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73

2-4 Trouble Shooting

Condition Cause

Remedy

Engine does not start.

Defective key switch
Insufficient charging or completely discharged
battery.
No fuel.
Air mixed in the fuel system.

Clogged fuel filter.
Irregular of improper fuel supply.

Defective glow plug.
Improper viscosity of lubricating oil.
Clogged air cleaner.
Not compressed.
Defective engine stop solenoid.

Connect or correct contact points properly.
Charge.

Replenish the fuel.
Correct points allowing the air to enter the
fuel.
Replace the fuel filter.
Trouble of injection pump. Have corrected
in work specified by Nippon Denso.
Replace.
Check and change.
Clean the air cleaner.
Check and correct each part.
Check or replace wiring.

Irregular engine speed

Air mixed in the fuel system.
Uneven fuel injection.

Clogged fuel filter.
Trouble of speed governor.
Improper function of engine main body.

Discharge air from the fuel.
Trouble of injection pump. Have corrected
or replaced in a work specified by Nippon
Denso.
Replace the fuel filter.
Check and adjust.
Overhaul, check and correct each part.

Engine stops during
operation

No fuel in fuel tank.
Clogged fuel filter.
Air mixed in the fuel system.

Improper functions of engine main body.

Replenish fuel.
Replace the filter.
Correct points to allow the air to enter the
fuel system.
Check and correct each part.

Engine overheat

Insufficient cooling water.

Loosened or slipping fan belt.
Failure of fan belt.
Clogged radiator.
Clogged radiator fin.
Cooling water passage clogged with dust, fur, etc.
Improper function of thermostat.
Insufficient lubricating oil.
Overload.

Replenish the cooling water, and check and
repair water leaking points.
Clean oil dust, etc. and retighten.
Replace.
Clean the radiator.
Clean.
Wash.
Check and replace
Replenish.
Decrease the load.

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Summary of Contents for CM284

Page 1: ...FRONT MOWER CM284 CM364 WORKSHOP MANUAL Downloaded from www Manualslib com manuals search engine ...

Page 2: ...tions maintenance and service of models CM284 and CM364 so that their functions are fully exhibited in actual operation Please read this carefully to promote sales and service to improve the service techniques and guide users for proper operation of Shibaura tractors Figures or other conditions in this manual may be changed without notice in order to improve the performance or for other objects Do...

Page 3: ... UNIT REMOVAL 121 3 PRECAUTIONS BEFORE DISASSEMBLY 124 4 DISASSEMBLY 124 5 INSPECTION 125 6 REASSEMBLY 126 7 ASSEMBLY 126 8 ADJUSTMENT 128 9 TROUBLE SHOOTING AND SPECIFICATIONS 132 Chapter 5 POWER STEERING 135 1 OIL FLOW 136 2 CONTROL VALVE ASSEMBLY 141 3 POWER STEERING CYLINDER 145 4 PIPING 146 5 TROUBLE SHOOTING 147 Chapter 6 REAR AXLE ASSEMBLY 149 1 DESCRIPTION AND OPERATION 150 2 REAR AXLE REM...

Page 4: ...3 Chapter 1 GENERAL Downloaded from www Manualslib com manuals search engine ...

Page 5: ...le speed Transmission System L H Switching All Hydraulic Continuously Variable Speed HST Brake Wet Disc Brake Lift Control Valve Relief Set Pressure 9 8 MPa 100 kgf cm2 Relief Set Pressure Steering 5 88 6 56 MPa 60 67 kgf cm2 Full Hydraulic Power Steering Running Speed Forward L 0 10 0 km h Forward H 0 17 2 km h Reverse L 60 70 of Forward Speed Reverse H 60 70 of Forward Speed Capacity Fuel Tank 5...

Page 6: ...and hydraulic apparatus have been specially manufactured to high accuracy so that care shall be exercised to maintain them in clean state and not to do any unnecessary disassembly 2 Defective parts due to wear and other causes shall be discarded and new parts ordered with the tractor model serial No code No and part name clearly defined Keep the defective parts on hand to enable showing it to the ...

Page 7: ...T 1 0 4 9 6 9 7T 8 3 11 3 10T 11 7 15 7 M8 4T 1 25 12 7 16 7 1 0 15 2 20 1 7T 22 6 28 4 26 5 34 3 10T 28 5 36 3 30 4 40 2 M10 4T 1 5 25 5 33 3 1 25 28 4 36 2 7T 44 1 55 9 49 0 62 8 10T 54 0 69 6 57 9 73 5 M12 4T 1 75 37 3 47 1 1 25 43 1 54 9 7T 65 7 83 4 74 5 94 1 10T 92 2 116 99 0 127 M14 4T 2 0 62 8 80 4 1 5 69 6 87 3 7T 104 131 117 148 11T 139 175 147 186 M16 4T 2 0 86 3 110 1 5 91 2 115 7T 149...

Page 8: ...ue to Pollutant Regulations some of parts relating to Engine exhaust are not available for spares as an individual part Engine Model Tractor Model J843 CM284 N843L CM364 Downloaded from www Manualslib com manuals search engine ...

Page 9: ...il pressure switch 11 Disconnect the wiring from the glow plug connector 12 Disconnect the wiring from the engine stop solenoid 13 Disconnect the fuel pipe from the injection pump 14 Remove the accelerator wire from the engine 15 Disconnect the drain hose from the drain cock 16 Disconnect the oil hoses from the hydraulic oil pump 17 Remove the engine attaching nuts and hoist the engine from the fl...

Page 10: ...Injection pump NOTE 1 Remove the injection pipes and engine stop solenoid before remove the injection pump 2 Raise the injection pump and disconnect the governor link from the control rack by remove the snap pin 3 Injection timing has been adjusted by the shims between injection pump and cylinder block Take note of their thickness and number when removing the injection pump Downloaded from www Man...

Page 11: ...hermostat case Gasket 15 Head cover O Ring Intake manifold Spacer 16 Rocker arm assembly O Ring Cap NOTE Remove the caps from intake valves and exhaust valves 17 Push rod 18 Cylinder head assembly Head gasket NOTE 1 Untighten the cylinder head bolts in several steps and remove the cylinder head assembly 19 Tappet Downloaded from www Manualslib com manuals search engine ...

Page 12: ...l pump Cover Drain cock 24 Timing gear case assembly Gasket NOTE Remove the engine stop solenoid and injection pump assembly at first 25 Idle gear Oil pump assembly 26 Cam shaft assembly Plate NOTE Remove the bolts and plate at first and draw out the cam shaft assembly 27 Front plate Gasket Downloaded from www Manualslib com manuals search engine ...

Page 13: ...ly NOTE 1 Before extracting piston remove the carbon deposit from the TDC in the cylinder 2 Place the connecting rod cap and bearing removed in order of the cylinders 33 Crank shaft and bearing holder assembly NOTE Remove the four bolts and draw out the crank shaft and bearing holder assembly as a set Downloaded from www Manualslib com manuals search engine ...

Page 14: ...e to be combined as specified should be attached match marks beforehand to prevent confusion 1 Rocker arm ass y Disassembly 1 Extract the screw from the rocker arm bracket 2 Screw in a M8 bolt from the front side of the rocker arm bracket and extract the rocker arm shaft 3 Take out the spring and rocker arm from the rocker arm bracket 1 Screw 2 Rocker arm shaft 3 Rocker arm 4 Spring 5 Shim Inspect...

Page 15: ...linder head ass y Disassembly 1 Compress the valve spring with a valve spring replacer and remove the valve cotter retainer spring and valve 2 Remove the valve guide seal if required Inspection and service 1 Distortion of cylinder head bottom surface Apply a straight edge to the bottom surface of the cylinder head and insert a thickness gauge at 6 points from A to F in the right figure and measure...

Page 16: ...rvice limit Standard assembling value Service limit 6 955 6 97 6 89 6 94 6 95 6 84 c Replace a valve if its head thickness is less than service limit Valve head thickness mm Standard assembling value Service limit 0 775 1 075 0 5 d Replace the valve if the clearance between the stem and guide exceeds the service limit Clearance between valve stem and valve guide mm Intake valve Exhaust valve Stand...

Page 17: ...dth mm Standard assembling value Repair value Intake 1 66 1 87 2 5 Exhaust 1 66 1 73 c When the seat recess exceeds the service limit replace the valve seat or valve Valve seat recess mm Standard assembling value Service limit 0 85 1 15 1 8 d Coat the valve seat surface with compound and lap the contact surface turning the valve e Check that the valve contact surface is within the standard value a...

Page 18: ...mit Squareness mm 1 2 2 Free length mm 35 33 5 Spring force when compressed to 30 4 mm 8 1 7 5 Inspection of combustion chamber Check and clean the inside of the combustion chamber 022X Reassembly Reassemble parts in the order reverse to disassembly taking care for the following points 1 When assembling the valve spring retainer and cotter be careful not to damage the valve guide seal 2 Tighten th...

Page 19: ... bore at the top center and bottom respectively in the crankshaft direction A and the direction at right angle to it B If the repair value is exceeded replace engine long block assembly Distortion on cylinder block top surface mm Standard assembling value Repair value Less than 0 05 More than 0 12 122V Model Standard assembling value Repair value J843 N843L φ84 φ84 019 More than φ84 2 Replace engi...

Page 20: ...s exceeded Clearance between cylinder and piston mm Model Standard assembling value Service limit J843 N843L 0 0375 0 0715 0 25 Piston skirt bottom longer dia mm Model Standard assembling value Service limit J843 N843L φ83 9475 83 96 φ83 7 Model Piston size Skirt bottom longer dia J843 S T D 83 9475 83 9625 N843L S T D 83 9475 83 9625 d Measure the piston pin hole diameter and piston pin outside d...

Page 21: ...able Piston piston ring kit Model Size Part code No J843 S T D 115017390 N843L S T D 115017310 e Piston ring installing procedure Install the piston ring to the piston as shown in the right figure 3 Piston pin Measure the outside diameter of the piston pin and replace if the service limit is exceeded 027X Clearance between piston ring groove and ring mm Standard assembling value Service limit Top ...

Page 22: ...pin b Cut plasti gauge to the length same as the metal width and place it on the crank pin in parallel with the crankshaft avoiding the oil hole c Install the connecting rod metal and connecting rod cap and tighten with the specified tightening torque Tightening torque 49 53 9 N m 5 0 5 5 kgf m NOTE Never turn the connecting rod at this time Torsion and parallelism of connecting rod mm Standard as...

Page 23: ...ark in the piston and match mark at Ⓐ of the connecting rod 2 Care should be taken to the figure match mark at Ⓐ of the connecting rod 3 Install the piston ring to the piston facing the stamp at the end surface of the ring end gap upward 4 When the connecting rod or piston and piston pin are replaced weight variation among cylinders with the rod piston and piston ring installed should be within 10...

Page 24: ...L S T D 198517210 Upper 198517230 Upper 198517200 Lower 198517240 Lower Journal size Finished dimensions of crankshaft journal φ J843 N843L S T D 57 957 57 970 67 957 67 970 Thrust washer Check the thrust washer and replace if wear improper contact seizure or other damage is noticed or thickness exceeds the service limit Clearance between crankshaft center journal and metal oil clearance mm Models...

Page 25: ...itted with thrust washer on the flywheel side and the bearing holder with identification cutting mark at the center Bearing holder tightening torque 49 53 9 N m 5 5 5 kgf m 3 Install the thrust washer facing the oil groove towards the crankshaft thrust surface NOTE Be sure to confirm that the oil hole of the bearing holder and that of the cylinder block are in the same direction 035X Downloaded fr...

Page 26: ...2 Bush size Bush code No S T D J843 N843L 198517190 198517220 036X 037X Bush size Crankshaft journal outside dia Finishing dimension φ S T D J843 N843L 57 957 57 970 67 957 67 970 NOTE 1 Measure the dimensions in the A and B directions at the position 1 and 2 in the right figure avoiding the oil hole of the bearing bush and calculate difference from the maximum value of the crankshaft journal oil ...

Page 27: ...in the AA and BB directions at the position 1 and 2 avoiding the oil holes Irregular wear limit of crankshaft journal and pin 0 05 mm Crankshaft run out mm Standard assembling value Service limit Less than 0 03 0 06 039X 040X Model J843 Journal and pin size Shaft dia at crankshaft journal φ Shaft dia at crankshaft pin φ S T D Outside dia finishing dimension Repair value Outside dia finishing dimen...

Page 28: ...Correct insignificant uneven wear or scars on the cam surface using oil stone or the like A Height of intake exhaust valve cams mm Standard assembling value Service limit 34 441 34 5076 34 1 B Height of injection pump cams mm Standard assembling value Service limit 42 99 43 01 42 8 12 Timing gear Inspection 1 If pitting or remarkable wear is observed on the tooth face of gears replace the gear 2 M...

Page 29: ...28 13 Oil flow 045X Downloaded from www Manualslib com manuals search engine ...

Page 30: ...de clearance of the rotor and vane to 0 1 0 15 mm Refer to Fig 071X 15 Oil filter Structure and Functions 1 The cartridge type oil filter is excellent in filtering performance 2 Since it is of the full flow type when the filter is clogged the safety valve is opened to allow the oil to flow preventing seizure or other troubles 3 The oil fed under pressure with the oil pump enters Ⓐ is filtered by t...

Page 31: ...erve tank is returned into the radiator black arrow Specifications Fin type Corrugated Cooling water volume 5 1 ℓ J843 5 3 ℓ N843L Pressure valve starting pressure 0 75 1 05 kgf cm2 Negative pressure valve starting pressure Less than 0 05 kgf cm2 Heat radiation volume 28 400 kcal h 049X 1 Water pump ass y 2 Gasket 3 Set plate 050X Inspection a Check the radiator pipe and reserve tank for water lea...

Page 32: ...ring nut NOTE Take care to the O Ring fitted between the ring nut and filter body coat with grease before tightening 2 Apply the grease to the element attaching place of the filter body and install the element by hand 19 Governor Structure and functions Governor This governor is a mechanical all speed governor It is installed in the gear case The fly weight ass y is installed to the cam shaft and ...

Page 33: ...e does start 1 Fuel Shortage or air mixed in 2 Defective engine stop solenoid 1 Replenish fuel check air entering part bleed air 2 Check and replace the electric system 2 Engine starts but will not stop at once 1 Filter or pipes clogged 2 Air mixed in 3 Fuel tank filter cap air breathe clogged 4 Short circuit or disconnected wire of electric system of engine stop solenoid 1 Replace or clean out 2 ...

Page 34: ... to the nozzle body When the pressure exceeds the specified value it pushes the spring injected from the nozzle and at the same time lubricates and cools the nozzle and nozzle body The oil leaking at this time is returned to the tank by the return pipe 053X 054X Disassembly and inspection 1 Place the nozzle holder body in a vice and disassemble turning the nozzle nut NOTE Take care not to allow th...

Page 35: ...d value 11 76 MPa 120 kgf cm2 on Model J843 and 14 7 Mpa 150 kgf cm2 on Model N843L and check that the test oil does not drop form the nozzle end 22 Air Cleaner Structure and functions 1 The air cleaner is connected to the cylinder with the air cleaner hose 2 The air cleaner is of the cyclone type incorporating filter element and removes dust from the intake air 055X 035X Inspection and replacemen...

Page 36: ...Replace if the valve is opened even only slightly at normal temperature Immerse the thermostat in water increase the water temperature gradually and check the valve opening temperature and valve lift Specifications Type Wax pellet Opening temperature 80º 84ºC Full opening temperature 95ºC Valve lift at water temperature 95ºC 8 0 mm NOTE 3 to 5 minutes are required until the valve is operated 057X ...

Page 37: ...th O Ring Relief valve tightening torque Relief valve tightening torque 59 69 N m 6 0 7 0 kgf m 2 Crank shaft and bearing holder assembly Cylinder block to bearing holder tightening torque Bolts fixing bearing holder A Hexagon socket head blot 25 29 N m 2 5 3 0 kgf m B Hexagon bolt 49 54 N m 5 0 5 5 kgf m NOTE 1 Take care not to damage the bush in the cylinder block by the crank shaft gear when in...

Page 38: ...torque 22 6 28 4 N m 2 3 2 9 kgf m 5 Fly wheel Align the hole to the roll pin on the crankshaft Fly wheel tightening torque 69 78 N m 7 0 8 0 kgf m 6 Piston and connecting rod assembly Coat the metal surface piston and piston ring with engine oil 061X 062X 063X 064X Downloaded from www Manualslib com manuals search engine ...

Page 39: ...ncrease gradually Tighten the connecting rod cap with the specified torque and check for the axial play Connecting rod tightening torque 49 54 N m 5 0 5 5 kgf m NOTE 1 After tightening confirm that the crankshaft moves lightly 2 The connecting rod should move 0 1 0 3 mm in the axial direction 7 Suction pipe Suction filter Fit an O Ring to the suction pipe and insert the suction pipe to the cylinde...

Page 40: ...using 2 O Rings 10 Front plate Install the front plate together with the gasket 11 Cam shaft ass y Tachometer shaft Plate Install the tachometer shaft Install the cam shaft ass y taking care to the bearing Fix the tachometer shaft and cam shaft ass y with the plate Plate tightening torque 9 13 N m 0 9 1 3 kgf m NOTE Install the timing gear case taking care so that the slider is not dislocated from...

Page 41: ...p cover clockwise and counterclockwise fix the hole at the center of the spring pin inserting hole moving distance and then install the gear case Adjust the shims so that the oil pump rotor and vane side clearance is 0 1 0 15 mm 13 Timing gear case Cover Untighten the lock nut and remove the low idle set bolt Install the start spring between the timing gear case and governor link Inserting the lin...

Page 42: ...ion pump inserting a shim of 0 5 mm in thickness according to the procedure of order 15 Remove the delivery valve holder on the injection pump front side radiator side Extract the delivery valve IN and install the spring and delivery holder NOTE When installing the delivery holder adjust the delivery valve OUT to the correct position with a wire Move the governor lever in the fuel increasing direc...

Page 43: ...tightening torque 39 2 44 1 N m 4 0 4 5 kgf m Injection timing before TDC 18 20 Piston displacement before TDC J843 2 594 3 187 mm N843L 3 195 3 932 mm Crankshaft angle Model J843 N843L 17º 2 320 2 854 18º 2 594 3 195 19º 2 884 3 554 20º 3 187 3 932 21º 3 505 4 328 22º 3 837 4 741 077X 17 Drive gear ass y for hydraulic pump Hydraulic pump ass y Install the drive gear ass y to the hydraulic pump an...

Page 44: ...s than 0 8 111147500 t 1 4 NOTE Four smallest digits of the part code No are stamped on the top surface of the head gasket Tighten the cylinder head in several steps in the order as shown in the right figure and tighten with the specified torque finally Cylinder head tightening torque 98 103 N m 10 10 5 kgf m NOTE 1 Take care to the spring pin which positions the cylinder head ass y 2 Coat the thr...

Page 45: ...ed from the front side and adjust the No 2 intake and No 3 intake and exhaust valves Lock nut tightening torque 11 8 15 7 N m 1 2 1 6 kgf m 23 Oil pressure switch Oil pressure switch tightening torque 15 20 N m 1 5 2 0 kgf m 24 Oil pipe Eye bolt tightening torque M8 10 13 N m 1 0 1 3 kgf m 25 Water pump ass y Bypass hose Install and tighten the gasket and water pump ass y Connect the thermostat ca...

Page 46: ...torque 15 25 N m 1 5 2 5 kgf m 30 Intake manifold Spacer Exhaust manifold Install the gasket spacer gasket and intake manifold in this order Install the exhaust manifold 31 Alternator Install the alternator taking care to the direction of the adjusting plate 32 V belt Fan pulley Cooling fan Install the fan pulley and cooling fan and then V belt Adjust the belt tension with the alternator so that i...

Page 47: ...ew driver Carefully separate the front bracket pulley and rotor assembly away from the stator and rear bracket assembly Place the rotor in a vice with soft jaws and remove the pulley nut washer pulley spacer and front bracket from the rotor Unsolder three stator leads and remove the stator Remove the voltage regulator assembly and rectifier assembly as a set 088X 089X 090X Downloaded from www Manu...

Page 48: ...h the slip rings If there is no continuity the field coil is defective Replace the rotor assembly Check for continuity between the slip ring and shaft or core If there is continuity it means that the coil or slip ring is grounded Replace the rotor assembly 2 Stator Check for continuity between the leads of the stator coil If there is no continuity the stator coil is defective Replace the stator as...

Page 49: ...rcuited Replace the rectifier assembly Negative Heatsink Check for continuity between the negative heat sink and stator coil lead connection terminal with a circuit tester If there is continuity in both directions the diode is short circuited Replace the rectifier assembly Diode Trio Using a circuit tester check the three small diodes for continuity in both directions If there is either continuity...

Page 50: ...s into brush holder insert a wire to hold them in raised position before install the rectifier and regulator assembly Install rotor and remove wire NOTE Since rear bearing and rear bracket fitting is tight heat the bearing box in the rear bracket to 50 60ºC 122 140ºF before installing rotor 2 Lubrication to bearing box for bearing with resin band grease should not be applied Remove oils completely...

Page 51: ...s shown in the section on Service Specifications If the output is less than specified value the alternator should be disassembled and checked 101X 5 Precautions 1 Reversed battery connections will damage the alternator and or wiring 2 When connecting a booster battery make certain to connect negative battery terminals together and positive battery terminals together 3 When a fast charger is used t...

Page 52: ... mm 18 5 Limit mm 5 0 Brush spring tension Original N 4 6 5 8 470 590 gf Limit N 2 6 270gf Bearing Rear side ECSC8 Front side 6303DDG Slip ring diameter Original mm 22 7 Limit mm 22 1 Slip ring diameter eccentric wear To be repaired mm 0 05 Allowable limit mm 0 2 Slip rings surface condition If dirty or damaged correct with emery cloth Rotor shaft bending To be repaired mm 0 07 Field coil resistan...

Page 53: ...lator Replace Battery Defective battery Replace Over charge Battery Internal short circuit Replace Regulator Defective regulator Replace Unstable charging current Wiring Disconnection or breakage of wire Replace Alternator Slackened alternator drive belt Replace Short of rotor coil breakage of wire Replace Shortage of stator coil breakage of wire Replace Insufficient contact of brush stained brush...

Page 54: ...structure is different from that of direct drive type but the electrical wiring is the same between two types The magnetic field is produced by six permanent magnets The magnets are mounted in the yoke and positioned according to polarity They are permanently attached to the yoke and are not removable Rear Bracket Overrunning Clutch Planetary Gears Armature Front Bracket Rubber Cover Switch Bearin...

Page 55: ...deformed if mishandled Remove switch terminal nut 1 and disconnect connecting wire 2 Remove screws 3 securing switch and remove switch and plunger 4 Remove brush holder securing screws 5 and through bolts 6 Remove rear bracket 7 but do not remove brush holder 8 Install a socket outer diameter 30mm on the armature commutator see Figure 103X Then slide the brush holder 8 onto the socket Leave the so...

Page 56: ...n tap the pipe with a hammer to remove the stop ring and expose snap ring 22 Remove the pipe from the shaft c Remove the snap ring and the stop ring and separate the over running clutch 18 from the gear shaft 17 If the snap ring is distorted it will be necessary to use a new one on reassembly 3 Inspections 1 Armature Inspect the armature coil for short circuit with a growler tester Replace armatur...

Page 57: ...ction not necessarily easily but should not rotate in opposite direction If the clutch does not function properly replace it If pinion gear is worn or burred replace it NOTE Overrunning clutch should not be cleaned with grease dissolving solvents since these would dissolve the lubricant in the clutch mechanism 5 Front bracket Replace front bracket as an assembly including ball bearing if the beari...

Page 58: ...mature shaft end play No adjustment 3 Pinion position adjustment After completing reassembly check pinion position to be sure that it is between 0 5 and 2 0 mm To adjust proceed as follows Connect the starter to a battery as shown in Fig 110X Close switch This will shift pinion into cranking position Push pinion back by hand and measure the amount of the pinion movement as shown in Fig 111X If the...

Page 59: ...tions If any abnormality is noted check it according to the inspections 112X 6 Service Specifications Item Standard Value or Service Limit No load Characteristic Volts 11 Amps 110 Max RPM 2400 min Commutator Outer Dia 29 4 mm Service Limit 28 8 mm Brush Length 17 5 mm Service Limit 10 mm Brush spring Tention 22 5 32 5 N 2 3 3 3 kgf Service Limit 10 N 1 02 kgf Pinion Movement Pinion Gap 0 5 2 0 mm ...

Page 60: ...motor does not start Unit Cause Remedy Wiring Disconnected wire connecting the battery and magnet switch Insufficient tightening of the lead wire connecting the magnet switch and motor Repair retightening or replace the wire Starting motor Locked ball bearing Improper installation Worn out brush improper contact of brush spring Stained commutator Defective armature or field coil Insufficient tight...

Page 61: ...wed from pinion Clockwise Loaded Terminal voltage V 7 6 Current A Less than 400 Clutch type Overrunning Torque N m kgf m More than 16 7 1 7 Engaging type Magnetic shift 2 General Description The newly developed reduction starter is a positive shift type starter and consists of the motor reduction gear overrunning clutch and pinion magnetic switch The magnetic switch and sliding pinion mechanism ar...

Page 62: ...the yoke 8 Remove the screws from the drive end frame 9 Remove the drive end frame from the magnetic switch 10 Remove the over running clutch from the drive end frame NOTE If the pinion is installed on the drive end frame externally attached to overrunning clutch shaft it will be necessary to remove pinion prior to removing overrunning clutch 11 Remove the steel ball from the overrunning clutch 12...

Page 63: ...rease as follows Nippondenso No 50 grease or equivalent Esso beacon 325 Retainer and rollers Overrunning clutch Steel ball Return spring Armature bearing Felt washer 2 Fixing torque Item Torque N m kg m Throught blot 8 82 11 76 0 9 1 2 Drive end flame fixing screw 8 82 11 76 0 9 1 2 C terminal nut 9 8 13 72 1 0 1 4 3 Cautions for installation Do not forget to assemble the steel ball and return spr...

Page 64: ...hort time 3 to 5 sec to prevent the magnetic switch winding from burning Each test should be performed with specified voltage is applied Pull in test Connect the test leads as shown in Figure When connecting terminal C and M T are closed the pinion should jump out Hold in test With the same condition as in the pull in test open the connecting terminal C The pinion should remain in jumped out posit...

Page 65: ... applied The ammeter should indicate less than the specified current and the tachometer should indicate more than the specified speed 3 Lock torque test Read the torque meter and ammeter when the tachometer reading becomes 0 rpm after applying the load The torque meter should indicate more than the specified torque and the ammeter should indicate less than the specified current 8 Diagnosis and tes...

Page 66: ...D Remove starter from engine and repair it Replace magnetic switch Repair or replace the key switch relay and wiring Replace magnetic switch GOOD NO GOOD Perform test 2 on next page Perform test 1 on next page GOOD NO GOOD Does magnetic switch click Check starting system circuit GOOD NO GOOD Remove starter and repair Recharge or replace battery GOOD NO GOOD Is battery in good condition Clean and r...

Page 67: ...ould be continuity If there is no continuity the hold in winding is open circuited Replace the magnetic switch if open circuited 122X 123X Discrimination of starter terminals Each terminal can be discriminated as follows M T Main terminal to which the main cable from battery is connected C T C terminal to which the lead wire from the yoke is connected 50 50 terminal to which the lead wire from the...

Page 68: ... Commutator irregular wear Standard value mm 0 02 Repair value mm 0 05 Brush length Standard value mm 15 0 Repair value mm 12 0 Tightening torque N m kgf cm End frame bolt 2 94 4 7 30 48 Through bolt 8 82 11 76 90 120 Magnetic switch cover bolt 3 63 4 6 37 47 M terminal nut Inside 13 7 19 6 140 200 M terminal nut Outside 5 88 9 8 60 100 C terminal nut 9 8 13 7 100 140 Housing bolt 8 82 11 76 90 12...

Page 69: ...d in sintered magnesium oxide powder One end of this heat wire is welded to the sheath end and another end is welded to the center electrode By setting the key switch at the heat H and start START positions power is supplied heats the air in the combustion chamber and preheats the heat wire 125X 2 Circuit diagram 126X 3 Inspection 1 Disconnect the connector 2 Connect the circuit tester to the cent...

Page 70: ...oling water temperature rises and indicator of the receiver indicates the corresponding position 2 Inspection 1 Thermosensor a Remove the thermosensor from the thermostat case b Connect a circuit tester to the thermosensor c Measure the resistance value at each temperature while heating with a heater 2 Thermometer a Disconnect the wiring from the themosensor b Turn the key switch to ON position No...

Page 71: ...ened at 103ºC If buzzer is alarmed clean the radiator front screen and radiator screen and inspect the coolant quantity after coolant temperature become cold 2 Engine oil pressure warning alarm system The oil pressure switch is located on the cylinder head Relay and buzzer are located on the fire wall compartment The buzzer is alarmed with the oil pressure switch and relay The switch is closed whe...

Page 72: ...pecific gravity of the electrolyte using a hydrometer residual capacity of the battery can be known The specific gravity value measured by the hydrometer should be compensated with respect to temperature The specific gravity of battery electrolyte is based on the temperature of 20 C As the temperature varies 1 C the specific gravity value increases or decreases 0 0007 Therefore measured values can...

Page 73: ...connect the negative cord of the battery when inspecting or servicing the wiring harness 2 Check each wiring for damage of sheathing due to wiring or for some other reason or looseness at the connecting parts at the time of its inspection or service If there is some defective point repair the insulation or replace the wiring harness The band becomes breakable when becoming old Be sure to substitut...

Page 74: ...overnor Improper function of engine main body Discharge air from the fuel Trouble of injection pump Have corrected or replaced in a work specified by Nippon Denso Replace the fuel filter Check and adjust Overhaul check and correct each part Engine stops during operation No fuel in fuel tank Clogged fuel filter Air mixed in the fuel system Improper functions of engine main body Replenish fuel Repla...

Page 75: ...r does not operate Loosened or disconnected wiring of each part Dropped battery voltage Defective safety switch Trouble in starting motor Disconnected wire of fusible link Check and install or tighten Charge the battery Replace Check and correct the starting motor Replace Oil pressure lamp does not go out Insufficient engine oil Trouble in oil pressure switch Oil leakage from lubricating system Cl...

Page 76: ...ontact width Intake 1 66 1 87 2 5 Exhaust 1 66 1 73 2 5 Cylinder block Bore φ84 φ84 84 019 φ84 2 φ84 2 Distortion on cylinder block top surface Less than 0 05 0 12 Piston Longer dia at skirt φ83 955 φ83 9475 83 96 φ83 7 Clearance to cylinder 0 0375 0 0715 0 25 At 20 C Clearance between piston pin hole and pin 0 010 0 007 0 02 Piston pin Pin outside dia φ25 φ24 996 25 0 φ24 98 Clearance between rod...

Page 77: ...l and pin finishing accuracy 1 6Z Run out of crankshaft Less than 0 03 0 06 Axial play of crankshaft 0 1 0 4 0 5 Thrust washer thickness 3 2 95 3 00 2 8 Bush journal metal bore outside dia φ58 φ62 Clearance between crank journal and bush journal metal 0 044 0 116 0 2 Oil clearance Center bearing bore outside dia φ58 φ62 Clearance between crank journal and center bearing 0 044 0 116 0 2 Oil clearan...

Page 78: ...er diameter φ6 3 Rocker arm Wear of rocker arm shaft φ11 66 φ11 65 11 67 φ11 57 Clearance between rocker arm and shaft 0 032 0 068 0 2 Oil clearance Oil pump Oil pressure switch working pressure kPa kgf cm2 29 4 0 3 19 6 39 2 0 2 0 4 Relief valve opening pressure kPa kgf cm2 24 5 34 3 2 5 3 5 Lubrication oil volume ℓ 4 6 At replacing filter Tip clearance between rotor and vane 0 01 0 15 0 25 Side ...

Page 79: ...f 5 10 Dimension A 36 5 Start to open pressure of radiator cap pressure valve kPa kgf cm2 73 5 0 75 88 2 0 9 Start to open pressure of radiator cap negative pressure valve kPa kgf cm2 4 9 0 05 Less than 4 9 0 05 Starting motor Model M001T66081 No of teeth of pinion gear 9 Pinion gear shifting method Magnetic shifting Wear of commutator dia φ29 4 φ28 8 Brush length 17 5 10 Brush spring pressure N k...

Page 80: ...ake 1 66 1 87 2 5 Exhaust 1 66 1 73 2 5 Cylinder block Bore φ84 φ84 84 019 φ84 2 φ84 2 Distortion on cylinder block top surface Less than 0 05 0 12 Piston Longer dia at skirt φ83 955 φ83 948 83 963 φ83 7 Clearance to cylinder 0 0375 0 0715 0 25 At 20 C Clearance between piston pin hole and pin 0 010 0 007 0 02 Piston pin Pin outside dia φ28 φ27 996 28 0 φ27 98 Clearance between rod small end bush ...

Page 81: ...90 φ51 9 Run out of crankshaft Less than 0 03 0 06 Axial play of crankshaft 0 1 0 4 0 5 Thrust washer thickness 3 2 95 3 00 2 8 Bush journal metal bore outside dia φ58 φ62 Clearance between crank journal and bush journal metal 0 044 0 116 0 2 Oil clearance Center bearing bore outside dia φ58 φ62 Clearance between crank journal and center bearing 0 044 0 102 0 2 Oil clearance Bearing holder upper a...

Page 82: ...174 5 Outer diameter φ6 3 Rocker arm Wear of rocker arm shaft φ14 95 14 97 φ14 87 Clearance between rocker arm and shaft 0 032 0 068 0 2 Oil clearance Oil pump Oil pressure switch working pressure kPa kgf cm2 29 4 0 3 19 6 39 2 0 2 0 4 Relief valve opening pressure kPa kgf cm2 24 5 34 3 2 5 3 5 Lubrication oil volume ℓ 5 6 At replacing filter 5 0 ℓ Tip clearance between rotor and vane 0 01 0 15 0 ...

Page 83: ...ss load at center 49 N 5 kgf 5 Dimension A 36 5 Start to open pressure of radiator cap pressure valve kPa kgf cm2 73 5 0 75 88 2 0 9 Start to open pressure of radiator cap negative pressure valve kPa kgf cm2 4 9 0 05 Less than 4 9 0 05 Starting motor Model RA 228000 5121 No of teeth of pinion gear 9 Pinion gear shifting method Magnetic shifting Wear of commutator dia φ35 0 φ34 0 Brush length 15 12...

Page 84: ...83 Chapter 3 TRANSMISSION AND BRAKE Downloaded from www Manualslib com manuals search engine ...

Page 85: ...les and brakes 300X Transaxle Assembly 1 Transmission 5 Fixed Gears Gearbox 2 Speed 6 Pinion Drive Gear 2 Differential 7 Rear Wheel Drive Assembly Output Shaft and 3 Input Gear Cluster Two Way Clutch 4 Sliding Gears 8 PTO Clutch Assembly 9 PTO Shaft 301X Transaxle Assembly 1 Differential Lock 3 Axle Housing Lever 4 Inboard Brake 2 Differential 5 Drive Axle Assembly Downloaded from www Manualslib c...

Page 86: ...differential lock coupler pinion differential and two bevel side gears splined directly to the axle shafts 2 Brakes The brakes are located in the front axle housing The brakes are wet type disc brakes and consists of stator disc steel ball spring actuate plate and brake lever The brakes are mechanically applied by individual pedals located on the left side of the steering column Dealer option A ma...

Page 87: ...86 4 Power Flow Range gear 304X 305X Downloaded from www Manualslib com manuals search engine ...

Page 88: ...87 5 Power Flow PTO 306X 307X Downloaded from www Manualslib com manuals search engine ...

Page 89: ...nd remove the seat assembly from the seat floor 4 Pull up the lever and open the floor and remove the split pin and separate the damper from the frame 5 Remove the floor and floor bracket from the upper frame 6 Disconnect the parking brake wire from the both brake levers 7 Remove the split pin washer and pin and disconnect the brake rod from the both brake levers 8 Remove the split pin and pin and...

Page 90: ...emove the rear axle assembly pipe drive shaft and coupling from the tractor 12 Remove the fire wall sealed from under the radiator 13 Remove the bolt from the universal joint and disconnect the joint from the HST input shaft by slide the joint to rearward 14 Disconnect the wire connector from the HST neutral switch 311X 312X 313X Downloaded from www Manualslib com manuals search engine ...

Page 91: ... Untighten the hose bands and disconnect the return hose from the vent hose on the transmission housing 18 Disconnect the fork joint by remove the split pin and pin for the PTO clutch control lever 19 Remove the spring from the PTO clutch control lever 20 Disconnect the oil pipe from HST charge pump to power steering control valve 314X 315X 316X Downloaded from www Manualslib com manuals search en...

Page 92: ...e spring from under the HST speed control lever 25 Remove the splits pin washer and disconnect the four wheel drive control rod and range gear control rod from the change lever 26 Remove the banjo bolt and clamp for the oil cooler return pipe and disconnect the return pipe from the oil cooler 27 Use the two wrenches and disconnect the feed pipe for the HST on the top of the HST unit Fig 315X 317X ...

Page 93: ...move the front axle and transmission housing assembly from the main frame 32 Remove the rear frame from the rear transmission housing 33 Un hook the spring remove the shift arm and shift guide as a set from the transmission If necessary remove the control lever from the HST unit 321X 322X 323X 324X Downloaded from www Manualslib com manuals search engine ...

Page 94: ...t 2 Remove the HST unit from the transmission assembly HST Unit O Ring O Ring Bolt 3 Remove the L H wheel shaft housing and bearing holder NOTE Note the total amount of shims and thickness used between differential bearing and bearing holder 325X 326X 327X Downloaded from www Manualslib com manuals search engine ...

Page 95: ...l bearing and bearing holder 5 Separate the rear transmission housing from the front transmission housing 6 Remove the seal cover with oil seal and O Ring from the transmission housing 7 Drive out the PTO shaft and remove the fixed gear snap ring bearings and from the transmission housing 328X 329X 330X Downloaded from www Manualslib com manuals search engine ...

Page 96: ...ion shaft thrust washer and shims to the front of the transmission housing 13 Remove the bearings and from the housing 14 If necessary drive out the seal cover for inspect the ring gear backlash 15 Remove the snap ring and pull out the counter shaft with bearing and collar 4 16 Take out the fixed gear and bearing from the housing NOTE Put the identity make on the fixed gear by paint 331X 332X 333X...

Page 97: ...mponents with a suitable cleaning solvent and air dry 2 Inspect all bearings for excess wear score marks discoloration from overheating or other damage Rotate the bearings by hand and check for roughness while slowly rotating the inner and outer races 3 Lubricate all bearings with a clean lubricant before installation 4 Inspect the transmission case for cracks worn bearing bores or other damage 5 ...

Page 98: ...ic oil on assembly During assembly observe the followings 1 Remove the oil stained from the bolts thread and thread holes of clutch shaft with the solvent and then apply the thread sealant to threads when install the clutch fork 2 Position the lever of clutch shaft as shown figure before install the PTO clutch assembly 337X 338X Downloaded from www Manualslib com manuals search engine ...

Page 99: ...n shaft spline and a pull scale Tighten the pinion nut to obtain the specified pounds of constant pull to rotate the pinion assembly Pinion Bearing Pre Load Constant Pull 196 N 20 kgf NOTE Turn drive pinion several times by hand before performing pull scale test 6 Bend the lock nut flange by the chisel at the ditch of the pinion shaft after adjust the pre load 339X 340X 341X Downloaded from www Ma...

Page 100: ...arings and install them on the PTO clutch drive shaft The 17 mm inside diameter of bearing race is installed to the coupling with apply the grease in the rear transmission housing 342X 342 1X 10 Apply requid gasket to the matching surfaces of both transmission housing 11 PTO cluch separater plates tooth are lined up before install rear transmission housing 343X Downloaded from www Manualslib com m...

Page 101: ...ion housing Align the drive pinion shaft and center to 4WD one way clutch center Align the PTO clutch sepatater plates with coupling of rear transmission housing Align the fixed gear on the drive pinion shaft and fixed gear on the range counter shaft while rotating the mainshaft 344X Downloaded from www Manualslib com manuals search engine ...

Page 102: ...owel over the top of the shift fork to restrain the detent ball when the rail is removed from the fork The detent ball will be expelled with considerable force when it is released 5 Drive out the roll pin and remove the change lever 6 Remove the bolt and plate and pull out the shift arm in the transmission 7 Remove the snap ring and fixed gear from range gear counter shaft 8 Remove the snap ring a...

Page 103: ...ion from overheating or other damage Rotate the bearings by hand and check for roughness while slowly rotating the inner and outer races 3 Lubricate all bearings with a clean lubricant before installation 4 Inspect the transmission case for cracks worn bearing bores or other damage 349X 350X 5 Check the detent springs for wear chipped or weak spring extension 6 Inspect the detent balls for excess ...

Page 104: ...housing at first 2 Install the range slide gear shifter fork as follows Install the spring and steel ball in the shifter fork and press them Assemble the stick out side diameter is Ø14 Ø14 5 length is 45 50 mm in the hole of shifter fork Place the assembled shifter fork on the range sliding gear in the rear transmission housing Install the shifter rod through the housing and shifter fork and secur...

Page 105: ...the housing Install the large thrust washer on the two way clutch assembly with the oil ditch toward the two way clutch assembly Remove the oil stained from the bolt thread and thread holes of shaft with the solvent and then apply the thread sealant to threads when install the shifter fork NOTE Take care the direction of the tips on the shifter fork as shown Figure 354 1X 4 Installation of the rea...

Page 106: ... NOTE The spring is installed under the washer Use care when removing the snap ring as the spring will be expelled with considerable force when released Cover the PTO clutch with a shop towel to contain the spring while removing the snap ring 4 Press the clutch lifter and remove the snap ring NOTE Never remove the six bolts Figure 358X because they will be broken by fixed them thread sealant 355X ...

Page 107: ... damage If either is defective replace the PTO clutch assembly Standard Wear Limit Disc Plate Thickness 2 0 mm 1 4 mm Brake Disc Thickness 3 0 mm 2 2 mm 3 Assembly Prior to assembly coat the clean hydraulic oil to each parts Assembly of the PTO clutch generally follows disassembly procedures in reverse however the following must be observed When install the snap ring it s gap avoid from the groove...

Page 108: ... shown illustration Use care the thrust bearing order when install it The small inside diameter race is installed on the release hub and the large inside diameter race is installed in the clutch lifter 361X 362X Downloaded from www Manualslib com manuals search engine ...

Page 109: ... out the brake cam from the housing 4 Remove the snap ring and drive out the wheel shaft from the wheel shaft housing 5 Remove the bearings and and oil seal from wheel shaft housing 6 Drive out the roll pin and draw out the diff lock shaft from the bearing holder L H 7 Remove the spring diff lock fork and diff lock clutch from the bearing holder 363X 364X 365X Downloaded from www Manualslib com ma...

Page 110: ...ally follows the disassembly procedure in reverse During assembly observe the following 1 Be sure all components are free of dirt and foreign matter and lubricate all components with clean hydraulic oil on assembly 2 Install the oil seal at the steel face to outward Brake Disc Wear Check Minimum Groove Depth 0 1 mm 366X Brake Stator Wear Check Level Difference 0 1 mm 367X 4 Brake Adjustment 1 Chec...

Page 111: ... the drive cam center cam and driven cam mating areas for excessive wear Replace if found defective 3 Inspect all thrust washers for excessive wear and replace if necessary 4 Inspect the compression spring for distortion Replace as required 3 Assembly Reference Figure 368X 1 Install thrust washer driven cam compression spring and center cam in the one way clutch assembly housing 2 Install the keep...

Page 112: ...ness See Specifications 3 Inspect the differential pinion shaft and gears for excessive wear See Specifications 4 Inspect the drive pinion to ring gear tooth wear pattern See Figure 377X for wear indications and shimming adjustments 5 Inspect the bearings for excessive wear or binding when rotated by hand 370X Differential Gear Case Disassembly 1 Ball bearing 6 Gear 12 Ring Gear 17 O Ring 2 Shim 7...

Page 113: ...is less on the new pinion than on the old pinion the number of shims must be decreased Example Replaced pinion 0 2 mm New pinion 0 0 mm 0 2 0 0 0 2 Decrease the shims by 0 2 mm 4 Differential ring Gear and Pinion Assembly 1 Assemble the differential pinion shaft pinion gears thrust washers dowel pins and side gears as shown Figure 370X 2 Install the ring gear on the case and tighten new bolts and ...

Page 114: ...el shaft assembly to the front transmission housing 8 Position the differential assembly in the housing NOTE When installing the original components use the same quantity and thickness shims on each side as removed during disassembly 9 Install the bearing fixed gear PTO shaft and bearing in the housing 10 Install the seal cover with oil seal and O Ring to the housing 373X Pinion Pre Load Adjustmen...

Page 115: ...g gear back and forth and observe the dial indicator reading Adjust the shims to obtain the correct backlash See Specifications Using Prussian blue on the pinion gear teeth rotate the pinion gear and check the gear tooth pattern Adjust the differential and pinion shims to obtain the correct tooth contact 376X Ring Gear and Pinion Backlash Check 1 Dial Indicator 2 Ring Gear 13 Install the seal cove...

Page 116: ...o hook the spring at correct direction and position as shown Figure 378X If not correct hooking the spring it will not be properly working the two way clutch assembly 378X 1 Spring 3 Transmission Assembly 2 4WD Change Lever Downloaded from www Manualslib com manuals search engine ...

Page 117: ...116 Downloaded from www Manualslib com manuals search engine ...

Page 118: ...117 Chapter 4 HST SYSTEM Downloaded from www Manualslib com manuals search engine ...

Page 119: ...kgf c pressure to the feed check valves 5 and 9 at all times Fluid flow past the feed check valves pressurizes the passages A and B and the pump and motor cylinder blocks Because of equal pressures in passages A and B the motor does not rotate 400X 1 Charge Pump 8 Input Shaft 2 Filter 9 Feed Check Valve A 3 Filter 10 Hydrostatic Pump 4 Power Steering Control Valve 11 Reservoir 5 Feed Check Valve B...

Page 120: ...drostatic motor at A2 into passage B2 flows back to the hydrostatic pump to complete the cycle When fluid leakage in the system causes a drop in pressure on the suction passage B and the feed check valve opens and provides make up fluid from the charge pump Excess fluid from the charge pump is returned to the sump via the charge relief valve when above 0 49 MPa 5kgf c 401X 1 Charge Pump 8 Input Sh...

Page 121: ...on Fluid is discharged from the hydrostatic motor at A2 into passage A flows back to the hydrostatic pump to complete the cycle When fluid leakage in the system causes a drop in pressure on the suction passage A and feed check valve opens and provides make up fluid from the charge pump Excess fluid from the charge pump is returned to the sump via the charge relief valve when above 0 49 MPa 5 kgf c...

Page 122: ...e 16 HST Supply Line Hose 5 HST Unit 11 Power Steering Supply Line 17 Power Steering Return Line 6 HST Filter 12 Cooler Supply Line Separate the HST unit from the transmission housing after separate the transmission assembly See the Chapter 3 2 TRANSMISSION UNIT 1 Removal NOTE When separating the HST unit from the transmission housing be careful not to lose the O Rings and HST Unit O Ring O Ring 4...

Page 123: ...pin washer and disconnect the HST speed control rod from the HST control lever 5 Remove the U nut and remove the damper from the HST control lever 6 Unhook the spring from under the HST speed control lever 7 Disconnect the wire connector from the HST neutral switch 8 Remove the two bolts and remove the HST shift guide and shift arm as a set 9 Remove the bolt from the universal joint and disconnect...

Page 124: ...3 Remove rear axle assembly pipe and rear drive shaft see REAR AXLE ASSEMBLY of chapter 6 14 Remove the rear frame from main frame and rear of transmission see TRANSMISSION AND BRAKE of CHAPTER 3 15 Install the special tool to HST return pipe attaching hole with hoist 16 Remove the four bolts and remove the HST unit to slide the rearward and downward from the transmission housing 409X 410X 410 1X ...

Page 125: ... 7 Remove the cylinder block assembly 5 for the pump 8 Remove the cylinder block assembly 2 for the motor 9 Remove the swash plate 6 and take out the roller bearing 82 bush 35 and slide metal 24 10 Remove the thrust plate 80 from the pump swash plate 6 11 Remove the thrust plate 12 for the motor in the housing 12 Remove the screws 61 and trunnion cover 57 from the housing 13 Remove the snap ring 4...

Page 126: ...2 mm 0 03 mm Replace the piston assembly if the shoe thickness is below the service limit Standard assembling value Service limit 3 00 mm 2 9 mm 2 Charge pump assembly Measure the side clearance of the trochoid rotor and replace if the service limit is exceeded Standard assembling value Service limit 0 025 mm 0 055 mm 3 Lapping distance should be less than 0 005 mm if each sliding surface is damag...

Page 127: ...cover 22 in the housing 1 and secure with snap ring 41 4 Install the cover as follows Install the O ring 46 and pins 39 on the housing Install the oil seal 62 in the cover 21 and install them on the housing and tighten the bolt 69 to 17 2 N m 5 Install the thrust plate as follows Align the thrust plate s projection 12 for motor to housing s ditch 6 Install the swash plate as follows Install the pi...

Page 128: ...the bolts to 49 0 5 N m 9 Install the trunnion cover to the housing as follows Install the slide metal 24 and position the pin hole against the port block direction in the swash plate sub assembly 6 Install the bearing 16 in the trunnion cover 57 Install the washer 18 in the trunnion cover Install the oil seal 66 in the housing to 1 mm depth from the cover surface Install the trunnion shaft 15 in ...

Page 129: ... in the low range position 4 If the wheels rotate at this time loosen the bolt 1 and rotate the eccentric sleeve 2 until the wheels stop and tighten the bolt Figure 421X NOTE Turning the control lever 3 clockwise will cause wheels to rotate in forward and turning counterclockwise the wheels will rotate in the reverse direction 5 Stop the engine and remove the jack stands Lower the wheels to the gr...

Page 130: ...ck nuts 2 and recheck the continuity test after move the speed control rod 4 to forward and reverse several times 422X 3 HST SPEED CONTROL PEDAL POSITION ADJUSTMENT 1 Adjust the pedal height by lengthening or shortening the speed control rod 1 Untighten the two lock nuts 2 and turn the rod 1 by wrench until the forward speed control pedal and reverse speed control pedal 3 are at the same flat leve...

Page 131: ...rol pedal stroke Untighten the lock nuts and adjust the stopper length by turn them as shown illustration Forward speed control pedal stopper length is about 20 mm Reverse speed control pedal stopper length is about 30 mm 424X 425X Downloaded from www Manualslib com manuals search engine ...

Page 132: ...hin specifications replace the high pressure relief valve 7 Stop the engine and install the pressure gauge and hose into B port Figure 426X 8 Install the plug to port A 9 Depress the reverse pedal and master break pedal and read the pressure The pressure reading must be 49 MPa 500 kgf cm2 If pressure is not within specifications replace the valve assembly 2 LOW PRESSURE RELIEF VALVE 1 Disconnect t...

Page 133: ... mixture in the HST oil circuit 3 Lack of charge pump capacity by abnormal oil temperature 4 High pressure oil leakage due to wear of the pump and motor assembly Replace the oil filter Check the suction piping connection and transmission oil level Warm up the tractor when too low oil temperature Stop the engine until the oil temperature become low when too high oil temperature Wash oil circuit and...

Page 134: ...0 096 MPa 0 98 kgf cm2 Max Pump Capacity Variable Type 0 18 2 cc rev Motor Capacity 0 18 2 cc rev Charge Pump Capacity 4 9 cc rev BOLT TORQUES Swash Plate Covers 6 2 7 6 N m 0 63 0 76 kgf m Charge Pump Case Screws 44 54 N m 4 5 5 5 kgf m Relief Valve High Pressure Check Plug 29 4 N m 3 0 kgf m Check and High Pressure Relief Valve s Plug 63 7 N m 6 5 kgf m Port Block Screws 44 54 N m 4 5 5 5 kgf m ...

Page 135: ...134 Downloaded from www Manualslib com manuals search engine ...

Page 136: ...135 Chapter 5 POWER STEERING Downloaded from www Manualslib com manuals search engine ...

Page 137: ...he steering cylinder for right or left turns Return oil from the power steering cylinder is directed by the steering control valve to the HST transmission The relief valve in the steering motor protects the system from over loading 500X 1 Filter 4 Cylinder 2 Charge Pump 5 HST Unit 3 Steering Motor 6 Oil Filter Downloaded from www Manualslib com manuals search engine ...

Page 138: ...sage to ports L and R leading to the cylinder are blocked by the spool and sleeve Oil contained in the tubes and cylinder is trapped and the cylinder remains in a fixed position In this position the front wheels hold at a same condition The system is fully hydraulic and as such there is no road feel or front wheel reaction transmitted to the steering wheel 501X 1 Spool 4 Oil Tank 7 Check Valve Kic...

Page 139: ...Gerotor gear pump Since the Gerotor pump is being turned counterclockwise the oil flows through the valve body to the port L From port L the pressurized oil flows to the piston side of the power steering cylinder and causes the front wheels to turn left 502X 1 Relief Valve 4 Steering Cylinder 2 Oil Pump 5 Gear Pump Gerotor pump 3 Oil Tank 6 Check Valve Kick Back Downloaded from www Manualslib com ...

Page 140: ... flows through the valve body to the port R From port R the pressurized oil flows to the rod side of the power steering cylinder and causes the front wheels to turn right The oil contained in the piston side of the cylinder is forced out and returns to the control valve L port and is directed back to the reservoir through port T 503X 1 Relief Valve 4 Steering Cylinder 2 Oil Pump 5 Gear Pump Geroto...

Page 141: ... required as directed by the rotation of the steering wheel On the suction side of the Gerotor pump return oil flows from the cylinder and is drawn through the check valve 7 to feed the Gerotor When additional oil supply is required as in making a left turn make up oil from the valve 7 to feed the Gerotor pump 504X 1 Relief Valve 4 Steering Cylinder 7 Check Valve 2 Oil Pump 5 Gear Pump Gerotor Pum...

Page 142: ...the Gerotor gear pump 19 and O Ring 16 NOTE The inner rotor separates easily from the outer pump body rotor Use care in handling to prevent damage to these components 4 Remove the second large O Ring 16 5 Remove the drive shaft 18 spacer plate 17 and third large O Ring 16 6 Remove the check ball 24 7 Remove the retaining ring 2 NOTE Remove the valve from the vise and place on a clean lint free sho...

Page 143: ... Plate Retaining Bolt 6 Bearing Race Curved 18 Shaft 24 Ball Check 7 Bearing 12 Spring Flat 19 Gerotor Pump 3 Inspection 1 Inspect the spool and sleeve for evidence of sticking scuff marks and any damage If defective replace the spool and sleeve as a matched set 2 Upon disassembly replace all seals and O Rings with new 4 Assembly 1 Insert the spool in to the sleeve while slowly rotate the spool NO...

Page 144: ... and spool 10 Install the dust seal 1 to the gland 3 bushing 11 Install the oil seal 5 to the gland Be sure the seal is not cocked in any way 12 Position the gland assembly in the bore being sure its outer end face is parallel with the valve body end face 13 Install the retaining ring in the valve body groove 14 Position the valve body in a soft jawed vise to support the assembly Do not over grip ...

Page 145: ... and D 24 Install the O ring 16 onto the end cap 21 and position the assembly on the valve body Align the bolt holes and install the retaining bolts 22 NOTE Lubricate the bolt threads and tighten to specified torque in two steps to maintain equal pressure on the valve body Tighten the bolts in the sequence as shown Tightening torque 20 N m 2kgf m Recheck the valve spool to be sure it rotates smoot...

Page 146: ...ts 1 If the pressure gauge reading rises before the steering wheel is turned it indicates that steering control valve timing is off and the steering unit will have to be disassembled and inspect 2 If the pressure gauge reading rises to the relief valve setting 5 9 6 6 MPa 60 67 kgf c when the steering wheel is turned it indicates the pump and relief valve are working properly 3 POWER STEERING CYLI...

Page 147: ...not to allow the tape to flow into the hydraulic piping Be careful to keep oil hoses and oil pipes off other part Fix clamps securely 1 Tightening Torque of Piping 520X 1 Flare nuts of oil pipe for charge pump to steering motor 29 4 39 2 N m 3 4 kgf m 2 Flare nuts of oil pipes for steering motor to power steering cylinder L and R port 29 4 39 2 N m 3 4 kgf m 3 Nuts for oil hose to power steering c...

Page 148: ...mn shaft binding 1 Low pressure 2 Steering motor binding 1 Kinked hose 2 Bent tubes 3 Restricted re centering of steering motor 1 Lack of transmission oil 2 ORBITROL control valve unit 1 ORTITROL not aligned to steering column 2 Spool and sleeve combination is seized because of foreign matter 3 Over tightening of the end cap bolts 3 Oil pump HST Charge Pump 1 The pump is stuck and will not work 2 ...

Page 149: ... Internal oil leakage because of damaged piston seal Repair Bleed air out Replace the seal Steering wheel will kick back 1 ORBITROL 1 ORBITROL has been improperly rebuilt resulting in valve mistiming 2 Piping 1 Pipes are improperly connected to the four ports of ORBITROL Repair Correct the pipe connections Oil leakage 1 From the splined connection of column to spool 2 From mated face joints valve ...

Page 150: ...149 Chapter 6 REAR AXLE ASSEMBLY Downloaded from www Manualslib com manuals search engine ...

Page 151: ... shaft 1 in the range gear box is contained in a two way clutch assembly 4 The two way clutch assembly 4 is installed on the front wheel drive pinion 2 During operation placing the lever into the Automatic four wheel drive position will automatically give the operator full four wheel drive when the front wheels lose traction Since the rear wheel drive axle gears rotate slightly faster than the ran...

Page 152: ...om the power steering cylinder 2 Place the safety stands under the main frame 3 Remove the rear axle bearing holders from the frame and remove the rear axle assembly 4 If necessary remove the pipe drive shaft and coupling from the transmission 603X 1 Oil Pipe 3 Rear Axle 2 Bearing Holder Assembly 3 INSTALLATION Installation generally follows removal procedure in reverse however the following must ...

Page 153: ...drive shaft 11 to downward NOTE If necessary remove the seal 12 and bearing 13 from the case 5 Remove the bolts 14 and remove the idler gear case 15 assembly 6 Remove the snap ring 16 bearings 17 and idler bevel gears 18 from the idler gear case 15 1 Power steering cylinder 6 Bolt 11 Drive shaft 16 Snap ring 2 Rear wheel 7 Arm 12 Seal 17 Bevel gear 3 Tie rod 8 King pin 13 Bearing 4 Outer case cove...

Page 154: ... lock nut 8 and pry the oil seal 9 and discard 10 Remove the snap ring 10 and draw out the drive pinion 11 collars 12 and 13 and bearings 14 and 15 as a set NOTE If necessary remove the bearings 14 and 15 collars 12 and 13 O ring 17 and spacer 16 from the pinion shaft 11 605X Reference Figure 606X 11 Remove the bearing 1 and final gear 2 12 Remove the snap ring 3 and drive out the wheel shaft 4 fr...

Page 155: ...hers if thickness is less than 0 9 mm 6 Measure the thickness of the thrust washers 7 Replace the thrust washers if thickness is less than 0 9 mm 7 Measure the outside diameter of the pinion shaft 8 and inside diameter of the pinion gears 6 Replace the pinion or gear if clearance is more than 0 5 mm 8 Measure the outside diameter of the pivot shaft 1 and inside diameter of the bushings 2 Replace t...

Page 156: ...inion shaft 1 and install a new O ring 5 1 Drive Pinion Shaft 4 Collar 2 Bearing 5 O ring 3 Bearing 4 Install the drive pinion 1 as a set and spacer 2 secure with snap ring 3 in the left axle housing 4 5 Install the new oil seal 5 in the left axle housing 6 Install the collar 6 on the drive pinion shaft 7 Install the lock nut 7 and tighten to 65 7 83 3N m 6 7 8 5 kgf m Stake the nut to the pinion ...

Page 157: ...A equals measurement B For example If measurement B is 20 5 mm and measurement A is 20 0 mm the difference is 0 5 mm Place the selected shim s into the right axle housing 1 prior to assembly This procedure will give you the collect ring gear to pinion backlash 7 INSTALLATION Installation generally follows removal procedure in reverse however the following must be observed Adjust the toe in A B wit...

Page 158: ...157 Chapter 7 HYDRAULIC LIFT SYSTEM Downloaded from www Manualslib com manuals search engine ...

Page 159: ...arms The oil pump is a gear type which is installed on the engine timing gear case The control valve consists of a body valve spool weight transfer valve relief valve and float detent assembly 700X 1 Oil Filter 5 Lift Cylinders 2 Oil Pump 6 Lift Arms 3 Control Valve 7 Cooler 4 Weight Transfer Valve Grip 8 Transmission Reservoir Downloaded from www Manualslib com manuals search engine ...

Page 160: ...and then to the cooler and transmission The oil in the lift cylinders port A is trapped by the spool and holds the lift arms in a constant position 701X 1 Oil Filter 5 Restriction Valve 9 Spool 2 HST Unit 6 Lift Cylinder 10 Control Lever 3 Oil Pump 7 Weight Transfer Valve 11 Relief Valve 4 Control Valve 8 Oil Cooler Downloaded from www Manualslib com manuals search engine ...

Page 161: ... directed to the transmission Holding the lift lever in the raised position with the lift arms fully raised will cause the relief valve in the control valve to open and direct the oil to the cooler circuit 702X 1 Oil Filter 5 Restriction Valve 9 Spool 2 HST Unit 6 Lift Cylinder 10 Control Lever 3 Oil Pump 7 Weight Transfer Valve 11 Relief Valve 4 Control Valve 8 Oil Cooler Downloaded from www Manu...

Page 162: ...d through the weight transfer valve to the transmission and the implement lowers Turning the adjuster in on the weight transfer valve will reduce the flow rate and the pressure in the lift cylinder A side can be changed to reduce the weight of the implement on the gauge wheels The weight transfer valve contains a drilled passage to allow oil to flow if the knob is fully closed 703X 1 Oil Filter 5 ...

Page 163: ...ap ring to far The snap ring will become deformed and will not hold during assembly 3 Using care not to lose balls 7 and 8 remove the holders 6 and spring 9 from the spool NOTE Do not remove the stopper 15 spring and seat from the spool 4 Remove the sealing plate 11 wiper 12 spacer 13 and O ring 14 from the valve body 3 Inspection 1 Wash all parts in a suitable solvent and air dry 2 Discard all O ...

Page 164: ...ing grease Install the snap ring 1 with the rounded edge facing the cap Tighten the sealing plate bolts 10 to 5 5 N m 0 55 kgf m and check the spool for smooth operation Figure 705X 706X 1 Relief Valve Assembly 2 Weight Transfer Valve 707X 2 Remote Valve On units equipped with a remote valve the repair procedure are the same as the control valve The remote valve does not utilize a detent float pos...

Page 165: ...se 5 from the adapter 5 Remove the bolts 6 and pins 7 and remove the cylinder 4 from the frame while supporting the lift arms NOTE Do not disassemble the lift cylinder assembly If oil leaking and or trouble is evident from cylinder assembly replace the cylinder assembly 2 Inspection 1 Inspect the anchor pins and bushings for excess wear and excessive clearance Replace cylinder assembly and or pins...

Page 166: ... cm2 5 Push the hand throttle lever to forward and keep the engine high idle speed 6 Pull the lift control lever to rearward and read the pressure gauge immediately 7 Stop the engine TEST RESULT If pressure rises to the relief valve setting to 9 8 MPa 100 kgf cm2 it indicates that the system is operating properly NOTE If removed restriction valve use care at the direction of it The orifice toward ...

Page 167: ...166 Downloaded from www Manualslib com manuals search engine ...

Page 168: ...167 Chapter 8 IMPLEMENT DRIVE Downloaded from www Manualslib com manuals search engine ...

Page 169: ...e pressure plate is pressed and engages the clutch disc and plate assembly 7 by spring load however if the implement is raise before highest position of the lift arm 8 the PTO will automatically disengaged A cable 9 on the lift arm pulls the bell crank 10 to downward and then shift plate cam 11 is unhooked from the PTO lever 1 and moved to rearward by spring in the PTO clutch assembly 800X 1 PTO l...

Page 170: ...aft 5 The PTO lever 3 is in the ON position the clutch fork 6 is turned and push the release bearing 7 then the pressure plate pressed by the clutch spring 8 and then the clutch discs and plates 4 are engaged and the power flows to PTO shaft 5 via the helical gears 9 801X 1 Input Shaft 6 Clutch Fork 2 PTO clutch Coupling 7 Release Bearing 3 PTO Lever 8 Clutch Spring 4 Clutch Disc and Plate 9 Helic...

Page 171: ... 2 and through the idler gear 3 to fixed gear 4 and then to the PTO counter shaft 5 The side PTO is live PTO type then the side PTO shaft is rotated while engine is running 802X 1 HST Input Shaft 4 Fixed Gear 2 PTO Clutch Coupling 5 Side PTO Counter Shaft 3 Idler Gear Downloaded from www Manualslib com manuals search engine ...

Page 172: ... shift plate cam s groove 8 from the pin 7 of the PTO lever 3 Pin 4 Cable 5 Pin 6 Pin 7 Pin 8 Groove When the lift arm raised highest position the pin 3 of bell crank is pulled more bottom ward by the cable 4 the shift plate cam s groove 8 is unhooked from the pin 7 and then the shift plate cam 1 and lever 9 are moved to OFF position by the springs are in the PTO clutch assembly The power flows to...

Page 173: ...d recheck the position 2 PTO Release Cable 1 Place the hydraulic lift control lever into the down position and manually push down the lift arms 2 If necessary remove the side cover 3 Untighten the lock nuts 1 and 2 and release the wire cable 3 4 Start the engine and raise the lift arms to the highest position 5 Move the PTO lever 5 to the locking position 6 Turn the lock nut 1 until the cable is s...

Page 174: ...173 Chapter 9 MAINTENANCE STANDARDS TABLE Downloaded from www Manualslib com manuals search engine ...

Page 175: ...ve pinion preload N kgf 196 20 Load when pulled with string wound on spline Drive pinion ring gear backlash 0 1 0 2 0 4 PTO shaft end run out Less than 0 1 0 3 Gear oil quantity ℓ 20 Front wheel Rim run out 3 5 Wheel rug height Tire size 23 10 50 12 4PR Brake Brake lining groove depth 0 1 0 Level difference to stator on lining contact surface 0 0 1 Pedal shaft bush clearance 0 05 0 35 1 0 Pedal pl...

Page 176: ...ont 0 02 0 15 0 3 Toe in 5 5 10 10 Rim run out 3 0 5 0 Wheel rug height Tire size 20 8 00 10 4PR Gear oil ℓ Differential chamber 1 3 Gear chamber 0 5 on one side Power Steering Relief valve working pressure MPa kgf cm2 5 88 6 56 60 67 At 16 ℓ min Oil quantity ℓ 20 Common use HST oil Oil type ISO VG32 Hydraulic oil Hydraulic cylinder piston clearance 0 7 Cylinder head bush piston rod clearance 0 3 ...

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Page 178: ...177 Chapter 10 ELECTRICAL SYSTEM Downloaded from www Manualslib com manuals search engine ...

Page 179: ...vel sending unit is located inside the fuel tank it sends a signal indicating fuel level to the instrument panel 7 Engine Coolant Temperature Sensor Engine coolant temperature sensor is located in the thermostat housing of front left side of the engine cylinder head This sender regulates a variable resistance to ground with translates into the movement of the temperature gauge 8 Engine Coolant Tem...

Page 180: ...lor are different for discrimination 19 Alarm Buzzer Buzzer is located on the left side of the compartment fire wall The buzzer is alarmed when the engine oil pressure is lower and or engine is over heated 20 Air Cleaner Restriction Sending Unit Air cleaner restriction sending unit is located on the top of the engine It warns when the air cleaner element is clogged 21 Electric Fuel Pump Electric f...

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Page 182: ...es to a connector that links into the main wiring harness 3 Parking Brake Switch The switch is normally close The switch is closed at the parking brake lever is locked position and is opened the lever is released position a Inspection Use an ohmmeter to test the parking brake switch With the button at the OUT position there will be continuity across the terminal leads With the button at the IN pos...

Page 183: ... pushed position and closes when the HST pedal is the released position adjust by turn the switch position 5 B PTO Neutral Switch PTO Neutral Switch is ON position when the PTO lever is in the OFF position a Inspection Use an ohmmeter to test the PTO neutral switch With the button at the IN position there will be continuity across the terminal leads With the button at the OUT position there will b...

Page 184: ... or master brake pedal is not depressed when the parking brake lever is locked a Inspection Use an ohmmeter to test the seat switch With the seated there will be continuity across the terminal leads With the unseated there will be no continuity across the terminal leads If test result are not outlined above replace the seat switch b Adjustment The seat switch is non adjustable 6 Fuel Level Sending...

Page 185: ...sensor 1006X 9 Starter Starter rotates the engine for starting See CHAPTER 2 ELECTRICAL UNIT 10 Head Light Switch Head light switch controls current to head lamp a Inspection Use an ohmmeter to test the continuity of the head light switch connector terminals With the switch in the OFF released position there will be continuity between the terminals B and C and D and E With the switch in the ON pus...

Page 186: ...tance reading indicates an open circuit the start switch need to be replaced 12 Engine Oil Pressure Sending Unit Engine oil pressure sending unit provides waning of low engine oil pressure and indicates the oil pressure lamp go on and alarms buzzer 13 Head Light Head light is controlled by head light switch 1008X 1009X 1010X 14 Instrument Panel Instrument panel is monitors tractor functions Instru...

Page 187: ...cleaner restriction warning lamp 4 Glow plug indicator lamp 8 Parking brake warning lamp Instrument panel wiring 1012X NOTE Do not keep the instrument panel turned upside down while removed the silicone oil in the gauge will leak out and the gauges will not move smoothly Downloaded from www Manualslib com manuals search engine ...

Page 188: ...asured the instrument panel should be replaced 15 Fuel Shut Off Solenoid Fuel shut off solenoid is shuts off fuel flow to the injection pump to stop the engine When the solenoid is energized as when the key switch is turned to the ON and START positions the solenoid plunger is retracted and the governor linkage moves the pump control rack rearward into operating position Testing a With the solenoi...

Page 189: ... connector s color are different for discrimination and as follows Connector color BLUE is for safety start relay Connector color RED is for engine stop solenoid relay Connector color GREEN is for engine over heat warning buzzer relay Connector color BLACK is for engine oil pressure warning buzzer relay Connector color WHITE is for cruise control relay a Four terminals relay A relay consists of tw...

Page 190: ...agnet Terminals C D and E are actually part of a single pole double throw switch The SPDT switch is spring loaded so terminals D and E are opened when the coil is not energized When the coil is energized the switch is thrown and terminals C and E are connected 1 Coil 2 Switch INSPECTION a Four terminals relay To test a relay disconnect it from the circuit 1 Connect the ohmmeter leads to terminals ...

Page 191: ...ct the ohmmeter leads to terminals C and E 4 There is continuity between terminals C and E if the relay is working properly Next use the ohmmeter to verify energized conditions 1 Energized the coil by applying 12 volts of current across terminals A and B 2 Connect the ohmmeter leads to terminals D and E 3 There is continuity between terminals D and E if the relay is working properly 4 Connect the ...

Page 192: ...ere will be continuity If test result are not outlined above replace the switch 21 Electric Fuel Pump Electric fuel pump is supplies fuel under pressure to the fuel injection pump INSPECTION If a fuel system malfunction indicates a faulty fuel pump a simple shop test of the fuel pump can be performed using water as the liquid for testing To test a fuel pump remove it from the tractor a Set up the ...

Page 193: ...l magnet INSPECTION Remove the switch from the wiring harness NOTE The switch terminals are identified on the back of the switch Number 1 and 4 are blank a Use an ohmmeter depress the switch to the ON position and connect the ohmmeter leads across terminals 5 and 6 then across terminals 2 and 3 If continuity exists across these terminals the switch is operating properly b Next place the switch in ...

Page 194: ...ge in place by switch to set constant speed INSPECTION Use the ohmmeter to test the cruise control magnet a Disconnect the magnet from the tractor wiring harness and connect the ohmmeter leads to the two leads coming from the magnet b A meter reading of 11 12 ohms is normal c Disconnect the ohmmeter from the magnet and apply 12 volts across the magnet leads d The surface will become magnetized and...

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Page 208: ...207 Chapter 11 MOWER Downloaded from www Manualslib com manuals search engine ...

Page 209: ...208 11 1 Sectional View FM60SD 1101X Downloaded from www Manualslib com manuals search engine ...

Page 210: ...idth mm 1520 Mowing height mm 38 115 7 steps Mowing blade speed rpm 2899 Mowing blade end speed m sec 79 No of mowing blades 3 Standard mowing blade dimensions T W L mm 7 50 518 Gear oil ℓ 0 6 Total weight kg 175 Applicable models CM284 364 Power flow 1102X Downloaded from www Manualslib com manuals search engine ...

Page 211: ...and pulley NOTE The pulley nut is threaded reversely and should be disassembled carefully Untighten the tension lock reduce the belt tension and remove the belt and blade 1104X 3 Bearing case left and right Remove the nut and take off the pulley Remove the key from the shaft 1105X Remove the bearing case from the mower deck cover 1106X Downloaded from www Manualslib com manuals search engine ...

Page 212: ...3 Spring washer M20 4 Washer 5 Pulley B 6 Bearing 6008Z 7 Collar 8 Bolt M 12 30 9 Bearing case 10 Bearing 6206 11 Oil seal UE45629 12 Rotary shaft B 13 Key 14 Blade 15 Spacer 16 Spring washer M18 17 Bolt 1108X 4 Gear box ass y Bearing case ass y Remove the gear box and bearing case together from the mower deck Drain the gear oil from the gear box 1109X Downloaded from www Manualslib com manuals se...

Page 213: ...ts packings between the gear box and case 1111X Remove the bevel gear NOTE Note the thickness and number of shims between the bevel gear and bearing if any Remove the Ø62 snap ring Drive out the shaft and bearing in the arrow mark direction Drive out the oil seal 1112X Remove the box cover Remove the Ø17 snap ring Drive out the shaft downwards and detach the gear box and bearing case 1113X Downloa...

Page 214: ...ar 2 Case 11 Gasket 20 Washer 29 Gasket 3 Bolt M8 20 12 Shim 0 1 mm 21 Packing 30 Plug 4 Bolt M8 25 13 Shim 0 2 mm 22 Bolt M6 16 31 Bearing 6205 5 Rubber 14 Bolt M12 20 23 Box cover 32 Snap ring Ø52 6 U nut 15 Spring washer 24 Packing 33 Oil seal UE25528 7 Cover Joint 16 Stay 25 Snap ring Ø17 34 Stay 8 Bearing 6305 17 Gear box 26 Bearing 6303 35 Vent 9 Shaft 18 Bevel gear 27 Collar 36 Shim 37 Spri...

Page 215: ...aring together and detach if necessary Remove the collar and drive out the bearing and oil seal 1117X Components bearing case 1 Bearing case 2 Bearing 6206 3 Oil seal UE45629 4 Shaft 5 Key 6 Collar 7 Bearing 6208Z 8 Pulley A 9 Snap ring Ø25 10 Grease nipple 11 Screw pipe 12 Bolt M6 10 1118X Downloaded from www Manualslib com manuals search engine ...

Page 216: ...Components 1 Castor arm 2 Washer 3 Gauge wheel ass y 4 Spacer 5 Bolt M8 14 6 Grease nipple 1120X 9 Front wheel Components 1 Wheel ass y 2 Bushing 3 Shaft 4 Washer 5 Snap ring 6 Shaft 7 Spring washer 8 Bolt 9 Spacer 10 Collar 11 Boss 12 Ball bearing 13 Cover 14 Tire 15 Disc wheel 16 Valve ass y 17 Grease nipple 1121X 10 Roller Components 1 Roller 2 Bolt 3 Shaft 4 Spring washer 5 Cap nut M10 6 Washe...

Page 217: ...hield surface on the pulley side Put in the oil seal from the case end surface and install Coat the lip with grease 2 Gear box Adjust the backlash by increasing or decreasing the shims or gaskets in the following procedure Select shims so that the backlash is 0 zero Remove shims corresponding to thickness of 0 4 0 6 mm from those of above item and install them NOTE In above item if the shim thickn...

Page 218: ...sembling value when new Service limit 1 61 10 0 Replace the blade with new one if its bend exceeds the specified value Bend of blade at end 0 3 mm Sharpening of blade Sharpen the blade edge to 45º and the blade end dimension to 0 4 mm as shown in the right figure NOTE 1 When sharpening the blade put on protection glasses and gloves 2 After completion of sharpening be sure to adjust the balance of ...

Page 219: ...the heavier side to balance Installation of blade Install the blade leaf spring and spring washer in this order and tighten the bolt with the specified torque Tightening torque 132 147 N m 13 5 15 kfg m NOTE Install the leaf spring with the recess positioned on the blade side 1 Blade 3 Spring washer 2 Leaf spring 4 Bolt 1130X 1131X Downloaded from www Manualslib com manuals search engine ...

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