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CHAPTER 3 8354/8404

3-12

D615-W02 May-2003

615W323A

615W322A

615W321A

2.6 DISASSEMBLY, MAINTENANCE

A. CLUTCH PEDAL CHECK AND ADJUST-

MENT

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

Play of clutch pedal (A)

Specified

30 ~ 40 mm

1.18 ~ 0.57 in.

(1) Clutch Pedal

(2) Clutch Rod

(3) Lock Nut

b. Second Stage (Adjustment of Clutch Pedal

Stopper Bolt)

1. W h e n w o r k i n g c l u t c h p e d a l w h e n c l u t c h i s

disconnected, avoid bolt setting to prevent exces-
sive force to clutch.

2. If setting (A) of stopper bolt exceeds the specified,

loosen lock nut (2), readjust the length, and then
set with lock nut.

Sect

Stopper bolt setting
length (A)

Specified

27 ~ 29 mm

1.06 ~ 1.14 in.

(1) Stopper Bolt

(2) Lock Nut

c. Third Stage (Adjustment of Safety Switch)

1. Measure clearance (A) of safety switch (1) and clutch

pedal (2).

2. If the measured value exceeds the specified, loosen

safety switch lock nut (3).

Readjust and then lock not to be loosen.

Sect

Clearance of safety switch
and clutch pedal (A)

Specified

3 ~ 4 mm

0.12 ~ 0.16 in.

(1) Safety Switch

(2) Clutch Pedal

(3) Lock Nut

•

Without working of clutch pedal, start
motor should not be prerated.

CAUTION

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

Summary of Contents for 8354

Page 1: ... 35 54 4 8 84 40 04 4 S SE ER RV VI IC CE E M MA AN NU UA AL L 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 ...

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Page 3: ...11 5 8 LUBRICANT 1 11 6 REGULAR CHECK LIST 1 12 7 OIL WATER SUPPLY LIST 1 13 CHAPTER 2 ENGINE SYSTEM 2 1 1 GENERAL 2 3 1 1 APPEARANCE 2 3 1 2 SPECIFICATIONS 2 4 1 3 PERFORMANCE CURVE 2 5 1 4 DIMENSIONS 2 6 1 5 GENERAL WARNING 2 6 2 STRUCTURE AND FUNCTION 2 7 2 1 BODY 2 7 2 2 LUBRICATING SYSTEM 2 11 2 3 COOLING SYSTEM 2 13 2 4 FUEL SYSTEM 2 15 3 DISASSEMBLING AND SERVICING 2 24 3 1 TROUBLESHOOTING ...

Page 4: ...HIFT 4 11 3 3 HI LO SHIFT 4 12 3 4 PTO SHIFT 4 12 3 5 CREEPER SPEED 4 12 3 6 MID PTO SHIFT 4 13 3 7 FRONT WHEEL DRIVE SHIFT 4 13 4 PTO CLUTCH 4 14 4 1 CHARACTERISTICS 4 14 4 2 HYDRAULIC CIRCUIT 4 14 4 3 OIL FLOW 4 15 5 DIFFERENTIAL GEAR 4 16 5 1 STRUCTURE 4 16 5 2 OPERATION 4 17 6 TROUBLESHOOTING 4 19 7 MAINTENANCE SPECIFICATION 4 20 8 TIGHTENING TORQUE 4 21 9 CLUTCH HOUSING 4 22 9 1 TRANSMISSION ...

Page 5: ...RVICE SPECIFICATION 5 5 4 DISASSEMBLY ASSEMBLY 5 6 4 1 DISCONNECTION OF REAR AXLE GROUP 5 6 4 2 DISASSEMBLY OF REAR AXLE 5 8 5 MAINTENANCE 5 9 5 1 BEARING CHECK 5 9 5 2 GEAR CHECK 5 9 5 3 CLEARANCE CHECK OF PLANETARY GEAR AND PLANETARY GEAR SHAFT 5 9 5 4 CHECK THRUST COLLAR FOR WORN 5 9 CHAPTER 6 BRAKE 6 1 1 STRUCTURE 6 3 2 OPERATION 6 4 3 TROUBLESHOOTING 6 5 4 MAINTENANCE SPECIFICATION 6 6 5 TIGH...

Page 6: ...FOR BEVEL GEAR BACKLASH AND TOOTH CONTACTED IN BEVEL GEAR CASE 7 19 9 4 CHECK FOR SHIM BETWEEN AXLE CASE SUPPORTAND FRONT AXLE CASE 7 19 9 5 CHECK FOR BACKLASH AND TOOTH CONTACTED BETWEEN BEVEL PINION SHAFT AND SPIRAL BEVEL GEAR 7 20 9 6 CLEARANCE CHECK BETWEEN DIFFERENTIAL PINION SHAFT AND DIFFERENTIAL PINION 7 21 9 7 CLEARANCE CHECK BETWEEN FRONT DIFFERENTIAL CASE DIFFERENTIAL CASE COVER AND DIF...

Page 7: ... OIL FILTER 9 7 5 2 FUNCTION AND OPERATION 9 7 6 CONTROL VALVE MLS VALVE 9 8 6 1 STRUCTURE 9 8 6 2 CIRCUIT DIAGRAM 9 8 6 3 OPERATION PRINCIPLE 9 9 7 RELIEF VALVE HYDRAULIC BLOCK 9 12 8 HYDRAULIC CYLINDER 9 13 9 STRUCTURE AND OPERATION 9 14 9 1 STRUCTURE 9 14 9 2 OPERATION 9 14 10 OUTSIDE HYDRAULIC EXTRACTION 9 18 10 1 HYDRAULIC BLOCK 9 18 10 2 ACTING VALVE 9 19 10 3 QUICK COUPLER 9 19 11 TOP LINK ...

Page 8: ...C SYSTEM 10 1 1 ELECTRONIC INSTRUMENTATION 10 3 1 1 INSTRUMENT GAUGE 10 3 1 2 INDICATORS AND WARNING LIGHTS 10 4 2 TROUBLE SHOOTING 10 6 3 SERVICING SPECIFICATIONS 10 8 4 MECHANISM 10 9 4 1 STARTING SYSTEM 10 9 4 2 CHARGING SYSTEM 10 12 4 3 PREHEATING SYSTEM 10 14 4 4 FUSE 10 15 4 5 GAUGE AND SENSORS 10 16 5 MAIN CIRCUIT DIAGRAM 10 17 www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 9: ...CHAPTER 1 GENERAL INFORMATION www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

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Page 11: ...GENERAL INFORMATION 1 3 D615 W02 May 2003 615W101A 1 TRACTOR VIEW www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 12: ...4 0 4 6 6 4 7 4 11 0 12 8 17 0 19 5 25 0 29 0 34 0 40 0 lbf ft 5 79 6 87 13 0 15 2 29 0 33 2 46 3 53 5 79 6 92 5 123 141 181 210 246 289 N m 9 80 11 2 23 6 27 4 48 1 55 8 77 5 90 1 124 147 196 225 275 318 368 431 Kgf m 1 00 1 15 2 4 2 8 4 9 5 7 7 9 9 2 12 6 15 0 20 0 23 0 28 0 32 5 37 5 44 0 lbf ft 7 24 8 32 17 4 20 2 35 5 41 2 57 2 66 5 91 2 108 145 166 203 235 272 318 N m 12 3 14 2 29 4 34 3 60 ...

Page 13: ...1 lbf ft 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 Tightening N m Torque kgf m lbf ft 1 8 9 8 1 7 2 1 4 24 5 2 5 18 0 1 4 24 5 2 5 18 0 3 8 49 0 5 36 1 3 8 49 0 5 36 1 1 2 58 8 6 43 3 3 4 117 7 12 86 8 1 137 3 14 101 2 www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 14: ...odel Type Number of cylinders Bore and stroke Total displacement Rated revolution Injection timing Injection order Compression ratio Lubricating system Cooling system Alternator Weight Dry Fuel tank Engine crankcase Engine coolant Transmission case Front axle case Overall length without 3p Overall length with 3p Overall width minimum tread Overall height Top of ROPS Wheelbase Ground clearance Capa...

Page 15: ...6 reverse speeds Wet disc type Connected with the traveling brake Bevel gear Position Draft and Mixed control 29 7 min 7 8 U S gal 17 8 min 4 7 U S gal SAE Category l SAE 1 3 8 6 splines Min turning radius without brake Traction system Weight with ROPS Traveling speed at 2700 engine speed with Std tires Forward creeper Reverse creeper Brake Traveling Parking Differential Hydraulic lift control sys...

Page 16: ...in the figure Engine serial number provides important information 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 1 Manufacture Plate 2 Transmission Serial Number 1 Engine Serial Number www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 17: ... shall be arranged orderly 2 Sort out the parts to be replaced from the ones to be reused 3 Be sure to use standard bolts and nuts that are designated 4 When assembling snap rings or spring pin types take care of assembling direction 5 Split pin shall be spread surely not to escape when installed 6 When using sealant such as gasket bond on the assembled surfaces apply it evenly and consis tently i...

Page 18: ...talling Disconnect battery negative terminal 4 Remove the connector by pulling the plastic section not the wiring 5 When connecting the connector insert it until it snaps 6 Be sure not to drop sensors and relays which are fragile 7 When replacing a broken fuse with a new one be sure to use the fuse of capacity as specified Be sure to turn the starting key OFF when connecting or disconnecting the c...

Page 19: ...other petroleum products on the hoses and rubber parts this may cause damage When assembling and fixing apply designated lubri cant where specified in accordance with this repair manual 5 7 TUBES AND RUBBERS 5 8 LUBRICANT www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 20: ...r hose s inlet bands if loosened Fuel pipe change Radiator hose change Hydraulic pipe joint change Steering hose change Toe in Deflection adjustment in front and rear of the front axle Direction control section Bolt nuts and pins of each part Battery positive code adjustment change Bleeding water in clutch housing Check injection nozzle 1yr 2yr Indicated Hours By Hour Meter Since Purchased 800 700...

Page 21: ...xits Supply when removed Recommended Spec No 2 D diesel fuel No 1 D diesel fuel if temperature is below 10 C 14 F Fresh clean water with antifreeze SAE 15 W 40 Universal tractor transmission hydraulic oil SAE multi purpose type grease Applying Grease Hydraulic control lever shaft section 3 point link section Brake pedal link section Bracket section in front and rear of the front axle Clutch releas...

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Page 23: ...CHAPTER 2 ENGINE SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 24: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 25: ...cle three or four cylinders diesel engines they concentrate DAEDONG s foremost technologies With swirl combustion chamber bosch K type fuel in jection pump well balanced designs they feature greater power low fuel consumption less vibration and noise and low emission www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 26: ...type 33 5 2 700 HP rpm 30 0 2 700 kW rpm 2 900 rpm 850 900 rpm 1 2 3 Counterclockwise viewed from flywheel side Bosch K TYPE mini pump 140 150 kgf cm 13 73 14 71 MPa 1 991 2 133 psi 18 22 1 Diesel fuel Engine oil SAE 15W 40 722 3 x 488 1 x 729 9 mm 28 4 x 19 2 x 28 7 in 179 kg 395 lbs 4A200B Vertical water cooled 4 cycle diesel engine 4 83 x 92 4 mm 3 27 x 3 64 in 1 999 cc 122 0 in3 Spherical type...

Page 27: ...ENGINE SYSTEM 2 5 D615 W02 May 2003 615W204A 615W203A 1 3 PERFORMANCE CURVE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 28: ...or connecting instru ments to electrical equipment first disconnect the battery negative terminal Replace gaskets or O rings with new ones when reassembling and apply grease on a O ring and the oil seal when reassembling When exchanging parts use Cub Cadet parts to maintain engine performance and safety To prevent oil and water leakage apply non drying adhesive to the gaskets according to this man...

Page 29: ...e DAEDONG vortex type combustion chamber is de signed for high combustion efficiency and reducing fuel consumption The glow plug assures easier than ever engine starts even at 15 C 5 F 1 Combustion Chamber 2 Inlet Port 3 Exhaust Port 4 Injection Nozzle 5 Glow Plug 6 Cylinder Head B CYLINDER BLOCK The engine has a high durability tunnel type cylinder block Furthermore liner less type allows effecti...

Page 30: ...l to the cylinder wall The second ring 2 is an undercut type which pre vents the oil from being carried up The oil ring 3 has chambered contact faces and an expander ring which increase the pressure of the oil ring against the cylin der wall to scrape the oil The top ring is plated with hard chrome to increase wear resistance The ring of 4A200T engine is made of a special steel E CONNECTING ROD Th...

Page 31: ...t 5 Rocker Arm Shaft 3 Adjusting Screw F CAMSHAFT The camshaft 3 is made of forged steel and its jour nal 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 force lubricated G FUEL CAMSHAFT This fuel camshaft is made of forged steel and its cams are hardened an...

Page 32: ...The appropriate timing can be obtained by aligning the mark on the crankshaft gear 6 with one the idle gear 5 idle gear with camshaft gear idle gear with injec tion pump gear when assembling 1 Injection Pump Gear 5 Idle Gear 2 Fuel Camshaft 6 Crankshaft Gear 3 Camshaft Gear 7 Crankshaft 4 Camshaft K FLYWHEEL The flywheel is installed on the rear end of the crankshaft Its inertia keeps the flywheel...

Page 33: ...ther The inner rotor which is driven by the crankshaft through the gears rotates the outer rotor in the same direction varying the space between the lobes While the rotors rotate from A to B the space lead ing to the inlet port increases which causes the oil to flow through the inlet port When the rotors rotate to C the port to which the space leads is changed from inlet to outlet At D the space d...

Page 34: ...l pressure rises more than 441 kPa 4 5 kgf cm 64 psi D 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 1 1 Bypass Valve 2 Bypass Adjusting Spring 3 Filter Element 4 Relief Valve Ball 5 Rel...

Page 35: ...adiator 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 When the water temperature is high the thermostat opens to allow the water to flow from the cylinder block to the radiator When the water temperature is low the thermostat...

Page 36: ...to allow the water to enter the radiator 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 The valve ...

Page 37: ... cylinders for combustion The excessive fuel from the injection pump to the injection nozzles is collected in the fuel overflow pipes 6 and returns to the fuel tank B FUEL FILTER The fuel filter removes dirt and water with its fine filter paper which collects particles of 90 microns 0 0034 in at 20 kPa 0 2 kgf cm 3 psi The fuel from the fuel feed pump is filtered by the filter element 6 while flow...

Page 38: ... Discharge Stroke When the diaphragm is pushed up by the cam the pressure in the chamber causes the inlet valve to close and forces out the fuel opening the outlet valve D FUEL INJECTION PUMP The injection pump is Bosch K type mini injection pump It features a compact and light weight design a From Fuel Tank b To Fuel Filter 1 Inlet Valve 5 Chamber 2 Push Rod 6 Diaphragm 3 Tappet 7 Fuel Camshaft 4...

Page 39: ... fuel chamber 5 B Beginning of Delivery When the plunger is pushed up by the cam and the head of the plunger closes the feed hole 4 the pres sure in the delivery chamber 1 rises to push the deliv ery valve 3 open C Delivery While the plunger 2 is rising delivery of fuel continues D End of Delivery When the plunger rises further and the control groove 6 on its periphery meets the feed hole the fuel...

Page 40: ...in the delivery chamber does not build up and no fuel is forced to the injection nozzle B Fuel Delivery The plunger is rotated by the control rack and the feed hole is not aligned with the lengthwise slot When the plunger is pushed up the feed hole is closed by the plunger The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until the control groove 6 meets th...

Page 41: ...ove the durability and reliability of the nozzle F GOVERNOR AND IDLE COMPENSATING a Disassembled View The governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load The en gine employs an all speed governor which controls centrifugal force of the steel ball 13 weight produced by rotation of the fuel camshaft 9...

Page 42: ...f steel ball 13 and forces start spring 1 governor spring 2 3 and idling limit spring are balanced providing stable idling IMPORTANT The idling speed has been factory set The idling adjusting screw 20 and spring 16 should not be disassembled and readjusted 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...

Page 43: ...sting bolt 17 After that when the force of torque spring 18 becomes greater than the centrifugal force of the steel ball fork lever 1 4 moves rightward to increase fuel injection causing the engine to run continuously at a high torque 4 To stop engine When the stop lever 19 is moved to the STOP position fork lever 1 4 is moved leftward and the control rack 14 is moved to the non injection position...

Page 44: ...R 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 The fine dust in the air is filtered with the air cleaner element 4 and the filtered air flows to the outlet port 1 A FLOW OF INTAKE AIR AND EXHAUST GAS a Intake Air b Exh...

Page 45: ...er clogged or dirty Air cleaner clogged Fuel leak due to loose injection pipe retaining nut Injection pump malfunctioning Incorrect nozzle opening pressure Nozzle stuck or clogged Fuel over flow pipe clogged Governor malfunctioning Replenish fuel Vent air Change fuel and repair or flush fuel system Clean Clean or replace Use the specified fuel or engine oil Use the specified fuel Tighten nut Adjus...

Page 46: ...essive oil clearance of crank pin bearings Excessive oil clearance of rocker arm bushings Oil passage closed Improper type of oil Oil pump defective Reduce to the specified level Repair or replace Adjust Adjust top clearance Lessen the load Use the specified fuel Clean or replace Clean or replace Adjust Repair or replace Repair or replace the injection pump Repair or replace the nozzle Replace hea...

Page 47: ...rect injection timing Unsuitable fuel used Battery electrolyte insufficient Fan belt slips Wiring disconnected Regulator defective Alternator defective Battery defective Use the specified type of oil Replace Replenish Replace or adjust Replenish Clean Clean or replace Clean or replace Replace Replace Replace Replace Replace Lesson the load Replace Adjust Use the specified fuel Replenish distilled ...

Page 48: ... Cylinder Head Gasket Thickness Free Tightened Compression Pressure When cranking with starting motor Variance of compression pressure among cylinders should be 10 or less b Valves 0 25 mm 0 0098 in 0 30 mm 0 0118 in 1 047 rad 60 0 785 rad 45 1 047 rad 60 0 785 rad 45 0 2 0 5 mm 0 0079 0 0197 in 0 040 0 070 mm 0 00157 0 00276 in 7 960 7 975 mm 0 31339 0 31398 in 8 015 8 030 mm 0 31555 0 31614 in 0...

Page 49: ...00244 in 23 959 23 980 mm 0 94327 0 94410 in 24 000 24 021 mm 0 94488 0 94571 in 0 07 mm 0 0028 in Item Factory Specification Allowable Limit Clearance between tappet and guide Tappet O D Tappet guide I D h Camshaft 0 01 mm 0 0004 in 33 59 mm 1 3224 in 33 69 mm 1 3264 in 0 050 0 091 mm 0 00197 0 00358 in 39 934 39 950 mm 1 57221 1 57284 in 40 000 40 025 mm 1 57480 1 57579 in 0 05 mm 0 0020 in 33 5...

Page 50: ...05 mm 0 07992 0 08070 in 1 97 1 99 mm 0 07756 0 07834 in 0 25 0 40 mm 0 0098 0 01570 in 0 55 0 70 mm 0 0217 0 0276 in 25 03 mm 0 9854 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 1 25 mm 0 0492 in 1 25 mm 0 0492 in Item Factory Specification Allowable Limit Piston pin bore I D Clearance between Oil ring and ring groove Oil ring groove width Oil ring width Clearance between 2nd ring and ring groove 2nd r...

Page 51: ...aft bearing 1 I D Clearance between Crankshaft and crank shaft bearing 2 Crankshaft O D Crankshaft bearing 1 I D Clearance between Crank pin and crank pin bearing Crank pin O D Crank pin bearing I D Crankshaft side clearance B LUBRICATING SYSTEM a Oil Pump more than 49 0 kPa 0 5 kgf cm2 7 11 psi 245 441 kPa 2 5 4 5 kgf cm2 35 6 64 0 psi 0 10 0 16 mm 0 0039 0 0063 in 0 11 0 19 mm 0 0043 0 0078 in 0...

Page 52: ...conds or more for pressure falling from 88 59 kPa from 0 9 0 6 kgf cm2 from 13 9 psi 7 9 mm 0 28 0 35 in D FUEL SYSTEM a Inject Pump b Injection Nozzle Fuel injection pressure Fuel tightness of nozzle valve seat 13 73 14 715 MPa 140 150 kgf cm2 1 991 2 134 psi No fuel leak for 5 sec at pressure 12 74 MPa 130 kgf cm2 1 849 psi NOTE Injection Sequence Four Cylinders 1 3 4 2 Three Cylinders 1 2 3 The...

Page 53: ... 0 48 1 55 9 32 4 37 3 19 6 24 5 14 7 19 6 49 1 68 7 24 5 34 3 kgf m 10 5 11 0 0 9 1 1 4 7 5 2 7 0 7 5 10 0 11 0 4 5 5 0 4 9 5 7 3 3 3 8 2 0 2 5 1 5 2 0 5 0 7 0 2 5 3 5 lbf ft 75 9 79 6 6 5 8 0 34 0 37 6 50 6 54 2 72 3 79 6 34 0 37 6 35 4 41 2 23 9 37 3 14 5 18 1 10 8 14 5 36 2 50 6 18 1 25 3 NOTE For marked screw bolts and nuts on the table apply engine oil to their threads and seats before tight...

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Page 55: ...linder Hear Cover 18 Push Rod 19 Tappet 20 Camshaft 21 Camshaft Gear 22 Idle Gear 23 Piston 24 Connecting Rod 25 Crankshaft 26 Flywheel 27 Flywheel Housing 28 Starter 29 Injection Pipe 30 Glow Plug 31 Nozzle 32 Fuel Injection Pump 33 Fuel Feed Pump 34 Fuel Camshaft 35 Fuel Camshaft Gear 36 Engine Stop Solenoid 37 Speed Control Plate 38 Fork Lever Governor 39 Impeller 40 Thermostat 41 Alternator 42...

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Page 57: ... body 1 Remove the muffler and exhaust manifold 7 2 Remove the starter 9 and the oil pressure switch 8 3 Pull out the oil gauge 6 4 Remove the alternator 5 and the fan belt 1 5 Remove the hour meter unit 2 6 Loosen the oil filter 3 with a filter wrench and re move it and the oil filter flange 4 When reassembling Apply liquid gasket three bond 1 215 or equivalent on the thread of the oil pressure s...

Page 58: ...stop lever 2 Pushing the solenoid 7 plunger to the bottom pull the stop lever 2 6 until the engine stop lever 2 is turned to the end then tighten the screws 3 Intake manifold and fuel pipes 1 Disconnect the fuel pipe 3 2 Loosen the injection pipe fitting with two wrenches and remove the injection pipes 2 3 Remove the intake manifold 1 and the fuel feed pump 4 IMPORTANT Tighten or loosen injection ...

Page 59: ...pressure does not reach the allowable limit apply a small amount of oil to the cylinder wall through the nozzle holder hole and check the pres sure again 7 If the pressure raises after oil is apply check the cylinder wall and piston ring 8 If the pressure is still low check the top clearance valve clearance and cylinder head NOTE Check the compression pressure with the specified valve clearance fo...

Page 60: ...heel 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 If the clearance is not within the factory specifications turn the adjusting screw to adjust 5 Turn the flywheel just one turn to po...

Page 61: ...e NOTE Use a philips screw driver that has a diameter which is bigger than the heat seal hole 1 4 in approx φ 6mm C Rocker arm assembly 1 Loosen the nuts in several steps and the specified sequence shown in the figure and remove them 2 Remove the rocker arm assembly and the push rod When reassembling Rest the end of push rod at the indent of tappet and install the rocker arm assembly Tighten the n...

Page 62: ...PORTANT Apply oil to the thread of screws and tighten in sev eral steps and the specified sequence shown in the figure to the specified torque Check the torque after 30 minutes operation of the assembled engine and adjust valve clearance Tightening torque Cylinder head screws 103 0 107 9 N m 10 5 11 0 kgf m 75 9 79 6 lbf ft 1 Cylinder Head 2 Water Flange E Valve 1 Compress the valve spring with a ...

Page 63: ...ing Gears and Camshafts A Injection pump 1 Remove the injection pump cover 3 with the en gine 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 Install the injection pump cover with the arm of en gine stop...

Page 64: ...ing 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 D Fan drive pulley 1 Install the stopper to the flywheel so that the crank shaft may not turn 2 Flatten the metal lock and loosen the crankshaft nut 2 3 Remove the fan drive fan dr...

Page 65: ...e gear 1 3 Remove the crankshaft gear 2 with a special use puller set When reassembling Heat the crankshaft gear to approx 80 C 176 F and insert the crankshaft Apply oil to the O ring 5 Tightening torque Relief valve cover screw 32 4 36 3 N m 3 3 3 7 kgf m 23 9 26 8 lbf ft 1 Water Pump Body 2 Relief Valve Cover IMPORTANT Install the idle gear aligning the alignment marks referring to the figure 1 ...

Page 66: ...r screws remove the fuel camshaft 4 with fork lever holder 5 fork lever 1 1 and 2 2 3 Remove the Injection pump gear 3 When reassembling Heat the injection pump gear to approx 80 C 176 F and insert the camshaft 4 2 Connecting rod and piston A Oil pan and oil filter 1 Remove the oil pan 2 Remove the oil strainer 1 When reassembling Be sure to install the O ring 2 between the oil strainer and the cy...

Page 67: ...ng the injection pump us ing a piston ring compressor IMPORTANT Mark the cylinder number on the piston and con necting rod to prevent interchanging Carefully insert the piston and ring assembly in the cylinder compressing the rings not to damage the chrome plate on the piston rings If the connecting rod cap screws can not be screwed to the end by hand replace the screw 615W287A 1 Piston Pin 2 Pist...

Page 68: ... 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 Install the piston rings with their manufacture s mark to the top of...

Page 69: ...e main bearing case 1 2 3 1 2 Remove the thrust bearing from the flywheel end bearing case 1 Main Bearing Case 1 2 3 2 Thrust Bearings 3 Main Bearing Case Assembly 1 4 Bearing Case Screw 1 5 Crankshaft Bearing 2 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 t...

Page 70: ...tive liquid A 4 Wash away the red permeative liquid on the cylin der head surface with the detergent B after ten minutes 5 Spray the cylinder head surface with the white de veloper C 6 If any flaw is found such as a red mark replace the cylinder head A Red Permeative Liquid B Detergent C White Developer 615W294A Tightening torque Bearing case screw 1 46 1 51 0 N m 4 7 5 2 kgf m 34 0 37 6 lbf ft IM...

Page 71: ...alve face evenly 4 Put the valve on its seat hold it with the valve flapper 5 Turn and lap the valve back and forth on the valve seat to lap 6 Remove the compound and clean the valve and the seat 7 Apply oil on the valve face and finish to complete fitting 8 Repeat lapping until the valve seats correctly 615W297A C Valve stem clearance 1 Remove the carbon from the valve guide 2 Measure the valve s...

Page 72: ... G Valve spring squareness Tilt 1 Place the spring on the surface plate and a square at its side 2 Measure the maximum distance A See figure ro tating spring 3 If the measurement exceeds the allowable limit re place Valve spring square ness Allowable limit 1 0 mm 0 039 in 615W2A0A F Valve spring 1 Measure the free length of the spring with venire calipers 2 Place the spring on a spring compression...

Page 73: ...m gear 2 and the camshaft stopper 3 3 If the clearance exceeds the allowable limit replace the camshaft stopper 3 Side clearance Factory spec Allowable limit 0 07 0 22 mm 0 0028 0 0087 in 0 3 mm 0 0118 in 1 Camshaft 3 Camshaft Stopper 2 Cam Gear Factory spec Allowable limit 615W2A3A 2 Timing gears and camshafts A Timing gear backlash 1 Set a dial indicator lever type with its tip on the gear tooth...

Page 74: ...nce Shaft O D Bushing I D Factory spec Allowable limit Factory spec Factory spec 0 025 0 066 mm 0 00098 0 00259 in 0 1 mm 0 004 in 37 959 37 975 mm 1 4944 1 4950 in 38 000 38 025 mm 1 4961 1 4970 in 615W2A6A D Injection pump gear side clearance 1 Pull the fuel camshaft and pull the injection pump gear 1 to each end 2 Measure the clearance A between the injection pump gear 1 and the snap ring 2 on ...

Page 75: ...ement is less than the allowable limit replace the camshaft Cam height Specification Allowable limit Specification Allowable limit 33 59 mm 1 322 in 33 54 mm 1 320 in 33 69 mm 1 326 in 33 64 mm 1 324 in 3A165 4A200 IN EX 615W2A9A G Camshaft oil clearance 1 Measure the I D of the camshaft bore on the crank case with an inside micrometer 2 Measure the O D of the camshaft journal with an outside micr...

Page 76: ... tool IMPORTANT Align the oil holes of the connecting rod and the bushing Piston pin and bushing clearance Piston pin O D Bushing I D Factory spec Allowable limit Factory spec Factory spec 0 014 0 038 mm 0 00055 0 00150 in 0 15 mm 0 0059 in 25 002 25 011 mm 0 98433 0 98469 in 25 025 25 040 mm 0 98524 0 98583 in 615W2B2A 3 Connecting rod and piston A Piston pin bore 1 Measure the I D of piston pin ...

Page 77: ... Allowable limit 0 04 0 08 mm 0 00157 0 00314 in 0 15 mm 0 0059 in 0 02 0 06 mm 0 00079 0 00236 in 0 15 mm 0 0059 in 2nd ring Oil ring 615W2B5A 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 ...

Page 78: ...he side bearing Deflection End play Allowable limit Factory spec Allowable limit 0 05 mm 0 0020 in 0 15 0 31 mm 0 0059 0 0122 in 0 5 mm 0 020 in 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 again...

Page 79: ...l taking due care to see that the seam of bearing 1 faces the exhaust manifold side Oil clearance Journal O D Bearing 1 I D Factory spec Allowable limit Allowable limit Allowable limit 0 040 0 118 mm 0 00157 0 00465 in 0 20 mm 0 0079 in 51 921 51 940 mm 2 04413 2 04488 in 51 980 52 039 mm 2 04646 20 4878 in 1 Seam 615W2B9A B Crankshaft alignment 1 Support the crankshaft with V blocks on the surfac...

Page 80: ...0 00343 in 0 20 mm 0 0079 in 46 959 46 975 mm 1 84878 1 84941 in 47 000 47 046 mm 1 85040 1 85221 in 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...

Page 81: ...Measure the cylinder liner I D at sit positions shown in the figure to find the maximum wear 4A200B 3A165D 83 000 83 022 mm 3 2677 3 269 in 87 000 87 022 mm 3 425 3 4261 in A Axial Direction B Transverse Direction 1 2 3 Measuring Points www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 82: ...f cm 35 6 64 0 psi 245 kPa 2 5 kgf cm 35 6 psi At idle speed At rated speed Reference Tightening torque Oil pressure switch 14 7 19 6 N m 1 5 2 0 kgf m 10 8 14 5 lbf ft B Oil filter and relief valve 1 Drain the engine oil and remove the oil filter to check it 2 Check the relief valve for dirt and the seat 2 and ball 1 for damage 3 If damaged replace 4 Check the free length of spring 3 5 If it is l...

Page 83: ...0423 0 00591 in 0 20 mm 0 0079 in b Servicing A Rotor and lobe clearance of oil pump 1 Measure the clearance between the outer and in ner 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 Outer and inner housing clearance Factory spec Allowable limit...

Page 84: ... with water to the specified amount and warm up the engine 2 Set a radiator tester and raise the water pressure to the specified pressure 3 Check the radiator for water leaks 4 For water leak from the pin hole repair with a radia tor cement and for other leaks replace the radiator Radiator water tightness Factory spec No leaks at 137 kPa 1 4 kgf cm 20 psi C Radiator cap tightness 1 Set a radiator ...

Page 85: ... 8 mm 0 315 in Of opening 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 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 Remove th...

Page 86: ...lent to the shim when reassembling Reference The timing advances by removing 0 15 mm 0 006 in of shim and retards by adding one approx 0 26 rad 1 5 of crank angle Approx 3 6 mm 0 142 in of turn at the outer rim of the flywheel equals 0 26 rad 1 5 of crank angle 1 Delivery Valve Holder 2 Shim B Delivery valve fuel tightness 1 Remove the injection pipes glow plugs and the in let manifold and install...

Page 87: ...si 1 Adjustment Washer 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 specifi cations adjus...

Page 88: ...ing its direction 1 Nozzle Holder 5 Distance Piece 2 Adjusting Washer 6 Nozzle 3 Nozzle Spring 7 Nozzle Nut 4 Push Rod 615W2E0A c Disassembling and Assembling 1 Injection pump IMPORTANT If replacing the pump element the amount of fuel injection should be adjusted on specified bench 1 Pump Body 5 Delivery Valve 2 Control Rack 6 Tappet Roller 3 Delivery Valve Holder 7 Cylinder 4 Delivery Valve Sprin...

Page 89: ...CHAPTER 3 CLUTCH www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 90: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 91: ...Y 1 1 DISASSEMBLY OF PANEL FRAME A FIRST STAGE 1 Disassemble side cover 1 bonnet 2 front grill assembly 3 and cover low 4 1 Side Cover Left Right 2 Bonnet 3 Front Grill Assembly 4 Cover Low Left Right www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 92: ...isconnect panel wiring harness assembly 9 and fender wiring harness assembly 10 5 Disconnect clutch rod 11 1 Steering Hose Assembly T 2 Steering Hose Assembly P 3 Steering Hose Assembly L 4 Steering Hose Assembly R 5 Frame Cover 6 Parallel Pin 7 Accelerator Cable 8 Indicator Cable 9 Panel Wiring Harness Assembly 10 Fender Wiring Harness Assembly 11 Clutch Rod 615W302A 615W303A 615W304A B SECOND ST...

Page 93: ...ng Port T P R L Hose Type Steering hose assembly T Green Steering hose assembly P Red Steering hose assembly R White Steering hose assembly L Yellow When connecting power steering unit hose see the specified torque Hose connecting nut tightening torque 46 6 58 9 N m 4 8 5 2 kgf m 18 1 21 7 lbf ft 1 Steering Hose Assembly T 2 Steering Hose Assembly P 3 Steering Hose Assembly R 4 Steering Hose Assem...

Page 94: ...b 4 Knob Range Lever 5 Knob Position Control Lever 6 Knob External Hydraulic Lever 7 Knob Front Wheel Lever 8 Transmission Shift Lever Guide 9 Hydraulic Lever Guide 10 Seat Lower Assembly 11 Differential Clamping Rod 12 Spring 13 Rear Light 14 Work Light 15 Stepladder Assembly 16 Bolt 17 Bolt www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 95: ...ctor from rear fender light 13 and work light 14 7 Loosen locking bolts 16 and 17 from the step ladder assembly 15 and seat lower assembly 10 Sect Stepladder assembly and seat lower assembly locking nut ROPS locking bolt nut Spec M16 M14 M12 Tightening Torque 196 225 N m 20 0 23 0 kgf m 145 166 lbf ft 166 7 196 1 N m 17 0 20 0 kgf m 123 144 lbf ft 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft B SEC...

Page 96: ... 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 PTO Clutch Is a wet multi plate clutch Control the PTO switch to connect and disconnect power of the PTO 5 Clutch Release Fork 6 Propulsion Shaft Case 7 Main Clutch Lever www mymowerparts com K T Saw Shop 606 678 9623 or 606...

Page 97: ... release hub pushes dia phragm spring 8 of clutch cover assembly 7 re leases clutch disc 10 between clutch pressure plate 9 and flywheel 11 and then disconnects power from engine 1 Clutch Pedal 2 Clutch Rod 3 Main Clutch Lever 4 Clutch Release Fork 5 Clutch Release Hub 6 Release Bearing 7 Clutch Cover Assembly 8 Diaphragm Spring 9 Pressure Plate 10 Clutch Disc 11 Flywheel www mymowerparts com K T ...

Page 98: ...ent Clutch disc boss worn or dusty Gear shaft bent Pressure plate or flywheel cracked or scratched Clutch disc spline boss or gear shaft spline worn Diaphragm spring not operating constantly or broken Clutch disc spline boss worn Thrust ball bearing worn or sticking Thrust ball bearing sticking or dry Clutch disc worn excessively Gear shaft bent Clutch disc rivet worn or broken Clutch parts broken...

Page 99: ...ce 0 3 mm 0 012 in 2 0 mm 0 079 in 0 2 mm 0 008 in 0 5 mm 0 020 in Allowable Limit 2 5 TIGHTENING TORQUE Clutch pedal Stopper bolt setting length Clearance between safety switch and clutch pedal Depth from disc to the top of rivet Play of clutch disc O D Pressure plate Diaphragm spring Item Play Height Gap Depth Displacement Flatness Difference 30 40 mm 1 18 1 57 in 27 29 mm 1 06 1 14 in 3 4 mm 0 ...

Page 100: ...edal when clutch is disconnected avoid bolt setting to prevent exces sive force to clutch 2 If setting A of stopper bolt exceeds the specified loosen lock nut 2 readjust the length and then set with lock nut Sect Stopper bolt setting length A Specified 27 29 mm 1 06 1 14 in 1 Stopper Bolt 2 Lock Nut c Third Stage Adjustment of Safety Switch 1 Measure clearance A of safety switch 1 and clutch pedal...

Page 101: ...ice that assembly direction and shorter spline boss A should be located toward flywheel when assembling clutch disc Take care to treat clutch disc and clean each fiction surface of flywheel and clutch pressure plate IMPORTANT When attaching the clutch cover 4 and clutch disk 5 with the flywheel you should set the clutch disk 5 in the right position And then tight bolt equally in the diagonal direc...

Page 102: ...Diameter Allowable Limit 2 0 mm 0 079 in b Check of Thrust Ball Bearing 1 Check to see if contacted is worn excessively 2 With inner wheel seized and outer wheel loaded check for abnormal noise or operation 3 If faulty replace it c Check of Worn Clutch Disc 1 Using a depth gauge measure the depth from the disc to rivet 2 If the measured value exceeds the allowable limit replace it Sect Depth to up...

Page 103: ...ty 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 Fatness of clutch pressure plate Allowable Limit 0 2 mm 0 008 in 1 Straight Rule 2 Gab Gauge www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 104: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 105: ...CHAPTER 4 TRANSMISSION www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 106: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 107: ... Stage Shuttle Synchro mesh Forward Reversing Hi Lo Shift Constant mesh 2nd Stage Low High Speed Creep Speed Constant mesh 2nd Stage Low High Speed PTO Fixed 1st Stage 1 Clutch Pack for PTO 2 Hi Low Shift Section 3 Creep Shift Section IF APPLICABLE 4 Main Gear Shift Section 5 Shuttle Shift Section 6 Front Wheel Drive Shift Section 7 MID PTO Section www mymowerparts com K T Saw Shop 606 678 9623 or...

Page 108: ...haft 1st Stage 25 Gear shaft 1 26 Gear 2 Main gear shaft 3 11 gear 7 36 gear 15 Shift 13 Synchro hub 14 Counter shaft 16 2nd Stage 25 Gear shaft 1 26 Gear 2 Main gear shaft 3 14 Gear 6 33 Gear 12 Shift 13 Synchro hub 14 Counter shaft 16 3rd Stage 25 Gear shaft 1 26 Gear 2 Main gear shaft 3 19 Gear 5 29 Gear 11 Shift 10 Synchro hub 9 Counter shaft 16 4th Stage 25 Gear shaft 1 26 Gear 2 Main gear sh...

Page 109: ...not slipped any longer by synchronizer ring 5 it will fall from shift 3 and the key will enter the groove of the synchronizer ring Synchronizer key shift and synchro hub 1 starts to rotate and the synchronizer ring and gear 6 ro tates simultaneously by tightening the chamfering of the shift and synchronizer ring 1 Synchro Hub 4 Synchronizer Spring 2 Synchronizer Key 5 Synchronize Ring 3 Shift 6 Ge...

Page 110: ...r 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 1 Synchro Hub 4 Synchronizer Spring 2 Synchronizer Key 5 Synchronize Ring 3 Shift 6 Gear www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 111: ...ft 5 2 2 SHUTTLE Employs double synchro mesh type with 8th stage in forward or reverse and improves the transmis sion shift power and durability as the contacted amount of cone increased twice 1 Shuttle Shaft 2 Spline Hub 3 Shift 4 19 Gear 5 23 21 Gear Shaft 6 23 Gear Power Transmission Flow Chart 7 16 Gear 8 18 Gear 9 21 Gear A FORWARD B REVERSE www mymowerparts com K T Saw Shop 606 678 9623 or 6...

Page 112: ...evel pinion gear 9 1 Hi Lo Shift Shaft 2 Spline Boss 3 Shift 4 18 Gear 5 32 Gear 6 42 Gear 2 3 HI LO SHIFT With High Low stage employs selective engage ment method and when setting the Hi Lo shift lever to the transmission position the power will be trans mitted Power Transmission Flow 7 17 Gear 8 42 17 18 Gear 9 Spiral Bevel Pinion Gear A HIGH SPEED B LOW SPEED www mymowerparts com K T Saw Shop 6...

Page 113: ...2 23 Gear 3 23 19 Gear 4 19 Gear 5 33 Gear 6 Counter shaft PTO 7 PTO clutch assembly 8 12 Gear shaft 9 12 Gear 10 30 Gear 11 PTO drive shaft 12 PTO shaft 13 Applicable Model 8354 8404 PTO type Independent PTO PTO stage 1st stage fixed type PTO rpm Engine rpm 540 2505 1 22 Gear Shaft PTO 2 22 Gear 3 23 Gear 4 23 19 Gear 5 19 Gear 6 33 Gear 7 Counter Shaft PTO 2 5 REAR PTO The independent PTO method...

Page 114: ... Lo shift lever and creep speed lever to the transmission position the power will then be transmitted A Power Transmission Flow Low Speed 42 17 18 Gear 1 18 Gear 2 41 Gear 4 13 Gear shaft 5 13 Gear 6 46 Gear 3 Spiral bevel pinion gear 7 High Speed 42 17 18 Gear 1 18 Gear 2 46 Gear 3 Spiral bevel pinion gear 7 1 42 17 18 Gear 5 13 Gear Shaft 2 18 Gear 6 13 Gear 3 46 Gear 7 Spiral Bevel Pinion Gear ...

Page 115: ...rm will be engaged with trans mission fork 5 in 3rd and 4th stage If the lever is moved to the front or rear 3rd and 4th transmission shift will be engage 1 Transmission Shift Lever 2 Main Transmission Shift Rod 3 Transmission Arm 4 Transmission Fork 1st 2nd 5 Transmission Fork 3rd 4th 6 Bearing Case 615W415A 3 2 SHUTTLE SHIFT Shuttle lever 1 is located to the left of the steering wheel and connec...

Page 116: ...615W416A 3 4 SHIFT 8354 and 8404 models employs 1st stage fixed type and enables manual or auto operation by means of a switch 3 3 HI LO SHIFT Aux transmission shift lever 1 is located towards the left of the driver s seat and is connected to Hi Lo shift rod 2 Hi Lo shift lever 1 3 Transmis sion arm 4 and the Transmission fork 5 If pushing Hi Lo shift lever forward Low Speed transmission shift wil...

Page 117: ...ngagement 1 Mid PTO Lever 2 Mid PTO Lever Assembly 3 Rod Mid PTO 4 Mid PTO Lever 1 5 Transmission Arm 6 Transmission Fork Mid A ENGAGED B DISENGAGED 615W419A 3 7 FRONT WHEEL DRIVE SHIFT Front wheel drive lever 2 1 is located at left lower of driver s seat and connected to front wheel drive lever 2 and transmission arm 3 in the method of gear engagement If pulling front wheel drive lever 2 1 upward...

Page 118: ...automati cally If PTO switch selected to MANUAL PTO power will be transmitted regardless of position of hydraulic elevating arm The PTO clutch valve has a built in Modulator valve which increases the pressure of the clutch slowly and takes a role of semi clutch The PTO clutch body is installed with a brake system to prevent the clutch body from rotating due to inertia force in OFF and to stop the ...

Page 119: ...haft 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 hy draulic 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 compres sion c Tighten clutch plate and clutch disc with pressure plate to drive PTO shaft by friction force d The pressure in th...

Page 120: ...o stop differential operation when slipping and stopping only one wheel according to road or pave ment conditions 1 Differential Gear Case 2 Cap 3 Parallel Pin 4 Bolt 5 Differential Pinion Shaft 1 6 Differential Pinion Shaft 2 7 Key 8 Differential Pinion 5 DIFFERENTIAL GEAR 9 Differential Pinion Washer 10 Differential Side Gear Right 11 Differential Side Gear Left 12 Differential Washer 13 Bolt 14...

Page 121: ... Differential Gear Shaft Left 8 Differential Gear Shaft Right 615W429A 5 2 OPERATION A Traveling Straight Ahead Rotation of spiral bevel pinion 1 will be transmit ted 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 dif ferential gear shaft 7 8 Will run...

Page 122: ...is the differen tial locking device restricts differential function and provides equal rpm s to both wheels If working the differential locking pedal differential locking fork shaft 1 will rotate and the differential locking fork 2 will moved to differential side gear 5 with differential locking shift 3 pin of shift en tered groove of side gear to lock side gear Rotation of spiral bevel gear 8 wil...

Page 123: ...torted Transmission arm shaft corroded Synchronizer broken Clutch restoration poor Gear worn or broken Synchronizer broken Differential gear transmission fork broken Differential gear transmission fork head pin broken Differential gear transmission shift pin bent or broken Differential gear fork shaft bent or broken Differential gear pedal return spring weaken or broken Differential gear transmiss...

Page 124: ...19 959 19 980 mm 0 78579 0 78661 in 0 13 0 25 mm 0 005 0 010 in Clearance Clearance Contacted rate Thickness Thickness Flatness Flatness Flatness Flatness Free tension Thickness Clearance Backlash Clearance I D O D Backlash I D Inside Diameter O D Outside Diameter Backlash Transmission shift and shift groove Between synchro and spline Synchronizer ring and gear taper Clutch disc Clutch plate Brake...

Page 125: ...ning nut Intermediate case and mission case tightening planting bolt Intermediate case modulate valve assembly tightening bolt Intermediate case bearing cover tightening bolt Intermediate case bearing cover transmission fork locking bolt Hydraulic pipe joint bolt Hydraulic block support and intake pipe tightening bolt Hydraulic block support and intake pipe tightening bolt Hydraulic cylinder assem...

Page 126: ...NTENANCE 1 22 Gear Shaft PTO 2 25 Gear Shaft 3 23 19 Gear Shaft PTO 4 Counter Shaft PTO 5 33 Gear PTO 6 26 Gear 7 Main Shaft Gear 8 24 Gear 9 29 Gear 10 33 Gear 11 36 Gear 12 Counter Shaft 9 CLUTCH HOUSING www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 127: ...r Disassembly 1 Disengage propulsion shaft covers 1 2 and bolt 3 from the lower of machine 2 After propulsion shaft cover is tighten inward pull out snap ring 4 and spring pin 5 3 With coupling 6 tightened to propulsion shaft 2 7 disconnect propulsion shaft 2 combined with propulsion shaft cover When reassembling Apply spline part of propulsion shaft 2 and O ring contacts at the end of propulsion ...

Page 128: ...1 Brake Rod 2 Intake Pipe 3 3 Intake Pipe 2 4 Rubber Pipe 5 Clamp 6 Hydraulic Pipe 1 Sect Spec Tightening Torque Joint bolt Tightening bolt M18 M8 M10 49 0 58 8 N m 5 0 6 0 kgf m 36 1 43 4 lbf ft 23 6 27 4 N m 2 4 2 8 kgf m 17 3 20 2 lbf ft 23 6 27 4 N m 2 4 2 8 kgf m 17 3 20 2 lbf ft When reassembling Make sure to clamp connecting rubber pipe of in take pipe to prevent air from entered Apply hydr...

Page 129: ...ct 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 1 Clutch Housing 3 Bolt 2 Flywheel Housing 4 Nut Sect Spec Tightening Torque Tightening bolt nut Stud M12 M12 77 5 90 2 N m 7 9 9 2 kgf m 57 2 66 5 lbf ft 39 2 49 0 N m 4 0 5 0 kgf m 28 9 36 2 lbf ft Sealing agent Three bond 1208D ...

Page 130: ...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 When assembling shuttle transmission arm the portion of transmission arm should be seated in the groove A of shuttle fork rod 1 Transmission Shift Rod 2 Spring Pin 3 Main Transmission Shift Rod 2 4 Shuttle Transmission Shift Arm 5 Flange Bol...

Page 131: ...ontacted surface of the clutch housing 3 and intermediate case 4 and apply a sealing agent Perform docking clutch housing 3 and intermedi ate case 4 and then make transmission arm 1 of shuttle transmission arm to be seated in the groove A of shuttle fork rod Sealing agent Three bond 1208D or equivalent 1 Shuttle Transmission Arm 2 Flange Bolt 3 Clutch Housing 4 Intermediate Case 5 Bolt 6 Nut Sect ...

Page 132: ...r oil from the contacted surface of clutch housing and main transmission cover and apply a sealing agent With main transmission fork set to Neutral set trans mission arm 4 at the groove of main transmission fork Sealing agent Three bond 1208D or equivalent 1 Main Transmission Cover 2 Bolt 3 Transmission Rod 4 Transmission Arm 5 Locking Bolt 6 Jawed Washer Sect Spec Tightening Torque Tightening bol...

Page 133: ...ssembling Apply the slip of propulsion case and release hub with grease Wipe out foreign matters or oil from the contacted surface of clutch housing and propulsion shaft case and apply with sealing agent Sealing agent Three bond 1208D or equivalent 1 Clutch Release Fork 5 Propulsion Shaft Case 2 Bolt With Washer 6 Bolt With Washer 3 Main Clutch Lever 7 Release Bearing 4 Clutch Release Hub 8 Servic...

Page 134: ...BLY 1 Loosen bearing cover 1 attaching bolt 2 and dis connect bearing cover with gears in a body When reassembling Renew oil seal 5 8 and 9 and apply grease to the contacted portion of assembly Make sure di rection of assembly is correct When difficult to disconnect bearing cover assembly make sure 23 gear tooth of main shaft gear 3 engaged with 22 gear shaft 4 tooth and dis connect with gear toot...

Page 135: ...g bolt When tightening the locking bolt ensure the as sembly position and the number of spring and bass are correct and then apply with grease Sect Spec Tightening Torque Locking bolt M10 48 1 55 9 N m 4 9 5 7 kgf m 35 4 41 2 lbf ft 1 Bearing Cover 2 Locking Bolt 3 Bolt 4 Ball 5 Spring 6 Main Transmission Fork 1st 2nd 7 Main Transmission Fork 3rd 4th 8 Spring Pin 9 Fork Rod 1st 2nd 10 Fork Rod 3rd...

Page 136: ...lutch housing and pull out bearing 4 When disassembling 25 gear shaft 1 tap lightly the end of shaft using plas tic hammer not to be damage CAUTION When disassembling locking bolt from bearing cover take care of ball not to be bounded CAUTION When reassembling Insert 22 gear shaft into gearing seat bearing in housing with snap ring for hole and tap lightly gear shaft Snap ring should be assembled ...

Page 137: ... side 25 30 20 33 Gear side 32 37 27 29 Gear side 32 37 27 36 Gear side 25 30 13 When assembling synchronizer ring 13 ensure the groove position of synchronizer key 14 is correct Ensure oil groove of thrust collar towards gear 1 Snap Ring 2 Ball Bearing 3 Ball Bearing 4 Thrust Collar 5 Needle Bearing 10 7 SEVENTH STAGE DISASSEMBLY OF MAIN TRANSMISSION COUNTER SHAFT 6 Needle Bearing 7 24 Gear 8 36 ...

Page 138: ...Bearing Needle 7 Hub Synchro 8 Shifter 9 Ring Synchronize 10 Key Synchronize 11 Spring 12 Cir clip 13 Gear 29 14 Bearing Needle 15 Gear 33 16 Gear 36 17 Bearing Needle 18 Cir clip 19 Collar Thrust 20 Bearing Ball 21 Spacer 22 Cir clip 23 Coupling 24 Pin Spring www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 139: ...ure slip or tooth surface is worn and replace it if necessary Sect Specified Allowable Limit Clearance of groove between transmission fork and shift 0 1 0 3 mm 0 004 0 012 in 0 8 mm 0 03 in 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 inne...

Page 140: ...spline and opposite gear spline using clearance gauge Sect Specified Allowable Limit Clearance of between synchro and gear spline 1 35 1 65 mm 0 053 0 065 in 0 5 mm 0 02 in 3 Apply O D of taper cone in gear with thin film of red lead tighten synchronizer ring firmly and check for contacted state Sect Specified Allowable Limit Clearance of between synchronizer ring and gear taper More than 80 More ...

Page 141: ... 4 37 D615 W02 May 2003 615W461A 1 PTO Clutch Assembly 2 12 Gear Shaft 3 23 21 Gear 4 19 Gear 5 16 Gear 6 Shuttle Shaft 7 18 Gear 11 INTERMEDIATE CASE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 142: ...ase 2 and transmission case 1 Sealing agent Three bond 1208D or equivalent Sect Spec Tightening Torque Tightening bolt nut Stud M12 M12 77 5 90 2 N m 7 9 9 2 kgf m 57 2 66 5 lbf ft 39 2 49 0 N m 4 0 5 0 kgf m 28 9 36 2 lbf ft 3 Bolt 4 Nut 11 1 DISASSEMBLY ASSEMBLY A Disconnection of Intermediate Case Group When reassembling Make sure PTO clutch assembly and spline hub is seated properly Apply the ...

Page 143: ...Clutch Assembly Sect Spec Tightening Torque Tightening bolt nut M10 48 1 55 9 N m 4 9 5 7 kgf m 35 4 41 2 lbf ft 1 Modulator Valve Assembly 4 O ring 2 Bolt 5 O ring 3 Connecting Pipe 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 c...

Page 144: ...sembly 3 from bearing cover 4 When reassembling Make sure the assembly position is correct when assembling gear shaft assembly into bearing cover 1 Shuttle Shaft Assembly 2 23 21 Gear Shaft Assembly 3 18 Gear Shaft Assembly 4 Bearing Cover Sect Spec Tightening Torque Tightening bolt M6 9 8 11 3 N m 1 0 1 15 kgf m 7 2 8 3 lbf ft When reassembling Insert spring and Ball into bearing cover and as sem...

Page 145: ... surface lightly with grease and take care of not to be damage Assembly direction of snap ring 1 should be with rounding toward spacer After installing clutch assembly on bearing cover blow oil groove with air and check for operation 1 Snap Ring 4 Bearing Cover 2 Spacer 5 Snap Ring 3 Clutch Body 6 Bearing e Fifth Stage Disassembly of Shuttle Shaft 1 Loosen snap ring 1 and disassemble spacer 2 2 Re...

Page 146: ... Plate 13 Clutch Body 14 Piston Ring 15 Piston Ring When reassembling Taking care of foreign matters not to be entered clutch body oil groove clean thoroughly if necessary Check piston ring 14 15 for status and apply the contacted surface with grease Locate the rounding portion of snap ring 1 toward pressure plate and forked portion at boss of clutch body as shown in the left figure CAUTION 2 Dise...

Page 147: ...t grove 0 1 0 3 mm 0 004 0 012 in 0 8 mm 0 031 in D Synchro Assembly Check 1 Check synchronizer key and spring for damage and replace it if necessary 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 bear ing ...

Page 148: ... than 80 3 Apply O D of taper cone in gear with thin red lead tighten synchronizer ring firmly and check for con tacted state E Checking Clutch disc Clutch plate brake disc for wear state 1 Using venire calipers measure the thickness of clutch disc clutch plate and brake plate 2 If exceeds allowable tolerance replace it Sect Specified Allowable Limit Thickness of clutch disc Thickness of clutch pl...

Page 149: ... tolerance replace it Sect Specified Allowable Limit Flatness of piston Flatness of pressure plate Flatness of return plate Sect Specified Allowable Limit Length of spring free tension 46 5 mm 1 83 in 42 0 mm 1 65 in 1 5 mm 0 006 in 0 3 mm 0 012 in 0 25 mm 0 010 in 0 05 mm 0 002 in 0 1 mm 0 004 in 0 1 mm 0 004 in H Checking seal ring for worn 1 Measure the thickness of seal ring using microme ter ...

Page 150: ...ke pipe 1 3 filter support 4 and at taching bolt 5 6 and disconnect intake pipe 1 filter support and hydraulic filter assembly 7 in as sembly 3 Loosen joint bolt 8 and disconnect hydraulic pipe 2 9 When reassembling Apply Hydraulic pipe connection O ring 10 11 with grease and take care of not damaged Sect Spec Tightening Torque Joint bolt Tightening bolt M18 M8 M0 49 0 58 8 N m 5 0 6 0 kgf m 36 2 ...

Page 151: ... Transmission Rod 6 Creep Speed Rod 7 Spring Pin 8 Aux Transmission Lever 9 Creep Speed Lever 10 Aux Transmission Lever 1 11 Creep Speed Lever 1 12 Front Wheel Driving Lever 13 Stopper 14 Stopper 15 Safety Switch 16 Shim c Third Stage Disconnection of Transmission Lever IMPORTANT After assembling aux transmission lever 8 and creep speed lever 9 check the safety switch 15 quick speed ON OFF switch ...

Page 152: ... m 4 9 5 7 kgf m 35 4 41 2 lbf ft Spec 615W485A Sect Spec Tightening Torque Tightening bolt Stud Tightening bolt M12 M12 M12 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft 39 2 49 0 N m 4 0 5 0 kgf m 28 9 36 0 lbf ft 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft e Fifth Stage Disconnection of Brake Case 1 Loosen bolt 1 and nut 2 and disconnect brake case 3 in assembly When reassembling Make sure asse...

Page 153: ...Ball Bearing 11 Oil Seal Collar 6 Oil Seal Sealing agent Three bond 1208D or equivalent Sect Spec Tightening Torque Locking nut M32 147 196 N m 15 20 kgf m 108 145 lbf ft 615W489A Sect Spec Tightening Torque Tightening bolt M10 48 1 55 9 N m 4 9 5 7 kgf m 35 4 41 2 lbf ft b Second Stage Disconnection of bearing cover assembly 1 Pull out transmission arm Aux Transmission Front wheel drive MID PTO o...

Page 154: ...od MID PTO 3 Transmission Fork MID PTO 4 Transmission Fork Hi Lo Shift 5 Fork Rod Hi Lo Shift 6 Spring 7 Ball d Fourth Stage Disassembly of Spiral Bevel Pinion Shaft 1 Pull out MID PTO transmission fork 3 and fork rod 2 from bearing cover 1 2 Pull out Hi Lo shift fork 4 and fork rod 5 3 Disassemble fork rod from each transmission fork Sect Spec Tightening Torque Tightening bolt M10 48 0 55 9 N m 4...

Page 155: ...n assembling gear shaft assembly into bear ing cover take a note of assembly position e Fifth Stage Disassembly of Gear Shaft Assembly 7 Pinion Shaft Assembly 8 Hi Lo Shift Shaft Assembly 9 13 Gear Shaft Optional 10 Ball Bearing 11 27 30 Gear 12 PTO Drive Shaft Assembly When assembling bearing case check depth Replace lock nut tighten and then perform cocking firmly to the specified torque Take ca...

Page 156: ... Seventh Stage Disassembly of Aux Transmission Shaft 1 Using bearing puller pull out bearing 1 and dis assemble spacer 2 and thrust collar 3 2 Loosen snap ring 4 5 for shaft and disassemble 18 spur gear 6 and needle bearing 7 spline boss 8 and shift 9 32 spur gear 10 and needle bear ing 11 and thrust collar 12 When reassembling Oil groove of thrust collar should be toward gear Spec Tightening Torq...

Page 157: ...ur gear take care of spring 4 and Ball 3 not to be bounded CAUTION When reassembling Taking care of 31 spur gear assembly direction 31 spur gear chamfering should be backward See the above figure Taking care of 41 spur gear assembly direction 41 spur gear chamfering should be forward See the above figure Rounding of snap ring should be toward bearing Apply oil seal contacted surface with grease an...

Page 158: ... bevel pinion in a set if necessary Make sure of assembly direction of differential gear assembly 1 Spring Pin 2 Snap Pin 3 Flat Washer 4 Pin 5 Differential Locking Fork Shaft 6 Differential Locking Fork k Tenth Stage Disconnection of Differential Gear Assembly 7 Oil Seal 8 Bearing Case Left 9 Bearing Case Right 10 Bolt 11 Shim 12 Differential Gear Assembly From rear view spiral bevel gear ring ge...

Page 159: ...multa neously 1 Taper Roller Bearing 2 Taper Roller Bearing 3 Differential Locking Shift 4 Cap 5 Spiral Bevel Gear 6 Bolt Bonding agent Three Bond 1372 or equivalent l Eleventh Stage Disassembly of Differential gear Sect Spec Tightening Torque Cap tightening bolt Spiral bevel gear tightening bolt M10 M10 UBS 48 0 55 9 N m 4 9 5 7 kgf m 35 5 41 2 lbf ft 68 6 88 2 N m 7 0 9 0 kgf m 50 6 65 1 lbf ft ...

Page 160: ...und replace it B Gear Check 1 Ensure slip or tooth surface is worn and replace it if necessary C Checking for Clearance Between Transmission Fork and Shift Groove 1 Measure groove depth of transmission shift using I D micrometer 2 Measure the depth of transmission fork hook using O D micrometer 3 Check the clearance with measured value of shift and fork and replace it if exceeded the limit Sect Sp...

Page 161: ...al Locking Shift 6 Bearing Case 7 Shim When adjusting backlash entire amount of shim should be kept CAUTION f Tooth Contact Checking Method Apply a few tooth surface with thin film of red lead at 3 positions where divided into 3 circumference ap ply bevel gear properly with load rotate bevel pin ion shaft and then ensure tooth contacted 615W4A8A 1 When assembling differential gear assembly into tr...

Page 162: ...f differential locking shift 5 to spi ral bevel gear 1 and move spiral bevel gear in the direction of arrow Repeat until good tooth contact and backlash obtained Increase shim 7 of bearing case 6 and move bevel pinion shaft 2 in the direction of arrow Move some shim 3 gear 1 to differential locking shift 5 of spiral bevel and move spiral bevel gear in the direction of arrow Repeat until good tooth...

Page 163: ...pe of Adjustment Shim 0 1 mm 0 004 in 0 2 mm 0 008 in 0 5 mm 0 020 in Sect Specified Limit Clearance of differential pinion and differential pinion shaft I D of differential pinion shaft O D of differential pinion shaft 0 020 0 062 mm 0 00079 0 00244 in 20 000 20 021 mm 0 78740 0 78823 in 19 959 19 980 mm 0 78579 0 78661 in 0 025mm 0 0098in 615W4B3A 1 Measure I D of differential case and cap 2 Mea...

Page 164: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 165: ...CHAPTER 5 REAR AXLE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 166: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 167: ...5W501A MODEL 8354 8404 1 Rear Axle Case 2 Rear Axle 3 55 Gear 8354 60 Gear 8404 4 10 Gear Shaft 8354 11 Gear Shaft 8404 5 Brake Case 6 Differential Gear Assembly 1 STRUCTURE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 168: ...t Planetary gear support attaching bolt Lock nut lbs ft 192 224 35 4 41 2 35 4 41 2 145 181 35 4 41 2 35 4 41 2 145 181 Kgf m 26 6 31 0 4 9 5 7 4 9 5 7 20 25 4 9 5 7 4 9 5 7 20 25 N m 260 8 303 8 48 0 55 9 48 0 55 9 196 245 48 0 55 9 48 0 55 9 196 245 Spec M16 M10 M39 M45 M10 M10 M10 M60 2 TIGHTENING TORQUE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 169: ...1 37831 1 37894 in 27 987 28 000 mm 1 10185 1 10236 in 3 494 3 500 mm 0 1376 0 1378 in 1 55 1 65 mm 0 0610 0 0650 in Backlash Clearance I D O D Pin diameter Thickness Internal gear and planetary gear support Planetary gear and planetary gear shaft Planetary gear Planetary gear Needle bearing Thrust collar Application Specified Limit 3 SERVICE SPECIFICATION www mymowerparts com K T Saw Shop 606 678...

Page 170: ...ar Axle Case 1 Loosen bolt 1 and nut 2 and disconnect rear axle case 3 in assembly When reassembling Wipe out oil or foreign matters from the contacted surface between brake case and rear axle case and apply with sealing agent Sect Spec Tightening torque Rear wheel tightening nut M16 260 8 303 8 N m 26 6 31 0 kgf m 192 3 224 2 lbf ft Sect Spec Tightening torque Tightening bolt nut M10 Sealing agen...

Page 171: ...and thrust collar 5 3 Pull out the spring pin 1 from the planetary gear shaft 2 When reassembling The spring pin should be assembled with forked portion toward vertical direction of shaft C Third Stage Disassembly of Planetary Gear 1 Spring Pin 4 Needle Bearing 2 Planetary Gear Shaft 5 Thrust Collar 3 Planetary Gear 1 Spring Pin www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 172: ...ect Spec Tightening torque Lock bolt M10 48 0 55 9 N m 4 9 5 7 kgf m 35 4 41 2 lbf ft 1 Rear Axle 7 RearAxle Case Cover 2 Ball Roller Bearing 8 Bolt 3 55 60 Gear 9 Ball Bearing 4 Nut 10 O Ring 5 Spacer Barrel 11 Oil Seal 6 Spacer Plate 615W508A 615W509A A Oil Seal Assembly Method Disconnect inner and outer wheels and assemble inner wheel into axle and outer wheel into cover to prevent damage using...

Page 173: ...th new one Sect Specified Limit Clearance between planetary gear and planetary gear shaft I D of planetary gear O D of planetary gear shaft Pin diameter of needle bearing 0 3 mm 0 0086 in 0 009 0 050 mm 0 00035 0 00197 in 35 009 35 025 mm 1 37831 1 37894 in 27 987 28 000 mm 1 10185 1 10236 in 3 494 3 500 mm 0 1376 0 1378 in 615W517A 5 1 BEARING CHECK 1 With bearing inner wheel seized pull in and o...

Page 174: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 175: ...CHAPTER 6 BRAKE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 176: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 177: ...king If brake pedal is locked with the parking brake lever pulled up it keeps the brakes locked Brake disc of wet disc type soaked in oil has more durability and braking force than an inside expandable dry brake type 1 Brake Case 2 Brake Cam Lever 3 Brake Rod 4 Brake Lever 1 STRUCTURE 5 Turn Buckle 6 Brake Pedal 615W601A 7 Parking Brake Lever www mymowerparts com K T Saw Shop 606 678 9623 or 606 5...

Page 178: ...e 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 As brake disc is pressurized by the cam plate it grips the gear shaft 6 by friction force of the disc then the brakes will be applied www mymowerparts com K T Saw Shop 606 678 96...

Page 179: ...o small Cam plate ball is worn unequally Brake pedal return spring is worn or broken Brake cam is corroded rust Brake pedal clearance is excessive Brake disc is worn Cam plate is bent Brake cam or lever is worn Transmission oil is improper Brake power is not constant Brake is trailed Brake power is weaken Trouble Probable Cause Remark Remedy 3 TROUBLESHOOTING www mymowerparts com K T Saw Shop 606 ...

Page 180: ... 0 189 in 2 54 2 66 mm 0 1000 0 1047 in Clearance Deviation Clearance Clearance I D O D Flatness Height Thickness Thickness Brake pedal Difference between left and right when not depressing brake pedal Brake pedal and stop switch Between brake lever bush and brake shaft Brake lever bush Brake shaft Cam plate Cam plate and ball Brake disc Plate Item Reference Value Allowable Limit 36 2 43 4 17 4 20...

Page 181: ...earance of pedal should be equal in left and right Sect Specified Clearance of brake pedal A 25 35 mm 0 98 1 38 in Sect Specified Gap between left and right when depressing brake pedal Within 5 mm Within 0 197 in 1 Connection Hook 3 Turn Buckle 2 Lock Nut 6 BRAKE PEDAL 615W606A 1 Check the clearance between brake pedal 1 and stop switch 2 and if it exceeds the specified limit loosen the lock nut 3...

Page 182: ...e with the measured value If exceeding the allowable limit replace bush Sect Specified Allowable Limit Clearance between brake lever bush and brake shaft I D of brake lever bush O D of brake shaft 0 085 0 327 mm 0 00335 0 01287 in 20 060 20 281 mm 0 78976 0 79846 in 19 954 19 975 mm 0 78559 0 78642 in 615W607A 1 Brake Lever Bush 2 Brake Shaft www mymowerparts com K T Saw Shop 606 678 9623 or 606 5...

Page 183: ... 3 in assembly When reassembling Make sure assembly position of lever shaft 4 bolt 1 and stud 5 is correct Assembly position see figure and following table Apply ball seat 8 with grease sufficiently and make sure ball 9 not escaped Bonding agent Three bond 1372 or equivalent 6 Packing 7 Packing 8 Ball Seat 9 Ball Replace packing 6 and 7 Apply stud 5 with bonding agent 7 BRAKE CASE www mymowerparts...

Page 184: ...t Spec Tightening torque 01754 51235 37150 2735 2 01754 51285 T2610 60561 T2615 24432 01173 51260 01176 51260 39 2 49 0 N m 4 0 5 0 kgf m 28 9 36 2 lbf ft 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft M12 2 12 2 2 Left 1 Right 1 6 2 Stud Stud Stud Stud Lever shaft Lever shaft MID Bolt Bolt Applicable Model 8404 Assembly position mark Drawing No Part name Qty Bolt Spec Tightening torque 01754 51235 ...

Page 185: ...brake disc into assembly position and when pressing plate by hand it should not move B Brake Case Disassembly a First Stage Disconnection of Brake Case 1 Loosen cam lever 1 attaching nut 2 and discon nect brake cam 3 O ring 4 and brake cam lever 2 Disconnect Cam plate 5 brake disc 6 and plate 7 1 Brake Cam Lever 5 Cam Plate 2 Nut 6 Brake Disc 3 Brake Cam 7 Plate 4 O Ring Make sure assembly positio...

Page 186: ...ring 3 from brake case 1 2 Pull out gear shaft 2 with bearing 1 Brake Case 3 Snap Ring 2 Gear Shaft 615W614A 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 dimen sion 1 Snap Ring www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 187: ...owable limit Height of ball from bottom of cam plate H 20 9 21 1 mm 0 8228 0 8307 in 20 5 mm 0 8071 in 615W617A B Wear Check of Cam Plate 1 Check brake disc contacted surface of cam plate for wear and measure the flatness using a clear ance gauge 2 If it exceeding the allowable limit replace it Sect Specified Allowable limit Flatness of cam plate 0 3 mm 0 012 in 0 3 mm 0 012 in 1 Clearance Gauge 6...

Page 188: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 189: ...CHAPTER 7 FRONT AXLE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 190: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 191: ... as well as to maximize rotation ability Front wheel steering angle Inner Wheel 56 58 1 Front Bracket 2 Rear Bracket 3 Front Axle Support 4 Spiral Bevel Pinion 5 Spiral Bevel Gear 6 Differential Gear Assembly 7 Differential Gear Shaft 8 Bevel Gear 9 Bevel Gear 10 Bevel Gear Shaft 11 Bevel Gear 12 Bevel Gear 13 Front Axle 14 Bevel Gear Case 15 Front Axle Case 16 Front Axle Cover www mymowerparts co...

Page 192: ... ability Tow in prevents one tire excessively worn though parallel running with tow in 615W705A 615W704A 615W702A 615W703A 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 King Pin Angle King pin angle B 12 5 Tow in Tow in rear full width 2 8 mm A Front Wid...

Page 193: ...olling of front wheel Tie rod end loosen Power steering unit intake air Propulsion shaft broken Front axle front wheel drive gear of transmission broken Front differential gear broken Transmission fork broken Coupling missing Improper gear backlash Lack in oil Bearing damage or broken Gear damage or broken Improper rotation torque of spiral bevel pinion shaft Left and right inclination of front wh...

Page 194: ...d turn operation angle Bevel gear backlash in front axle case Bevel gear tooth contacted in bevel gear case Bevel gear backlash in bevel gear case Bevel gear tooth contacted in bevel gear case Backlash of bevel pinion shaft and spiral bevel gear Tooth contacted between bevel pinion and differential pinion shaft Clearance between differential pinion and differential pinion shaft Differential pinion...

Page 195: ...heel attaching nut Axle case attaching bolt Front axle cover tightening bolt Bevel gear case attaching bolt nut Center pin attaching bolt Differential case cover tightening bolt Item lbf ft 37 5 44 0 12 6 15 0 4 8 5 2 12 6 15 0 17 0 19 0 7 9 9 2 2 4 2 8 12 6 15 0 7 9 9 2 4 9 5 7 Kgf m N m Spec M20 M14 M14 M16 M12 M8 M14 M12 M10 368 431 123 147 46 6 50 9 123 147 166 6 186 2 77 4 90 2 23 5 27 5 123 ...

Page 196: ... wheel to the maximum in left and right rotate it about a quarter counterclockwise near re lief valve and set lock bolt contacted with the side of bevel gear case and then tighten with nut 1 Stopper Bolt 3 Bevel Gear Case 2 Nut Sect Spec 7 16 8 16 Specified value Tire air pressure 1 8 2 2 kgf cm 25 6 31 3 psi 1 6 2 0 kgf cm 22 8 28 4 psi Sect Specified value Tow in Rear width front width 2 8 mm 0 ...

Page 197: ... Force 1 Raise the front axle and make sure both tires are off the ground 2 Using the front bracket adjusting bolt check for rock ing 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 8 lbf ft www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 198: ...ously When reassembling Apply propulsion shaft spline and O ring 7 8 and 9 with grease 1 Feeding Plug 3 Draining 2 Oil Level Plug 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 f...

Page 199: ... 91 2 108 lbf ft 166 6 186 2 N m 17 0 19 0 kgf m 123 0 137 5 lbf ft C Third Stage Disconnection of Steering Cylinder Hydraulic Hose 1 Loosen steering hydraulic hose 1 and 2 1 Steering Hose Assembly R 2 Steering Hose Assembly L When reassembling When connecting hydraulic hose assemble it prop erly ensuring its color and connection position Hose Connection position Steering hose assembly R Steering ...

Page 200: ... 1 suit and as semble in bevel gear case and front axle case with push ing O ring not to be damaged using assembly fixture 8 2 SECOND STAGE DISASSEMBLY OF FRONT AXLE 615W715A 8 1 FIRSTSTAGE DISCONNECTIONOFFRONT AXLECASEANDBEVELGEARCASE 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 Sect Spec Tighte...

Page 201: ...ct Apply DX bush 7 contacted surface with grease taking care of assembly direction 1 Snap Ring 5 Bevel Gear 2 Plug 6 Shim 3 Snap Ring 7 DX Bush 4 Ball Bearing 8 3 THIRD STAGE DISASSEMBLY OF FRONT AXLE CASE 615W718A A DX Bush Assembling Method Align bush hole with oil passage hole of front axle case and always use assembly fixture 1 Oil Passage 2 DX Bush www mymowerparts com K T Saw Shop 606 678 96...

Page 202: ...14 with bearing 15 When reassembling Make sure the type and number of shim is correct Apply oil seal and O ring with grease and make sure oil seal is assembled in the right direction Part No 5 shown in the above figure 8 4 FOURTH STAGE DISASSEMBLY OF FRONT AXLE SUPPORT 1 Bevel Gear Case 5 Oil Seal 2 Bolt 6 Ball Bearing 3 Plug 7 Snap Ring 4 Axle Case Support 8 Shim Sect Spec Tightening torque 9 Bev...

Page 203: ...13 When reassembling Apply O ring 14 15 16 and oil seal contacted surface with grease Make rounding of snap ring toward bearing Make sure the type and number of shim and adjust ing collar 10 is correct Check for spacer plate 17 thrust collar 18 of front and rear brackets 1 Front Bracket 2 Rear Bracket 3 Center Pin 4 Bolt 5 Front axle Support 6 Oil Seal 7 Snap Ring 8 Bevel Pinion Shaft 9 Taper Roll...

Page 204: ...rel 4 into pinion shaft and tighten lock nut by hand With bevel pinion shaft into assembly lock the outer of bearing into vice Wrap pinion shaft spline several times using rope pull out rope using push pull gage and check for rotation torque of pinion shaft If rotation torque exceeding the spec loosen lock nut and if less than the spec tighten lock nut and perform cocking so that the nut will not ...

Page 205: ...er ential pinion shaft 8 4 Disconnect differential pinion 7 differential side gear 6 differential pinion washer 10 and shim 9 from case 5 Mark disassembled part with its origi nal position in order to assemble again into original position CAUTION When reassembling Assemble each part into the original position marked prior to disassembly Apply differential gear operating part with molybde num Three...

Page 206: ...nd and measure the backlash 3 If exceeding the spec adjust with shim B Types of Adjusting Shim 0 2 mm 0 008 in 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 Allowable limit Bevel gear backlash 0 15 0 35 mm 0 059 0 0138 in Sect Allowable limit Bevel gear tooth contacted More than 35 center 1 3 1 2 from small end C Tooth Contacted Check At any bevel gear apply a few contacted ...

Page 207: ...nd then apply and one gear with load rotate the other gear several times and then check for tooth contacted amount Sect Allowable limit Bevel gear tooth contacted More than 35 center 1 3 1 2 from small end 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...

Page 208: ... 0 mm 0 079 in 2 3 mm 0 091 in C Types of Adjusting Collar 5 8 mm 0 228 in 5 9 mm 0 232 in 6 0 mm 0 236 in 6 1 mm 0 240 in 6 2 mm 0 244 in D Tooth Contacted Check At spiral bevel gear apply a few contacted surface from three positions divided by circumference with thin film of red lead and then apply bevel gear with load rotate bevel pinion shaft several times and then check for tooth contacted am...

Page 209: ...0 62929 in 0 25 mm 0 098 in 9 7 CLEARANCE CHECK BETWEEN FRONT DIFFERENTIAL CASE DIFFERENTIAL CASE COVER AND DIFFERENTIAL SIDE GEAR 1 Measure O D of differential side gear 2 Measure I D of differential side gear 3 Measure I D of differential case cover 4 Check the clearance as the measured value and if it exceeds the allowable limit replace it Sect Specified Allowable limit Clearance between front ...

Page 210: ...eplace differential pin ion washer and differential side gear shim A Types of Adjusting Shim 0 8mm 0 031 in 1 0mm 0 039 in 1 2mm 0 047 in B Tooth Contacted Check At spiral bevel gear apply a few contacted surface from three positions divided by circumference with the film of red lead and then apply bevel gear with load rotate bevel pinion shaft several times and then check for tooth contacted amou...

Page 211: ...CHAPTER 8 STEERING SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 212: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 213: ...hydraulic power steering and installed with two single rod cylinders The power steering unit is connected directly with hydraulic hoses and steering cylinders without additional linkage and has a superior steering power as transmission efficiency is increased It is applied with a load reaction type and when releasing the steering wheel in steering the wheel keeps in an almost straight direction ww...

Page 214: ...eering wheel control oil is passed through GEROTOR to steering cylinder where steering of front wheel will be done by the motion of cylinder rod Oil returned from steering cylinder returns to oil tank transmission case via power steering unit 1 Oil Tank 2 Oil Filter 3 Gear Pump 4 Hydraulic Cylinder 5 Hydraulic Block 6 Steering Unit 2 HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM www mymowerparts com ...

Page 215: ...wer steering hydraulic pumps use the pump hav ing superior volume efficiency and mechanical efficiency to extract power from engines right cam shaft gear 3 2 MAJOR SPECIFICATION Type Tandem Volume cc rev 12 First 7 2 Second Gear ratio 1 0 9 Rotation direction C C W RPM range 3515 Discharge flow rate in engine rated rotation l min gal min Q1 29 7 7 86 Q2 17 8 4 71 Qt 47 5 12 57 Attached position Ri...

Page 216: ...f two pumps having different 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 hy draulic pump from engine cam shaft drive gear and rotating pump gear 3 When gear is disconnected a vacuum will be made to enable oil inflow 1 to pump As gear is rotated...

Page 217: ...alve 1 Needle Bearing 6 Rotor 2 Spool 7 Centering Spring 3 Pin 8 Ball 4 Drive 9 Housing 5 Sleeve 4 POWER STEERING UNIT B Metering Device The metering device consists of a trochoid pump called a Gerotor 6 Oil passes metering device from hydrau lic pump via the steering cylinder This metering device consists of a trochoid pump and if driving rotor oil will be discharged from three cham bers as volum...

Page 218: ... 5 Rod 3 Bush A Rod O D B Tube I D 5 2 MAJOR SPECIFICATION Tube O D C φ 60 2 36 in 6 Ring 8 Bearing 7 Housing 9 Snap Ring C Tube O D D Stroke Tube I D B φ 50 1 97 in Rod O D A φ 32 1 26 in Stroke D 243 mm 9 57 in 5 STEERING CYLINDER www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 219: ... ment will be passed to control valve through the drive plate GEROTOR and drive link Valve plate 3 rotates to the right on the manifold and is located in the opposite direction of the valve plate 3 Port P flow of control valve is connected to GEROTOR 5 STATOR of GEROTOR 5 rotates as the steering wheel 2 is rotated and performs metering function and passes oil as steering wheel 2 is rotated Oil tha...

Page 220: ...al steering due to engine stop or hy draulic pump failure the GEROTOR operates as a manual trochoid pump If controlling steering wheel rotor inside of GEROTOR will be driven Oil will be flown through check valve 2 installed in housing from oil tank to port P where it operates cylinder in the same pas sage as power steering control 1 Steering Controller 4 Centering Spring 2 Steering Wheel 5 GEROTOR...

Page 221: ...orn Fluid oil dirty 2 O ring damage In disassembly and reassembly Modify Loosen tightening bolt with power steering unit can cause center mismatch Change Tighten equally into the speci fied torque Repair Change Reset pressure and flow rate Change Reset Change Modify Air bleeding Air bleeding Change Modify Modify Change fluid oil Change Trouble Probable Cause Steering wheel is heavy When releasing ...

Page 222: ...le limit 0 177 mm 0 007 in Allowable limit 25 75 mm 1 014 in 0 10 0 18 0 004 0 007 bushing short Description Assemble bushing into body Assemble drive shaft with idle gear Measure using clearance gage Measure shaft diameter using micrometer Measure bushing I D using micrometer Compare th difference from measured drive shaft diameter Measure the length of bushing using micrometer Measure bushing an...

Page 223: ...semble snap ring 1 and bearing 2 from drive shaft 4 Disassemble SECOND pump 20 bushing 16 seal ring 14 15 O ring 19 drive gear shaft 2 17 and passive gear 18 5 Disassemble cover 13 and coupling 12 6 Disassemble FIRST pump 6 bushing 9 seal ring 7 8 O ring 4 drive gear shaft 1 10 pas sive gear 11 7 Disassemble oil seal attached at cover front 3 1 If oil seal is cracked or damaged re place it with ne...

Page 224: ...ring hose 1 2 3 4 connect ing 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 Hose type Steering hose assembly T Green color Steering hose assembly P Red color Steering hose assembly R White color Steering hose assembly L Yellow color Sect Spec Tighteni...

Page 225: ... Spacer Plate 9 O Ring 10 Rotor 11 Drive 12 Sleeve 13 Pin 14 Centering Spring 15 Spool 16 Stop Ring 17 Retainer Ring 18 Bearing Less 19 Needing Bearing 20 Housing 21 Housing 22 Screw 23 O Ring 24 Inlet Check Valve Assembly 25 Poppet 26 Spring 27 Damper Collar 28 O Ring 29 Plug 30 O Ring 31 O Ring www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 226: ...crew 3 Loosen seven screws 1 4 Disassemble end cap 2 5 Disassemble O ring 3 from end cap 1 Screw 3 O Ring 2 End Cap 6 Detach spacer 5 7 and O ring 6 from inside spline of between rotor 10 and GEROTOR 4 4 Stator 7 Spacer 5 Spacer 10 Rotor 6 O Ring Power steering units with discharge capacity of 31 cc rev and 51 cc rev don t contain spacer CAUTION Never tighten firmly into vice with rigid plate and ...

Page 227: ...t seized with into housing I D 12 Pull out pin 13 from spool and sleeve assembly 8 Plate 11 Driver 9 O Ring 13 Push spool of sleeve forward and disassemble center spring from spool by hand Pull out sleeve from spool Rotate and pull out sleeve carefully 14 Pull out two bearing less 18 needle bearing 19 and retainer ring 17 Always insert needle bear ing between bearing less 17 Retainer Ring 18 Beari...

Page 228: ...ert slowly into sleeve 12 Take spline of spool and make sure spool lightly rotated in sleeve 4 Align two spring grooves between spool and sleeve at 180 and keep parallel Insert spring insert tool into spring groove and install centering spring in insert tool with tooth ends downward This time if raised spool from sleeve it is convenient for insert To easy pressure adjustment when reassembling meas...

Page 229: ...t spool and sleeve as sembly are rotated slightly in housing CAUTION 6 Insert pin 13 into hole of sleeve and spool and sleeve assembly into GEROTOR of housing 7 Insert driver 11 This time align with pin 13 and yoke of driver 8 Assemble O ring 31 on gerotor and assemble GEROTOR rotor into groove 9 Insert plate 5 O ring 6 and plate 7 into inside spline of GEROTOR rotor 10 Align bolt hole of housing ...

Page 230: ...embly ad just the pressure of relief valve Pres sure variance of relief adjusting plug 29 is 15 kgf cm Per one rotation CAUTION Precautions When Assembling Power Steering Unit 1 Make sure that the machined ends of sleeve spool and housing are not damaged 2 Perform disassembly and repair in a clean place and wipe out dust and dirt of body connectors with wire brush 3 Make sure parts not dropped cho...

Page 231: ... 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 A Clearance www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 232: ...L 3 Split Pin 4 Nut 5 Support Pin 6 Support Pin 7 Steering Cylinder Assembly 8 Center Pin 9 Bolt 10 Nut 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...

Page 233: ...kgf m 34 4 37 6 lbf ft 615W844A After assembling split pin make sure the end is not fallen Apply support pin and grease nipple with sufficient grease Sect Spec Tightening torque Nut M18 48 0 55 9 N m 4 9 5 7 kgf m 35 5 41 2 lbf ft Sealing agent Loctite 572 or equivalent Connecting port and hose color Steering hose assembly R White Steering hose assembly yellow Assembly position Right steering cyli...

Page 234: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 235: ...CHAPTER 9 HYDRAULIC SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 236: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 237: ...HYDRAULIC SYSTEM 9 3 D615 W03 May 2003 615W901B 1 HYDRAULIC CIRCUIT DIAGRAM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 238: ...trol are provided by control valve and link age installed at body of the hydraulic cylinder 2 Hydraulic extraction of the hydraulic block for op eration of hydraulic system in working machine 3 For hydraulic working machine hydraulic extraction through quick speed coupler installed with aux con trol valve assembly 1 Hydraulic Filter 2 Hydraulic Pump 3 Modulating Valve 4 Power Steering Unit 5 Hydra...

Page 239: ...hydraulic block and then connected with hydraulic circuit 3 Oil enters into position control valve through the distribution pipe 6 Front Hydraulic Block 7 Position Control Valve 8 Hydraulic Cylinder 9 Aux Control Valve 10 Hydraulic Cylinder Block 4 The position control valve selects oil flow and oil enters the hydraulic cylinder or exhausts into oil tank transmission case to operate 3 point hydrau...

Page 240: ...es while driving hy draulic pump from engine cam shaft drive gear and rotating pump gear 3 When gear is disconnected the vacuum will be made to enable oil inflow 1 to pump As gear rotated oil continues to flow 1 Snap Ring 2 Bearing 3 Cover Front 4 Seal Ring 5 Pin 6 1st Pump 7 Seal Ring 8 Seal Ring 9 Bushing 10 Drive Gear Shaft 1 11 Passive Gear 1 12 Coupling 13 Cover 14 Seal Ring 15 Seal Ring 16 B...

Page 241: ...ATION Hydraulic oil enters the IN port of filter bracket where transmission oil entering the hydraulic element as sembly 3 and flowing out to exhaust port through the element and flows to hydraulic pump This time sludge is filtered at element To sense filter clogged it is attached with vacuum sensor and temperature sensor Vacuum sensor is always set to OFF at less than 500 30 Hg and temperature se...

Page 242: ...CHAPTER 9 8354 8404 9 8 D615 W02 May 2003 615W910A 615W909A 6 1 STRUCTURE 6 2 CIRCUIT DIAGRAM 6 CONTROL VALVE MLS VALVE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 243: ...ol spool 1 is in such a position to connect the chamber 15 directly to the discharge through the hole 16 The oil coming from the pump will thus be able to move downward through the small regulator piston 2 and thus flow to the chamber 22 and by opening the holes 17 it will flow to the tank 1 Control Spool 2 Regulator Piston 3 Check Valve 4 Exhaust Valve 5 Relief Valve 15 Chamber 16 Hole 17 Hole 18...

Page 244: ... annular duct 19 it enters the hole 20 through the fixed throat 6 and the variable throat made by the con trol spool 1 with the hole 21 it opens the check valve 3 it enters in annular duct 18 and flows into the cylinder chamber 23 The small regulator piston 2 adjusts the oil flow to the cylinders because chambers 15 and 22 are sub ject to the difference of pressure made by the oil pas sage through...

Page 245: ...der cham ber 23 flows from annular duct 18 to the lowering regulator 8 and through hole 24 it enters the dis charge valve 4 flowing to the discharge from the hole 25 therefore causing the lowering of arms In this phase the lowering speed of the implement is controlled automatically by the lowering regulator 8 that is sensible to the dynamic force of the discharge oil consequently modifying the thr...

Page 246: ... the hydraulic pump to the inlet of hydraulic cylinder As the oil pressure of circuit increases that of damp ing chamber D C increases If pressure exceeds the specified valve and the spring tension the valve will open to flow oil through port T to transmission case If oil is discharged sufficiently and its pres sure is less than the specified the valve will be closed Relief valve setting pressure ...

Page 247: ...HYDRAULIC SYSTEM 9 13 D615 W02 May 2003 615W916A 8 HYDRAULIC CYLINDER www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 248: ...Shaft 12 Spring Pin 13 Cam 14 Snap Ring 15 Link 1 16 Link 2 17 Roller 4 18 Plain Washer 19 Pin 20 Roller 1 21 Roller 2 22 Snap Ring 23 Link 3 24 Arm 25 Lock Screw 26 Cam 1 27 Pin 28 Nut 29 Link 30 Snap Ring 31 Arm 32 Nut 33 Bolt 34 Pin 35 Pin 36 Spring 37 Link 38 Pin 39 Snap Ring 40 Bush 9 STRUCTURE AND OPERATION www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 249: ...the distributor shaft 21 into delivery position C thus causing the arms to be lifted 1 Position Control Lever 2 Draft Control Lever 3 Shaft 4 Arm 5 Roller 1 6 Cam 1 7 Lever 8 Friction Shock Absorber 9 Arm 10 Pin During the lifting movement of the arms crank 13 with pin 10 will rotate in a counter clockwise direction and via link 3 14 will cause the positioning cam 1 6 to rotate clockwise When roll...

Page 250: ...ever 2 Draft Control Lever 3 Shaft 7 Lever 8 Friction Shock Absorber 9 Arm 11 Roller 4 12 Cam 15 Crank 16 Shaft 17 Rod 18 Tension Rod This causes the lever 7 to rotate clockwise of trans mission arm 9 thus setting the distributor shaft 21 in delivery position C and consequently lifting the arms The arms will come to a stop only as soon as the piston comes into contact with the pin of the limit sto...

Page 251: ...e system as previously explained C Combined Operation of Positioning and Drawbar Pull Fig 615W918A 615W919A To utilize the lifting device in this condition it is neces sary to observe the following instructions Move the positioning control lever 1 upwards in relation to the lower backstop on the sector until the maximum work ing depth has been attained Determine the desired minimum working depth b...

Page 252: ... hydraulic block 4 Install the hydraulic take off adaptors screw size PT 3 8 to OUT port and IN port Connect the hydraulic hose to the adaptor OUT port side and to the implement control valve IN port Connect the other hydraulic hose to the adaptor IN port side an to the implement control valve TANK RETURN port Turn the slit on the spool 3 end to the arrow side fully as shown in the figure A To the...

Page 253: ...ansmis sion case This type is equipped with a special non return valve which ensures that oil under pressure is held where required This guarantees that implements will be held at a steady height which no change of lowering B Circuit diagram 615W923A 10 3 QUICK COUPLER 1 Coupler Socket Male 4 Ball 2 Coupler Socket Female 5 Sleeve 3 Pocket 615W947B 1 Body 17 Elastic Pin 2 Nut 18 Plug 3 Screw 19 O R...

Page 254: ... connected to linkage by plate 7 and tie rod 9 to elevate the imple ment This time the oil flow passage will be changed by link age in the MLS valve 11 1 STRUCTURE 1 Top Link Holder 2 Flange 3 Cover 4 Spring 5 Nut 6 Hex Bolt 7 Plate 8 Crank 9 Tie Rod 10 MLS Control Valve 11 TOP LINK BRACKET DEVICE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 255: ...ulty MLS valve sensitivity control faulty Draft control lever faulty Position lever control faultily Inside connection control faulty Power transmission tie rod 7 faulty Position lever control faulty Sensitivity control faulty Sticking of OUTLET valve Poor sealing of MLS valve Relief valve and safety valve control faulty Bad pump efficiency Bad efficiency of MLS valve Piston gasket worn Valve sens...

Page 256: ...d 2700 rpm Pressure 16 0 17 2 Mpa 165 175 kgf m cm 2347 2489 psi Oil temp 40 60 C 104 140 F Housing Relationship between gear shaft and bush Bush Item Reference Dimension Allowable Limit Relief valve condition Engine speed Max Oil temp 40 60 C 104 140 F Setting pressure 16 2 17 2 Mpa 165 175 kgf cm 2347 2379 Psi Reference Dimension 13 3 LINK CONTROL Item Reference Dimension Allowable Limit Lift ar...

Page 257: ...m shaft Right O D Left Bush I D Right Left 90 000 90 100 mm 3 5433 3 5472 in 0 125 1 230 mm 0 00492 0 00906 in 0 125 0 220 mm 0 00492 0 00866 in 49 970 49 940 mm 1 96732 1 96614 in 44 975 44 950 mm 1 77066 1 76968 in 50 075 50 115 mm 1 97145 1 97303 in 45 075 45 115 mm 1 77460 1 77618 in 90 150 mm 3 5492 in 0 50 mm 0 0197 in 0 50 mm 0 0197 in www mymowerparts com K T Saw Shop 606 678 9623 or 606 5...

Page 258: ... Hydraulic cylinder attaching bolt nut M10 MLS Control valve attaching bolt M10 lbf ft 36 2 43 4 35 5 41 2 17 4 20 2 17 4 20 2 17 4 20 2 35 5 41 2 35 5 41 2 72 3 83 1 145 166 57 1 66 5 123 144 192 224 362 420 35 5 41 2 35 5 41 2 35 5 41 2 Kgf m 5 0 6 0 4 9 5 7 2 4 2 8 2 4 2 8 2 4 2 8 4 9 5 7 4 9 5 7 10 0 11 5 20 23 7 9 9 2 17 0 20 0 26 6 31 0 50 0 58 4 9 5 7 4 9 5 7 4 9 5 7 N m 49 0 58 8 48 1 55 8...

Page 259: ...ightening torque 23 6 27 4 N m 2 4 2 8 kgf m 17 4 20 2 lbf ft 49 0 58 8 N m 5 0 6 0 kgf m 36 2 43 4 lbf ft Hydraulic pipe 1 attaching bolt M8 1 25 Hydraulic pipe 1 attaching bolt joint bolt 18 1 25 Apply O ring with grease to prevent damage 1 Hydraulic Pipe 1 2 O Ring 3 O Ring 4 Joint Bolt 5 Bolt 1 Gear Pump 4 Hydraulic Pipe 2 Bolt 5 Suction Pipe 3 Hydraulic Pipe 15 DISASSEMBLY ASSEMBLY www mymowe...

Page 260: ...a new part If the seal ring is damaged replace it with a new one Make sure the assembly direction of seal ring is correct CAUTION When reassembling Assemble the drive gear as in the original direction When assembling bush 9 16 reassemble each in the original position Make sure seal ring and O ring are not damaged After reassembling hydraulic pump assembly in stall long arm of about 100 mm 3 39 in ...

Page 261: ...amaged IMPORTANT After disassembling or assembling the relief valve always adjust the setting pressure of the relief valve 1 Disengage joint bolt 9 and install the pressure gauge 2 Start the engine and set it to max speed 3 Until relief valve is operated move position lever and read gage 4 If the pressure is out of reference disengage the plug of hydraulic block 7 and adjust the adjusting shim See...

Page 262: ...detach aux control valve from the power lift body When reassembling Make sure the O ring is not damage 1 Pipe A 2 Pipe B 5 Bracket 6 O Ring 8 Joint Bolt 2 15 4 HYDRAULIC CYLINDER A DISASSEMBLY ASSEMBLY a Pipe Aux Control Valve If Attached 9 Quick Coupler 10 Bolt 11 Seal Washer 12 Stud 13 Double Acting Valve 14 O Ring 15 O Ring 16 Flange 17 Washer 18 Nut www mymowerparts com K T Saw Shop 606 678 96...

Page 263: ...side link 2 Disengage bolt 2 and remove relevant parts entirely 615W931A When reassembling Tightening torque 48 1 55 8 N m 4 9 5 7 kgf m 35 5 41 2 lbf ft Hydraulic cylinder attaching bolt nut 1 Disengage joint bolt 1 2 Disengage the hydraulic cylinder assembly mount ing bolts 6 7 8 9 spring washer 5 and nut 4 3 Raise and then detach the hydraulic cylinder as sembly with a nylon rope supported 1 Jo...

Page 264: ...g bolt e Lift Arm Hydraulic Cylinder Arm Hydraulic Arm Shaft 1 Loosen the cylinder attaching screw 13 16 and crank attaching screw 6 2 Disengage snap ring 1 and detach the hydraulic arm shaft and elevating arm tapping on it using a urethane hammer 3 Remove hydraulic cylinder 14 piston 11 con necting rod 10 and crank 7 1 Snap Ring 9 Pin 2 Lift Arm Left 10 Connecting Rod 3 Lift Arm Right 11 Piston 4...

Page 265: ... 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 1 Shaft 3 Elevating Arm 2 Crank A Hole B Mark www mymowerparts com K T Saw Shop 606 678 96...

Page 266: ...Adjusting Valve 10 O Ring 2 Valve Body 11 Ball 3 Spool 12 Spacer 4 Valve 13 Spring 5 O Ring 14 Spacer 6 O Ring 15 Disc 7 Adjusting Screw 16 Adjusting Screw 8 Spring 17 Adjusting Screw 9 Plug 18 Nut 26 Valve Set 19 Spring 27 Valve 20 Valve 28 Pin 21 O Ring 29 Spring 22 O Ring 30 Plug 23 Cover 31 Adjusting Screw 24 Valve 32 Bolt 25 Spring 33 Nut Since disc 15 might fly away due to the spring tension...

Page 267: ...olt 6 in the assembly 1 Top Link Holder 12 Plate 2 Flange 13 Bolt 3 Cover 14 Lock Washer 4 Spring 15 Roller 5 Roller 16 Nut 6 Bolt 17 Tie Rod 7 Bolt 18 Snap Ring 8 Lock Washer 19 Crank 9 Bolt 20 Pin 10 Pin 21 Nut 11 Snap Ring Don t change the assembled position of plate when disassembling flange 2 Make sure top link holder 1 does not fall to ground when disassembling pin 10 When assembling bolt 7 ...

Page 268: ... the calculated clearance exceeds the allowable limits replace the bush Cylinder I D A 90 000 90 050 mm 3 54330 3 54527 in 90 150 mm 3 54921 in Reference dimension Allowable limit Hydraulic arm shaft O D 49 970 49 940 mm 1 96732 1 96614 in 44 975 44 950 mm 1 77066 1 76968 in Right B Left A Bush I D After assembled 50 075 50 115 mm 1 97145 1 97303 in 45 075 45 115 mm 1 77460 1 77618 in Right B Left...

Page 269: ... 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 Reaction spring assembly initial length L 50 mm 1 9685 in Reference dimension A Setting length 112 mm 4 4094 in Reference dimension B Setting length 50 5 mm 1 9881 in Reference dimension www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 270: ... it for operation and make sure it is located at the same position at the highest 4 With minimum rpm lower the position control lever 6 to stopper 8 and then slowly raise the Draft control lever 5 toward stopper 7 so that the el evating arm might be raised 5 Until smooth down of elevating arm is obtained de crease and adjust the length L of feedback rod gradually one rotation a time 6 After a comp...

Page 271: ...ve 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 4 After a completion of the adjustment mentioned above rotate the preventative screw 2 1 4 turns clockwise to set into position firmly This time the sensitivity of the MLS valve will be set to the ma...

Page 272: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 273: ...CHAPTER 10 ELECTRIC SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 274: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 275: ...ETER 1 Records the hours and portions of hours that tractor has been operated Use the hourmeter as a guide to determine hourly service and maintenance intervals If the engine is operated in approx 2000RPM of engine speed for an hour 1 hour of hour meter will be accumulated The lowest numbers on white ground indicate one tenth of an hour C TEMPERATURE GAUGE 2 Indicates coolant temperature It is act...

Page 276: ...ge tank C DIFFERENTIAL LOCK OPERATION LAMP 6 The light will illuminate when the differential lock pedal is engaged 1 2 INDICATORS AND WARNING LIGHTS D ENGINE OIL PRESSURE LAMP 7 The light will illuminate when the engine oil pressure is below than set value As soon as the light illuminate stop the engine and in vestigate the cause And must visit the nearest main tenance facilities E BATTERY CHARGIN...

Page 277: ...NG LAMP 10 If the hydraulic filter is restricted or the vacuum pres sure of filter is increased over specified level this lamp turns on Stop the engine and check the hydraulic line H HEADLAMP HIGH BEAM INDICATOR 11 The light will be illuminated when the headlamp switch is located at high beam position I PARKING BRAKE WARNING LAMP 12 The light will be illuminate when the parking lever is pulled up ...

Page 278: ... Fusible link blown Wiring harness disconnected or improperly connected Main switch defective Glow plug indicator defective Timer relay defective Fuse blown Regulator relay defective Wiring harness disconnected or improperly connected Wiring harness disconnected or improperly connected Alternator defective Regulator relay defective Fuse blown Bulb blown Wiring harness disconnected or improperly co...

Page 279: ...fective Engine oil pressure too low Engine oil insufficient Oil pressure switch defective Short circuit between oil pressure switch lead and chassis Bulb blown Oil pressure switch defective Wiring harness disconnected or improperly connected Circuit in instrument panel defective Fuse blown Coolant temperature gauge or fuel gauge fuel sender defective Wiring harness disconnected or improperly conne...

Page 280: ... 2 0kw 12V 50A 14V 3 4W Capacity factory spec Regulator built in type Feature Battery Start motor Alternator Indicator bulb Rated voltage capacity Rated voltage Rated power Rated voltage Rated current Rated voltage Rated power www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 281: ... 3 Start motor 4 Key s w 5 Safety s w 6 PTO safety relay 7 PTO fuse 8 Neutral 9 Auto 10 Manual 11 PTO control s w 12 Micro s w 4 MECHANISM 615WA04B 4 1 STARTING SYSTEM A CIRCUiT DIAGRAM FOR STARTING SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 282: ...ther and current to flow through the motor section It is composed of the pull in coil holding plunger drive lever contact plate etc 1 PC Pull in coil 6 Armature 2 HC Holding coil 7 Pole cor 3 S Switch 8 Commutator 4 Drive lever clutch 9 Contact plate 5 Screw spline A Construction B Starter circuit 1 lever 2 Internal Gear Ass y 3 Front Bracket Ass y 4 Needle Bearing 5 6 Roller ORC Ass y 6 Planet Ge...

Page 283: ...ani cal power which turns the engine crankshaft At this time the pinion is moved forward by the screw spline for more contact Since the pull in coil ends are short circuited by the contact plate the plunger is held only by force of the holding coil 615WA08A E When key switch is release When the key switch is release a current flows instan taneously through the pull in coil in the opposite direc ti...

Page 284: ...glow plugs are quick heating type which make starting easier with short pre heating time 1 Housing 3 Insulating powder 2 Metal tube 4 Heat coil 1 Key s w 2 Main Fuse 3 Alternator 615WA11B 4 2 CHARGING SYSTEM A CIRCUIT DIAGRAM FOR CHARGING SYSTEM 4 Diode 5 Battery charge warning lamp 6 Regulator 7 Battery www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 285: ... 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 www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 286: ...0A 2 Capacity of the preheating controller DC12V B OPERATION FOR PREHEATING SYSTEM If the key switch is in ON position preheating system is operated automatically according to the coolant temperature If the coolant temperature is bellow 60 É the glow plug is heated up for 15 seconds Due to this combustion chambers are also heated up so that the engine becomes easier to start If the coolant tempera...

Page 287: ...in this tractor The one is main fuse which connected to the main wring near the start motor the other is sub fuse which fixed in fuse box Fuse box is located by clutch pedal If the main fuse is failed it makes impossible to operate any electri cal devices of tractor Replace it with new one If this fuse failure continued investigate the whole wirings whether there are any short circuit to the groun...

Page 288: ...GAUGE The fuel sender consists of float variable resister thermister which are installed in the fuel tank As the float lowers the resistance of variable resister varies Resis tance of the thermister increases in the fuel and de creases in the air When the fuel tank is empty fuel indicator of instrument panel lights up by current increase 615WA17A 1 Float 3 Thermister 2 Variable Resister 1 Terminal...

Page 289: ...ELECTRIC SYSTEM 10 17 D615 W02 May 2003 615WA18A 5 MAIN CIRCUIT DIAGRAM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

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