel (11), and then disconnects power from engine.
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www.mymowerparts.com CHAPTER 3 8354/8404 2.
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www.mymowerparts.com CLUTCH 2.4 SPECIFICATION Item Clutch pedal Reference Play Allowable Limit 30 ~ 40 mm - 1.18 ~ 1.57 in. Stopper bolt setting length Height 27 ~ 29 mm - 1.06 ~ 1.14 in. Clearance between safety switch and clutch pedal Gap Depth from disc to the top of rivet Depth 3 ~ 4 mm - 0.12 ~ 0.16 in. 0.3 mm - 0.012 in. Displacement Play of clutch disc O.D. 2.0 mm - 0.079 in. Flatness Pressure plate 0.2 mm - 0.008 in. Difference Diaphragm spring 0.5 mm - 0.020 in. 2.
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www.mymowerparts.com CHAPTER 3 8354/8404 2.6 DISASSEMBLY, MAINTENANCE A. CLUTCH PEDAL CHECK AND ADJUSTMENT a . First Stage (Clutch Pedal Play Adjustment) 1. Press clutch pedal (1) by hand and measure play (A) at the end of pedal. 2. If measurement exceeds the specified, loosen lock nut (3) of clutch rod (2), re-adjust the length of clutch rod, set pedal play and then tighten with lock nut. Sect Specified Play of clutch pedal (A) 30 ~ 40 mm 1.18 ~ 0.57 in.
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www.mymowerparts.com CLUTCH B. DISASSEMBLY, ASSEMBLY a . First Stage (Disconnection of Clutch Housing and Flywheel Housing) 1. Support clutch housing (1) and engine with hydraulic jack. 2. Disengage clutch housing (1), flywheel housing (2), tightening bolt (3) nut (4). 3. Disconnect clutch housing and engine. (When reassembling) • Apply spline with grease. • Apply the contacted surface between clutch housing and flywheel housing with sealing agent. Three bond 1208D or equivalent Sealing agent Sect.
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www.mymowerparts.com CHAPTER 3 8354/8404 C. MAINTENANCE a . Check of Play Between Clutch Disc Spline Boss and Gear Shaft 1. Attach gear shaft with clutch disc. 2. With the gear shaft locked, rotate the disc slightly and measure the play at O.D. end of disc. 3. If the measured value exceeds the allowable limit, replace the disc. Sect. Allowable Limit Play at O.D. end of disc (O.D.: Outside Diameter) 2.0 mm 0.079 in. 615W326A b. Check of Thrust Ball Bearing 1.
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www.mymowerparts.com CLUTCH d. Check of Flywheel and Clutch Pressure Plate 1. Check to see if the flywheel and clutch pressure plate are faulty or scored. 2. If a dent or score is found then replace it. 3. Put a straight rule on clutch pressure plate and check the flatness using a gab gauge, if it exceeds the allowable limit, replace it. Sct. Allowable Limit Fatness of clutch pressure plate 0.2 mm 0.008 in.
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www.mymowerparts.com TRANSMISSION 1. STRUCTURE Sect.
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www.mymowerparts.com CHAPTER 4 8354/8404 2. POWER TRANSMISSION 2.1 MAIN TRANSMISSION • Consists of full synchro mesh and employs key type as synchro. A.
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www.mymowerparts.com TRANSMISSION B. Synchro Operation 1st Stage • By shifting the main transmission shift lever, shifter (3) and key (2) are moved and the end of the key contacts with cone of gear (6) with synchronizer ring (5) pushed. • By friction power occurred in the cone of synchronizer key (2), and synchro hub (1) rotates in a body.
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www.mymowerparts.com CHAPTER 4 8354/8404 Final Stage • When the rotation speed of shift (3) are equal with that of gear (6), the rotation force of synchronizer ring (4), will not affect on shift any longer. The Shift is rotated with the synchronizer ring and gear (6), engaged for perfect transmission.
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www.mymowerparts.com TRANSMISSION 2.2 SHUTTLE • Employs double synchro mesh type with 8th stage in forward or reverse and improves the transmission shift power and durability as the contacted amount of cone increased twice.
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www.mymowerparts.com CHAPTER 4 8354/8404 2.3 HI-LO SHIFT • With High/Low stage, employs selective engagement method and when setting the Hi-Lo shift lever to the transmission position, the power will be transmitted.
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www.mymowerparts.com TRANSMISSION 2.4 MID PTO • Consists of an independent PTO, which uses a gear engagement shift method and performs gear transmission when PTO clutch is set to OFF. Power Transmission Flow • 12 gear shaft (1) → 20 spur gear (2) → 41 spur gear (3) → 14 gear (4) → Mid PTO shaft (5) 615W409A (1) 12 Gear Shaft (4) 14 Gear (2) 20 Spur Gear (5) Mid PTO Shaft (3) 41 Spur Gear 2.5 REAR PTO • The independent PTO method in the 1st stage is the fixed type, and employs a hydraulic clutch.
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www.mymowerparts.com CHAPTER 4 8354/8404 2.6 CREEPER SPEED (IF APPLICABLE ) • The High/Low stage, employs a gear engagement method and when setting the Hi-Lo shift lever and creep speed lever to the transmission position, the power will then be transmitted. A.
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www.mymowerparts.com TRANSMISSION 3. TRANSMISSION SHIFT LINK STRUCTURE 3.1 MAIN SHIFT • The transmission shift lever (1) is located in left of the driver’s seat and is connected to transmission arm (3), transmission fork (4), and (5). • One transmission shift lever is enabled from the 1st to the 4th stage and is easy to operate. • If the transmission shift lever moved to left, the transmission arm will be engaged with transmission fork (4) in 1st and 2nd stage.
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www.mymowerparts.com CHAPTER 4 8354/8404 3.3 HI-LO SHIFT • Aux. transmission shift lever (1) is located towards the left of the driver’s seat and is connected to HiLo shift rod (2), Hi-Lo shift lever 1 (3), Transmission arm (4), and the Transmission fork (5). • If pushing Hi-Lo shift lever forward, [Low Speed] transmission shift will be done and if pulling backward, [High Speed] transmission shift done. 615W416A (1) Aux. Transmission Shift Lever (2) Aux. Transmission Rod (3) Aux.
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www.mymowerparts.com TRANSMISSION 3.6 MID PTO SHIFT • Mid PTO lever (1) is located to the right of the driver’s seat and connected to the mid PTO lever assembly (2), rod (3), mid PTO lever 1 (4), transmission arm (5), and the transmission fork (6). • Set the PTO switch at Neutral and convert switch into Manual or Auto after a completion of transmission shift. • If pushing mid PTO lever forward, it will be set to [Disengagement] and if pulling backward, set to [Engagement].
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www.mymowerparts.com CHAPTER 4 8354/8404 4. PTO CLUTCH 4.1 CHARACTERISTICS • PTO clutch body is a wet multiplate hydraulic clutch and the clutch valve is set to [ON] or [OFF] to supply the PTO, using PTO switch. • When PTO clutch is set to [ON], it can be selected automatically or manually. If PTO switch is selected to [AUTO] and hydraulic elevating arm located to lncrease, PTO power will be disconnected automatically.
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www.mymowerparts.com TRANSMISSION 4.3 OIL FLOW A. With PTO Clutch ON a. If PTO conversion switch is set to [ON], the PTO clutch valve will be operated to flow oil from the hydraulic pump to PTO clutch “A” port. b. This oil flows to the piston, where it pushes the piston in the direction of arrow with spring compression. c. Tighten clutch plate and clutch disc with pressure plate to drive PTO shaft by friction force. d.
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www.mymowerparts.com CHAPTER 4 8354/8404 5. DIFFERENTIAL GEAR 5.1 STRUCTURE • Differential gear is a 4 pin type, distributes and provides suitable rpm’s automatically to the left and right wheel for tractor’s turning and efficient running on off road or curve. • It is equipped with a pin type differential locking device to stop differential operation when slipping, and stopping only one wheel according to road or pavement conditions.
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www.mymowerparts.com TRANSMISSION 5.2 OPERATION A. Traveling Straight Ahead • Rotation of spiral bevel pinion (1) will be transmitted to spiral bevel gear (2) and if road resistance is transmitted to both wheels equally, the differential pinion (4) and differential side gear (5), (6) will be rotated with differential case (3) in a body and differential gear shaft (7). (8) Will run at the same speed, transmitting equal rotation to both wheels.
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www.mymowerparts.com CHAPTER 4 8354/8404 C. Differential Lock • When the resistance of the right and left tires varies from the ground or work conditions, it could cause the wheels to slip and one wheel will be rotating faster than the other. Therefore, towing power will be decreased. To compensate for this, the differential locking device restricts differential function and provides equal rpm’s to both wheels.
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www.mymowerparts.com TRANSMISSION 6. TROUBLESHOOTING Trouble Probable Cause Transmission noise excessive • Lack in transmission oil or unsuitable oil used.
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www.mymowerparts.com CHAPTER 4 8354/8404 7. MAINTENANCE SPECIFICATION Item Reference Value Allowable Limit Transmission shift and shift groove Clearance 0.10 ~ 0.3 mm 0.004 ~ 0.012 in. 0.8 mm 0.031 in. Between synchro and spline Clearance 1.35 ~ 1.65 mm 0.053 ~ 0.065 in. 0.5 mm 0.02 in. Contacted rate 80 % 80 % Clutch disc Thickness 2.10 ~ 2.30 mm 0.089 ~ 0.091 in. 2.05 mm 0.081 in. Clutch plate Thickness 1.45 ~ 1.55 mm 0.057 ~ 0.061 in. 2.05 mm 0.081 in.
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www.mymowerparts.com TRANSMISSION 8. TIGHTENING TORQUE The following nut and bolt tightening torque was specified specially. Spec N·m Kgf·m lbf·ft M18 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4 Hydraulic block support tightening bolt M8 23.6 ~ 27.4 2.4 ~ 2.8 17.4 ~ 20.2 Hydraulic block support tightening bolt M10 48.1 ~ 55.8 4.9 ~ 5.7 35.5 ~ 41.2 Clutch housing and flywheel housing tightening bolt M12 77.5 ~ 90.2 7.9 ~ 9.0 57.2 ~ 66.
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www.mymowerparts.com CHAPTER 4 8354/8404 9.
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www.mymowerparts.com TRANSMISSION 9.1 TRANSMISSION OIL DRAINING 1. Loosen oil drain plug in the lower of clutch housing and transmission case. 2. Drain transmission oil. 3. Reconnect oil drain plug. (When reassembling) • Disconnect plug from filler neck and then fill oil to the scale of oil gauge. • After running the engine properly, recheck the scale of oil gauge and add fluid if necessary. Mission oil specified amount 44 (11.6 US.gal) 615W436A (1) Oil Drain Plug 9.
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www.mymowerparts.com CHAPTER 4 8354/8404 B. Second Stage (Hydraulic Pipe Disconnection) 615W439A (1) Brake Rod (7) Hydraulic Pipe 2 (12) Hydraulic Block (2) Intake Pipe 3 (8) Bolt (13) Hydraulic Block Support (3) Intake Pipe 2 (9) Joint Bolt (14) Washer Holding Bolt (4) Rubber Pipe (10) PTO Hydraulic Pipe (15) Washer Holding Bolt (5) Clamp (11) Bolt (16) Intake Pipe 1 (6) Hydraulic Pipe 1 1. Disconnect brake rod (1) from the left and right of tractor body. 2.
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www.mymowerparts.com TRANSMISSION C. Third Stage (Disconnection of Clutch Housing and Flywheel Housing) 1. Support the lower of clutch housing (1) and engine with a hydraulic jack. 2. Loosen tightening bolt (3) and nut (4) of clutch housing and flywheel housing (2). 3. Disconnect the clutch housing and engine. (When reassembling) • Apply grease on the spline part. • Apply a sealing agent on the contacted surface of clutch housing and flywheel housing. Sect. Spec.
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www.mymowerparts.com CHAPTER 4 8354/8404 D. Fourth Stage (Transmission Rod Disconnection) 1. Pull out spring pin (2) of transmission shift rod (1) and disconnect the main transmission shift rod 2 (3). 2. Disengage the shuttle transmission arm (4) locking bolt (5) and raise the transmission arm. (When reassembling) • When using spring pin type in transmission rod, the forked area should be toward the direction of shaft.
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www.mymowerparts.com TRANSMISSION E. Fifth Stage (Disconnection of Intermediate Case and Clutch Housing) 1. Disengage the shuttle transmission arm (1) locking bolt (2) and pull up transmission arm. 2. Disengage tightening bolt (5) and nut (6) of clutch housing (3) and intermediate case (4). 3. Disconnect clutch housing (3) from intermediate case (4). (When reassembling) • Remove foreign matters or oil from the contacted surface of the clutch housing (3) and intermediate case (4) and apply a sealing agent.
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www.mymowerparts.com CHAPTER 4 8354/8404 10. CLUTCH HOUSING DISASSEMBLY 10.1 FIRST STAGE (DISCONNECTION OF MAIN TRANSMISSION COVER) 1. Disengage main transmission cover (1) attaching bolt (2) and disconnect transmission cover. (When reassembling) • Engage transmission rod (3) with transmission arm (4) locking bolt (5) and perform locking both ends of jawed washer firmly to prevent loosening.
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www.mymowerparts.com TRANSMISSION 10.2 SECOND STAGE (DISCONNECTION OF PROPULSION SHAFT CASE) 1. Loosen clutch release fork (1) locking bolt (2) and pull out main clutch lever (3). 2. Disconnect clutch release hub (4) and release bearing (7). 3. Loosen propulsion shaft case (5) attaching bolt (6) and using M6 service bolt (two), disconnect propulsion case. (When reassembling) • Apply the slip of propulsion case and release hub with grease.
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www.mymowerparts.com CHAPTER 4 8354/8404 10.3 THIRD STAGE (DISASSEMBLY OF 25 GEAR SHAFT AND PROPULSION SHAFT 1) 1. Pull out 25 gear shaft (2) from propulsion shaft cover (1). 2. Loosen snap ring (3) for shaft and pull out 26 gear (4). 3. Pull out oil seal (5) from clutch housing and loosen snap ring (6) for hole. 4. Pull out propulsion shaft 1 (7) with bearing.
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www.mymowerparts.com TRANSMISSION 10.5 FIFTH STAGE (DISCONNECTION OF TRANSMISSION FORK) (When reassembling) 1. Loosen locking bolt (2), (3) from bearing cover (1) and pull out ball (4) and spring (5). 2. Pull out spring pin (8) from transmission fork (6), (7) and disconnect transmission fork and fork rod (9), (10). 3. Disconnect gear shaft assembly (11), (12), (13), (14) from bearing cover. • With transmission fork set to Neutral, insert ball and spring and tighten locking bolt.
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www.mymowerparts.com CHAPTER 4 8354/8404 10.6 SIXTH STAGE (DISASSEMBLY OF 22 GEAR SHAFT) 1. Disengage snap ring (2) for 22 gear shaft (1) and pull out 22 gear shaft from the clutch housing. 2. Loosen snap ring (3) for hole of clutch housing and pull out bearing (4). • When disassembling 25 gear shaft (1), tap lightly the end of shaft using plastic hammer not to be damage.
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www.mymowerparts.com TRANSMISSION 10.7 SEVENTH STAGE (DISASSEMBLY OF MAIN TRANSMISSION COUNTER SHAFT) 615W455A (1) Snap Ring (6) Needle Bearing (11) 29 Gear (2) Ball Bearing (7) 24 Gear (12) 33 Gear (3) Ball Bearing (8) 36 Gear (13) Synchronizer Ring (4) Thrust Collar (9) Snap Ring (14) Synchronizer Key (10) Synchro Hub Assembly (5) Needle Bearing 1. Loosen snap ring (1) for shaft. 2. Pull out bearing (2), (3) using bearing puller. 3.
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www.mymowerparts.com TRANSMISSION 10.8 MAINTENANCE A. Bearing Checking 1. With bearing inner wheel seized, pull in and out outer wheel left and right and check for wear and clearance. 2. Apply bearing ball with transmission oil and with bearing inner wheel seized and outer wheel rotated, check for abnormal noise and operation. 3. If damage and failure found, replace it. 615W457A B. Gear Checking 1. Ensure slip or tooth surface is worn and replace it if necessary. C.
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www.mymowerparts.com CHAPTER 4 8354/8404 D. Synchro Assembly Check 1. Check synchronizer key and spring for damage and replace it if necessary. 2. With synchronizer ring contacted with taper cone of the opposite gear, measure the clearance between synchro spline and opposite gear spline using clearance gauge. Sect. Clearance of between synchro and gear spline(A) Specified Allowable Limit 1.35 ~ 1.65 mm 0.5 mm 0.053 ~ 0.065 in. 0.02 in. 615W459A 3. Apply O.D.
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www.mymowerparts.com TRANSMISSION 11.
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www.mymowerparts.com CHAPTER 4 8354/8404 11.1 DISASSEMBLY, ASSEMBLY A. Disconnection of Intermediate Case Group 615W463A (1) Transmission Case (3) Bolt (2) Intermediate Case (4) Nut a. First Stage (Disconnection of Intermediate Case and Transmission Case) 1. Support the lower of transmission case (1) with a hydraulic jack. 2. Disengage tightening bolt (3) and nut (4) from intermediate case (2) and transmission case.
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www.mymowerparts.com TRANSMISSION B. Disassembly of Intermediate Case a. First Stage (Disconnection of Modulator Valve Assembly) 1. Disengage modulator valve assembly (1) attaching bolt (2) and disconnect valve assembly. (When reassembling) • Check valve assembly, connecting pipe (3), and Oring (4), (5) and apply the contacted surface with grease. • Take great care to prevent foreign matters from being entered inside of valve assembly and connecting pipe. 615W464A Sect. Spec.
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www.mymowerparts.com CHAPTER 4 8354/8404 c. Third Stage (Disassembly of Shuttle Fork) 1. Straighten cocking of lock washer (1) and loosen lock bolt (2). 2. Pull out fork rod (4) from bearing cover (3) and disassemble transmission fork (5). • When disassembling fork rod from bearing cover, take care of Spring (6) and Ball (7) not to be bounded. CAUTION 615W467A (When reassembling) • Insert spring and Ball into bearing cover and assemble with groove (A) of fork rod upward.
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www.mymowerparts.com TRANSMISSION e . Fifth Stage (Disassembly of Shuttle Shaft) 1. Loosen snap ring (1) and disassemble spacer (2). 2. Remove bearing (3), (4) using bearing puller. 3. Disassemble thrust collar (5), needle bearing (6), 19 gear (7) and 16 gear (8). 4. Loosen snap ring (9) and disassemble spline hub (10). (When reassembling) • Thrust collar oil groove should be toward gear. Assembly direction of snap ring (1) should be with rounding toward spacer.
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www.mymowerparts.com CHAPTER 4 8354/8404 b. Second Stage (Disconnection of PTO Clutch) 1. Disengage snap ring (1) for hole and pull out pressure plate (2), clutch plate (3), clutch disc (4), spline hub (5) and bearing (6). 2. Disengage snap ring (7) for shaft and pull out spacer (8), spring (9), piston (10), return plate (11), and brake plate (12).
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www.mymowerparts.com TRANSMISSION 11.2 MAINTENANCE A. Bearing Check 1. With bearing inner wheel seized, pull in and out outer wheel left and right and check for wear and clearance. 2. Apply bearing ball with transmission oil and check for abnormal noise or operation, while taking bearing inner wheel and rotating outer wheel by hand. 3. If damage of failure found, replace it. 615W457A B. Gear Check 1. Ensure slip or tooth surface is worn and replace it if vecessary. C.
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www.mymowerparts.com CHAPTER 4 8354/8404 2. With synchronizer ring contacted with taper cone of the opposite gear, measure the clearance between synchro spline and opposite gear spline using clearance gage. Sect. Specified Limit Clearance between synchro and gear spline (A) 1.35 ~ 1.65 mm 0.5 mm 0.053 ~ 0.065 in. 0.02 in. 3. Apply O.D. of taper cone in gear with thin red lead, tighten synchronizer ring firmly, and check for contacted state. 615W460A Sect.
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www.mymowerparts.com TRANSMISSION F. Checking piston, pressure plate and return plate for flatness 1. Using feeler gage, measure the flatness of piston, pressure plate, and return plate. 2. If exceeds allowable tolerance, replace it. Sect. Specified Allowable Limit Flatness of piston 0.05 mm 1.5 mm 0.002 in. 0.006 in. Flatness of pressure plate 0.1 mm 0.3 mm 0.004 in. 0.012 in. 0.1 mm 0.25 mm 0.004 in. 0.010 in. Flatness of return plate 615W475A G.
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www.mymowerparts.com CHAPTER 4 8354/8404 12. TRANSMISSION CASE 615W478A (1) Aux. Shift Shaft (5) Idle Shaft (2) Spiral Bevel Pinion (6) Mid PTO Shaft (3) Front Drive Shaft (7) PTO Drive Shaft (4) 13 Gear Shaft (CR option) (8) PTO Shaft (9) PTO Drive Shaft 12.1 DISASSEMBLY, ASSEMBLY A. Disconnection of Transmission Group a. First Stage (Disconnection of Hydraulic Pipe) 1. Loosen bolt (1) and disconnect intake pipe2 (2). 2.
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www.mymowerparts.com TRANSMISSION b. Second Stage (Disconnection of Hydraulic Cylinder Assembly) 1. Disengage hydraulic cylinder assembly (1) attaching bolt (3) and nut (2) and disconnect hydraulic cylinder assembly (1). (When reassembling) • Replace packing. Sect. Tightening bolt Spec. Tightening Torque M10 48.1 ~ 55.8 N·m 615W481A 4.9 ~ 5.7 kgf·m 35.5 ~ 41.2 lbf·ft (1) Hydraulic Cylinder Assembly (2) Nut (3) Bolt (4) Packing c. Third Stage (Disconnection of Transmission Lever) 1.
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www.mymowerparts.com CHAPTER 4 8354/8404 d. Fourth Stage (Disconnection of Rear Axle Case) 1. Loosen bolt (1) and nut (2) and disconnect rear axle case (3) in assembly. (When reassembling) • Remove foreign matters or oil from contacted surface between brake case and rear axle case and apply it with sealing agent. Sealing agent Three bond 1208D or equivalent Sect. Spec. Tightening Torque Tightening bolt, nut M10 48.1 ~ 55.9 N·m 4.9 ~ 5.7 kgf·m 35.4 ~ 41.
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www.mymowerparts.com TRANSMISSION B. Disconnection of Transmission Case a. First Stage (Disconnection of PTO Shaft) 1. Loosen bearing case (1) attaching bolt (2) and disconnect PTO shaft (3) and bearing case in assembly. 2. Loosen snap ring (4) and pull out PTO shaft with bearing (5). (When reassembling) • Make sure assembly direction of oil seal (6), (7) are correct and apply the contacted with grease. • When assembling sleeve (8) into PTO shaft, apply the inside with bonding agent and then push fit.
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www.mymowerparts.com CHAPTER 4 8354/8404 c. Third Stage (Disassembly of Front wheel drive gear assembly/MID PTO Case assembly) 1. Loosen MID PTO case (1) attaching bolt (2) and disconnect case and gear in assembly. 2. Disconnect front wheel drive shaft assembly (3) from transmission case. (When reassembling) • Wipe out oil or foreign matters from contacted surface between MID PTO case (1) and transmission case and apply with sealing agent.
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www.mymowerparts.com TRANSMISSION e. Fifth Stage (Disassembly of Gear Shaft Assembly) 615W495A (1) Nut (7) Pinion Shaft Assembly (2) Bearing Cover (8) Hi-Lo Shift Shaft Assembly (3) Bolt (9) 13 Gear Shaft (Optional) (4) Bearing Case (10) Ball Bearing (5) Shim (11) 27 (30) Gear (6) Taper Roller Bearing Assembly (12) PTO Drive Shaft Assembly 1. Straighten cocking of lock nut (1) and loosen nut (1). 2.
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www.mymowerparts.com CHAPTER 4 8354/8404 f. Sixth Stage (Disassembly of Spiral bevel pinion shaft) 1. Pull out taper roller bearing (1) using bearing puller and disassemble spacer (2), 25 spur gear (3), and 42-17 gear (4). (When reassembling) • Take care of assembly direction of 25 spur gear. Side oil groove should be toward needle bearing. 615W496A (1) Taper Roller Bearing (3) 25 Spur Gear (2) Spacer (4) 42-17 Gear g. Seventh Stage (Disassembly of Aux. Transmission Shaft) 1.
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www.mymowerparts.com TRANSMISSION i. Ninth Stage (Disassembly of Creep Speed Shaft) 1. Loosen snap ring (1) and disassemble thrust collar (2), 26-20 gear (3), needle bearing (4), and spacer (5). (When reassembling) • Oil groove of thrust collar should be toward gear. • When assembling, rounding part of Snap ring should be toward gear. 615W4A0A (1) Snap Ring (4) Needle Bearing (2) Thrust Collar (5) Spacer (3) 26-20 Gear j. (Disassembly of Front Wheel Drive/Mid PTO) 1.
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www.mymowerparts.com CHAPTER 4 8354/8404 k. Tenth Stage (Disconnection of Differential Gear Assembly) 615W4A4A (1) Spring Pin (7) Oil Seal (2) Snap Pin (8) Bearing Case (Left) (3) Flat Washer (9) Bearing Case (Right) (10) Bolt (4) Pin (5) Differential Locking Fork Shaft (11) Shim (6) Differential Locking Fork (12) Differential Gear Assembly 1. Pull out spring pin (1). • 2. Pull out snap pin (2) and disassemble flat washer (3) and pin (4).
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www.mymowerparts.com TRANSMISSION l. Eleventh Stage (Disassembly of Differential gear) 615W4A5A (1) Taper Roller Bearing (7) Differential Pinion Shaft 1 (2) Taper Roller Bearing (8) Differential Pinion Shaft 2 (3) Differential Locking Shift (9) Differential Side Gear (4) Cap (10) Differential Washer (5) Spiral Bevel Gear (11) Differential Pinion (6) Bolt (12) Differential Pinion Washer 1. Disassemble taper roller bearing (1), (2) using special tool.
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www.mymowerparts.com CHAPTER 4 8354/8404 12.2 MAINTENANCE A. Bearing Check 1. With bearing inner wheel seized, pull in and out outer wheel left and right and check for wear and looseness. 2. Apply bearing ball with transmission oil and with bearing inner wheel seized and outer wheel rotated, check for abnormal noise and operation. 3. If damage and failure found, replace it. 615W4A6A B. Gear Check 1. Ensure slip or tooth surface is worn and replace it if necessary. C.
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www.mymowerparts.com TRANSMISSION D. Bevel Pinion Shaft and Spiral Bevel Gear Setting 1. When assembling differential gear assembly into transmission case, adjust pre-load of taper roller bearing (1), (2). a. Adjustment Method • Insert datum shim (0.75 mm) in left and right bearing case (3), (4) and check bearing pre-load with rotation torque of spiral bevel gear (5). If rotation torque exceeds the specified, increase the amount of shim and if less than the specified, decrease it. b.
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www.mymowerparts.com CHAPTER 4 8354/8404 • More than 35% tooth contacted. The center is located between one third and one half from small. 615W4B0A • Decrease shim (7) of bearing case (6) and move bevel pinion shaft (2) in the direction of arrow. Move some shim (4) of differential locking shift (5) to spiral bevel gear (1) and move spiral bevel gear in the direction of arrow. * Repeat until good tooth contact and backlash obtained.
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www.mymowerparts.com TRANSMISSION E. Check Differential Gear for Worn a. Clearance Check of Differential Case, Cap, and Differential Side Gear Sect. Specified Limit Clearance of 0.35mm 0.050 ~ 0.15 mm differential case, 0. 0.00197 ~ 0.00594 in. differential case 0138in. cap, and differential side gear 40.500 ~ 40.561 mm I.D. of differential case and differen1.59449 ~ 1.59693 in. tial case cap 40.411 ~ 40.450 mm O.D. of differential side gear 1.59098 ~ 1.59252 in. 615W4B3A 1. Measure I.D.
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www.mymowerparts.com REAR AXLE 1.
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www.mymowerparts.com CHAPTER 5 8354/8404 2. TIGHTENING TORQUE Item Spec. N·m Kgf·m lbs·ft Rear wheel tightening bolt M16 260.8 ~ 303.8 26.6 ~ 31.0 192 ~ 224 Brake case and rear wheel case M10 48.0 ~ 55.9 4.9 ~ 5.7 35.4 ~ 41.2 M39, M45 48.0 ~ 55.9 4.9 ~ 5.7 35.4 ~ 41.2 Tightening bolt, nut Lock nut M10 196 ~ 245 20 ~ 25 145 ~ 181 Rear axle case cover tightening bolt M10 48.0 ~ 55.9 4.9 ~ 5.7 35.4 ~ 41.2 Planetary gear support attaching bolt M10 48.0 ~ 55.9 4.9 ~ 5.7 35.
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www.mymowerparts.com REAR AXLE 3. SERVICE SPECIFICATION Application Specified Limit Internal gear and planetary gear support Backlash 0.1 ~ 0.2 mm 0.0039 ~ 0.0079 in. 0.5 mm 0.197 in. Planetary gear and planetary gear shaft Clearance 0.009 ~ 0.050 mm 0.00035 ~ 0.00197 in. 0.3 mm 0.086 in. Planetary gear I.D. - Planetary gear O.D. 35.009 ~ 35.025 mm 1.37831 ~ 1.37894 in. 27.987 ~ 28.000 mm 1.10185 ~ 1.10236 in. Needle bearing Pin diameter 3.494 ~ 3.500 mm 0.1376 ~ 0.1378 in.
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www.mymowerparts.com CHAPTER 5 8354/8404 4. DISASSEMBLY, ASSEMBLY 4.1 DISCONNECTION OF REAR AXLE GROUP A. First Stage (Disconnection of Rear Wheel) 1. Support the transmission case with a hydraulic jack to raise tire the tires from the ground. 2. Loosen the wheel lug nuts and disconnect the tires from axle. (When reassembling) Sect. Rear wheel tightening nut Spec. Tightening torque M16 260.8 ~ 303.8 N·m 26.6 ~ 31.0 kgf·m 192.3 ~ 224.
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www.mymowerparts.com REAR AXLE C. Third Stage (Disassembly of Planetary Gear) 1. Insert spring pin (1) into planetary gear shaft (2). 2. When pulling out the planetary gear shaft (2), remove the planetary gear (3), needle bearing (4) and thrust collar (5). 3. Pull out the spring pin (1) from the planetary gear shaft (2).
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www.mymowerparts.com CHAPTER 5 8354/8404 4.2 DISASSEMBLY OF REAR AXLE 1. Using bearing puller, pull out ball (roller) bearing (2) from the rear axle (1). 2. Straighten cocking of 55 (60) gear (3) locking nut (4). 3. Disassemble 55 (60) gear, spacer barrel (5), and spacer plate (6). 4. Loosen attaching bolt (8) of rear axle case cover (7) and pull out axle and cover from axle case in a body. 5. Using bearing puller, pull out rear axle case cover (7) and bearing (9) from axle. Sect. Lock bolt Spec.
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www.mymowerparts.com REAR AXLE 5. MAINTENANCE 5.1 BEARING CHECK 1. With bearing inner wheel seized, pull in and out outside of bearing left and right and check for wear and clearance. 2. Apply the bearing ball with transmission oil and rotate the inside bearing while holding the outside of bearing still, checking for abnormal noise and operation. 3. If damage and failure found, replace it. 5.2 GEAR CHECK 1. Ensure slip or tooth surface is worn or scratched and replace it if necessary. 615W517A 5.
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www.mymowerparts.com BRAKE 1. STRUCTURE 615W601A (1) Brake Case (2) Brake Cam Lever (3) Brake Rod (4) Brake Lever (5) Turn Buckle (6) Brake Pedal (7) Parking Brake Lever • For the left and right running brake, an independent mechanical wet disc brake is used and operated through brake pedal by mechanical linkage. • It enables the parking brake when parking. If brake pedal is locked with the parking brake lever pulled up, it keeps the brakes locked.
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www.mymowerparts.com CHAPTER 6 8354/8404 2. OPERATION 615W602A (1) Cam Plate (3) Brake Plate (5) Ball (7) Brake Cam (2) Brake Disc (4) Brake Case (6) Gear Shaft (8) Brake Cam Lever Operational Principle If depressing brake pedal, brake cam lever (8) will be moved in the arrow direction by linkage as shown in the above figure. The cam plate (1) is rotated in the direction of the arrow and raised above ball (5) and brake disc (2) when it is applied with pressure.
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www.mymowerparts.com BRAKE 3.
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www.mymowerparts.com CHAPTER 6 8354/8404 4. MAINTENANCE SPECIFICATION Item Brake pedal Clearance Difference between left and right when not depressing brake pedal Deviation Brake pedal and stop switch Clearance Between brake lever bush and brake shaft Clearance Brake lever bush I.D Brake shaft O.D Cam plate Flatness Cam plate and ball Height Brake disc Thickness Plate Thickness Reference Value Allowable Limit 25 ~ 35 mm (0.98 ~ 1.38 in.) 5 mm (0.197 in.) - 0 ~ 1 mm (1 ~ 0.039 in.
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www.mymowerparts.com BRAKE 6. BRAKE PEDAL 6.1 DISASSEMBLY, MAINTENANCE [CHECK AND ADJUSTMENT] A. First Stage (Clearance Adjustment of Brake Pedal) 1. Disengage the brake pedal connection hook (1) and measure the clearance of left and right pedals. 2. If the clearance of left and right pedals exceeds the specified limit, loosen lock nut (2) and adjust clearance using a turn buckle (3). 3. If setting clearance of pedal, tighten firmly with lock nut.
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www.mymowerparts.com CHAPTER 6 8354/8404 6.2 MAINTENANCE Check the clearance between brake lever bush and brake shaft 1. Measure I.D. of brake lever bush. 2. Measure O.D. of brake shaft. 3. Calculate the clearance with the measured value. If exceeding the allowable limit, replace bush. Sect. Specified Allowable Limit Clearance 0.085 ~ 0.327 mm between brake (0.00335 ~ 0.01287 in.) lever bush and brake shaft - I.D. of brake lever bush 20.060 ~ 20.281 mm (0.78976 ~ 0.79846 in.) - O.D.
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www.mymowerparts.com BRAKE 7. BRAKE CASE 7.1 DISASSEMBLY AND ASSEMBLY A. Disconnection of Brake Case Group a. First Stage (Disconnection of Brake Case) 615W608A (1) Bolt (6) Packing (2) Nut (7) Packing (3) Brake Case (8) Ball Seat (4) Lever Shaft (9) Ball (5) Stud 1. Disengage bolt (1) and nut (2) and disconnect brake case (3) in assembly. • Replace packing (6) and (7). • Apply stud (5) with bonding agent.
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www.mymowerparts.com CHAPTER 6 8354/8404 615W609A Bolt, Nut Assembly Position and Tightening Torque Applicable Model: 8354 Assembly position (mark) Drawing No. Part name Qty. (Bolt) ♣ 01754 - 51235 Stud. 2 37150 - 2735-2 Stud. 10 4.0 ~ 5.0 kgf·m 01754 - 51285 Stud. 2 28.9 ~ 36.2 lbf·ft T2610 - 60561 Lever shaft Left: 1 T2615 - 24432 Lever shaft (MID) Right: 1 7.9 ~ 9.2kg f·m 01173 - 51260 Bolt 8 57.1 ~ 66.5 lbf·ft 01176 - 51260 Bolt 4 Spec. Tightening torque 39.2 ~ 49.
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www.mymowerparts.com BRAKE B. Brake Case Disassembly a. First Stage (Disconnection of Brake Case) 1. Loosen cam lever (1) attaching nut (2) and disconnect brake cam (3), O-ring (4) and brake cam lever. 2. Disconnect Cam plate (5), brake disc (6) and plate (7). 615W612A (1) Brake Cam Lever (5) Cam Plate (2) Nut (6) Brake Disc (3) Brake Cam (7) Plate (4) O-Ring • Align with oil passage “A” of brake disc. It should be passed more than 70 %. • Apply O-ring with grease, taking care not to damage it.
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www.mymowerparts.com CHAPTER 6 8354/8404 7.2 OPERATION CHECK OF BRAKE CAM LEVER A. Operation Check of Brake Cam Lever 1. Move brake cam lever front to rear and check for proper operation. 2. If not operated smoothly, check the parts for dimension. 615W614A a. Second Stage (Disassembly of Gear Shaft) 1. Pull out snap ring (3) from brake case (1). 2. Pull out gear shaft (2) with bearing.
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www.mymowerparts.com BRAKE B. Wear Check of Cam Plate 1. Check brake disc contacted surface of cam plate for wear, and measure the flatness using a clearance gauge. 2. If it exceeding the allowable limit, replace it. Sect. Flatness of cam plate Specified Allowable limit 0.3 mm 0.3 mm 0.012 in. 0.012 in. 615W617A (1) Clearance Gauge C. Height Check of Cam Plate and Ball 1. Seat ball into cam plate and measure the height of the ball in the bottom of cam plate. 2.
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www.mymowerparts.com FRONT AXLE 1. STRUCTURE 615W701B (1) Front Bracket (7) Differential Gear Shaft (12) Bevel Gear (2) Rear Bracket (8) Bevel Gear (13) Front Axle (3) Front Axle Support (9) Bevel Gear (14) Bevel Gear Case (4) Spiral Bevel Pinion (10) Bevel Gear Shaft (15) Front Axle Case (5) Spiral Bevel Gear (11) Bevel Gear (16) Front Axle Cover (6) Differential Gear Assembly • The front axle is applied with a bevel gear type to improve work ability and extend the applicable range.
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www.mymowerparts.com CHAPTER 7 8354/8404 2. WHEEL ALIGNMENT To improve control and safety running, front wheel is applied with adequate inclination in the direction of left, right and forward. Camber Angle Camber angle (A) = 2° Caster Angle Caster angle (C) = 1.5° Camber not only decreases bending and warping against vertical load and running resistance but also keeps safety. 615W702A Caster angle improves steering ability. King Pin Angle King pin angle (B) = 12.
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www.mymowerparts.com FRONT AXLE 3. TROUBLESHOOTING Trouble Probable Cause Left and right inclination of front wheel. • Improper pressure of tire • Inadequate tow-in adjustment • Excessive rolling of front wheel Replace Adjust Tighten Air bleeding • Propulsion shaft broken • Front axle front wheel drive gear of transmission broken Replace Replace • Front differential gear broken Replace • Improper gear backlash Front axle noise.
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www.mymowerparts.com CHAPTER 7 8354/8404 4. MAINTENANCE SPECIFICATION Item Reference Value Allowable Limit 2 ~ 8 mm 0.08 ~ 0.32 in. 1.8 kgf/cm² 25.6 psi 1.6 kgf/cm² 22.8 psi 49.0 ~ 117.6 N 5.0 ~ 12.0 kgf 11.0 ~ 26.5 lbs - 7.8 Left: 35° ± 1° Right: 33° ± 1° - - Tooth contacted between bevel pinion and differential pinion shaft 0.15 ~ 0.35 mm 0.059 ~ 0.01377 in. More than 35 %, center 1/3 ~ 1/2 from small end 0.15 ~ 0.35 mm 0.059 ~ 0.01377 in. More than 35 %, center 1/3 ~ 1/2 from small end 0.
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www.mymowerparts.com FRONT AXLE 5. TIGHTENING TORQUE Spec N·m Kgf·m lbf·ft Tie rod locking nut M20 368 ~ 431 37.5 ~ 44.0 272 ~ 318 Front wheel steering angle setting lock bolt, nut M14 123 ~ 147 12.6 ~ 15.0 91.2 ~ 108 46.6 ~ 50.9 4.8 ~ 5.2 34.4 ~ 37.6 Item Steering hose assembly connection tightening torque Front bracket and rear bracket attaching bolt M14 123 ~ 147 12.6 ~ 15.0 91.2 ~ 108 Front wheel attaching nut M16 166.6 ~ 186.2 17.0 ~ 19.0 123.0 ~ 137.
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www.mymowerparts.com CHAPTER 7 8354/8404 6. DISASSEMBLY, MAINTENANCE 6.1 CHECK AND ADJUSTMENT A. First Stage (Tow-In) 1. Set tire to the specified air pressure. 2. Align front wheel tire in straight driving, measure front width and rear width of front wheel and calculate its difference (tow-in). 3. If it exceeds the specification, loosen lock nut, adjust the length of tie rod, and then firmly set with lock nut. Sect. Tire air pressure Spec. Specified value 7 - 16 1.8 (2.2) kgf/cm² 25.6 (31.
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www.mymowerparts.com FRONT AXLE C. Third Stage (Adjustment of Front Axle Rocking Force) 1. Raise the front axle and make sure both tires are off the ground. 2. Using the front bracket adjusting bolt, check for rocking force and then tighten with nut. Sect. Specified value Rocking force (F) 49.0 ~ 117.6 N·m 5.0 ~ 12.0 kgf·m 36.2 ~ 86.
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www.mymowerparts.com CHAPTER 7 8354/8404 7. DISCONNECTION OF FRONT AXLE GROUP 7.1 DISASSEMBLY, ASSEMBLY A. First Stage (Front Axle Case Oil Draining) 1. Loosen oil draining plug (1) of front axle support and front axle case lower section, oil filling plug (3) and drain oil. 2. Drain oil and retighten plug. (When supplying with oil) • Loosen oil filling plug and fill up to the position of oil level plug. • Rotate front axle several times and then fill up to the specified level.
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www.mymowerparts.com FRONT AXLE C. Third Stage (Disconnection of Steering Cylinder Hydraulic Hose) 1. Loosen steering hydraulic hose (1) and (2). Hose Connection position Steering hose assembly R Right of steering cylinder Steering hose assembly L Left of steering cylinder Sect. Tightening torque Steering hose assembly 46.6 ~ 50.9 N·m Connection torque 4.8 ~ 5.2 kgf·m 34.4 ~ 37.
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www.mymowerparts.com CHAPTER 7 8354/8404 8. DISASSEMBLY OF FRONT AXLE 8.1 FIRST STAGE (DISCONNECTION OF FRONT AXLE CASE AND BEVEL GEAR CASE) 1. Disengage axle case support (1) attaching bolt (2). 2. Disconnect front axle case (3) from bevel gear case (4), taking care not to drop it. (When reassembling) • CAUTION Make sure floating seal (5) is not damaged and the O-ring has not deteriorated with grease, oil, or other foreign matters.
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www.mymowerparts.com FRONT AXLE 8.3 THIRD STAGE (DISASSEMBLY OF FRONT AXLE CASE) 1. Pull out snap ring (1) and disassemble plug (2). 2. Pull out snap ring (3) and disassemble bevel gear (5) and shim (6). (When reassembling) • Make sure the type and number of shim is correct. • Apply DX bush (7) contacted surface with grease, taking care of assembly direction. 615W717A (1) Snap Ring (5) Bevel Gear (2) Plug (6) Shim (3) Snap Ring (7) DX Bush (4) Ball Bearing A.
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www.mymowerparts.com CHAPTER 7 8354/8404 8.4 FOURTH STAGE (DISASSEMBLY OF FRONT AXLE SUPPORT) 615W719B (1) Bevel Gear Case (5) Oil Seal (9) Bevel Gear (13) Spacer Barrel (2) Bolt (6) Ball Bearing (10) Ball Bearing (14) Bevel Gear (3) Plug (7) Snap Ring (11) Snap Ring (15) Ball Bearing (4) Axle Case Support (8) Shim (12) Shim 1. Disengage the attaching bolt (2) of bevel gear case (1) and disconnect bevel gear case assembly from front axle support. 2. Loosen plug (3). 3.
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www.mymowerparts.com FRONT AXLE 8.5 FIFTH STAGE (DISASSEMBLY OF FRONT AXLE SUPPORT) 615W721A (1) Front Bracket (8) Bevel Pinion Shaft (15) O-Ring (2) Rear Bracket (9) Taper Rolling Bearing (16) O-Ring (3) Center Pin (10) Adjusting Collar (17) Spacer Plate (4) Bolt (11) Snap Ring (18) Thrust Collar (5) Front axle Support (12) Shim (19) Grease Nipple (6) Oil Seal (13) Front Differential Gear Assembly (20) DX Bush (7) Snap Ring (14) O-Ring (21) Dx Bush 1.
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www.mymowerparts.com CHAPTER 7 8354/8404 • When assembling DX bush (20), (21) into front and rear brackets, align hole of DX bush with assembly hole of grease nipple (19) (See the following figure). • Make sure the oil seal assembly direction of bevel Pinion shaft is correct (See the following figure). CAUTION Sect. Spec. Tightening torque The attaching bolt of center pin M12 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.2 ~ 66.5 lbf·ft 8.6 SIXTH STAGE (DISASSEMBLY OF BEVEL PINION SHAFT) 1.
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www.mymowerparts.com FRONT AXLE 8.7 SEVENTH STAGE (DISASSEMBLY OF DIFFERENTIAL GEAR) 1. Using bearing puller, pull out spiral bevel gear (2) and bearing (1) simultaneously. 2. Loosen bolt (3) and disconnect differential case cover (4). 3. Pull out parallel pin (11) and then disconnect differential pinion shaft (8). 4. Disconnect differential pinion (7), differential side gear (6), differential pinion washer (10), and shim (9) from case (5).
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www.mymowerparts.com CHAPTER 7 8354/8404 9. MAINTENANCE 9.1 CLEARANCE CHECK BETWEEN CENTER PIN, FRONT AXLE SUPPORT BOSS AND FRONT AND REAL BRACKETS 1. Check to see if DX bush of the front and rear brackets are worn. 2. If shaft contacted part is worn and bare metal surface, renew it. 615W727A 9.2 CHECK FOR BACKLASH AND TOOTH CONTACTED IN FRONT AXLE CASE A. Backlash Measurement 1. Set dial gage in bevel gear shaft spline. 2. Lock the front axle, move bevel gear shaft by hand and measure the backlash. 3.
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www.mymowerparts.com FRONT AXLE 9.3 CHECK FOR BEVEL GEAR BACKLASH AND TOOTH CONTACTED IN BEVEL GEAR CASE A. Backlash Measurement 1. Set the dial gage in bevel gear shaft spline. 2. Lock a gear into the differential gear shaft, move bevel gear shaft by hand and measure the backlash. 3. If exceeding the spec., adjust with a shim. B. Types of Adjusting Shim 0.4 mm (0.016 in.) 0.8 mm (0.031 in.) 1.0 mm (0.039 in.) 1.2 mm (0.047 in.) Sect. 615W729A Allowable limit Bevel gear backlash 0.15 ~ 0.35 mm 0.
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www.mymowerparts.com CHAPTER 7 8354/8404 9.5 CHECK FOR BACKLASH AND TOOTH CONTACTED BETWEEN BEVEL PINION SHAFT AND SPIRAL BEVEL GEAR A. Backlash Measurement 1. Set dial gage in bevel gear shaft spline. 2. Lock spiral bevel gear, move bevel gear shaft by hand and measure the backlash. 3. If exceeding the spec., adjust with shim and adjusting collar. B. Types of Adjusting Shim 0.8 mm (0.031 in.) 1.0 mm (0.039 in.) 615W740A 1.2 mm (0.047 in.) 2.0 mm (0.079 in.) 2.3 mm (0.091 in.) C.
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www.mymowerparts.com FRONT AXLE 9.6 CLEARANCE CHECK BETWEEN DIFFERENTIAL PINION SHAFT AND DIFFERENTIAL PINION 1. Measure O.D. of differential pinion shaft. 2. Measure I.D. of differential pinion shaft. 3. Check clearance as the measured value and if exceeding allowable limit, renew it. Sect. Specified Allowable limit Clearance between 0.016 ~ 0.052 mm 0.25 mm differential pinion (0.00063 ~ 000205 in.) (0.098 in.) and differential pinion shaft 16.000 ~ 16.018 mm Differential pinion I.D. (0.62992 ~ 0.
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www.mymowerparts.com CHAPTER 7 8354/8404 9.8 CHECK FOR BACKLASH AND TOOTH CONTACTED BETWEEN DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 1. Set a dial gauge on the differential pinion gear tooth surface in vertical. 2. Fix differential side gear, move pinion gear by hand and measure backlash. 3. If exceeding allowable limit, replace differential pinion washer and differential side gear shim. A. Types of Adjusting Shim 0.8mm (0.031 in.) 1.0mm (0.039 in.) 615W743A 1.2mm (0.047 in.) Sect.
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www.mymowerparts.com STEERING SYSTEM 1. CHARACTERISTICS 615W802A (1) Hydraulic Filter (5) Hydraulic Block (2) Hydraulic Pump (6) Aux. Control Valve (3) Modulating Valve (7) MLS(Control) Valve (4) Power Steering Unit (8) Power Lift Assembly • Steering system is applied with full hydraulic power steering and installed with two single rod cylinders.
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www.mymowerparts.com CHAPTER 8 8354/8404 2. HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM R L 615W803B (1) Oil Tank (4) Hydraulic Cylinder (2) Oil Filter (5) Hydraulic Block (3) Gear Pump (6) Steering Unit HYDRAULIC OIL FLOW • When the engine is started, the hydraulic pump will be driven to pass oil in transmission case through a modulator valve to the power steering unit.
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www.mymowerparts.com STEERING SYSTEM 3. GEAR PUMP 3.1 PUMP CHARACTERISTICS The power steering hydraulic pumps use the pump having superior volume efficiency and mechanical efficiency to extract power from engines right cam shaft gear. 3.2 MAJOR SPECIFICATION Type Volume (cc/rev) Tandem • 12 First 7.2 Second Gear ratio Rotation direction RPM range 1 : 0.9 C.C.W ~ 3515 Discharge flow rate in engine rated rotation (l/min, gal/min) Q1: 29.7 Q2: 17.8 Qt: 47.5 7.86 4.71 12.
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www.mymowerparts.com CHAPTER 8 8354/8404 3.4 OPERATION a. Hydraulic pump ate the steering hydraulic pump having different provides constant oil flow to operwheel, and hydraulic cylinder. The assembly consists of two pumps displacement. b. Two pumps operate equally and use outside gear design to move the amount of fluid determined at each rotation and positive displacement. c. Oil inflow and outflow continues while driving hydraulic pump from engine cam shaft, drive gear, and rotating pump gear (3).
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www.mymowerparts.com STEERING SYSTEM 4. POWER STEERING UNIT 4.1 MAJOR SPEC. Power Steering Unit Volume Relief pressure 51 cc/rev 120 kgf/cm² 8.4 psi 4.2 STRUCTURE AND OPERATION • Power steering controller consists of steering valve and relief valve. • Steering valve is divided into control valve and metering device. 615W806A (1) Relief Valve (2) Steering Valve A. Control Valve The control valve consists of control valve housing (9), spool (2), and sleeve (5).
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www.mymowerparts.com CHAPTER 8 8354/8404 5. STEERING CYLINDER 5.1 STRUCTURE 615W809A (1) Tube (4) Dust Seal (6) Ring (8) Bearing (2) Packing (5) Rod (7) Housing (9) Snap Ring [B] Tube I.D [C] Tube O.D [D] Stroke (3) Bush [A] Rod O.D 5.2 MAJOR SPECIFICATION 8-8 Tube O.D. (C) Tube I.D. (B) Rod O.D (A) Stroke (D) φ 60 (2.36 in.) φ 50 (1.97 in.) φ 32 (1.26 in.) 243 mm (9.57 in.
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www.mymowerparts.com STEERING SYSTEM 6. OIL FLOW 6.1 IN NEUTRAL If the steering wheel is not rotated, valve plate (3) keeps in neutral by using a centering spring (4). This time oil flow will be formed between port P (from pump) of control valve and port t of transmission case and all oil supplied from the gear pump will be drained to the port. Besides, flow from cylinder port R and L will be shut off at control valve.
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www.mymowerparts.com CHAPTER 8 8354/8404 6.3 TURNING TO THE LEFT The steering system operates in the same direction as in rotating to the left, except for flow in and flow out directions to steering cylinder in the opposite when turning to the right. 615W812A (1) Steering Controller (4) Centering Spring (2) Steering Wheel (5) GEROTOR (3) Valve Plate (6) Steering Cylinder 6.
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www.mymowerparts.com STEERING SYSTEM 7. TROUBLESHOOTING Trouble Steering wheel is heavy Probable Cause 1. Power steering unit (1) Column and center mismatched. (2) Spool and sleeve dirty (3) Excessive tightening torque of end cover bolt (7) 2. Pump Remedy * Modify (Loosen tightening bolt with power steering unit can cause center mismatch * Change * Tighten equally into the specified torque (1) Not drive. * Repair (2) Worn, faulty (3) Rated poor * Change * Reset pressure and flow rate 3.
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www.mymowerparts.com CHAPTER 8 8354/8404 8. DISASSEMBLY, MAINTENANCE 8.1 GEAR PUMP A. Tightening Torques Item No. Clearance between drive gear and body 1 Allowable limit: 0.05 mm (0.002 in.) Number Description Reference Value - Assemble bushing into body. - Assemble drive shaft with idle gear. - - Measure using clearance gage. Drive shaft worn 2 Allowable limit: 19.25 mm (0.758 in.) Allowable Clearance between drive shaft and bushing limit: 0.177 mm (0.007 in.
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www.mymowerparts.com STEERING SYSTEM b. Disassembly of Gear Pump 23 22 21 615W815A (1) Snap Ring (9) Bushing (17) Drive Gear Shaft2 (2) Bearing (10) Drive Gear Shaft (18) Passive Gear (3) Cover (Front) (11) Passive Drive Gear (19) Sealing (4) Sealing (12) Coupling (20) Second Pump (5) Pin (13) Cover (21) Cover (6) First Pump (14) Sealing (22) Spring Washer (7) Sealing (15) Sealing (23) Bolt (8) Sealing (16) Bushing 1. If oil seal is cracked or damaged, replace it with new part. 1.
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www.mymowerparts.com CHAPTER 8 8354/8404 8.2 POWER STEERING UNIT A. Disassembly, Assembly a. Disconnection of Power Steering Unit Assembly First Stage (Disconnection of Steering Hose) • Disengage steering hose (1), (2), (3), (4) connecting nut and disconnect hose from power steering unit (5). (When reassembling) • When connecting with power steering unit hose, make sure color and connecting port of hose are correct. Connecting port T P R L Sect.
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www.mymowerparts.com STEERING SYSTEM B.
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www.mymowerparts.com CHAPTER 8 8354/8404 C. Disassembly of Power Steering Unit a. Disassembly of GEROTOR 1. With end cap upward, lock port of body housing lightly into vice. 2. Loosen two screws (22) and disassemble housing (21). • Never tighten firmly into vice with rigid plate and etc. CAUTION 615W819A (21) Housing (23) O-ring (22) Screw 3. Loosen seven screws (1). 4. Disassemble end cap (2). 5. Disassemble O-ring (3) from end cap. 615W820A (1) Screw (3) O-Ring (2) End Cap 6.
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www.mymowerparts.com STEERING SYSTEM 7. Disassemble GEROTOR. Make sure rotor not dropped from outer ring of GEROTOR. 8. Pull out spacer plate (8) and O-ring (9). 9. Pull out driver (11). 10. Pull out O-ring from housing. 615W822A (8) Plate (11) Driver (9) O-Ring 11. Push inside spline of spool by the thumb and pull out spool and sleeve assembly from the opposite side of the housing flange. This time, make sure sleeve O.D. is not seized with into housing I.D. 12.
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www.mymowerparts.com CHAPTER 8 8354/8404 b. Disassembly of Relief Valve 1. Disassemble retainer screw (1) from plug (29) of housing (20) and pull out retainer pin (2) and ball (3). 2. With flanged surface of housing (20) upward, disassemble relief-adjusting plug (29) and pull out Oring (28). 3. Pull out damper collar (27) and spring (26). 4. Pull out poppet (25) from housing (20) using pincette.
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www.mymowerparts.com STEERING SYSTEM • Make sure the number of centering spring is correct, as it is different as input torque spec. of the product. CAUTION 5. While raising spool and from sleeve and compressing the opposite end of centering spring by hand, push spool into the groove of sleeve. This time, slide insert tool at the same speed of spring compression. After inserting, align the end of spring with outer circumference of sleeve. CAUTION • Align with position alignment mark when disassembling.
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www.mymowerparts.com CHAPTER 8 8354/8404 b. Assembly of Relief Valve 1. Insert poppet (25) into flange of housing with spring guide seized using pincette. 2. Insert spring (26) and damper collar (27). 3. Insert O-ring into relief adjusting plug (29) and tighten to housing. • CAUTION When completing the assembly, adjust the pressure of relief valve.· Pressure variance of relief adjusting plug (29) is 15 kgf/cm² Per one rotation.
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www.mymowerparts.com STEERING SYSTEM 8.3 STEERING CYLINDER A. Check a. Steering Wheel Clearance • After starting engine, wait for the engine to idle. • Rotate the steering wheel by hand and measure clearance. • If clearance exceeding the spec., check steering connection device for link. Sect. Specified Steering wheel clearance 20 ~ 40 mm 0.79 ~ 1.97 in.
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www.mymowerparts.com CHAPTER 8 8354/8404 B. Disassembly, Assembly a. Disconnection of Steering Cylinder Assembly • Disconnect steering hose assembly (1) and (2). • Pull out split pin (3) and disengage nut (4). • With tapping the end of support pin (5) using plastic hammer, pull out support pin from front axle case. • Disengage pin (6) locking bolt (9) and pull out pin from center pin (8). • Disconnect steering cylinder assembly (7).
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www.mymowerparts.com STEERING SYSTEM • After assembling split pin, make sure the end is not fallen. • Apply support pin and grease nipple with sufficient grease. Sect. Nut Spec. Tightening torque M18 48.0 ~ 55.9 N·m 4.9 ~ 5.7 kgf·m 35.5 ~ 41.2 lbf·ft • When assembly steering cylinder connector, apply screw with sealing agent. • When connecting with steering cylinder hose, make sure the color and connecting port is correct. • After assembly steering hose, perform air bleeding.
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www.mymowerparts.com HYDRAULIC SYSTEM 1.
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www.mymowerparts.com CHAPTER 9 8354/8404 2. STRUCTURE 6305 615W903A (1) Hydraulic Filter (5) Hydraulic Block (2) Hydraulic Pump (6) Aux. Control Valve (3) Modulating Valve (7) MLS(Control) Valve (4) Power Steering Unit (8) Power Lift Assembly The hydraulic system consists of major components as shown in the above figure. This system has the following three functions. 1.
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www.mymowerparts.com HYDRAULIC SYSTEM 3. HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HYDRAULIC SYSTEM 615W904B (1) Oil Tank (Transmission Case) (6) Front Hydraulic Block (2) Oil Filter (7) Position Control Valve (3) Hydraulic Pump (8) Hydraulic Cylinder (4) Engine (9) Aux. Control Valve (5) Relief Valve (10) Hydraulic Cylinder Block HYDRAULIC OIL FLOW 1. If the engine (4) is started and the hydraulic pump (3) is rotated, hydraulic pump intakes oil from transmission case (1) through intake pipe.
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www.mymowerparts.com CHAPTER 9 8354/8404 4. HYDRAULIC PUMP 4.1 STRUCTURE OF HYDRAULIC PUMP 23 22 21 615W905A (1) Snap Ring (7) Seal Ring (13) Cover (19) Seal Ring (2) Bearing (8) Seal Ring (14) Seal Ring (20) 2nd Pump (3) Cover (Front) (9) Bushing (15) Seal Ring (21) Cover (10) Drive Gear Shaft 1 (16) Bushing (22) Spring Washer (5) Pin (11) Passive Gear 1 (17) Drive Gear Shaft 2 (23) Bolt (6) 1st Pump (12) Coupling (18) Passive Gear (4) Seal Ring 4.2 OPERATION A.
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www.mymowerparts.com HYDRAULIC SYSTEM 5. OIL FILTER 5.1 STRUCTURE OF OIL FILTER A. Function • Filters particle or sludge from oil. B. Operation • Oil filter consists of filter bracket, magnet assembly and element assembly as intake filter installed at intake side of gear pump. • Filter used in M24 series is a hydraulic elevating and steering filter.
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www.mymowerparts.com CHAPTER 9 8354/8404 6. CONTROL VALVE (MLS VALVE) 6.1 STRUCTURE 615W909A 6.
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www.mymowerparts.com HYDRAULIC SYSTEM 6.3 OPERATION PRINCIPLE • Since the control valve of the hydraulic cylinder is available to control oil flowing in and out of the hydraulic cylinder. It also controls the implement up and down at a constant speed regardless of the implement load. A high work performance can be achieved without impact, along with the operation principle classified into 3 phases of neutral, delivery and discharge. A.
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www.mymowerparts.com CHAPTER 9 8354/8404 B. Delivery Phase 615W912A (1) Control Spool (18) Annular Duct (2) Regulator Piston (19) Annular Duct (3) Check Valve (20) Hole (6) Fixed Throat (21) Hole (7) Safety Valve (22) Chamber (15) Chamber (23) Cylinder Chamber (17) Hole During this phase the control valve supplies the oil on pressure to the cylinder and it consequently lifts the arms.
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www.mymowerparts.com HYDRAULIC SYSTEM C. Discharge Phase 615W913A (1) Control Spool (17) Hole (2) Regulator Piston (18) Annular Duct (4) Exhaust Valve (23) Cylinder Chamber (8) Regulator (24) Hole (15) Chamber (25) Hole (16) Exhaust Hole During this phases the control valve supplies, at the same time, the oil coming from the pump and the oil contained in the cylinder to the discharge causing the lowering of the arms.
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www.mymowerparts.com CHAPTER 9 8354/8404 7. RELIEF VALVE (HYDRAULIC BLOCK) • As shown in the figure, a guide is attached at poppet (6) and valve chamber D.C (damping chamber) located at the bottom of the guide piston. Intake of valve enable through sliding part of guide and clearance of seat (5) to chamber and minimizes valve vibration as damping effect of chamber.
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www.mymowerparts.com HYDRAULIC SYSTEM 8.
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www.mymowerparts.com CHAPTER 9 8354/8404 9. STRUCTURE AND OPERATION 9.
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www.mymowerparts.com HYDRAULIC SYSTEM 9.2 OPERATION Operation is Divided Into Position Control, Draft Control and Mixed Operation. A.
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www.mymowerparts.com CHAPTER 9 8354/8404 B. Draft Control (Fig.
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www.mymowerparts.com HYDRAULIC SYSTEM When roller 4 (11) meets the inclined plane of the drawbar pull cam (12), it permits the counterclockwise rotation of lever (7) which by means of shock absorbers (8) will rotate transmission arm (9) in a clockwise manner thus releasing the distributor shaft (21) to move into neutral position “N”. In discharge position “S”, the lever (2) will continue its downward movement and cause the arms to lower.
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www.mymowerparts.com CHAPTER 9 8354/8404 10. OUTSIDE HYDRAULIC EXTRACTION 10.1 HYDRAULIC BLOCK A: To implement control valve “IN” port B: From implement control valve “TANK” port C: Without attaching implement D: With attaching implement NOTE: • When an implement is not attached, turn the slit on the spool end to the horizontal position fully.
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www.mymowerparts.com HYDRAULIC SYSTEM 10.2 ACTING VALVE A. Operation principle A double acting detent type auxiliary control valve is used, and the construction is shown in the figure right. When the auxiliary control valve operating lever is moved to the implement cylinder actuating position, the spool is moved and the oil from the pump port flows into A to B, causing the implement cylinder to operate.
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www.mymowerparts.com CHAPTER 9 8354/8404 11. TOP LINK BRACKET DEVICE 11.1 STRUCTURE 615W924A (1) Top Link Holder (6) Hex. Bolt (2) Flange (7) Plate (3) Cover (8) Crank (4) Spring (9) Tie Rod (5) Nut (10) MLS (Control) Valve 11.2 OPERATION If shock is applied to the implement, it will be absorbed by cover (3), spring (4), and top link and connected to linkage by plate (7) and tie rod (9) to elevate the implement. This time, the oil flow passage will be changed by linkage in the MLS valve.
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www.mymowerparts.com HYDRAULIC SYSTEM 12. TROUBLESHOOTING Trouble Probable Cause Remedy * Lack in tank (mission case) oil * Intake filter clogged Fill in oil to adequate level. Clean or replace filter. * Intake line mixed with air Check intake pipe, O-ring, and bolt for looseness.
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www.mymowerparts.com CHAPTER 9 8354/8404 13. MAINTENANCE SPECIFICATION 13.1 3-POINT SYSTEM HYDRAULIC PUMP Condition and Point Applicable Model and Item Reference Dimension Allowable Limit Hydraulic pump condition * Engine speed (2700 rpm) * Pressure 16.0 ~ 17.2 Mpa 8354 165 ~ 175 kgf·m/cm² 2347 ~ 2489 psi * Oil temp. 29.7 l/m 8404 7.85 U.S.gal/min 40 ~ 60°C 104 ~ 140°F Housing Depth of scratch 0.09 mm 0.035 in. Relationship between gear shaft Clearance and bush Bush Length 0.11 mm 0.
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www.mymowerparts.com HYDRAULIC SYSTEM 13.4 HYDRAULIC CYLINDER Item Cylinder bore I.D. Relationship Right between hydraulic are Shaft and bush Left Clearance Hydraulic arm shaft Right Reference Dimension Allowable Limit 90.000 ~ 90.100 mm 90.150 mm 3.5433 ~ 3.5472 in. 3.5492 in. 0.125 ~ 1.230 mm 0.50 mm 0.00492 ~ 0.00906 in. 0.0197 in. 0.125 ~ 0.220 mm 0.50 mm 0.00492 ~ 0.00866 in. 0.0197 in. 49.970 ~ 49.940 mm 1.96732 ~ 1.96614 in. O.D. Left 44.975 ~ 44.950 mm 1.77066 ~ 1.76968 in.
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www.mymowerparts.com CHAPTER 9 8354/8404 14. TIGHTENING TORQUE N·m Kgf·m lbf·ft Hydraulic pipe joint bolt 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4 Hydraulic pipe attaching bolt (M10) 48.1 ~ 55.8 4.9 ~ 5.7 35.5 ~ 41.2 Hydraulic block support attaching bolt (M8) 23.6 ~ 27.4 2.4 ~ 2.8 17.4 ~ 20.2 Hydraulic pipe attaching bolt (M8) 23.6 ~ 27.4 2.4 ~ 2.8 17.4 ~ 20.2 Intake pipe 3 attaching bolt (M8) 23.6 ~ 27.4 2.4 ~ 2.8 17.4 ~ 20.2 Filter support attaching bolt (M10) 48.1 ~ 55.8 4.9 ~ 5.
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www.mymowerparts.com HYDRAULIC SYSTEM 15. DISASSEMBLY, ASSEMBLY 15.1 GEAR PUMP A. Disconnection of Gear Pump Assembly 1. Disassemble hydraulic pipe (3, 4) and intake pipe (5) assembled into gear pump (1). 2. Disassemble bolt (2). 3. Detach gear pump (1). 615W925A (1) Gear Pump (4) Hydraulic Pipe (2) Bolt (5) Suction Pipe (3) Hydraulic Pipe (When reassembling) * Apply O-ring with grease to prevent damage. Tightening torque Hydraulic pipe 1 attaching bolt (M8*1.25) 23.6 ~ 27.4 N·m 2.4 ~ 2.8 kgf/m 17.
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www.mymowerparts.com CHAPTER 9 8354/8404 B. Disassembly and Assembly of Gear Pump 615W927A (1) (2) (3) (4) (5) (6) Snap Ring Bearing Cover (Front) Seal Ring Pin 1st Pump (7) (8) (9) (10) (11) (12) Seal Ring Seal Ring Bushing Drive Gear Shaft 1 Passive Gear 1 Coupling (13) (14) (15) (16) (17) (18) Cover Seal Ring Seal Ring Bushing Drive Gear Shaft 2 Passive Gear (19) (20) (21) (22) (23) Seal Ring 2nd Pump Cover Spring Washer Bolt 1. Place the gear pump assembly into a vice.
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www.mymowerparts.com HYDRAULIC SYSTEM 15.2 MAINTENANCE Housing Bore (Depth of Scratch) 1. Check if scratch occurred by gear in the surface of housing. 2. If scratched more than half of inside housing surface, the replace pump assembly. 3. Measure housing I.D. of inside surface without scratch and measure housing I.D. with scratch. 4. If the value obtained from both measurements exceeds the allowable limit, replace the hydraulic pump. (Ref.) 615W928B Use cylinder gauge to measure housing I.D.
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www.mymowerparts.com CHAPTER 9 8354/8404 15.4 HYDRAULIC CYLINDER A. DISASSEMBLY, ASSEMBLY a . Pipe, Aux. Control Valve (If Attached) 615W930B (1) Pipe A (9) Quick Coupler (14) O-Ring (2) Pipe B (10) Bolt (15) O-Ring (5) Bracket (11) Seal Washer (16) Flange (6) O-Ring (12) Stud (17) Washer (8) Joint Bolt 2 (13) Double-Acting Valve (18) Nut 1. Disengage joint bolt 2 (8) and detach the hydraulic pipe (1), (2) bracket (5), and quick coupler entirely. 2.
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www.mymowerparts.com HYDRAULIC SYSTEM b. Hydraulic Cylinder Assembly 1. Disengage joint bolt (1). 2. Disengage the hydraulic cylinder assembly mounting bolts [(6), (7), (8), (9)], spring washer (5) and nut (4). 3. Raise and then detach the hydraulic cylinder assembly with a nylon rope supported. (When reassembling) Tightening torque Hydraulic cylinder attaching bolt, nut 48.1 ~ 55.8 N·m 4.9 ~ 5.7 kgf·m 35.5 ~ 41.
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www.mymowerparts.com CHAPTER 9 8354/8404 d. Control Valve 1. Disengage the control valve attaching bolt (1). 2. Detach control valve (3) carefully. (When reassembling) Make sure O-ring not damage. Tightening torque Attaching bolt 23.6 ~ 27.4 N·m 2.4 ~ 2.8 kgf·m 17.4 ~ 20.2 lbf·ft 615W934A (1) Bolt (2) Lock Washer (3) Control Valve Assembly (4) Power Lift Body (Hydraulic Cylinder Block) e . Lift Arm, Hydraulic Cylinder Arm, Hydraulic Arm Shaft 1.
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www.mymowerparts.com HYDRAULIC SYSTEM (When Reassembling) • Taking care of seal (12), insert into piston (11). • Apply the cylinder with transmission oil and insert the piston. • Apply the bottom of the piston that contacts with the connecting rod with grease. • Align with holes of shaft (8) and crank (7). • Apply the left and right bushes of the power lift body with grease. 615W936A (1) Shaft (3) Elevating Arm (2) Crank [A] Hole [B] Mark f. Bush 1.
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www.mymowerparts.com CHAPTER 9 8354/8404 g.
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www.mymowerparts.com HYDRAULIC SYSTEM h. Top Link Bracket a) Disassembly 1. Before disassembling the top link holder assembly, disassemble the socket support and coupler socket assembly. 2. Disassemble bolt (13), lock washer (14), roller (15), and plate (12). 3. Disassemble nut (21). 4. Remove snap ring (11) and then disassemble pin (10). 5. Disassemble top link bracket (1). 6. Pull out bolt (7), (9), and then disassemble flange (2). 7.
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www.mymowerparts.com CHAPTER 9 8354/8404 15.5 CHECK AND ADJUSTMENT A. Hydraulic Cylinder Bore 1. Check the cylinder inside surface for scratches or damage. 2. Using a cylinder gauge, measure cylinder I.D. 3. If the measured exceeds the allowable limits, replace the hydraulic cylinder block. Cylinder I.D. (A) Reference dimension 90.000 ~ 90.050 mm 3.54330 ~ 3.54527 in. 90.150 mm Allowable limit 615W940A 3.54921 in. B. Clearance Relationship Between Hydraulic Arm Shaft and Bush 1. Using a O.D.
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www.mymowerparts.com HYDRAULIC SYSTEM C. Reaction Spring Assembly Reference Dimension Reaction spring assembly initial length (L) Reference dimension 50 mm 1.9685 in. 615W942A (1) Spring (3) Nut (2) Hex. Bolt D. Dimensional Setting of Position Control Bolt 1. When assembling the control valve (MLS valve) into power lift body, “A” dimension will be 112 mm. 2. If adjusting control bolt (1), loosen nut (2) and then tighten-lock nut (2).
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www.mymowerparts.com CHAPTER 9 8354/8404 E. Lever Position Setting a. Adjustment of Position Control Lever The position control lever can be adjusted with a little load applied to the elevating arm. 1. Loosen the position control shaft (3), and lever tightening bolt (4). 2. Using a 13 mm spanner, rotate the position control shaft (3) counterclockwise until the elevating arm has stopped to climb by inside hydraulic limit. Because of safety, the area remained though the elevating arm moved to its max.
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www.mymowerparts.com HYDRAULIC SYSTEM F. Sensitivity Control of Control Valve (MLS) 1. Apply the elevating arm with load of 500 kg (1100 lbs) and move control lever upward to be the center. This time, the MLS valve is positioned at neutral. 2. Perform a sensitivity control while rotating the preventative screw (2) counterclockwise using a hex. wrench until elevating arm is swung. 3. Rotate the preventative screw (2) clockwise until the elevating arm stops moving and make sure it is locked at that position.
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www.mymowerparts.com ELECTRICAL SYSTEM 1. ELECTRONIC INSTRUMENTATION 615WA01B (1) Tachometer (8) Battery Charge Warning Lamp (2) Temperature Gauge (9) Grow Plug Indicator (3) Fuel Gauge (10) Hydraulic Filter Warning Lamp (4) PTO On Indicator (11) Upward Indicator (5) Engine Coolant Low Level Warning lamp (12) Parking Brake Indicator (6) Differential Lock Operation lamp (13) 4WD Lamp (7) Engine Oil Pressure Warning Lamp (14, 15) Turning Signal Indicator 1.1 INSTRUMENT GAUGE A.
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www.mymowerparts.com CHAPTER 10 8354/8404 1.2 INDICATORS AND WARNING LIGHTS A. POWER-TAKE-OFF OPERATION LAMP (4) Light will illuminate when the PTO selection switch is located at Auto or Manual mode. Before you start the engine, be sure that the PTO selection switch is located at the Neutral position. B. ENGINE COOLANT LOW LEVEL WARNING LAMP (5) Light will illuminate when the engine coolant is not enough to operate the tractor. As soon as the light illuminate, stop the engine and investigate the cause.
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www.mymowerparts.com ELECTRICAL SYSTEM F. PRE-HEAT CONTROL OPERATION LAMP (9) When the key switch is in the “ON” position, light will illuminate. When the whether is cold, remain the key switch in the “ON” position before starting for a while or until the lamp goes out. During this period, glow plug and combustion chambers are heated up and the engine becomes easier to start. G.
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www.mymowerparts.com CHAPTER 10 8354/8404 2.
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www.mymowerparts.com CHAPTER 10 8354/8404 3. SERVICING SPECIFICATIONS Capacity (factory spec.) Item Battery Rated voltage capacity Feature 12V 80AH Start motor Alternator Indicator bulb 10-8 Rated voltage 12V Rated power 2.0kw Rated voltage 12V Rated current 50A Rated voltage 14V Rated power 3.
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www.mymowerparts.com ELECTRICAL SYSTEM 4. MECHANISM 4.1 STARTING SYSTEM A.
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www.mymowerparts.com CHAPTER 10 8354/8404 B. OPERATION OF START MOTOR a. Starter The magnet-switch type starter is composed of two main sections. The first section converts battery current into mechanical rotation to turn the engine crankshaft. It is composed of the field coil, armature, brush, commutator, pinion, overrunning clutch, etc. The second section allows the pinion and flywheel to engage together and current to flow through the motor section.
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www.mymowerparts.com ELECTRICAL SYSTEM (C) When key switch is on: When the key switch is turned on, a current flows from the battery through the pull-in coil in the magnet switch section to the holding coil, energizing the plunger to pull it in. At this time, the pinion moves by the lever to engage with the ring gear.
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www.mymowerparts.com CHAPTER 10 8354/8404 b. Glow plus Glow plugs are used for each pre-combustion chamber of the cylinder head to make starting easier. The glow plugs are quick-heating type, which make starting easier with short pre-heating time. 615WA10A (1) Housing (3) Insulating powder (2) Metal tube (4) Heat coil 4.2 CHARGING SYSTEM A.
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www.mymowerparts.com ELECTRICAL SYSTEM B. CIRCUIT DIAGRAM FOR ALTERNATOR UNIT 615WA12A C. OPERATION OF CHARGING SYSTEM · The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs. · The alternator generates AC (alternating current) and the regulator converts AC into DC (direct current). It also controls the output voltage for charging current to the battery. · The regulator is built in inside of alternator.
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www.mymowerparts.com CHAPTER 10 8354/8404 4.3 PREHEATING SYSTEM A. CIRCUIT DIAGRAM FOR PREHEATING SYSTEM 615WA13B (1) Alternator (5) Glow plug indicator (2) Key s/w (6) Glow plug (3) Preheating Controller (7) Glow Relay (4) Coolant temp. sensor PARTS SPECIFICATION (1) Capacity of the preheating relay : DC12V 70A (2) Capacity of the preheating controller : DC12V B.
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www.mymowerparts.com ELECTRICAL SYSTEM 4.4 FUSE A. FUSE BOX DIAGRAM Classifi- Cable cation standard Connec- Appli- Remark tion cable terminal fuse 3 AVS3.OR 5 5 AVS2.OW 3 11 AVS3.ORL 21 13 AVS2.OWR 6 20A 21 AVS0.85YR 11 10A 6 AVS3.ORW 7,13,15, 6WAY 36,66,77 TERMINAL 25A AVS0.85BY 6 10A 15 AVS2.OOR 6 20A 36 AVS0.85RG 6 10A 66 AVS0.85RW 6 10A 77 AVS0.85YW 6 10A 7 615WA14A B. CAUTION FOR FUSE REPLACEMENT There are two kinds of fuse in this tractor.
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www.mymowerparts.com CHAPTER 10 8354/8404 4.5 GAUGE AND SENSORS A. OIL PRESSURE SWITCH The oil pressure switch is installed on the cylinder block and leads to the oil passage of the lubricating oil. When the oil pressure falls below the specified value, the contacts of the oil pressure switch closes to turn on the warning lamp. 615WA15A (1) Terminal contact (2) Diaphragm B. COOLANT TEMPERATURE SENSOR The coolant temperature sensor consists of terminal, thermister, insulator.
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ELECTRIC SYSTEM 5. MAIN CIRCUIT DIAGRAM www.mymowerparts.