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Cub Cadet 7360SS, Service Manual

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62

    Keep the rear bracket with washer for

    installation.

(3)Brush holder removal

   With the brushes (two) kept apart from the

   commutator, remove the yoke and brush

   holder assembly. Remove the armature.

(1)Magnetic switch

(a)Loosen the nut that holds the connector

    to the M terminal of the magnetic switch

    and disconnect the connector from the

    magnetic switch.

(b)Remove the bolts(two) that hold the

    magnetic switch in position and remove

    the magnetic switch.

(2)Rear bracket removal

    Remove the through bolts(two) and the bolts

    (two) that hold the brush holder in position.

    Remove the rear bracket.

(8)ELECTRICAL SYSTEM DISASSEMBLY

1. Starter disassembly

(1)magnetic switch
(2)rear bracket
(3)brush holder assembly
(4)yoke
(5)armature
(6)cover
(7)center bracket
(8)gear
(9)spring set
(10)stopper ring
(11)stopper
(12)pinion
(13)spring
(14)pinion shaft
(15)lever

(16)front bracket

Summary of Contents for 7360SS

Page 1: ...SERVICE MANUAL CUB CADET P O BOX 368023 CLEVELAND OHIO 44136 9723 SERIES 7000 COMPACT TRACTOR Model Number 7360SS...

Page 2: ...ALLATION 13 1 1 FRONT AXLE ASSY REMOVAL 13 1 2 FRONT AXLE ASSY REINSTALLATION 14 2 ENGINE ASSY REMOVAL AND REINSTALLATION 15 2 1 ENGINE ASSY REMOVAL 15 2 2 ENGINE ASSY REINSTALLATION 19 3 CLUTCH HOUSI...

Page 3: ...REASSEMBLING 130 7 7 CHECK AND MAINTENANCE 131 8 FRONT AXLE 132 8 1 FRONT AXLE DISASSEMBLING 132 8 2 FRONT AXLE REASSEMBLING 135 8 3 FRONT AXLE CHECK AND MAINTENANCE 139 9 STEERING 141 9 1 OPERATOR CO...

Page 4: ...3 I GENERAL...

Page 5: ...4 1 SAFETY...

Page 6: ...5...

Page 7: ...er See next paragraph for ordering parts 2 ENGINE SERIAL NO Engine serial No is punched on right side of engine block by the injection pump 3 TRACTOR SERIAL NO Tractor Serial No is punched on right si...

Page 8: ...P I Gravity Min 34 Flash Point Min 60 C 140 F Cloud Point Wax Appearance Point Max 21 C 5 8 F Pour Point Max 26 C 14 8 F Distillation Temperature 90 Point 282 to 338flC 539 to 640flF Viscosity at 38fl...

Page 9: ...8 4 POWER TRANSMISSION DIAGRAM...

Page 10: ...9 5 TIGHTENING TORQUES...

Page 11: ...10 6 PRECAUTIONS FOR DISASSEMBLY Place snap ring that square side face to force Slit Slit Shaft movement Shaft movement...

Page 12: ...11 7 GENERAL INFORMATION...

Page 13: ...12 II ASSY REMOVAL AND REINSTALLATION...

Page 14: ...ear side from the shaft groove 3 Move the joint to front side and remove the 4WD shaft 2 STEERING HOSE REMOVAL 1 Remove the two hoses from steering cylinder 3 BATTERY CODE DISCONNECTION 1 Disconnect B...

Page 15: ...der first Tightening Torque 86 8 97 6lbf ft 12 13 5 kgf m 2 Measure the clearance between front holder and chassis Put the shims of which thickness is half of the measured clearance Tighten the mounti...

Page 16: ...sses at alternator and starter motor Disconnect the tachometer cable 4 Disconnect the harnesses at water temperature gauge water temperature sensor and glow plug 5 Disconnect the harnesses at oil pres...

Page 17: ...16 2 PANEL REMOVAL 1 Disconnect the clutch rod and brake rods Left and right brake rods 2 Disconnect the shuttle wire Transmission side Lever side 3 Disassemble the operator seat area...

Page 18: ...xing bolts at column cover Lift up the panel assy 4 Disconnect the connectors of harness B 5 Remove the steering hoses from the flow divider and transmission case Flow divider Transmission case Column...

Page 19: ...n hose from engine 6 Remove the fuel tank bracket and fuel tank 7 Remove the muffler from engine 8 Remove the suction and pressure pipe from pump I and II 9 Put the jack under the transmission case to...

Page 20: ...packing Threebond 1208D to the mating surface of engine rear plate and clutch housing 2 When installing the engine make sure that main shaft and clutch center is aligned 3 Tightening torque of engine...

Page 21: ...wire length by nut to obtain the shuttle shift lever neutral position at lever guide In the neutral position shuttle shift lever can be move side to side 7 Brake pedal adjustment See page 127 Free pla...

Page 22: ...h housing and remove it from center case 2 CENTER CASE REMOVAL 1 Remove the fixing bolts between center case and transmission case 2 Remove the main shift lever linkages 3 Lift the center case and rem...

Page 23: ...e by removing the fixing bolts 3 Remove the top link bracket 4 Remove the fixing bolts of hydraulic lift case and lift up the hydraulic lift case to remove 8 REAR AXLE CASE REMOVAL 1 Remove the ROPS 1...

Page 24: ...1 Apply the liquid packing Threebond 1280D to the mating surface of the rear axle case and transmission case 2 Tightening torque of rear axle case mounting bolts 61 5 68 7lbf ft 8 5 9 5 kgf m 2 Hydra...

Page 25: ...he liquid packing Threebond 1208D to the mating surface of the center case and transmission case 2 Tightening torque of center case fixing bolts 86 8 97 6 lbf ft 12 13 5 kgf m 4 Clutch housing reinsta...

Page 26: ...es these troubles occur concurrently Some of them are directly caused by low compression pressure but others are not Among the troubles listed above 2 and 6 are caused by a fuel injection pump imprope...

Page 27: ...nents from which they were removed at disassembly This means that all parts must be set aside separately in groups each marked for its component so that the same combination or set can be reproduced a...

Page 28: ...pan and allow the oil to drain Refil capacity 1 19 gal 4 5 L Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 2 Coolant draining Loosen the drain plu...

Page 29: ...ck More or less knock occurs in diesel engines This may be caused either by an excessively large delay period or by a too fast rate of fuel injection 1 Items to be checked for ahead Clogged air cleane...

Page 30: ...ry to check the difference between the ambient temper ature when the engine is in normal operation with the thermostat fully open If the ambient temperature is higher than the normal coolant temperatu...

Page 31: ...checked for ahead Clogged air cleaner Poor quality fuel 2 Inspection procedure Problem 4 Erratic idle speeds 1 Items to be checked for ahead Maladjusted engine control Wrong oil grade for weather cond...

Page 32: ...wer or loss of power 1 Items to be checked for ahead Stuck running parts Wrong oil grade for weather conditions Poor quality fuel Clogged air cleaner Restricted exhaust line Faulty power take off 2 In...

Page 33: ...32 Problem 6 Starting system troubleshooting...

Page 34: ...33...

Page 35: ...bolts that hold the rocker stays in position and remove the rocker shaft assembly 2 Remove the valve caps 2 Rocker shaft disassembly Put identification on each rocker arm as to its location on the roc...

Page 36: ...nder head with a plastic hammer 5 Valve and valve spring removal 1 Compress the valve spring with a valve lifter and remove the valve lock 2 Remove the retainer spring and valve The valves retainers s...

Page 37: ...in Step 2 Remove the remaining bolts 4 Hold the flywheel by hands and withdraw it from the crankshaft Joggling the flywheel back and forth will facilitate removal When removing the flywheel wear heav...

Page 38: ...into the oil pan if the camshaft is removed before the tappets are removed 5 Speedometer driven gear removal Remove the lock plate and speedometer driven gear in that order Unless the speedometer driv...

Page 39: ...emove the bolts that hold the thrust plate 2 Pull the camshaft out of the cylinder block 8 Timing gear backlash measurement Measure the backlash of each gear and keep a record of it for correct instal...

Page 40: ...e the pump Do not cause the damage to the lobes or bearing journals when removing the camshaft 11 Fuel injection pump camshaft removal 1 Remove the stopper bolt 2 Tap the rear end of the camshaft with...

Page 41: ...an by inserting a screwdriver or a chisel between the oil pan and cylinder block Damage to the oil pan can be the result 1 Oil pan 2 Oil screen 3 Connecting rod cap 4 Connecting rod bearing lower Remo...

Page 42: ...rance for connecting rod big end Standard 0 10 to o 35 0 0039 to 0 0138 Limit 0 50 0 0197 4 Connecting rod cap removal 1 Lay the cylinder block on its side 2 Put identification on each connecting rod...

Page 43: ...s a greater force for removal 6 End play measurement for crankshaft Set a dial indicator so that it will touch the end of the crankshaft and measure the end play If the end play exceeds the limit repl...

Page 44: ...Insert the push rod of the tool into the bore in the piston for the piston pin and using an arbor press remove the piston pin 3 Use this Piston Pin Setting Tool to install the connecting rod to the pi...

Page 45: ...er head with reverse procedure of disassembling Use the following values as adjustment and service standard 1 Cylinder head bottom face cleaning Scrape the gasket from the bottom face of the cylinder...

Page 46: ...n 1 Thoroughly clean the top faces of the cylinder block and pistons 2 Install two guide bolts M10x1 25 in the bolt holes in the cylinder block 3 Put new cylinder head gasket in position on the cylind...

Page 47: ...rque 8 Valve push rod installation 1 Put the valve push rod into position through the bore in the cylinder head 2 Make sure the ball end of the push rod has been put into position over the top of the...

Page 48: ...in alignment with the holes in the cylinder block 3 Put the front plate in position Install four bolts and tighten them 2 Oil pump installation 1 Make sure the packing has been put in position on the...

Page 49: ...gear with a plastic hammer to fit the bearing in position 3 Make sure the camshaft rotates freely 4 Tighten the stopper bolt 5 Camshaft installation 1 Lubricate the lobes and journals with engine oil...

Page 50: ...3 tighten the bolts that hold the timing gear case 8 Crankshaft pulley nut tightening 1 Install two bolts M12x1 25 in the flywheel bolt holes in the crankshaft and hold the crankshaft 2 Tighten the c...

Page 51: ...ock 12 Oil seal case installation 1 Put new gasket in position on the oil seal case 2 Lubricate the oil seal lip with engine oil and install the oil seal in position in the cylinder block 13 Rear plat...

Page 52: ...he valve caps in position on the top of the valves 2 Put the rocker shaft assembly in position on the cylinder head Tighten the bolts that hold the rocker shaft assembly to the specified torque 1 5 0...

Page 53: ...lower halves in the main bearing caps so their tabs fit into the notches in the cylinder block and the main bearing caps 2 Install the flanged bearing in the No 3 journal 3 Lightly lubricate the insid...

Page 54: ...re the number arrow head on the main bearing cap is toward the front of the engine 3 Tighten the main bearing cap bolts finger tight only Install the front and bearing caps in position so their end fa...

Page 55: ...s and push in them by hand as far as possible with their rounded side toward the outside of the cylinder block 3 Using a flat plate push the seals into position taking care not to bend them 5 Piston a...

Page 56: ...ine oil 2 Move the piston rings on the piston so that the end gaps are apart from a direction parallel to or transverse to the piston pin 3 Install the connecting rod bearing upper half to the rod mak...

Page 57: ...n turn the crankshaft 180 while pushing on the top of the piston 2 Install the lower halt of the connecting rod bearing in the connecting rod cap making sure the tab in the back of the bearing is in t...

Page 58: ...n thick bar of sealing compound three Bond from the tube and put it on the flange of the oil pan as shown 2 Tighten the bolts that hold the oil pan to the cylinder block in a crisscross pattern to the...

Page 59: ...TEM DISASSEMBLY REMOVAL 1 Cooling fan removal Hold the fan by one hand remove the four bolts that hold the fan in position Remove the fan and spacers Keep the spacers with the for installation 2 Therm...

Page 60: ...er head Remove the gaskets from the cylinder head with a screwdriver or the like Discard defective gaskets 3 Governor assembly removal 1 Remove the tie rod cover 2 Remove the spring from the tie rod w...

Page 61: ...OVAL 1 Exhaust manifold removal Remove the exhaust manifold from the cylinder head 2 Air inlet cover removal Remove the air inlet cover from the cylinder head 3 Remove the fuel injection pump Keep a r...

Page 62: ...ith Oil Pressure Switch Socket Wrench MD998054 special tool 1 Oil filter removal 1 Put a container under the oil filter to catch the oil 2 Remove the oil filter from the cylinder block with a filter w...

Page 63: ...r from the magnetic switch b Remove the bolts two that hold the magnetic switch in position and remove the magnetic switch 2 Rear bracket removal Remove the through bolts two and the bolts two that ho...

Page 64: ...move the stopper ring with a pliers and remove the pinion Any time the pinion is removed a new stopper ring must be installed 7 Pinion shaft removal Remove the spring lever reduction gear and pinion s...

Page 65: ...the nut that holds the pulley in position and remove the pulley and spacer b Remove the rotor assembly from the front bracket 1 through bolts 2 pulley 3 rotor 4 rear bearing 5 bearing retainer 6 fron...

Page 66: ...idle speed Use a tachometer Standard farm engine 980 rpm Exhaust smoke 1 Check by quickly increasing Not too much black or gray engine speed under no load smoke condition 2 Check by staring load Orif...

Page 67: ...l the lever in correct position 9 ELECTRICAL SYSTEM REASSEMBLING 1 starter Follow the reverse of disassembly and use the procedure that follows 1 Lubrication Lubrication the following starter componen...

Page 68: ...to 2 0mm With the pinion held in cranking position lightly push it toward commutator end to measure free movement clearance If the clearance is not correct make adjustment to it Increase the amount o...

Page 69: ...groove b When installing the new rear bearing put it in position with the side that has a groove toward the slip rings of the rotor c To install the rear bearing in the rear bracket heat the rear brac...

Page 70: ...off solenoid 30 to 45 turn the clearance between the control rackandplungerwillbe0 0059to0 0070 in 0 15 to 0 20 mm and tighten the nut to the specified torque g Start the engine and make sure the engi...

Page 71: ...on on the water pump flange Install the water pump in position on the cylinder block 2 Thermostat installation 1 Put the thermostat in the thermostat case 2 Put a new gasket in position on the thermos...

Page 72: ...osition Install the adjusting plate bolt in position to hold the alternator in position 2 Put the belt in position on the pulley Move the alternator away from the engine to make an adjustment to the b...

Page 73: ...nstall the new filter element by hand When the gasket contacts the base tighten one turn more 3 Oil pressure switch installation Coat the threads of the switch with thread sealant Three Bond 1102 Use...

Page 74: ...n the rear end of the fuel injection pump camshaft and tighten the sliding sleeve shaft to the specified torque 4 Sliding sleeve installation Install the sliding sleeve on the sliding sleeve shaft and...

Page 75: ...tion line installation 1 Put the fuel leak off line in position and connect it to the fuel injection nozzles 2 Put the fuel injection lines in position and connect them to the fuel injection pump Inst...

Page 76: ...the clearance 2 No load characteristics a Connect the starter to a 12 volt battery with an ammeter capable of indicating several hundred amperes as shown in the illustration b Close the switch to make...

Page 77: ...pinion to see if it remains there If the pinion returns the magnetic switch is faulty Due to the amount of current being passed through the solenoid series winding this test must be made within 10 sec...

Page 78: ...s a list of basic precautions that should always be observed for removal 1 When installing the battery care must be used to make sure the negative termi nal is grounded 2 Do not use a megger an instru...

Page 79: ...tery ground negative cable 2 Connect one ammeter lead to the B terminal of the alternator and the other lead to the positive terminal of the battery Connect one voltmeter lead to the B terminal and th...

Page 80: ...e clearance between the arm and shaft If the clearance has reached the limit replace the rocker arm If it exceeds the limit replace both arm and shaft Unit mm in Item Nominal Standard Limit size Bore...

Page 81: ...rometer caliper to find the clearance between the stem and guide If the clearance exceeds the limit replace the guide or valve whichever is badly worn Unit mm in Item Nominal Standard Limit size 0 02...

Page 82: ...nst the seat to check its contact b The width of contact must be uniform all the way around both seat and valve If the contact is bad reface the valve and seat c If the valve margin valve lip thicknes...

Page 83: ...put lapping compound on the valve face and lap the valve in the valve seat 7 Valve lapping Be sure to lap the valves in the seas after refacing or replacing the valves or valve seats a Put a small amo...

Page 84: ...nt Replace the combustion jets only when they are cracked or defective 1 To remove the jet insert a 6mm 0 24in diameter round bar through the bore in the cylinder head for the glow plug and tap around...

Page 85: ...er of the journal and the bore in the bushing for the shaft to find the clearance as shown in the illustration If the clearance exceeds the limit replace the bushing Unit mm in Item Standard Clearance...

Page 86: ...Replace the tappet if the face is defective 2 Clearance between tappet and cylinder block Measure the diameter of the tappet and the bore in the cylinder block for the tappet to find the clearance If...

Page 87: ...n in the illustration to find the flatness If the flatness exceeds the limit grind the face Unit mm in Item Standard Limit Flatness of 0 15 0 0059 0 50 flywheel maximum 0 0197 a Removal Heat the ring...

Page 88: ...7 Maximum permissible difference between average 5 0 18 weight of all pistons in one engine g oz Unit mm in Item Standard Limit No 1 comp 0 06 to 0 10 0 30 0 0118 ression ring 0 0024 to 0 0039 No 2 co...

Page 89: ...e exceeds the limit replace the piston or pin whichever is badly worn 2 Connecting rods Check the connecting rod for bend or twist as follows a Measure C and L If C exceeds0 05 mm 0 0020 in per 100 mm...

Page 90: ...s shown in the illustration to find the clearance between the crankpin and connecting rod bearing Unit mm in Item Nominal size Standard Limit Diameter 48 47 950to of crankpin 1 89 47965 standard 1 887...

Page 91: ...985to of journal 2 05 52 000 standard 2 04665to 2 04724 clearance 0 030 to between 0 077 journal and 0 00118to 0 100 main bearing 0 00303 0 00394 c If the clearance exceeds the limit install a new be...

Page 92: ...0 00098 0 05 0 0020 4 Crankshaft gear removal Use a gear puller to remove the gear from the crankshaft Do not remove the gear unless the gear or crankshaft is defective 5 Crankshaft gear installation...

Page 93: ...heck the top face for warpage in two positions lengthwise two crosswise and two widthwise as shown in the illustration If warpage exceeds the limit reface the top face with a surface grinder The maxim...

Page 94: ...the thermounit 50 C 122 F 80 10 Standard 80 C 176 F 29 5 2 5 120 C 248 F 10 0 3 Antifreeze in the pan is hot Any contact can cause severe burns 4 COOLING SYSTEM 1 Water pump Check the impeller and sh...

Page 95: ...ation or other defects Replace the pump assembly if defective 2 Oil pressure switch 1 Test for continuity between the terminal and body with an ohmmeter as shown in the illustration No continuity is t...

Page 96: ...the limit of the commutator diameter Unit mm in ltem Standard Limit Runout of 0 03 0 10 commutator 0 0012 0 0039 6 ELECTRICAL SYSTEM 1 Starter 1 Brushes a Wear Replace the brushes if they are worn dow...

Page 97: ...Place the armature on growler and slowly rotate it with a hacksaw blade held above the armature core The hacksaw blade vibrates against the core when it is above a slot containing a shorted winding A...

Page 98: ...to run freely 5 Overrunning clutch Replace the overrunning clutch assembly if a The pinion is not locked when spun freely when spun in the reverse direction clockwise b The pinion is worn or chipped...

Page 99: ...he positive prod of an ohmmeter to the diode then the negative prod If the resistance is infinite in both cases the diode is open If it is nearly zero in both cases the diode is shorted Do the same st...

Page 100: ...holder for replacement unsolder the leads from the brushes This will permit removal of the brushes and springs c To install the new brushes put them in position in the brush holder and solder the lea...

Page 101: ...rankshaft two or three times and make sure the valve clearance is correct 4 6 ADJUSTMENT 1 VALVE CLEARANCE Make an adjustment to the valve clearance when the engine is cold 1 Slightly loosen the cylin...

Page 102: ...Turn the starter switch key to ON position Fuel will come from the injection pipe with high pressure when the starter switch key is turned to ON position if the engine is equipped with an electric fue...

Page 103: ...0 0079 in 0 3 mm 0 0118 in 0 4 mm 0 0157 in and 0 8 mm 0 0315 in These shims have no identification measure the thickness of each shim with calipers before using it Apply sealant to both faces of eac...

Page 104: ...he set bolt to make the engine run at the specified rpm Tighten the lock nut 3 To set the high idle rpm loosen lock nut for the high idle set bolt and turn the set bolt to make the engine run at the s...

Page 105: ...uid begins to flow through the injection nozzle The discharge must be straight Any change is an indication of a bad nozzle b Operate the tester handle at a speed of one stroke per second to make sure...

Page 106: ...the tip and slide the needle valve in the body in clean diesel fuel to wash off inhibitor completely 3 Nozzle tip washing and replacement a Loosen the retaining nut and remove the tip from the injecti...

Page 107: ...98 N force midway between the alternator pulley and the crankshaft pulley 2 Adjust the belt if the deflection is not correct Loosen the adjusting bolt and move the alternator to obtain the required b...

Page 108: ...IAL TOOLS In addition these special tools commercially available tools such as bearing puller valve seat cutting tool valve guide installing tool valve spring compressing tool oil filter wrench etc ar...

Page 109: ...the installation of release bearing depress the inner hub 2 Make sure the direction of release lever and release hub for the reassembling 3 Apply the lithium grease inside of release hub before assemb...

Page 110: ...e of clutch disk 4 Before installing the clutch assy to engine clean flywheel end Aline the center of clutch disk ID and flywheel bearing ID 5 Tightening torque of clutch assy fixing bolts 18 21 7 lbf...

Page 111: ...ing limit replace the clutch disk assy Item Standard value Service limit Depth to rivet 0 05 0 075 in 0 012in 3 In case that the oil is stick to the lining lining is carbonized or damaged replace the...

Page 112: ...ounter shaft from cover A 3 Remove gear 31T with needle bearing and washers 4 Remove snap ring 2 3 and remove gear 27T from counter shaft 3 Remove drive shaft 6 TRANSMISSION 6 1 CLUTCH HOUSING DISASSE...

Page 113: ...clutch assy 1 Case 9 Brake disk 2 Piston 10 Seal ring set 3 Seal ring 11 Gear set 40T 4 Disk assy 12 Seal ring 5 Ring set 13 Ring 6 Spring 14 Back plate 7 Washer 15 Belleville spring 8 Return plate 16...

Page 114: ...gear 21 and collar 22 1 Select shaft 13 Spring 2 Gear 23T 14 Ball bearing 3 Gear 26T 15 Ball bearing 4 Gear 35T 16 Ball bearing 5 Gear 40T 17 Needle bearing 6 Retainer A 18 Snap ring 7 Retainer B 19...

Page 115: ...remove holder 3 Remove stopper bolt 4 COVER D REMOVAL Remove fixing bolts of cover and remove cover from center case 5 COVER D SUB ASSY DISASSEMBLING 1 Disassemble drive shaft 1 Remove drive shaft wi...

Page 116: ...R DIFFERENTIAL CASE REMOVAL 1 Remove differential lock pedal fixing bolt and remove the pedal 2 Remove spring pin 1 washer and spring pin 2 3 Pull out the shaft and remove shift fork cum and spring at...

Page 117: ...ER E SUB ASSY DISASSEMBLING 1 Disassemble pinion shaft 1 Remove lock nut from pinion gear and remove pinion shaft 2 Disassemble drive shaft 1 Move snap ring 3 and remove gear 23T and 35T from pipe sha...

Page 118: ...ER B REINSTALLATION Reinstall the cover B with reverse procedure of removal Use following adjustment and service standards for the reassembling 2 COVER B REASSEMBLING Reassemble the cover B with rever...

Page 119: ...y with reverse procedure of removal Use following values as adjustment and service standard for reassembling 1 Apply liquid packing three bond 1208D at the mating surface of center case and lever hold...

Page 120: ...ion of spring between both sides of hub 2 COVER C REASSEMBLING Reassemble the cover C with reverse procedure of disassembling Use following values as adjustment and service standard for reassembling 1...

Page 121: ...ollowing values as adjustment and service standard for reassembling 1 Shuttle Shaft 1 Adjust the endplay at A and B to 0 002 0 079in by shim 2 Shuttle linkage Adjust the wire length See page 16 4 COVE...

Page 122: ...1 REAR DIFFERENTIAL CASE REASSEMBLING Reassemble the rear differential case with reverse procedure of disassembling Use following values as adjustment and service standard for reassembling 1 Different...

Page 123: ...shaft to 0 002 0 079 in by liner 3 Adjust the pre load at pinion shaft to 0 72 0 94 lbf ft by tightening the nut and calk the nut _ 4 4WD Shaft 3 PTO SHAFT REINSTALLATION Reinstall the PTO shaft with...

Page 124: ...ck the backlash of differential ring gears Backlash Standard value 0 004 0 008 in Service limit 0 012 in Replace the gear if backlash is out of service limit 3 Check the clearance between shift fork a...

Page 125: ...gear Measure the clearance A In case that clearance is out of limit replace them limit 0 197 in Replace outer ring inner ring and corn by set 2 Synchronizer sleeve Hub a Make sure synchronizer sleeve...

Page 126: ...2 Steel plate Check the flatness of steel plate In case that the flatness of steel plate is out of service limit replace the steel plate Flatness Standard value Less than 0 0059 in Service limit 0 01...

Page 127: ...rear axle housing 7 REAR AXLE 7 1 DIFFERENTIAL CASE ASSY DISASSEMBLING 1 DIFFERENTIAL CASE ASSY REMOVAL See page 21 2 DIFFERENTIAL ASSY DISASSEMBLING 1 Remove the differential lock hub 5 and steel bal...

Page 128: ...H 6 brake pedal R H and brake link R H 3 Remove the spring pin and remove the brake pedal L H 2 R H and brake shaft 1 from bracket 4 Remove snap ring from link shaft 5 5 Remove fixing bolts of link s...

Page 129: ...n by adjusting liner 9 2 Apply bond threebond 137 to the fixing bolts of ring gear Tightening torque of ring gear fixing bolts 30 38 36 17lbf ft 3 Install the spring pin in the manner that the directi...

Page 130: ...EASSEMBLING Reassemble the rear axle with reverse procedure of disassembling Use following values for rear axle reassembling as adjustment and service standard 1 Apply lithium grease at lip of oil sea...

Page 131: ...and R H must be adjusted less than 0 118 in 2 Adjust the clearance between bracket 7 and parking brake lever 6 to be less than 0 197 in by liner 7 6 BRAKE CONTROL REASSEMBLING Reassemble the brake co...

Page 132: ...t of following standard replace them Item Standard in Service limit in Backlash between final 0 004 0 012 0 02 gear and diff shaft 2 BRAKE DISK 1 Check the worn out of brake disks In case that the mea...

Page 133: ...ASSY DISASSEMBLING 1 Remove rear bracket 1 from front axle assy 2 Remove fixing bolts of bearing case 7 and remove bearing case from front axle assy 3 Remove nut 10 and remove pinion shaft 6 bearing o...

Page 134: ...ng bolts of cover and remove cover from gear case 3 Remove snap ring 1 and remove bearing 2 gear 38T liner and axle shaft from cover 4 Remove snap ring 3 and bearing 4 from cover 1 KING PIN CASE 2 KIN...

Page 135: ...fixing bolts of cover 12 and remove cover 12 from king pin case 1 4 Remove king pin shaft 2 liners 3 bearings 13 14 gear 18T and gear 13T from king pin case 1 1 Remove gear 14T 8 bearing 15 and diff s...

Page 136: ...se to o rings for assembling 2 Adjust the turning torque of pinion shaft to 6 51 8 68 lbf ft by tightening the nut 3 Select the shim by calculating the shim thickness as follows and install between ax...

Page 137: ...mbling of knuckle arm and final case as adjustment and service standard 1 Apply lithium grease to o ring and lip of oil seal for assembling 2 Apply liquid packing threebond 1208D to installation surfa...

Page 138: ...adjustment and service standard 1 Apply lithium grease at o ring and oil seal 2 Wind seal tape to fixing bolts 15 of arm holder 3 Tightening torque of plug 16 8 68 12 3lbf ft 4 King pin case assemblin...

Page 139: ...57 86 in 3 Diff case assy assembling 1 Make sure the backlash between pinion and side gear is in the range of 0 0004 0 0118in 2 Apply threebond 1374 to tightening torque of ring gear fixing bolts Tigh...

Page 140: ...of bevel gears In case that the backlash is out of standard readjust it Item Standard value in Backlash between bevel 0 008 0 0157 gear14T and 18T Backlash between bevel 0 008 0 0157 gear 13T and 38T...

Page 141: ...tandard replace it Item Standard value in Service limit in Clearance between 0 00118 0 0079 holderandbushing 0 00236 4 CLEARANCE BETWEEN HOLDER AND KNUCKLE ARM Check the clearance between holder and k...

Page 142: ...bracket and remove bracket and levers 5 Remove lock nut 18 column fixing bolts 17 disk spring 18 Bothsides and column 2 6 Remove spring 16 lock nut 15 tilt lever fixing bolt 14 and tilt lever 13 7 Rem...

Page 143: ...ve steering unit fixing bolt and remove steering unit from column 2 STEERING UNIT DISASSEMBLING 1 DUST SEAL 2 RETAINING NUT 3 SEAL GRAND BUSHING 4 O RING 5 OIL SEAL X RING 6 NEEDLE BEARING KIT 7 RELEA...

Page 144: ...g 1 Remove retaining ring 2 from housing 2 Turn spool 17 and sleeve 16 until pin 20 comes to horizontal Push spool 17 and sleeve 16 and remove seal grand bushing 3 from housing 2 Remove rota set 24 an...

Page 145: ...ure setting at dealer 9 3 HYDRAULIC CYLINDER DISASSEMBLING 1 HYDRAULIC CYLINDER ASSY REMOVAL 1 Remove hydraulic hoses 2 hoses from hydraulic cylinder 2 Drain coolant from radiator and remove radiator...

Page 146: ...tor hoses and air cleaner hose from engine 5 Remove fixing bolts of front holder 6 Remove chassis and radiator 7 Remove hydraulic cylinder assy 2 HYDRAULIC CYLINDER ASSY DISASSEMBLING 1 Remove tie rod...

Page 147: ...n 0 079 in 2 Tightening torques 36 17lbf ft Hoses 18 08lbf ft 1 Adjustment of tilt lever 1 Tighten the bolts 17 until locking the steering column 2 Loosen the bolts 17 of L H side and R H side equally...

Page 148: ...REASSEMBLING Reassemble steering unit with reverse procedure of disassembling 1 STEERING UNIT REASSEMBLING 1 DUST SEAL 2 RETAINING NUT 3 SEAL GRAND BUSHING 4 O RING 5 OIL SEAL X RING 6 NEEDLE BEARING...

Page 149: ...nd tapped hole of housing Put the mark line at spline end surface of drive 23 to ensure the position 7 Install o ring 21 to rota set 24 8 Face o ring groove side of rota set 24 to spacer plate 22 and...

Page 150: ...ow Make sure that seal grand bushing is contacting to bearing race 7 1 Assemble the spool and sleeve that the groove for spring is alined 2 Make sure that the spool 17 can be turned smoothly 3 In case...

Page 151: ...ollowing values for reassembling as adjustment and service standard 1 Packing case tightening torque 72 33lbf ft Apply the threebond 1901 to thread In case of removing the hose take the following proc...

Page 152: ...Tightening torque of front bracket 61 48 68 71lbf ft 2 Tightening torque of chassis 61 48 68 71lbf ft 2 Direction of installation of dust seal and U packing is as shown in the following drawing 3 Afte...

Page 153: ...side of rods to be equalized dimension C and lock the lock nut Tightening torque of lock nut 108 50 122 96lbf ft Bolt head of rod bolt should be set to upper side 2 STEERING WHEEL FREE PLAY 1 Measure...

Page 154: ...to power steering and PTO clutch 2 Pump I disassembling 1 Remove fixing bolts 17 and remove cover 9 housing 1 backup elements 12 seal elements 13 busing 2 drive gear 3 bushing 14 bushing 5 driven gea...

Page 155: ...linkage at control valve spool and remove fixing bolts of control valve 3 bolts and lubrication pipe guide and control valve 2 Control valve disassembling 1 Remove plug at unload valve and remove spri...

Page 156: ...Lift shaft disassembling 1 Remove snap rings and remove lift arms 2 2 Remove colors 6 and o rings 5 3 Remove set bolt and washer at power arm 8 and remove lift shaft 1 with bushing 3 Do not hit shaft...

Page 157: ...and link 6 and remove link H 7 pin and collars 3 3 Remove spring 4 4 Remove snap ring at position shaft 9 and draft shaft 10 and disconnect from link B 17 5 Remove snap rings at link J 18 and remove l...

Page 158: ...control lever 2 Remove rod A 3 Remove plate F 4 FLOW CONTROL VALVE DISASSEMBLING 1 Loosen lock nuts 3 and remove screw 4 plate 5 washer and spring 6 2 Remove sleeve 8 ball 9 and spring 10 3 Remove fix...

Page 159: ...dard of reassembling 1 Tightening torque of pump bolts 18 08 21 7 lbf ft 2 Apply oil at o rings and oil seals for the assembling 2 CONTROL VALVE ASSEMBLING Reassemble and reinstall the control valve w...

Page 160: ...Aline the bolt hole for lock bolt on the power arm and lift shaft Tightening torque of lock bolt 8 68 12 3lbf ft 2 Aline the punch mark on the lift shaft and lift arm 2 Valve neutral adjustment 1 Put...

Page 161: ...bushings 3 to lift case Bushing should be placed with its seam coming as shown in the following drawing 5 Drive in bushing at lift shaft to 0 374 0 394 in deep as shown in the following drawing 6 Appl...

Page 162: ...he control valve adjust the dimension M to 132 2 132 8 mm with pushing the spool to make 0 0118 0 0354 in of clearance at T by adjusting position of plate 8 2 Sticking out amount N of screw on plate 8...

Page 163: ...ut until o ring groove comes to out side of housing Fit the o ring in the groove apply grease and pull in the shaft Drawing from 4501 7 53 2 Adjust side play S at link H 7 to be less than 0 0118in by...

Page 164: ...usting the rod A length 4 Flow control valve reassembling 1 Adjust the height of plate 7 by shim 1 and 2 to turn the screw 4 smoothly 2 Tightening torque of sleeve 8 61 48 68 71lbf ft 3 Adjust the pos...

Page 165: ...Assemble the parts with care not to get contamination to the hydraulic ports 2 Filter installation 1 Wipe the installation surface of filter base and apply the oil to the packing of filter for the in...

Page 166: ...165 3 Tightening torques of hydraulic line...

Page 167: ...tween 0 000984 lift shaft and 0 011811 bushing 0 003504 Clearance between 0 000787 piston rod and 0 011811 bushing 0 003268 Check the Shaft and replace it if seized Replace bushing if the inside coati...

Page 168: ...167...

Page 169: ...11 ELECTRICS 11 1 ELECTRIC DIAGRAM 168 169...

Page 170: ...Top Stud Terminals Alternator 12 Volt 50 Ampere Output Voltage Regulator IC Built in Alternator Starter Motor 12 Volt 2 kw with Solenoid Switch Head Lamp 35 Watt Flasher Lamp 23 Watt Rear Red Lamp 20...

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