workshop manual f2880,f3680,rck72-f36, rck72r-f36

Transcription

WORKSHOP MANUAL
F2880,F3680,RCK72-F36,
RCK72R-F36,RCK60-F36,
RCK60R-F36
KiSC issued 04, 2006 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of KUBOTA F2880, F3680,
KUBOTA Mower RCK72-F36, RCK72R-F36, RCK60-F36, RCK60R-F36. It is divided
into three parts, “General”, “Mechanism” and “Servicing” for each section.
■ General
Information on the tractor identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
■ Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine / Tractor Mechanism Workshop Manual (Code No. 9789701873 / 97897-18200) for the one which has not been described to this workshop
manual.
■ Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
January 2006
© KUBOTA Corporation 2006
F2880, F3680, RCK72-F36, RCK72R-F36, RCK60-F36, RCK60R-F36, WSM
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER
: Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
: Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
■ IMPORTANT
: Indicates that equipment or property damage could result if instructions are not
followed.
■ NOTE
: Gives helpful information.
BEFORE SERVICING AND REPAIRING
• Read all instructions including safety instructions in
this manual and your machine safety decals.
• Clean the work area and machine.
• Park the machine on firm and level ground, and set
the parking brake.
• Lower the implement to the ground.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag on the operators
platform.
1
SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Do not alter or remove any part of machine safety
system.
• Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Never start the engine while standing on the ground.
Start the engine only from operator’s seat.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
2
SAFETY INSTRUCTIONS
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
3
SAFETY INSTRUCTIONS
SAFETY DECALS
The following safety decals are installed on the machine.
If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in
the parts list.
4
SAFETY INSTRUCTIONS
5
SAFETY INSTRUCTIONS
6
SPECIFICATIONS
SPECIFICATIONS
Model
F2880
F3680
Model
D1105-E2-FM2-EU
V1505-E2-FM3-EU
Engine gross power (SAE) *1
20.4 kW (27.3 HP)
26.3 kW (35.3 HP)
Type
Indirect Injection, vertical, water-cooled, 4-cycle diesel
Number of cylinders
3
78.0 × 78.4 mm (3.07 × 3.09 in.)
Bore and stroke
Total displacement
Engine
1123 cm3 (68.58 cu.in.)
Rated revolution
(rpm)
Forced lubrication by gear pump
Cooling system
Pressurized radiator, forced circulation with water pump
Battery
12 V, CCA : 490 A, RC : 112 min.
Diesel fuel No. 1 [below −10 °C (14 °F)]
Diesel fuel No. 2-D
Fuel
Fuel tank
61 L (16.1 U.S.gals, 13.4 Imp.gals)
Engine crankcase
3.8 L (4.0 U.S.qts., 3.3 Imp.qts)
Engine coolant
4.6 L (4.9 U.S.qts., 4.0 Imp.qts)
Recovery tank
0.6 L (0.6 U.S.qts, 0.5 Imp.qts)
Transmission case
14.0 L (14.8 U.S.qts, 12.3 Imp.qts)
Rear axle differential case
1.5 L (1.59 U.S.qts, 1.32 Imp.qts)
Rear axle gear case
0.5 L (0.53 U.S.qts, 0.44 Imp.qts)
24 × 12 – 12 (4PR) Turf
Front
18 × 9.5 – 8 (4PR) Turf
Rear
Forward
Travelling
speeds
Reverse
Low
0 to 9.0 km/h (0 to 5.6 mph) *2
High
0 to 20.0 km/h (0 to 12.6 mph) *2
Low
0 to 4.8 km/h (0 to 3.0 mph) *2
High
0 to 11.0 km/h (0 to 6.9 mph) *2
Overall length
Dimensions
-1
Electric starter 12 V, 1.1 kW
Lubricating system
Tire
1498 cm3 (91.42 cu.in.)
3000min
Starting system
Capacities
4
2500 mm (98.4 in.)
Overall width
1370 mm (53.9 in.)
Overall height
1350 mm (53.1 in.)
Wheel base
1300 mm (51.2 in.)
Min. ground clearance
Tread
Weight (without mower deck)
185 mm (7.3 in.)
Front
1063 mm (41.9 in.)
Rear
1020 mm (40.2 in.)
727 kg (1603 lbs)
744 kg (1640 lbs)
W1028103
7
SPECIFICATIONS
Model
F2880
Revolution
PTO
Drive system
Shaft drive. KUBOTA 10-tooth involute spline (2545 rpm)
Clutch type
Wet multi plates
PTO brake
Wet single plate
Steering
Hydraulic power steering
Transmission
Hydrostatic transmission, High-Low gear shift (2 forward, 2 reverse)
Brake
Wet disk type
Minimum turning radius
Differential
F3680
1 speed (2545 rpm at 3000 engine rpm)
Less than 750 mm (29.5 in.) (inside of front tire)
Front
Bevel gear
Rear
Bevel gear
4WD system
Dual-acting overrunning 4WD
(Specifications and design subject to change without notice)
NOTE: *1 : Manufacture’s estimate.
*2 : At 2700 engine min-1 (rpm).
W1031842
8
DIMENSIONS
DIMENSIONS
9
G
GENERAL
GENERAL
CONTENTS
1. IDENTIFICATION............................................................................................. G-1
2. GENERAL PRECAUTIONS ............................................................................ G-2
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3
[1] WIRING...................................................................................................... G-3
[2] BATTERY................................................................................................... G-5
[3] FUSE.......................................................................................................... G-5
[4] CONNECTOR ............................................................................................ G-5
[5] HANDLING OF CIRCUIT TESTER......................................................... G-6
4. LUBRICANTS, FUEL AND COOLANT ......................................................... G-7
5. TIGHTENING TORQUES ............................................................................... G-8
[1] GENERAL USE SCREWS, BOLTS AND NUTS................................... G-8
[2] METRIC SCREWS, BOLTS AND NUTS ............................................... G-8
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS ................................................................................. G-9
[4] PLUGS ....................................................................................................... G-9
6. MAINTENANCE CHECK LIST ..................................................................... G-10
7. CHECK AND MAINTENANCE ..................................................................... G-12
[1] DAILY CHECK ........................................................................................ G-12
[2] CHECK POINTS OF INITIAL 50 HOURS ........................................... G-17
[3] CHECK POINTS OF EVERY 50 HOURS ........................................... G-19
[4] CHECK POINTS OF EVERY 100 HOURS ......................................... G-25
[7] CHECK POINTS OF EVERY 1500 HOURS ....................................... G-30
[8] CHECK POINTS OF EVERY 3000 HOURS ....................................... G-30
[9] CHECK POINTS OF EVERY 1 YEAR ................................................ G-30
[10]CHECK POINTS OF EVERY 2 YEARS.............................................. G-33
[11]OTHERS .................................................................................................. G-34
8. SPECIAL TOOLS .......................................................................................... G-35
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-35
[2] SPECIAL TOOLS FOR MACHINE........................................................ G-42
9. TIRES............................................................................................................. G-43
[1] TIRE PRESSURE ................................................................................... G-43
10. IMPLEMENT LIMITATIONS.......................................................................... G-44
G GENERAL
1. IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
engine model name, engine serial number and machine serial
number.
■ Engine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
• Year of manufacture
Alphabet or
Number
Year
1
2001
F
2015
2
2002
G
2016
3
2003
H
2017
4
2004
J
2018
5
2005
K
2019
6
2006
L
2020
7
2007
M
2021
8
2008
N
2022
Alphabet or
Number
Year
9
2009
P
2023
A
2010
R
2024
B
2011
S
2025
C
2012
T
2026
D
2013
V
2027
E
2014
• Month of manufacture
Month
Engine Serial Number
0001 ~ 9999
10000 ~
January
A0001 ~ A9999
B0001 ~
February
C0001 ~ C9999
D0001 ~
March
E0001 ~ E9999
F0001 ~
April
G0001 ~ G9999
H0001 ~
May
J0001 ~ J9999
K0001 ~
June
L0001 ~ L9999
M0001 ~
July
N0001 ~ N9999
P0001 ~
August
Q0001 ~ Q9999
R0001 ~
September
S0001 ~ S9999
T0001 ~
October
U0001 ~ U9999
V0001 ~
November
W0001 ~ W9999
X0001 ~
December
Y0001 ~ Y9999
Z0001 ~
e.g. D1105-5A0001
“5” indicates 2005 and “A” indicates January.
So, 5A indicates that the engine was manufactured in January,
2005.
(1) Engine Model Name
(2) Engine Serial Number
(3) Machine Serial Number
W1010714
G-1
G GENERAL
2. GENERAL PRECAUTIONS
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
installed in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
See the figure left side.
• When reassembling external snap rings or internal snap rings,
they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure left side.
• When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
• To prevent damage to the hydraulic system, use only specified
fluid or equivalent.
(1)
(2)
(3)
(4)
(5)
Grease
Force
Sharp Edge
Axial Force
Rotating Movement
(A) External Snap Ring
(B) Internal Snap Ring
W10109040
G-2
G GENERAL
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING
To ensure safety and prevent damage to the machine and
surrounding equipment, heed the following precautions in handling
electrical parts and wiring.
■ IMPORTANT
• Check electrical wiring for damage and loosened
connection every year. To this end, educate the customer to
do his or her own check and at the same time recommend
the dealer to perform periodic check.
• Do not attempt to modify any electrical parts and wiring.
• When removing the battery cables, disconnect the negative
cable first. When installing the battery cables, connect the
positive cable first.
(1) Negative Terminal
(2) Positive Terminal
W10111140
[1] WIRING
• Securely tighten wiring terminals.
(1) Correct
(Securely Tighten)
(2) Incorrect
(Loosening Leads to Faulty Contact)
W10112160
• Do not let wiring contact dangerous part.
(1) Dangerous Part
(2) Wiring (Incorrect)
(3) Wiring (Correct)
(4) Dangerous Part
W10113130
• Securely insert grommet.
(1) Grommet
(A) Correct
(B) Incorrect
W10113880
G-3
G GENERAL
• Securely clamp, being careful not to damage wiring.
(1) Clamp
• Wind Clamp Spirally
(2) Wire Harness
(3) Clamp
W10114580
• Clamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag may be
required.
(1) Wiring
(2) Clamp
(A) Correct
(B) Incorrect
W10115870
• When installing a part, take care not to trap or damage the wiring.
(1) Wiring
(A) Incorrect
W10116700
• After installing wiring, check protection of terminals and clamped
condition of wiring before connecting battery.
(1) Cover
• Securely Install Cover
W10117350
G-4
G GENERAL
[2] BATTERY
• Take care not to confuse positive and negative terminal posts.
• When removing battery cables, disconnect negative cable first.
When installing battery cables, check for polarity and connect
positive cable first.
• Do not install any battery with capacity other than is specified
(Ah).
• After connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal covers.
• Do not allow dirt and dust to collect on battery.
•
•
•
•
CAUTION
Take care not to let battery liquid spill on your skin and
clothes. If contaminated, wash it off with water immediately.
Before recharging the battery, remove it from the machine.
Before recharging, remove cell caps.
Recharging should take place in a well-ventilated place
where there is no open flame nearby, as hydrogen gas and
oxygen are produced, which is highly flammable.
W10118160
[3] FUSE
• Use fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
• Never use steel or copper wire in place of fuse.
• Do not install working light, radio set, etc. on machine without a
separate power supply.
• Do not install accessories if fuse capacity of reserve power
supply is exceeded.
(1) Fuse
(2) Slow Blow Fuse
W10120920
[4] CONNECTOR
• For connector with lock, push lock to separate.
(A) Push
W10122110
• In separating connectors, do not pull wire harnesses.
• Hold connector bodies to separate.
(A) Correct
(B) Incorrect
W10122720
G-5
G GENERAL
• Use sandpaper to remove rust from terminals.
• Repair damaged terminals. Make certain there is no terminal
being exposed or displaced.
(1) Exposed Terminal
(2) Deformed Terminal
(3) Sandpaper
(4) Rust
W10123460
• Make certain that there is no uninsulated femal connectors.
(A) Correct
(B) Incorrect
W10124300
• Make certain the plastic cover is large enough to cover whole
connector.
(1) Cover
(A) Correct
(B) Incorrect
W10125190
[5] HANDLING OF CIRCUIT TESTER
• Use the tester, according to its own operating instructions.
• Check for polarity and range.
W10126840
G-6
G GENERAL
4. LUBRICANTS, FUEL AND COOLANT
No.
1
2
Place
Capacity
F2880
61 L
16.1 U.S.gals
13.4 Imp.gals
Fuel
Lubricants, fuel and coolant
F3680
Cooling
system
4.6 L
4.9 U.S.qts
4.0 Imp.qts
Recovery
tank
0.6 L
0.6 U.S.qts
0.5 Imp.qts
Coolant
Fresh clean water with anti-freeze
5.3 L
5.6 U.S.qts
4.7 Imp.qts
3.8 L
4.0 U.S.qts
3.3 Imp.qts
3
Engine crankcase
4
Transmission case
14.0 L
14.8 U.S.qts
12.3 Imp.qts
5
Rear axle differential
case
1.5 L
1.59 U.S.qts
1.32 Imp.qts
6
Rear axle gear case
0.5 L
0.53 U.S.qts
0.44 Imp.qts
No. 2-D diesel fuel
No.1-D diesel fuel if temperature
is below – 10 °C (14 °F)
Engine oil : API Service
Classification CD, CE or CF Below
0 °C (32 °F)
:
SAE10W, 10W-30 or 10W-40
0 to 25 °C (32 to 77 °F):
SAE20, 10W-30 or 10W-40
Above 25 °C (77 °F):
SAE30, 10W-30 or 10W-40
KUBOTA UDT or SUPER UDT
fluid*
KUBOTA UDT, SUPER UDT
fluid* or SAE85W, SAE90 gear oil
(API Service Classification : more
than GL-3)
* KUBOTA original transmission hydraulic fluid.
Greasing
Speed control pedal
shaft
No. of greasing points
F2880
F3680
Capacity
Type of grease
1
Link pivots
(RH and LH)
2
Differential lock pedal
boss
1
Universal joint
1
Rear wheel drive
shaft (Front and Rear)
2
Knuckle arm
(RH and LH)
2
Seat adjuster
2
HST neutral shaft
1
Cable (Throttle)
1
Until grease
overflows
Multipurpose Grease
NLGI-2 or NLGI-1
(GC-LB)
Moderate
amount
Oil
G-7
G GENERAL
5. TIGHTENING TORQUES
[1] GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened
according to the table below.
Indication on top of
bolt
No-grade or 4T
Material of bolt
Material of opponent
part
Unit
Diameter
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
7T
SS400, S20C
Ordinariness
N·m
7.85
to
9.31
17.7
to
20.5
39.3
to
45.1
62.8
to
72.5
108
to
125
167
to
191
246
to
284
334
to
392
0.80
to
0.95
1.8
to
2.1
4.0
to
4.6
6.4
to
7.4
11.0
to
12.8
17.0
to
19.5
25.0
to
29.0
34.0
to
40.0
5.79
to
6.87
13.1
to
15.1
29.0
to
33.2
46.3
to
53.5
79.6
to
92.5
123
to
141
181
to
209
246
to
289
SCr435,
SCM435
S43C, S48C
Aluminum
kgf·m ft-lbs
9T
Ordinariness
Aluminum
Ordinariness
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
N·m
kgf·m ft-lbs
7.85
to
8.82
16.7
to
19.6
31.4
to
34.3
0.80
to
0.90
1.7
to
2.0
3.2
to
3.5
5.79
to
6.50
12.3
to
14.4
23.2
to
25.3
–
–
–
5.79
to
6.50
13.1
to
15.1
29.0
to
32.5
46.3
to
53.5
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
7.24
to
8.31
17.4
to
20.2
35.5
to
41.2
57.2
to
66.5
91.2
to
108
145
to
166
203
to
235
272
to
318
0.80
to
0.90
1.8
to
2.1
4.0
to
4.5
6.4
to
7.4
–
1.00
to
1.15
2.4
to
2.8
4.9
to
5.7
7.9
to
9.2
12.6
to
15.0
20.0
to
23.0
28.0
to
32.5
37.5
to
44.0
7.85
to
8.82
17.7
to
20.5
39.3
to
44.1
62.8
to
72.5
–
9.81
to
11.2
23.6
to
27.4
48.1
to
55.8
77.5
to
90.2
124
to
147
197
to
225
275
to
318
368
to
431
–
–
–
N·m
kgf·m
ft-lbs
12.3
to
14.2
29.5
to
34.3
60.9
to
70.6
103
to
117
167
to
196
260
to
304
344
to
402
491
to
568
1.25
to
1.45
3.0
to
3.5
6.2
to
7.2
10.5
to
12.0
17.0
to
20.0
26.5
to
31.0
35.0
to
41.0
50.0
to
58.0
9.05
to
10.4
21.7
to
25.3
44.9
to
52.0
76.0
to
86.7
123
to
144
192
to
224
254
to
296
362
to
419
W1034542
[2] METRIC SCREWS, BOLTS AND NUTS
Property class 8.8
Property class 10.9
Grade
Unit
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
Nominal Diameter
M8
23.6 to 27.4
2.40 to 2.80
17.4 to 20.2
29.4 to 34.3
3.00 to 3.50
21.7 to 25.3
M10
48.1 to 55.8
4.90 to 5.70
35.5 to 41.2
60.8 to 70.5
6.20 to 7.20
44.9 to 52.1
M12
77.5 to 90.1
7.90 to 9.20
57.2 to 66.5
103.0 to 117.0
10.50 to 12.00
76.0 to 86.8
M14
124.0 to 147.0
12.60 to 15.00
91.2 to 108.0
167.0 to 196.0
17.00 to 20.00
123.0 to 144.0
M16
196.0 to 255.0
20.0 to 23.0
145.0 to 166.0
260.0 to 303.0
26.50 to 31.00
192.0 to 224.0
W1013689
G-8
G GENERAL
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR
UNF THREADS
SAE GR.5
SAE GR.8
Grade
Unit
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
5/16
23.1 to 27.8
2.35 to 2.84
17.0 to 20.5
32.5 to 39.3
3.31 to 4.01
24.0 to 29.0
3/8
47.5 to 57.0
4.84 to 5.82
35.0 to 42.0
61.0 to 73.2
6.22 to 7.47
45.0 to 54.0
1/2
108.5 to 130.2
11.07 to 13.29
80.0 to 96.0
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
9/16
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
217.0 to 260.4
22.14 to 26.57
160.0 to 192.0
5/8
203.4 to 244.1
20.75 to 24.91
150.0 to 180.0
298.3 to 358.0
30.44 to 36.53
220.0 to 264.0
Nominal Diameter
W1022485
[4] PLUGS
Material of opponent part
Shape
Tapered
screw
Straight
screw
Size
Ordinariness
Aluminum
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
R1/8
13 to 22
1.3 to 2.2
9.6 to 16.2
10 to 12
1.0 to 1.2
7.4 to 8.9
R1/4
29 to 44
3.0 to 4.5
21.4 to 32.5
20 to 29
2.0 to 3.0
14.8 to 21.4
G1/4
29 to 39
3.0 to 4.0
21.4 to 28.8
–
–
–
G3/8
49 to 59
5.0 to 6.0
36.1 to 43.5
–
–
–
G1/2
59 to 78
6.0 to 8.0
43.5 to 57.5
–
–
–
0000001666E
G-9
G GENERAL
6. MAINTENANCE CHECK LIST
■ IMPORTANT
• The jobs indicated by ”★” must be done initially during pre-delivery inspection.
• *1 : This maintenance should be done daily more in dusty conditions than in normal conditions.
Suggested cleaning interval is every 100 hours in normal conditions.
• The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the
U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of
the required maintenance on the engine according to the above instruction.
Period
No.
Service Interval
50
100 150 200 250 300 350 400 450 500 550 600
After
since
Important
Item
Reference
page
1
Safety device
Check
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
every
50Hr
G-19
2
Greasing
–
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
every
50Hr
G-20
3
Oiling
–
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
every
50Hr
G-21
4
Battery condition
Check
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
every
50Hr
G-22
Clean
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
every
50Hr
5
Air cleaner element
✩
✩
✩
✩
✩
every
100Hr
G-17
Adjust
✩
✩
✩
✩
✩
✩
every
100Hr
G-25
Adjust
✩
✩
✩
✩
✩
✩
every
100Hr
G-25
Check
✩
✩
✩
✩
✩
✩
every
100Hr
Engine oil
Change
7
Fan belt
8
Brake pedal free travel
★
Fuel filter
✩
Replace
G-25
@
every
400Hr
G-29
✩
✩
✩
every
200Hr
G-17
★
✩
✩
every
200Hr
G-26
✩
✩
✩
every
200Hr
★
✩
✩
every
200Hr
G-26
Rear axle differential case
Change
fluid
★
✩
✩
every
200Hr
G-27
Rear axle gear case (RH
and LH) fluid
Change
★
✩
✩
every
200Hr
G-27
Check
✩
✩
✩
every
200Hr
G-27
every 2
years
G-33
every
200Hr
G-28
every 2
years
G-33
10
Engine oil filter cartridge
Replace
11
Transmission fluid
Change
12
Transmission oil filter
cartridge
Replace
13
Transmission oil strainer
Clean
14
15
★
★
Radiator hose and clamp
Replace
Check
17
G-30
✩
6
16
G-24
@
every 1
year
Replace
9
*1
✩
✩
Hydraulic hose
Replace
✩
*1
G-18
W1035769
G-10
G GENERAL
(Continued)
Period
No.
Service Interval
50
100 150 200 250 300 350 400 450 500 550 600
After
since
Important
Item
Check
18
✩
✩
✩
Fuel line
every 2
years
Replace
Check
19
every
200Hr
✩
✩
Intake air line
✩
every
200Hr
every 2
years
Replace
✩
Reference
page
G-28
@
G-33
G-29
@
–
every
400Hr
20
Rear axle pivot
Adjust
21
Fuel injection nozzle
(injection pressure)
Check
every
1500Hr
@
G-30
22
Injection pump
Check
every
3000Hr
@
G-30
23
Radiator
Clean
every 1
year
24
Coolant
Change
every 1
year
25
Fuel system
Bleed
26
Fuse
Replace
27
Light bulb
Replace
28
Lift spring
Adjust
G-29
G-31
@
G-31
G-34
Service
as
Required
G-34
G-34
G-34
W1023987
G-11
G GENERAL
7. CHECK AND MAINTENANCE
CAUTION
• Be sure to check and service the machine on a flat area with engine shut off, the parking brake set and
chock the weel.
[1] DAILY CHECK
To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items
before starting.
Checking
• Walk around the machine.
1. The tire pressure, wear and damage
2. Oil and water leak
3. Engine oil level
4. Transmission fluid level
5. Battery electrolyte
6. Coolant level in the recovery tank
7. Damage of machine body, tightness of all screws, bolts and nuts
8. Radiator screen
9. Bonnet screen
10.Brake pedal free travel
11.Fuel level
12.Air cleaner
• While sitting in the operator’s seat
1. Speed control pedal
2. Brake pedal
3. Parking brake
• Turning the key switch “ON”.
1. Performance of the easy checker light
2. Head light
• Starting the engine.
1. Color of the exhaust fumes
2. Safety start switch, seat safety control and another safety devices
3. Check for abnormal noise and vibration
• Others.
1. Check the areas where previous trouble was experienced
G-12
G GENERAL
Checking Engine Oil Level
•
1.
2.
3.
4.
5.
6.
CAUTION
Always stop the engine and remove the key before checking
oil.
Check engine oil before starting and 5 minutes or more after the
engine has stopped.
Wipe dipstick (2) area clean.
To check the oil level, remove the dipstick (2), wipe it clean,
reinsert it, and draw it out again. Check to see that the oil level
is between the two notches.
Add new oil to the prescribed level at the oil inlet (1) if necessary.
When using a different brand or viscosity oil from the previous
one, remove all of the old oil and oil filter. Never mix two different
types of oil.
Use the proper Engine Oil SAE according to the ambient
temperatures. (See page G-7.)
(1) Engine Oil Inlet
(2) Oil Level Dipstick
A : Oil level is acceptable within this
range
W1047516
G-13
G GENERAL
Checking Amount of Fuel and Refueling
CAUTION
• Handle fuel carefully. If the engine is running, do not fill the
fuel tank. If engine is hot, let engine cool for several minutes
before adding fuel.
Do not smoke while filling the fuel tank or servicing the fuel
system. Fill fuel tank only to bottom of filler neck.
Check the fuel level. Take care that the fuel tank does not
become empty.
61 L
16.1 U.S.gals
13.4 Imp.gals
Fuel tank capacity
■
•
1.
2.
3.
IMPORTANT
Use Diesel Fuel Only.
Use No.2-D diesel fuel.
Use No.1-D diesel fuel if the temperature is below -10 °C (14 °F).
Always use a strainer when refueling to prevent fuel injection
pump contamination.
■ NOTE
• No.2-D is a distillate fuel of lower volatility for engines in
industrial and heavy mobile service.
(SAE J313 JUN87)
Grade of Diesel Fuel Oil according to ASTM D975
Water and
sediment,
volume %
Flash point °C
Carbon residue
on, 10 percent
residuum %
Ash, weight %
Min
Max
Max
Max
52
0.05
0.35
0.01
Distillation
temperatures °C 90 %
point
Kinematics viscosity
cSt or mm2/S at 40 °C
Saybolt viscosity, SUS
at 100 °F
Min
Max
Max
Max
Max
Max
282
338
1.9
4.1
32.6
40.1
Sulfur, weight
Copper strip corrosion
Cetane number
Max
Max
Min
0.50
No. 3
40
(1) Fuel Cap
W1048002
G-14
G GENERAL
Checking and Cleaning Radiator to Prevent Overheating
CAUTION
• Be sure to stop the engine and remove the key before
cleaning.
■ IMPORTANT
• The air intake area must be clear of debris to prevent the
engine from overheating.
Daily or after every 5 hours of operation, check to be sure the
radiator screen (1) and bonnet screen (2) are clean. Dirt or chaff on
the radiator screen (1) or bonnet screen (2) decrease cooling
performance.
1. Open the bonnet and remove the radiator screen (2).
2. Remove the dust from between the fins and the tube.
3. Tighten the fan drive belt as necessary. For this, refer to
"CHECK POINT EVERY 100 HOURS".
4. If scale forms in the tube, clean with scale inhibitor or its
equivalent.
5. Each time the bonnet screen (2) is covered with grass during
operation, remove the grass from bonnet screen by hand. Check
the radiator screen (1) from time to time if grass accumulates.
(1) Radiator Screen
(2) Bonnet Screen
W1050141
Checking Tire Pressure
WARNING
• Do not attempt to mount a tire on a rim. This should be done
by a qualified person with the proper equipment
• Always maintain the correct tire pressure.
Do not inflate tires above the recommended pressure.
CAUTION
• Never operate machine with a loose rim, wheel or axle.
• Whenever bolts are loosened, retighten to specified torque.
• Check all bolts frequently and keep them tightened.
■ Inflation Pressure
Though the inflation pressure is factory-set to the prescribed
level, it naturally drops slowly in the course of time. Thus, check it
every day and inflate as necessary.
Tire Sizes
Recommended
inflation pressure
Front
24 × 12-12, 4PR
140 kPa
(1.4 kgf/cm2, 20 psi)
Rear
18 × 9.5-8, 4PR
200 kPa
(2.0 kgf/cm2, 28 psi)
(1) Ground
(A) Insufficient
(B) Normal
(C) Excessive
W1051028
G-15
G GENERAL
Checking Transmission Fluid Level
1. Park the machine on a flat surface, lower the implement to the
ground and shut off engine and remove the key.
2. To check the oil level, draw out the dipstick (2), wipe it clean,
reinsert it, and draw it out again. Check to see that the oil level
lies between the two notches. If the level is too low, add new oil
to the prescribed level at the oil inlet (1). (See page G-7.)
■ IMPORTANT
• If oil level is low, do not run engine.
(1) Oil Inlet
(2) Oil Level Dipstick
A : Upper Level
B : Lower Level
W1052183
Checking Coolant Level
CAUTION
• Do not remove the radiator cap when the engine is hot.
Loosen cap slightly, to the stop, to relieve any excess
pressure before removing cap completely.
Check the coolant level daily both the radiator and the recovery
tank (2) before starting engine
1. Remove the radiator cap (1) and check to see that the coolant
level is just below the fill port.
2. Check to see that the coolant level is between the "FULL" and
"LOW" marks of recovery tank (2).
3. When the coolant level drops due to evaporation, add water only
up to just below the fill port of the radiator and the full level of the
recovery tank (2).
In case of leakage, add coolant and water in the specified mixing
ratio up to the full level. (See page G-7.)
■ IMPORTANT
• If the radiator cap has to be removed, follow the caution
above and securely retighten the cap.
• Use clean, distilled coolant and water to fill the radiator and
recovery tank.
(1) Radiator Cap
(2) Recovery Tank
A : FULL
B : LOW
W1053725
G-16
G GENERAL
[2] CHECK POINTS OF INITIAL 50 HOURS
Changing Engine Oil
CAUTION
changing oil.
• Allow engine to cool down sufficiently. Oil can be hot and
may cause burns.
1. Place an oil pan underneath the engine.
2. To drain the used oil, remove the drain plugs (1) at the bottom of
the engine and drain the oil completely.
3. Screw in the drain plugs (1) and tighten.
4. Fill with new oil up to upper line on the dipstick (3).
■ IMPORTANT
• When using an oil of different manufacture or viscosity from
the previous one, remove all of the old oil.
• Never mix two different types of oil.
• Use the proper SAE Engine Oil according to ambient
temperatures.
Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7).
(1) Drain Plug
(2) Oil Inlet Plug
(3) Dipstick
(A) Oil level is acceptable within this
range.
W1030749
Replacing Engine Oil Filter Cartridge
•
•
1.
2.
3.
4.
5.
6.
■
•
CAUTION
Be sure to stop the engine and remove the key before
changing the oil and the oil filter cartridge.
Allow engine to cool down sufficiently; oil can be hot and
may cause burns.
Remove the oil filter cartridge (1) with the filter wrench.
Put a film of engine oil on the rubber seal of the new filter
cartridge.
Tighten the filter cartridge quickly until it contacts the mounting
surface.
Tighten the filter cartridge by hand an additional 1/2 turn only.
After the new filter is replaced, the engine oil normally decreases
a little. Check that the engine oil does not leak through the seal
and be sure to check the oil level on the dipstick.
Then, replenish the engine oil up to the prescribed level.
IMPORTANT
To prevent serious damage to the engine. Use only a
genuine KUBOTA filter.
(1) Engine Oil Filter Cartridge
W1030949
G-17
G GENERAL
Replacing Transmission Oil Filter Cartridge
•
•
1.
2.
3.
4.
5.
■
•
CAUTION
Be sure to stop the engine and remove the key before
changing the oil filter cartridge.
Allow transmission case to cool down sufficiently; oil can be
hot and may cause burns.
Remove the transmission oil filter cartridge (1) with the filter
wrench.
Apply a slight coat of oil onto the cartridge gasket.
To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of the rubber gasket.
After the new cartridge is replaced, the transmission fluid level
normally decreases a little. Add fluid if necessary.
Check for oil leaks around the filter gasket.
IMPORTANT
To prevent serious damage to the hydraulic system,
replacement oil filter cartridge must be highly efficient. Use
only a genuine KUBOTA filter.
(1) Transmission Oil Filter Cartridge
W1031068
G-18
G GENERAL
[3] CHECK POINTS OF EVERY 50 HOURS
Checking Safety Devices
The Safety Devices are on your machine help to protect you
while operating. Please check these Safety Devices periodically daily is best - to test the safety systems function correctly before
operation.
CAUTION
• Do not allow anyone near the machine while testing.
• If the machine does not pass a test, do not operate the
machine.
• Sit on operator’s seat for all tests except for Test 1.
1. Perform the following tests before operating the machine.
2. If the machine does not pass one of the following tests, do not
operate the machine, and check the safety switches and the
wiring harness.
■ Test 1 : Switch for the operator’s seat
1. Do not sit on the operator’s seat.
2. Depress the brake pedal (2) fully.
3. Shift the PTO lever (3) to the “DISENGAGE” position.
4. Turn the main switch (1) to the “START” position.
5. The engine must not crank.
■ Test 2 : Switch for the brake pedal
1. Sit on the operator’s seat.
2. Do not depress the brake pedal (2).
3. Shift the PTO lever (3) to the “DISENGAGE” position.
■ Test 3 : Switch for the PTO lever
1. Sit on the operator’s seat.
2. Depress the brake pedal (2) fully.
3. Shift the PTO lever (3) to the “ENGAGE” position.
■ Test 4 : Switch for the operator’s seat (OPC)
1. Start the engine.
2. Shift the PTO lever (3) to “DISENGAGE” position.
3. Release the brake pedal (2).
4. Stand up. (Do not get off the machine.)
5. The engine must shut off
2. Shift the PTO lever (3) to “ENGAGE” position.
3. Release the brake pedal (2).
4. Stand up. (Do not get off the machine.).
5. The engine must shut off.
2. Depress the brake pedal (2) fully and lock the parking brake.
3. Shift the PTO lever (3) to “ENGAGE” position.
4. Stand up. (Do not get off the machine).
5. The engine must shut off.
(1) Main Switch
(2) Brake Pedal
(3) PTO Lever
W1050412
G-19
G GENERAL
Lubricating All Grease Nipple
1. Apply grease to the following locations as shown in the figures.
CAUTION
greasing.
(1) Speed Control Pedal Shaft
(2) Link Pivot (LH and RH)
(3) Differential Lock Pedal Boss
(4) Universal Joint
W1033255
G-20
G GENERAL
Lubricating All Grease Nipple (Continued)
1. Apply grease to the following locations as shown in the figures.
CAUTION
greasing.
(1) Rear Wheel Drive Shaft
(2) Knuckle Arm (LH)
(3) Knuckle Arm (RH)
W1033769
Oiling
1. Apply oil to the following locations as shown in the figures.
CAUTION
• Be sure to stop the engine and remove the key before oiling.
(1) Seat Adjuster
(2) Accelerator Cable
W1034719
G-21
G GENERAL
Checking Battery Condition
DANGER
To avoid the possibility of battery explosion:
For the refillable type battery, follow the instructions below.
• Do not use or charge the refillable type battery if the fluid
level is below the LOWER (lower limit level) mark. Otherwise,
the battery component parts may prematurely deteriorate,
which may shorten the battery's service life or cause an
explosion. Check the fluid level regularly and add distilled
water as required so that the fluid level is between the
UPPER and LOWER levels.
•
•
•
1.
2.
CAUTION
Never remove the vent plugs while the engine is running.
Keep electrolyte away from eyes, hands and clothes. If you
are spattered with it, immediately wash it away completely
with water and get medical attention.
Wear eye protection and rubber gloves when working
around the battery.
Mishandling the battery shortens the service life and adds to
maintenance costs.
Machine may have a maintenance free battery. If engine cranks
slowly or lights become dim; check and clean connections,
charge battery, and load test battery.
(1) Battery
W1015551
G-22
G GENERAL
Battery Charging
DANGER
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep sparks
and flames away from the battery at all times, especially
when charging the battery.
CAUTION
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first.
• Never check battery charge by placing a metal object across
the posts.
• Use a voltmeter or hydrometer.
• Take care not to reverse connections (polarity) at the battery
as this could lead to electrical circuit damage, battery
damage, or battery explosion.
1. Make sure each electrolyte level is somewhere between the
markings (1) and (2). Add the correct amount of distilled water
up to the highest level as required.
2. The water in the electrolyte evaporates during recharging. Liquid
shortage damages the battery. Excessive liquid may spill over
and damages the machine body.
3. To slow charge the battery, connect the battery positive terminal
to the charge positive terminal and the negative to the negative,
then recharge in the standard fashion.
4. A boost charge is only for emergencies. It partially charges the
battery at a high rate and in a short time.
When using a boost-charged battery, it is necessary to recharge
the battery as early as possible.
Failure to do this will shorten the battery’s service life.
5. When the specific gravity of electrolyte is between 1.27 and 1.29,
charge has been completed.
6. When exchanging an old battery for a new one, use a battery of
equal specification shown in table 1 and 2.
■ Direction for Storage
1. When storing the machine for a long period, remove the battery
from the machine, adjust the electrolyte to the proper level and
store in a dry place out of direct sunlight.
2. The battery self-discharges while it is stored.
Recharge it once a month in hot seasons and once every 2
months in cold seasons.
Table 1
Battery Type
Volts (V)
capacity at
5 H.R (A.H)
70D2; 3R-CF-MF
12
52
Reverse Capacity
(min)
Cold Cranking Amps
Normal Charging Rate
(A)
112
490
6.5
Table 2
(1) Highest Level
(2) Lowest Level
W1041310
G-23
G GENERAL
Cleaning Air Cleaner Element
1. Remove the air cleaner cover (1) and element (3).
2. Clean the element :
• When by dust adheres to the element, blow compressed air from
the inside turning the element. Pressure of compressed air must
be under 205 kPa (2.1 kgf/cm2, 30 psi).
• When carbon or oil adheres to the element, soak the element in
detergent for 15 minutes then wash it several times in water,
rinse with clean water and let air dry.
• After element is fully dried, inspect inside of the element with a
light and check if it is damaged or not.
3. Replace the air cleaner element (3) :
• Once a year or after every six times of cleaning, whichever
comes first.
■ IMPORTANT
• Be sure to clean the inside of air cleaner and cover.
• The air cleaner uses a dry element, never apply oil.
• Do not run the engine with filter element removed.
• Be sure to refit the air cleaner cover (1) with the arrow ↑ (on
the rear of cover) upright. If the air cleaner cover is
improperly fitted, evacuator valve (2) will not function and
dust will adhere to the element.
■ Evacuator Valve
Open the evacuator valve once a week under ordinary conditions
or daily when used in dusty conditions to get rid of large particles of
dust and dirt.
(1) Air Cleaner Cover
(2) Evacuator Valve
(3) Air Cleaner Element
(4) Air Cleaner Body
W1042118
G-24
G GENERAL
Changing Engine Oil
1. See page G-13.
W1043451
Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbs).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws and relocate the alternator to
adjust.
Deflection (A)
Factory spec.
7.0 to 9.0 mm
0.28 to 0.35 in.
(A) Deflection
W10356670
Adjusting Brake Pedal Free Travel
•
■
•
1.
2.
3.
4.
CAUTION
Stop the engine and chock the wheels before checking
brake pedal.
NOTE
If turn assist brake device and speed set device are
attached, see the instruction manuals.
Release the parking brake.
Slightly depress the main brake pedal and measure free travel
“S1” at top of pedal stroke.
If adjustment is needed, loosen the lock nut (2) and turn the
turnbuckle (3) to adjust the rod length within acceptable limits.
Retighten the lock nut.
Main brake pedal free
travel (S1)
(1) Main Brake Pedal
(2) Lock Nut
(3) Turnbuckle
Factory spec.
20 to 40 mm
0.8 to 1.6 in.
S1 : Free Travel
W1045829
Checking Fuel Filter
1. Checking the fuel filter (1) for the impurities and water.
2. If the impurities or water have collected in the fuel filter, replace
the fuel filter.
(1) Fuel Filter
W1043576
G-25
G GENERAL
Changing Transmission Fluid
CAUTION
• Be sure to stop the engine before checking and changing
the transmission oil.
1. Place an oil pan underneath the transmission case.
2. Remove the drain plugs (1) at the bottom of the transmission
case.
3. Drain the transmission fluid. (See “Cleaning Transmission Oil
Strainer” below)
4. After draining, screw in the three drain plugs and tighten.
5. Fill the transmission fluid from oil inlet (3) up to the upper line on
the dipstick (2).
6. After running the engine for a few minutes, stop it and check the
fluid level again, add the fluid to the prescribed level if it is not
correct.
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oils may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
• Never work the machine immediately after changing the
transmission fluid. Keeping the engine at medium speed for
a few minutes to prevents damage to the transmission.
• Do not mix different brands fluid together.
(1) Drain Plug
(2) Dipstick
(3) Oil Inlet
A : Upper Level
B : Lower Level
W1046657
Replacing Transmission Oil Filter Cartridge
1. See page G-20.
W1037242
Cleaning Transmission Oil Strainer
1. Place an oil pan underneath the transmission oil strainer.
2. When changing the transmission oil, be sure to clean the
transmission oil strainer (1) with appropriate cleaning fluid.
3. If the oil strainer is deformed or broken, replace it.
■ IMPORTANT
• Be careful not to damage the transmission oil strainer parts
when installing.
(1) Transmission Oil Strainer
(2) O-ring
(3) Front Suction Pipe
W1047188
G-26
G GENERAL
Changing Rear Axle Differential Case Oil
1. Place the machine on level ground.
2. Place an oil pan underneath the rear axle differential case.
3. Remove the drain plug (2) and oil filler plug (1), and drain the
used oil completely.
4. After draining the oil, reinstall the drain plug and tighten.
5. Fill with new oil up to the upper level on the oil filler plug.
■ IMPORTANT
• Use the specified oil.
Refer to “LUBIRICANTS, FUEL AND COOLANT”.
(See page G-7.)
(1) Oil Filler Plug
(2) Drain Plug
range.
W1047321
Changing Rear Axle Gear Case Oil
1. Place the machine on level ground.
2. Place an oil pan underneath the rear axle gear cases.
3. Remove the drain plug (3) and oil filler plug (1), and drain the
used oil completely.
4. After draining the oil, reinstall the drain plug and tighten.
5. Fill with new oil up to the level of the oil filler plug.
■ IMPORTANT
(See page G-7.)
(1) Oil Filler Plug
(2) Hexagon Wrench
(3) Drain Plug
W1047609
Checking Radiator Hose and Hose Clamp
■ NOTE
• Check to see if the radiator hoses are properly connected
every 200 hours of operation or six months, whichever
comes first.
1. If the hose clamps (2) are loose or water leaks, tighten the hose
clamps (2) securely.
2. Replace the radiator hoses (1) and tighten the hose clamps (2)
securely, if the radiator hoses (1) are swollen, hardened or
cracked.
■ Precaution at Overheating
Take the following actions in the event coolant temperature near
or more than the boiling point, what is called “Overheating”.
1. Stop the machine operation in a safe place and keep the engine
unloaded idling.
2. Don’t stop the engine suddenly, but stop it after about 5 minutes
of unloaded idling.
3. Keep yourself well away from the machine for further 10 minutes
or while the steam blows out.
4. After engine cools, check for cause of overheat and repair before
starting engine.
(1) Radiator Hose
(2) Hose Clamp
G-27
G GENERAL
Checking Hydraulic Hose
1. Check to see that all hydraulic hoses (1), (2) and hose clamps are
tight and not damaged.
2. If hoses and clamps are worn or damaged, replace or repair at
once.
(1) Power Steering Hose
(2) Delivery Hose
Checking Fuel Line
•
•
1.
2.
3.
4.
5.
■
•
CAUTION
Stop the engine before attempting to carry out the work as
discribed below.
Remember to check the fuel line periodically. The fuel line
is subject to wear and again, fuel may leak out onto the
running engine, causing a fire.
Check to see that all lines and hose clamps are tight and not
damaged.
If hoses and clamps are worn or damaged, replace or repair them
at once.
The fuel line is made of rubber and deteriorates regardless of
period of service. Replace the fuel hose together with the clamp
every two years and tighten securely.
However if the fuel hose and clamp are found damaged or
deteriorated earlier than two years, repair before running
machine.
After the fuel line and clamp have been changed, bleed the fuel
system.
IMPORTANT
When the fuel line is disconnected for change, close both
ends of the fuel line with a piece of clean cloth or paper to
prevent dust and dirt from entering. Entrance of dust and
dirt causes malfunction of the fuel injection pump. In
addition, particular care must be taken not to admit dust and
dirt into the fuel pump.
(1) Fuel Hose
(2) Hose Clamp
G-28
G GENERAL
Checking Intake Air Line
1. Check to see that hoses (2) and hose clamps (1) are tight and not
damaged.
2. If hoses (2) and hose clamps (1) are found worn or damaged,
replace or repair them at once.
(1) Hose Clamp
(2) Hose
W1038340
Adjusting Rear Axle Pivot
1. Loosen the lock nut (2), tighten the adjusting screw (1) all the
way, and then loosen the adjusting screw (1) by 1/6 turn.
2. Retighten the lock nut (2).
(1) Adjusting Screw
(2) Lock Nut
Replacing Fuel Filter
1. Replace the fuel filter (1).
(1) Fuel Filter
G-29
G GENERAL
Checking Fuel Injection Nozzle
1. See page 1-S17 (“ENGINE” Section).
W1047797
Checking Injection Pump
1. See page 1-S16 (“ENGINE” Section).
[9] CHECK POINTS OF EVERY 1 YEAR
Replacing Air Cleaner Element
1. Replace the air cleaner element (3).
■ IMPORTANT
• The air cleaner uses a dry element, never apply oil.
• Do not run the engine with filter element removed.
• Be sure to refit the air cleaner cover (1) with the arrow ↑ (on
the rear of cover) upright. If the air cleaner cover is
improperly fitted, evacuator valve (2) will not function and
dust will adhere to the element.
(1) Air Cleaner Cover
(2) Evacuator Valve
(3) Air Cleaner Element
(4) Air Cleaner Body
W1049835
G-30
G GENERAL
Flush Cooling System and Changing Coolant
CAUTION
• Do not remove the radiator cap when the engine is hot.
When engine is cool, loosen cap slightly to the stop to
relieve any excess pressure before removing cap
completely.
1. Stop the engine and let it cool down.
2. To drain the coolant, open the radiator drain plug (1) and remove
the radiator cap. The radiator cap must be removed to
completely drain the coolant.
3. After all coolant is drained, install the drain plug (1).
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the fill port.
7. Fill with clean water and anti-freeze up to the “FULL” mark on the
recovery tank (2).
8. Start and operate the engine for few minutes.
9. Stop the engine. Check coolant level of recovery tank (2) and
add coolant if necessary.
10.Install the radiator cap (1) securely.
■ IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh water and anti-freeze to fill the radiator and
recovery tank.
Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.)
• When the anti-freeze is mixed with water, the anti-freeze
mixing ratio must be less than 50 %.
• Securely tighten the radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Drain Plug
(2) Recovery Tank
A : FULL
B : LOW
W1049995
G-31
G GENERAL
Flush Cooling System and Changing Coolant (Continued)
■ Anti-Freeze
It is not recommended to use plain water as coolant. water
freazes at 0 °C (32 °F) ambient temperature. If coolant freezes in
the engine, it will damage the engine block, head and radiator.
1. There are two types of anti-freeze available ; use the permanent
type (PT) for this engine.
2. Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh water and draining it a few times.
3. The procedure for mixing of water and anti-freeze differs
according to the make of the anti-freeze and the ambient
temperature, basically it should be referred to SAE J1034, more
specifically also to SAE J814c.
4. Mix the anti-freeze with water, and then fill the radiator.
Vol % Antifreeze
Freezing Point
°C
°F
°C
Boiling Point*
°F
40
-24
-12
106
222
50
-37
-34
108
226
* At 101kPa (760 mmHg) Pressure (atmospheric). A higher boiling point is obtained
by using a radiator pressure cap which permits the development of pressure within
the cooling system.
■ NOTE
• The above data represent industry standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add water
only. In case of leakage, add anti-freeze and water in the
specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant. (Anti-freeze contains an anticorrosive agent, which will react with the radiator cleaning
agent forming sludge which will affect the engine parts.)
W1050214
G-32
G GENERAL
[10] CHECK POINTS OF EVERY 2 YEARS
Replacing Radiator Hose and Hose Clamp
1. Replace the radiator hoses (1) and hose clamp (2).
Refer to “Checking Radiator Hose and Hose Clamp” (See
page G-27.).
(1) Radiator Hose
(2) Hose Clamp
W1050581
Replacing Hydraulic Hose
1. Replacing the hydraulic hoses every 2 years or earlier if checked
and found that the hydraulic hoses are swollen, hardened or
crocked.
(1) Radiator Hose
(2) Hose Clamp
W1039376
Replacing Fuel Line
1. replace the fuel hoses (1) and hose clamps (2).
Refer to “Checking Fuel Line”. (See page G-28.)
(1) Fuel Hose
(2) Hose Clamp
W1050661
G-33
G GENERAL
[11] OTHERS
Bleeding Fuel System
CAUTION
• Do not bleed the fuel system when the engine is hot.
Air must removed :
1. When the fuel filter or lines are removed.
2. When tank is completely empty.
3. After the machine has not been used for a long period of time.
Bleeding procedure is as follows :
1. Fill the fuel tank with fuel.
2. Turn the key switch to the “ON” position.
3. Loosen the bleed screw (1).
When bubbles disappear from fuel coming out of the plug, tighten
the bleed screw.
(1) Bleed Screw
W1051059
Replacing Fuse
1. The electrical system is protected from potential damage by
fuses.
A blown fuse indicates that there is an overload or short
somewhere in the electrical system.
2. If any of the fuses should blow, replace with a new one of the
same capacity.
■ IMPORTANT
• Before replacing a blown fuse, determine why the fuse blew
and make any necessary repairs. Failure to follow this
procedure may result in serious damage to the electrical
system.
■ Protected circuit
Fuse No.
Capacity (A)
Protected Circuit
(1)
5
ACC
(2)
10
Head Light, Fuel Pump
(3)
15
Working Light
(4)
Slow Blow Fuse 50
Check circuit against wrong
battery connection
W1051895
Replacing Light Bulb
1. Head light
Take the bulb out of the light body and replace with a new one.
Light
Capacity
Head light
15 W
W1052077
Adjusting Lift Springs
1. In order to help improve traction, adjust the lift spring.
Refer to page 2-S16 (“TRANSMISSION” Section).
W1039531
G-34
G GENERAL
8. SPECIAL TOOLS
[1] SPECIAL TOOLS FOR ENGINE
Special Use Puller Set
Code No: 07916-09032
Application: Use exclusively for pulling out bearing, gears and other
parts with ease.
W1024050
Piston Ring Compressor
Code No: 07909-32111
Application: Use exclusively for pushing in the piston with piston
rings into the cylinder.
W1024100
Piston Ring Tool
Code No: 07909-32121
Application: Use exclusively for removing or installing the piston ring
with ease.
W1024150
Diesel Engine Compression Tester (for Injection Nozzle)
Code No: 07909-30208 (Assembly)
07909-31251 (G)
07909-30934 (A to F)
07909-31271 (I)
07909-31211 (E and F)
07909-31281 (J)
07909-31231 (H)
Application: Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1)
(2)
(3)
(4)
(5)
(6)
Gauge
L Joint
Adaptor A
Adaptor B
Adaptor C
Adaptor E
(7)
(8)
(9)
(10)
(11)
Adaptor F
Adaptor G
Adaptor H
Adaptor I
Adaptor J
W1024200
G-35
G GENERAL
Diesel Engine Compression Tester (for Glow Plug)
Code No: 07909-39081 (Assembly) 07909-31301 (L)
07909-31291 (K)
07909-31311 (M)
Application: Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1) Gauge
(2) L Joint
(3) Adaptor K
(4) Adaptor L
(5) Adaptor M
0000001398E
Oil Pressure Tester
Code No: 07916-32032
Application: Use to measure lubricating oil pressure.
(1)
(2)
(3)
(4)
Gauge
Cable
Threaded Joint
Adaptor 1
(5)
(6)
(7)
(8)
Adaptor 2
Adaptor 3
Adaptor 4
Adaptor 5
W1024318
Valve Seat Cutter
Code No: 07909-33102
Application: Use to reseat valves.
Angle:
0.785 rad. (45°)
0.262 rad. (15°)
Diameter: 28.6 mm (1.126 in.)
31.6 mm (1.244 in.)
35.0 mm (1.378 in.)
38.0 mm (1.496 in.)
41.3 mm (1.626 in.)
50.8 mm (2.000 in.)
W1024458
Radiator Tester
Code No: 07909-31551
Application: Use to check of radiator cap pressure, and leaks from
cooling system.
Remarks: Adaptor (1) BANZAI Code No. RCT-2A-30S
W1024532
Connecting Rod Alignment Tool
Code No: 07909-31661
Application: Use to check the connecting rod alignment.
Applicable: Connecting rod big end I.D.
range
30 to 75 mm (1.18 to 2.95 in.) dia.
Connecting rod length
65 to 300 mm (2.56 to 11.81 in.)
W1024583
G-36
G GENERAL
Nozzle Tester
Code No: 07909-31361
Application: Use to check the fuel injection pressure and spray
pattern of nozzle.
Measuring: 0 to 50 MPa
range
(0 to 500 kgf/cm2, 0 to 7000 psi)
W1024653
Plastigage
Code No: 07909-30241
Application: Use to check the oil clearance between crankshaft and
bearing, etc.
Measuring: Green .... 0.025 to 0.076 mm (0.001 to 0.003 in.)
range
Red ....... 0.051 to 0.152 mm (0.002 to 0.006 in.)
Blue ....... 0.102 to 0.229 mm (0.004 to 0.009 in.)
W1024719
Red Check
Code No: 07909-31371
Application: Use to check cracks on cylinder head, cylinder block,
etc.
W1024909
G-37
G GENERAL
■ NOTE
• The following special tools are not provided, so make them referring to the figure.
Injection Pump Pressure Tester
Application: Use to check fuel tightness of injection pumps.
A
Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267
psi)
B
PF 1/2
C
Copper gasket
D
Flange (Material : Steel)
E
Hex. nut 27 mm (1.06 in.) across the plat
F
Adhesive application
G
Fillet welding on the enter circumference
H
Retaining nut
I
17 mm dia. (0.67 in. dia.)
J
8 mm dia. (0.31 in. dia.)
K
1.0 mm (0.039 in.)
L
17 mm dia. (0.67 in. dia.)
M
6.10 to 6.20 mm dia. (0.2402 to 0.2441 in. dia.)
N
8 mm (0.31 in.)
O
4 mm (0.16 in.)
P
11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q
PF 1/2
R
23 mm (0.91 in.)
S
17 mm (0.67 in.)
T
4 mm (0.16 in.)
U
12.00 to 12.02 mm dia. (0.4724 to 0.4732 in. dia.)
V
100 mm (3.94 in.)
W
M12 × P1.5
X
5 mm (0.20 in.)
W10252400
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
A
225 mm (8.86 in.)
B
70 mm (2.76 in.)
C
45 mm (1.77 in.)
D
20 mm dia. (0.79 in. dia.)
E
11.7 to 11.9 mm dia. (0.461 to 0.469 in. dia.)
F
6.5 to 6.6 mm dia. (0.256 to 0.260 in. dia.)
G
25 mm (0.98 in.)
H
6.7 to 7.0 mm dia. (0.264 to 0.276 in. dia.)
I
5 mm (0.197 in.)
J
20 mm dia. (0.787 in. dia.)
K
12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)
L
8.9 to 9.1 mm (0.350 to 358 in.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
C0.3
W10250170
G-38
G GENERAL
Bushing Replacing Tool
Application: Use to press out and press fit the bushing.
1. For small end bushing
A
157 mm (6.1811 in.)
B
24 mm (0.9449 in.)
C
120 mm (4.7244 in.)
D
21.8 to 21.9 mm dia. (0.8583 to 0.8622 in. dia.)
E
24.8 to 24.9 mm dia. (0.9764 to 0.9803 in. dia.)
F
20 mm dia. (0.7874 in. dia.)
a
6.3 µm (250 µin.)
b
6.3 µm (250 µin.)
2. For idle gear bushing
A
196 mm (7.7165 in.)
B
26 mm (1.0236 in.)
C
150 mm (5.9055 in.)
D
25.8 to 25.9 mm dia. (1.0157 to 1.0197 in. dia.)
E
28.8 to 28.9 mm dia. (1.1339 to 1.1378 in. dia.)
F
20 mm dia. (0.7874 in. dia.)
a
6.3 µm (250 µin.)
b
6.3 µm (250 µin.)
W12358870
Flywheel Stopper
Application: Use to loosen and tighten the flywheel screw.
A
20 mm (0.79 in.)
B
15 mm (0.59 in.)
C
10 mm dia. (0.39 in. dia.)
D
30 mm (1.18 in.)
E
8 mm (0.31 in.)
F
200 mm (7.87 in.)
W10259480
G-39
G GENERAL
Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft bearing 1.
[Press Out]
A
135 mm (5.31 in.)
B
72 mm (2.83 in.)
C
40 mm radius (1.57 in. radius)
D
10 mm (0.39 in.)
E
24 mm (0.95 in.)
F
20 mm dia. (0.79 in. dia.)
G
51.2 to 51.4 mm dia. (2.0157 to 2.0236 in. dia.)
H
47.3 to 47.5 mm dia. (1.862 to 1.870 in. dia.)
C1
C2
C0.3
[Press Fit]
A
135 mm (5.31 in.)
B
72 mm (2.83 in.)
C
40 mm radius (1.57 in. radius)
D
10 mm (0.39 in.)
E
24 mm (0.95 in.)
F
20 mm dia. (0.79 in. dia.)
G
68 mm dia. (2.68 in. dia.)
H
47.3 to 47.5 mm dia. (1.862 to 1.870 in. dia.)
C1
C2
C0.3
W10261390
Governor Gear Holder Bushing Replacing Tool
Application: Use to press out and to press fit the governor gear
holder bushing.
A
C1 : Chamfer 1.0 mm (0.039 in.)
B
73.9 to 74.0 mm dia. (29.09 to 29.13 in. dia.)
C
69.8 to 69.9 mm (2.748 to 2.751 in. dia.)
D
30 mm dia. (1.181 in. dia.)
E
C2 : Chamfer 2.0 mm (0.079 in.)
F
18 mm (0.7 in.)
G
150 mm (5.9 in.)
H
188 mm (7.4 in.)
W1023337
G-40
G GENERAL
Crank Sleeve Setter
Application: Use to fix the crankshaft sleeve.
(1) Auxiliary Socket for Pushing
A
130 mm (5.12 in.)
B
112 mm (4.41 in.)
C
107 mm (4.21 in.)
D
82 mm (3.23 in.)
E
72 mm (2.83 in.)
F
67 mm (2.64 in.)
G
47 mm (1.85 in.)
H
36.0 to 36.2 mm (1.417 to 1.425 in.)
I
17 mm (0.67 in.)
J
K
52 mm dia. (2.05 in. dia.)
L
40 mm dia. (1.57 in. dia.)
M
10 mm (0.39 in.)
N
33 mm (1.30 in.)
O
20 mm dia. (0.79 in. dia.)
P
40 mm dia. (1.57 in. dia.)
Q
72.10 to 72.15 mm dia. (2.840 to 2.841 in. dia.)
R
73 mm dia. (2.87 in. dia.)
S
83 mm dia. (3.27 in. dia.)
C0.3
C1
Chamfer 1 mm (0.04 in.)
C5
Chamfer 5 mm (0.2 in.)
(2) Sleeve Guide
A
42 mm (1.65 in.)
B
12 mm (0.47 in.)
C
30 mm (1.18 in.)
D
M10 × Pitch 1.25
E
2 mm (0.08 in.)
F
10 mm (0.39 in.)
G
2.0 mm (0.08 in.)
H
17.90 to 17.95 mm dia. (0.700 to 0.707 in. dia.)
I
J
1.8 mm (0.07 in.)
K
0.09 rad (5 °)
C0.5
W1026961
G-41
G GENERAL
[2] SPECIAL TOOLS FOR MACHINE
Relief Valve Pressure Tester
Code No: 07916-50045
Application: This allows easy measurement of relief set pressure.
(1)
(2)
(3)
(4)
(5)
Gauge (07916-50322)
Cable (07916-50331)
Threaded Joint (07916-50401)
Threaded Joint (07916-50341)
Adaptor B (M18 × P1.5)
(07916-50361)
(6)
(7)
(8)
(9)
(10)
Adaptor C (PS3/8) (07916-50371)
Adaptor D (PT1/8) (07916-50381)
Adaptor E (PS3/8) (07916-50392)
Adaptor F (PF1/2) (07916-62601)
Adaptor 58 (PT1/4) (07916-52391)
W1026741
Hydrostatic Transmission Tester and HST Adaptor Set
Code No: 07916-52040 (Hydrostatic Transmission Tester)
07916-53072 (HST Adaptor Set)
Application: This allows easy measurement of hydrostatic
transmission pressure.
(1) Hydrostatic Transmission Tester
(07916-52040)
(2) Gasket (04714-00200)
(3) Connector 3 (07916-51331)
(4) Vacuum Gauge (07916-51331)
(5) Pressure Gauge (Low Pressure)
(07916-51301)
(6) Pressure Gauge (High Pressure)
(in Relief Valve Set Pressure Tester)
(07916-50321)
(7) HN Tube (in Relief Valve Set
Pressure Tester) (07916-50331)
(8)
(9)
(10)
(11)
(12)
(13)
Valve Seat Driver (07916-60841)
Connector 1 (07916-60811)
Connector 2 (07916-60821)
Long Connector (07916-60831)
Adaptor 1 (07916-52621)
Adaptor 2 with Collar
(07916-52632)
(14) Adaptor 3 with Collar
(07916-52642)
(15) HST Adaptor Set (07916-53072)
W1023682
G-42
G GENERAL
9. TIRES
[1] TIRE PRESSURE
•
•
■
•
CAUTION
Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper
equipment.
Always maintain the correct tire pressure.
Do not inflate tires above the recommended pressure as shown below.
IMPORTANT
Do not use tires larger than specified.
Tire sizes
Recommended
Inflation Max.
Pressure
Front
24 × 12 - 12, 4PR
140 kPa
(1.4 kgf/cm2, 20 psi)
Rear
18 × 9.5 - 8, 4PR
200 kPa
(2.0 kgf/cm2, 28 psi)
W1044037
Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time.
Thus, check it everyday and inflate as necessary.
G-43
G GENERAL
10. IMPLEMENT LIMITATIONS
The KUBOTA Machine has been thoroughly tested for proper performance with implements sold or approved by
KUBOTA. Use of implements which are not sold or approved by KUBOTA and which exceed the maximum
specifications listed below, or which are otherwise unfit for use with the KUBOTA Machine may result in malfunctions
or failures of the machine, damage to other property and injury to the operator or others. [Any malfunctions or failures
of the machine resulting from use with improper implements are not covered by the warranty.]
Maximum loading weight
F2880
F3680
Front axle Wf
Rear axle Wr
Lift link end
maximum loading
weight W0
900 kg (1984 lbs)
600 kg (1323 lbs)
260 kg (573 lbs)
Maximum total
weight
1500 kg (3307 lbs)
G-44
1
ENGINE
MECHANISM
CONTENTS
1.
2.
3.
4.
ENGINE BODY ............................................................................................. 1-M1
LUBRICATING SYSTEM .............................................................................. 1-M2
COOLING SYSTEM ...................................................................................... 1-M3
FUEL SYSTEM ............................................................................................. 1-M4
[1] GOVERNOR ............................................................................................ 1-M5
ENGINE
1. ENGINE BODY
■ Closed Breather
Closed breather system has been adopted to prevent
the release of blow-by gas into the atmosphere.
After its oil content is filtered by oil shield (4), the blowby gas is fed back to the intake manifold through breather
valve (3) to be used for re-combustion.
(1) Breather Tube
(2) Cylinder Head Cover
(3) Breather Valve
(4) Oil Shield
(5) Rubber Packing
W1012956
1-M1
ENGINE
2. LUBRICATING SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Rocker Arm
Oil Pressure Switch
Rocker Arm Shaft
Valve
Governor Shaft
Idle Gear
Crankshaft
Oil Pump
Oil Strainer
Relief Valve
Push Rod
Tappet
Camshaft
Piston
Connecting Rod
Oil Filter Cartridge
W1013559
This engine's lubricating system consists of oil strainer (9), oil pump (8), relief valve (10), oil filter cartridge (16) and
oil pressure switch (2).
The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the filter
cartridge, where it is further filtered. Then the oil is forced to crankshaft (7), connecting rods (15), idle gear (6),
governor shaft (5), camshaft (13) and rocker arm shaft (3) to lubricate each part.
Some part of oil, splashed by the crankshaft or leaking and dropping from gaps of each part, lubricates these parts
: pistons (14), cylinders, small ends of connecting rods, tappets (12), push rods (11), inlet and exhaust valves (4) and
timing gears.
1-M2
ENGINE
3. COOLING SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
Radiator
Water Pump
Fan
Thermostat
Cylinder Head
Cylinder Head
The Cooling system consists of a radiator (1), centrifugal water pump (2), suction fan (3) and thermostat (4).
The coolant is cooled through the radiator core, and the fan set behind the radiator pulls cooling air through the
core to improve cooling.
The water pump (2) sucks the cooled coolant, forces it into the cylinder block and draws out the hot coolant. Then
the cooling is repeated. Furthermore, to control temperature of coolant, a thermostat is provided in the system. When
the thermostat opens, the coolant moves directly to radiator, but when it closes, the coolant moves toward the water
pump (2) through the bypass between thermostat and water pump (2).
1-M3
ENGINE
4. FUEL SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Fuel Overflow Pipe
Fuel Filter
Fuel Pump
Injection Nozzle
Fuel Tank
Fuel Filter
Injection Pump
Fuel from the fuel tank (5) passes through the fuel filter (2), and then enters the injection pump (7) after impurities
such as dirt, water, etc. are removed.
The fuel pressurized by the injection pump (7) to the opening pressure (13.73 to 14.71 MPa, 140 to 150 kgf/cm2,
1991 to 2133 psi), of the injection nozzle (4) is injected into the combustion chamber.
Part of the fuel fed to the injection nozzle (4) lubricates the moving parts of the plunger inside the nozzle, then
returns to the fuel tank through the fuel overflow pipe (1) from the upper part of the nozzle holder.
1-M4
ENGINE
[1] GOVERNOR
■ Three Lever Type Fork Lever
The governor system is a mechanical governor that
uses a governor weight (5).
The governor weight (5) is mounted on the governor
shaft that rotates at the same speed as the crankshaft.
Because the feature of this mechanism takes out the
engine speed directly as a centrifugal force of weight, the
speed control that the change in the engine rotational
speed is sensitively transmitted to fork lever assembly
(A) and high accuracy is enabled.
The fork lever assembly of this engine is composed of
fork lever 1 (6), fork lever 2 (9), and the floating lever (7).
A slide plate is installed in fork lever 1. The governor
spring (3) is hooked to fork lever 2 (9).
The floating lever (7) installs the torque pin (8) of the
output drop prevention at the overload. The start spring
(2) is hooked to a slide plate, and holds the control rack
in the direction of the full fuel position.
Fork lever 2 (9) and the floating lever are installed in
fork lever 1 (6) with the fork lever shaft (4). The max
torque limitation (1) device limits the amount of the fuel
exhalation at overload with the torque pin.
(1)
(2)
(3)
(4)
(5)
(6)
Max Torque Limiter
Start Spring
Governor Spring
Fork Lever Shaft
Governor Weight
Fork Lever 1
(7) Floating Lever
(8) Torque Pin
(9) Fork Lever 2
(A) Fork Lever Assembly
(At Rated Operation)
When the engine is running, the fork lever 2 (5) and
the floating lever (2) are moving with the fork lever 1 (3)
due to the tension of the governor spring.
During this time, the torque pin is pressed into the
floating lever by centrifugal force of the governor weight.
The fork lever 2 (5) comes in contact with the fuel
limitation bolt (4), and the fuel injection pump supplies
fuel necessary for rated operation.
(1) Max Torque Limiter
(2) Floating Lever
(3) Fork Lever 1
(4) Fuel Limitation Bolt
(5) Fork Lever 2
1-M5
ENGINE
(Overloaded Operation)
The amount of the movement of the fork lever
assembly is limited with the fuel limitation bolt (2) and can
not be moved in the direction of the fuel increase.
As overload reduces the centrifugal force of the
governor weight, which is pressing the torque pin (5) into
the floating lever (6), the floating lever pushes the fork
lever 1 (3) in the way to increase the fuel supply with the
help of the torque spring tension.
The fuel supply increases (b) in relation to the degree
of the torque pin motion, thus preventing the engine
speed from dropping.
At this time, the maximum torque limiter (1) prevents
superfluous fuel supply and suppresses the generation
of black smoke.
(1)
(2)
(3)
(4)
(5)
(6)
Max Torque Limiter
Fuel Limitation Bolt
Fork Lever 1
Fork Lever 2
Torque Pin
Floating Lever
(a) Distance to which torque
pin (5) pushes fork lever 1
(3) out
(b) Increase of fuel
1-M6
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................1-S1
SERVICING SPECIFICATIONS ....................................................................1-S4
TIGHTENING TORQUES ............................................................................1-S10
CHECKING, DISASSEMBLING AND SERVICING....................................1-S11
[1] CHECKING AND ADJUSTING .............................................................1-S11
(1) Engine Body......................................................................................1-S11
(2) Lubricating System ...........................................................................1-S13
(3) Cooling System.................................................................................1-S13
(4) Fuel System ......................................................................................1-S15
[2] PREPARATION ......................................................................................1-S19
(1) Separating Engine ............................................................................1-S19
[3] DISASSEMBLING AND ASSEMBLING................................................1-S24
(1) External Components .......................................................................1-S24
(2) Cylinder Head and Valve ..................................................................1-S24
(3) Oil Pan, Timing Gears, Camshaft and Fuel Camshaft ......................1-S28
(4) Piston and Connecting Rod ..............................................................1-S32
(5) Crankshaft.........................................................................................1-S35
[4] SERVICING ............................................................................................1-S37
(1) Cylinder Head and Valves ................................................................1-S37
(2) Timing Gears, Camshaft and Governor Gear ...................................1-S43
(3) Piston and Connecting Rod ..............................................................1-S46
(4) Crankshaft.........................................................................................1-S48
(5) Cylinder .............................................................................................1-S52
(6) Oil Pump ...........................................................................................1-S53
ENGINE
1. TROUBLESHOOTING
Symptom
Engine Does Not
Start
(Starter Does Not
Run)
Engine Revolution Is
Not Smooth
Probable
Reference
page
Solution
No fuel
Replenish fuel
G-7
Air in the fuel system
Bleed
G-34
Water in the fuel system
Change fuel and
repair or replace fuel
system
Fuel pipe clogged
Clean
G-34
Fuel filter clogged
Change
G-29
Excessively high viscosity of fuel or engine oil at
low temperature
Use specified fuel or
engine oil
G-7
Fuel with low cetane number
Use specified fuel
G-7
Fuel leak due to loose injection pipe retaining nut
Tighten retaining nut
1-S25
Incorrect injection timing
Adjust
1-S15
Fuel camshaft worn
Replace
Injection nozzle clogged
Repair or replace
1-S18
Injection pump malfunctioning
Repair or replace
1-S30
Seizure of crankshaft, camshaft, piston, cylinder
or bearing
Repair or replace
–
Compression leak from cylinder
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
1-S27
Improper valve timing
Correct or replace
timing gear
1-S31
Piston ring and cylinder worn
Repair or replace
1-S34
Excessive valve clearance
Adjust
1-S12
Battery discharged
Charge
G-22
Starter malfunctioning
Repair or replace
Main switch malfunctioning
Replace
8-S6 to S7
Brake switch defective
Replace
8-S10
PTO switch defective
Replace
8-S10
Seat switch defective
Replace
8-S9
Wiring disconnected
Connect
–
Fuel filter clogged or dirty
Change
G-29
Air cleaner clogged
Clean or replace
Fuel leak due to loose injection pipe retaining nut
Tighten retaining nut
1-S25
Injection pump malfunctioning
Replace
1-S30
Incorrect nozzle injection pressure
Adjust
1-S17
Injection nozzle stuck or clogged
Repair or replace
1-S18
Governor malfunctioning
Repair
–
–
8-S19 to
S21
G-24, 30
–
W1066187
1-S1
ENGINE
(Continued)
Symptom
Either White or Blue
Exhaust Gas Is
Observed
Either Black or Dark
Gray Exhaust Gas Is
Observed
Deficient Output
Excessive Lubricant
Oil Consumption
Fuel Mixed into
Lubricant Oil
Water Mixed into
Lubricant Oil
Probable
Solution
Reference
page
Excessive engine oil
Reduce to specified
level
G-7, 17
Piston ring and cylinder worn or stuck
Repair or replace
1-S34
Adjust
1-S15
Deficient compression
Adjust top clearance
1-S37
Overload
Lessen load
Low grade fuel used
Use specified fuel
G-7
Fuel filter clogged
Replace
G-29
Air cleaner clogged
Clean or replace
G-24, 30
Deficient nozzle injection
Repair or replace
nozzle
1-S18, S25
Adjust
Engine’s moving parts seem to be seizing
Repair or replace
–
Uneven fuel injection
Replace injection
pump
1-S30
Repair or replace
nozzle
1-S18, S25
Compression leak
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
1-S25, S27
Piston ring’s gap facing the same direction
Shift ring gap
direction
1-S33
Oil ring worn or stuck
Replace
1-S34
Piston ring groove worn
Replace piston
1-S34, S47
Valve stem and valve guide worn
Replace
1-S28, S38
to S39
Oil leaking due to defective seals or packing
Replace
–
Injection pump’s plunger worn
Replace
1-S30
Repair or replace
nozzle
Injection pump broken
Replace
1-S30
Head gasket defective
Replace
1-S27
Cylinder block or cylinder head flawed
Replace
–
–
1-S15
1-S18, S25
W1010717
1-S2
ENGINE
(Continued)
Symptom
Low Oil Pressure
High Oil Pressure
Engine Overheated
Probable
Reference
page
Solution
Engine oil insufficient
Replenish
G-7, 17
Oil strainer clogged
Clean
–
Relief valve stuck with dirt
Clean
–
Relief valve spring weaken or broken
Replace
–
Excessive oil clearance of crankshaft bearing
Replace
1-S50, S51
Excessive oil clearance of rocker arm
Replace
1-S41
Oil passage clogged
Clean
Different type of oil
Use specified type of
oil
Oil pump defective
Repair or replace
Different type of oil
Use specified type of
oil
Relief valve defective
Replace
Replenish
Fan belt broken or elongated
Replace or adjust
Cooling water insufficient
Replenish
Radiator net and radiator fin clogged with dust
Clean
Inside of radiator corroded
Clean or replace
G-31
Coolant flow route corroded
Clean or replace
G-31
Radiator cap defective
Replace
–
Overload running
Loosen load
–
Head gasket defective
Replace
1-S27
Adjust
1-S15
Unsuitable fuel used
Use specified fuel
–
G-7
1-S53
G-7
–
G-7
G-25, 1S13 to S14
G-7
–
G-7
W1012734
1-S3
ENGINE
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item
Compression Pressure
Difference among Cylinders
Valve Clearance (Cold)
Top Clearance
Factory Specification
Allowable Limit
3.72 to 4.12 MPa
38 to 42 kgf/cm2
539 to 596 psi
2.25 MPa
23.0 kgf/cm2
327 psi
–
10 % or less
0.145 to 0.185 mm
0.00571 to 0.00728 in.
–
0.55 to 0.70 mm
0.0217 to 0.0276 in.
–
–
0.05 mm
0.0020 in.
Cylinder Head Surface
Flatness
Valve Recessing
Intake and Exhaust
−0.05 to 0.25 mm
−0.0020 to 0.0098 in.
0.40 mm
0.0157 in.
Valve Stem to Valve Guide
Clearance
0.035 to 0.065 mm
0.0014 to 0.0025 in.
0.10 mm
0.0039 in.
Valve Stem
O.D.
6.960 to 6.975 mm
0.2741 to 0.2746 in.
–
Valve Guide
I.D.
7.010 to 7.025 mm
0.2760 to 0.2765 in.
–
Angle (Intake)
1.047 rad
60 °
–
Angle (Exhaust)
0.785 rad
45 °
–
Angle (Intake)
1.047 rad
60 °
–
Angle (Exhaust)
0.785 rad
45 °
–
Width
2.12 mm
0.0835 in.
Valve Face
Valve Seat
Valve Spring
–
1.0 mm
0.039 in.
Free Length
37.0 to 37.5 mm
1.457 to 1.476 in.
36.5 mm
1.437 in.
Setting Load
117.4 N / 31.0 mm
11.97 kgf / 31.0 mm
26.4 lbs / 1.22 in.
100.0 N / 31.0 mm
10.2 kgf / 31.0 mm
22.5 lbs / 1.22 in.
Tilt
W10138740
1-S4
ENGINE
ENGINE BODY (Continued)
Item
Rocker Arm Shaft to Rocker Arm
Clearance
Allowable Limit
0.016 to 0.045 mm
0.00063 to 0.00177 in.
0.10 mm
0.0039 in.
Rocker Arm Shaft
O.D.
11.973 to 11.984 mm
0.4714 to 0.4718 in.
–
Rocker Arm
I.D.
12.000 to 12.018 mm
0.4724 to 0.4731 in.
–
Push Rod
Alignment
–
0.25 mm
0.0098 in.
Tappet to Tappet Guide
Clearance
0.020 to 0.062 mm
0.0008 to 0.0024 in.
0.07 mm
0.0028 in.
Tappet
O.D.
19.959 to 19.980 mm
0.7858 to 0.7866 in.
–
Tappet Guide
I.D.
20.000 to 20.021 mm
0.7874 to 0.7882 in.
–
Backlash
0.032 to 0.115 mm
0.0013 to 0.0045 in.
0.15 mm
0.0059 in.
Idle Gear 1 to Cam Gear
Backlash
0.036 to 0.114 mm
0.0014 to 0.0045 in.
0.15 mm
0.0059 in.
Idle Gear 1 to Injection Pump Gear
Backlash
0.034 to 0.116 mm
0.0013 to 0.0046 in.
0.15 mm
0.0059 in.
Backlash
0.030 to 0.117 mm
0.0012 to 0.0046 in.
0.15 mm
0.0059 in.
Timing Gear
Crank Gear to Idle Gear 1
Governor Gear
Governor Gear to Injection Pump
Gear
W1013874
1-S5
ENGINE
Item
Allowable Limit
Idle Gear
Idle Gear 1
Side Clearance
0.20 to 0.51 mm
0.0079 to 0.0201 in.
0.80 mm
0.0315 in.
Camshaft
Side Clearance
0.07 to 0.22 mm
0.0028 to 0.0087 in.
0.30 mm
0.0118 in.
–
0.01 mm
0.0004 in.
Intake
28.80 mm
1.1339 in.
28.75 mm
1.1319 in.
Exhaust
29.0 mm
1.1417 in.
28.95 mm
1.1398 in.
Oil Clearance
0.050 to 0.091 mm
0.00197 to 0.00358 in.
0.15 mm
0.0059 in.
Camshaft Journal
O.D.
35.934 to 35.950 mm
1.4147 to 1.4153 in.
–
Cylinder Block Bore
I.D.
36.000 to 36.025 mm
1.4173 to 1.4183 in.
–
Oil Clearance
0.020 to 0.054 mm
0.0008 to 0.0021 in.
0.10 mm
0.0039 in.
Alignment
Cam Height
Camshaft Journal to Cylinder Block Bore
Idle Gear Shaft to Gear Bushing
Idle Gear 1
Idle Gear Shaft 1
O.D.
25.967 to 25.980 mm
1.0223 to 1.0228 in.
–
Idle Gear Bushing
I.D.
26.000 to 26.021 mm
1.0236 to 1.0244 in.
–
Piston Pin Bore
I.D.
22.000 to 22.013 mm
0.8661 to 0.8667 in.
22.03 mm
0.8673 in.
Piston Pin to Small End Bushing
Oil Clearance
0.014 to 0.038 mm
0.00055 to 0.00150 in.
0.15 mm
0.0059 in.
Piston Pin
O.D.
22.002 to 22.011 mm
0.8662 to 0.8666 in.
–
Small End Bushing
I.D.
22.025 to 22.040 mm
0.8671 to 0.8677 in.
–
W10138740
1-S6
ENGINE
Item
Allowable Limit
Connecting Rod
Alignment
–
0.05 mm
0.0020 in.
Piston Ring Gap
Top Ring
0.30 to 0.45 mm
0.0118 to 0.0177 in.
1.25 mm
0.0492 in.
Second Ring
0.30 to 0.45 mm
0.0118 to 0.0177 in.
1.25 mm
0.0492 in.
Oil Ring
0.25 to 0.40 mm
0.0098 to 0.0157 in.
1.25 mm
0.0492 in.
Clearance
0.085 to 0.112 mm
0.0033 to 0.0044 in.
0.2 mm
0.0079 in.
Clearance
0.020 to 0.055 mm
0.0008 to 0.0021 in.
0.15 mm
0.0059 in.
Side Clearance
0.15 to 0.31 mm
0.0059 to 0.0122 in.
0.50 mm
0.0197 in.
–
0.02 mm
0.0008 in.
0.029 to 0.091 mm
0.0011 to 0.0036 in.
0.20 mm
0.0079 in.
Piston Ring to Piston Ring Groove
Second Ring
Oil Ring
Crankshaft
Alignment
Crankpin to Crankpin Bearing
Oil Clearance
Crankpin
O.D.
39.959 to 39.975 mm
1.5732 to 1.5738 in.
–
Crankpin Bearing
I.D.
40.004 to 40.050 mm
1.5750 to 1.5768 in.
–
0.034 to 0.114 mm
0.0013 to 0.0045 in.
0.20 mm
0.0079 in.
Crankshaft to Crankshaft Bearing 1
Oil Clearance
Crankshaft journal
O.D.
47.934 to 47.950 mm
1.8872 to 1.8878 in.
–
Crankshaft Bearing 1
I.D.
47.984 to 48.048 mm
1.8891 to 1.8916 in.
–
Oil Clearance
0.034 to 0.095 mm
0.0013 to 0.0037 in.
0.20 mm
0.0079 in.
Crankshaft Journal
O.D.
47.934 to 47.950 mm
1.8872 to 1.8878 in.
–
I.D.
47.984 to 48.029 mm
1.8891 to 1.8909 in.
–
Oil Clearance
0.034 to 0.098 mm
0.0013 to 0.0039 in.
0.20 mm
0.0079 in.
Crankshaft Journal
O.D.
51.921 to 51.940 mm
2.0441 to 2.0449 in.
–
I.D.
51.974 to 52.019 mm
2.0462 to 2.0480 in.
–
W10138740
1-S7
ENGINE
Item
Allowable Limit
Cylinder Liner I.D.
78.000 to 78.019 mm
3.0709 to 3.0716 in.
78.15 mm
3.0768 in.
Cylinder (Oversized)
78.500 to 78.519 mm
3.0906 to 3.0913 in.
78.65 mm
3.0965 in.
W10138740
LUBRICATING SYSTEM
Item
Engine Oil Pressure
Allowable Limit
At Idle Speed
More than 49 kPa
0.5 kgf/cm2
7 psi
–
At Rated Speed
196 to 441 kPa
2.0 to 4.5 kgf/cm2
28 to 64 psi
147 kPa
1.5 kgf/cm2
21 psi
Inner Rotor to Outer Rotor
Clearance
0.06 to 0.18 mm
0.0024 to 0.0071 in.
–
Outer Rotor to Pump Body
Clearance
0.100 to 0.180 mm
0.0039 to 0.0071 in.
–
Inner Rotor to Cover
Clearance
0.025 to 0.075 mm
0.0010 to 0.0030 in.
–
W10139730
COOLING SYSTEM
Fan Belt
Tension
7.0 to 9.0 mm / 98 N
0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbs)
–
Radiator Cap
Pressure Falling
Time
10 seconds or more
88 → 59 kPa
0.9 → 0.6 kgf/cm2
13 → 9 psi
–
Radiator
Water Leakage
Test Pressure
No leak at specified
pressure
137 kPa
1.4 kgf/cm2
20 psi
–
Thermostat
Valve Opening
Temperature
(At Beginning)
80.5 to 83.5 °C
176.9 to 182.3 °F
–
Valve Opening
Temperature
(Opened
Completely)
95 °C
203 °F
–
W10135990
1-S8
ENGINE
FUEL SYSTEM
Item
Allowable Limit
0.30 to 0.33 rad
(17 to 19°)
before T.D.C.
–
Injection Pump
Injection Timing
(3000 min-1 (rpm))
Pump Element
Fuel Tightness
–
13.73 MPa
140 kgf/cm2
1991 psi
Delivery Valve
Fuel Tightness
10 seconds
13.73 → 12.75 MPa
140 → 130 kgf/cm2
1991 → 1849 psi
5 seconds
13.73 → 12.75 MPa
140 → 130 kgf/cm2
1991 → 1849 psi
Injection Nozzle
Injection Pressure
13.73 to 14.71 MPa
140 to 150 kgf/cm2
1991 to 2134 psi
–
Injection Nozzle Valve Seat
Valve Seat
Tightness
When the pressure is
12.75 MPa
(130 kgf/cm2, 1849 psi),
the valve seat must be
fuel tightness.
–
W10139730
1-S9
ENGINE
Tightening torques of screws bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8.)
Item
N·m
kgf·m
ft-lbs
98.1 to 137.2
10.0 to 14.0
72.4 to 101.2
ROPS mounting screw
123 to 147
12.6 to 14.9
90.8 to 108.4
Seat base mounting screw
17.7 to 20.5
1.8 to 2.1
13.1 to 15.1
Drive shaft mounting screw
19.6 to 29.4
2.0 to 3.0
14.5 to 21.7
Cylinder head cover cap nut
6.9 to 8.8
0.7 to 0.9
5.1 to 6.5
Injection pipe retaining nut
24.5 to 34.3
2.5 to 3.5
18.1 to 25.3
Nozzle holder assembly
49.0 to 68.6
5.0 to 7.0
36.2 to 50.6
Nozzle holder
34.3 to 39.2
3.5 to 4.0
25.3 to 28.9
Overflow pipe assembly retaining nut
19.6 to 24.5
2.0 to 2.5
14.5 to 18.1
Glow plug
7.8 to 14.7
0.8 to 1.5
5.8 to 10.8
* Rocker arm bracket nut
21.6 to 26.5
2.2 to 2.7
15.9 to 19.5
* Cylinder head screw
63.7 to 68.6
6.5 to 7.0
47.0 to 50.6
* Fan drive pulley screw
235.4 to 245.2
24.0 to 25.0
173.6 to 180.8
* Connecting rod screw
41.2 to 46.1
4.2 to 4.7
30.4 to 34.0
* Flywheel screw
53.9 to 58.8
5.5 to 6.0
39.8 to 43.4
Bearing case cover screw
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
* Main bearing case screw 1
29.4 to 34.3
3.0 to 3.5
21.7 to 25.3
* Main bearing case screw 2
49.0 to 53.9
5.0 to 5.5
36.2 to 39.8
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
14.7 to 19.6
1.5 to 2.0
10.8 to 14.5
Oil strainer
* Idle gear shaft 1 mounting screw
Oil pressure switch
■ NOTE
• For * marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
• The letter “M” in Size × Pitch means that the screw, bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm or the threads. The pitch is the nominal distance in mm between two
threads.
W1013236
1-S10
ENGINE
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine.
3. Remove the air cleaner, the muffler and all glow plugs (or
nozzles).
4. Set a compression tester with the adaptor to the glow plug hole
(or nozzle hole).
Nozzle hole : Adaptor H (07909-31231)
Glow plug hole : Adaptor L (07909-31301)
5. After making sure that the stop lever is set at the stop position
(non-injection), run the engine with the starter and measure the
compression pressure.
6. Repeat steps 4 and 5 for each cylinder.
7. If the measurement is below the allowable limit, apply a small
amount of oil to the cylinder wall through the glow plug hole (or
nozzle hole) and measure the compression pressure again.
8. If the compression pressure is still less than the allowable limit,
check the top clearance, valve clearance and cylinder head.
9. If the compression pressure increases after applying oil, check
the cylinder wall and piston rings.
■ NOTE
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.
Factory spec.
3.72 to 4.12 MPa
38 to 42 kgf/cm2
539 to 596 psi
Allowable limit
2.25 MPa
23.0 kgf/cm2
327 psi
Compression pressure
W10178940
1-S11
ENGINE
Valve Clearance
■ IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the cylinder head cover and the glow plugs.
2. Align the “1TC” mark (1) on the flywheel with alignment mark (2)
on the rear end plate so that the No. 1 piston comes to the
compression top dead center.
3. Check the following valve clearance marked with “✩” using a
thickness gauge.
4. If the clearance is not within the factory specifications, adjust with
the adjusting screw.
5. Then turn the flywheel 6.28 rad (360 °), and align the “1TC” mark
(1) on the flywheel and alignment mark (2) on the rear end plate
so that the No. 1 piston comes to the overlap position.
6. Check the following valve clearance marked with “✩“ using a
feeler gauge.
Number of cylinders
Valve arrangement
Adjustable cylinder
location of piston
1st
When No. 1 piston is
at compression top
dead center
D1105
IN.
EX.
IN.
EX.
✩
✩
✩
✩
✩
✩
2nd
3rd
V1505
✩
✩
✩
✩
4th
1st
When No. 1 piston is
at overlap position
2nd
✩
3rd
✩
✩
4th
Valve clearance
Factory spec.
✩
0.145 to 0.185 mm
0.00571 to 0.00728 in.
7. If the clearance is not with in the factory specifications, adjust
with the adjusting screw.
■ NOTE
• The sequence of cylinder numbers is given as No. 1, No. 2,
No. 3 and No. 4 starting from the gear case side.
• After adjusting the valve clearance, secure the adjusting
screw with the lock nut.
(1) “1TC” Mark
(2) Alignment Mark
W10155550
1-S12
ENGINE
(2) Lubricating System
Engine Oil Pressure
1. Remove the engine oil pressure switch, and install an oil
pressure tester.
2. Start the engine. After warming up, measure the oil pressure at
both idle and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
• Engine oil insufficient
• Oil pump defective
• Oil strainer clogged
• Oil filter cartridge clogged
• Oil gallery clogged
• Excessive oil clearance
• Foreign matter in the relief valve
At idle
speed
Engine oil pressure
At rated
speed
Factory
spec.
More than 49 kPa
0.5 kgf/cm2
7 psi
Factory
spec.
196 to 441 kPa
2.0 to 4.5 kgf/cm2
28 to 64 psi
Allowable
limit
147 kPa
1.5 kgf/cm2
21 psi
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
Tightening torque
Oil pressure switch
14.7 to 19.6 N·m
1.5 to 2.0 kgf·m
10.8 to 14.5 ft-lbs
W10349520
(3) Cooling System
Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbs).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws and relocate the alternator to
adjust.
Deflection (A)
Factory spec.
7.0 to 9.0 mm
0.28 to 0.35 in.
(A) Deflection
W10356670
1-S13
ENGINE
Fan Belt Damage and Wear
1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good
(B) Bad
W1016443
CAUTION
• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, there is risk of scalding to yourself and people rearby from steam and hot water.
Radiator Cap Air Leakage
1. Install radiator cap on adaptor (2) and radiator tester (1).
2. Apply the specified pressure 88 kPa (0.9 kgf/cm2, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6 kgf/cm2,
9 psi).
3. If the measurement is less than the factory specification, replace
the radiator cap.
Pressure falling time
(1) Radiator Tester
Factory spec.
More than 10 seconds
for pressure fall from
88 to 59 kPa
(from 0.9 to 0.6 kgf/cm2,
from 13 to 9 psi)
(2) Adaptor
W1054156
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Install a radiator tester (1) and an adapter (2), and raise the water
pressure to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from a pinhole, repair with the radiator cement.
When water leak is excessive, replace the radiator.
Radiator water leakage
test pressure
(1) Radiator Tester
Factory spec.
137 kPa
1.4 kgf/cm2
20 psi
(2) Adaptor
W1016903
1-S14
ENGINE
Thermostat Valve Opening Temperature
1. Suspend the thermostat in the water by a string with its end
inserted between the valve and seat.
2. Heating the water gradually, read the temperature when the
valve opens and leaves the string.
3. Continue heating and read the temperature when the valve
opens approx. 8 mm (0.315 in.).
4. If the measurement is not within the factory specifications,
replace the thermostat.
Thermostat’s valve
opening temperature
Factory spec.
80.5 to 83.5 °C
176.9 to 182.3 °F
Temperature at which
thermostat completely
opens
Factory spec.
95 °C
203 °F
W1035849
(4) Fuel System
Injection Timing
1. Remove the injection pipes.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (3) for
No. 1 cylinder.
4. After the fuel fills up to the hole of the delivery valve holder for No.
1 cylinder, turn back (clockwise) the flywheel around 1.57 rad
(90 °).
5. Turn the flywheel counterclockwise to set at around 0.44 rad
(25 °) before T.D.C..
6. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
7. Check to see the degree on flywheel.
The flywheel is marked “1TC”, “10” and “20” for the crank angle
before the top dead center of No. 1 cylinder.
8. If injection timing is out of adjustment, readjust the timing with
shims.
Injection timing
(3000 min-1 (rpm))
Factory spec.
0.30 to 0.33 rad (17 to
19 °) before T.D.C.
■ NOTE
• The liquid gasket is not required for assembling.
• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25
mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these
shims for adjustments.
• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or
advances the injection timing by approx. 0.0087 rad (0.5 °).
• In disassembling and replacing the injection pump, be sure
to use the same number of new shims with the same
thickness.
(1)
(2)
(3)
(4)
Timing Line
Alignment Mark
Delivery Valve Holder
Shim (Soft Metal Gasket Shim)
(5) Two-holes : 0.20 mm (0.0079 in.)
(6) One-hole : 0.25 mm (0.0098 in.)
(7) Without hole : 0.30 mm (0.0118 in.)
W1017170
1-S15
ENGINE
CAUTION
• If spray from injection nozzle comes in contact with human body, fuel can be injected under skin. Blood
poisoning and death may occur.
Fuel Tightness of Pump Element
2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to the
photo.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
Fuel tightness of pump
element
Allowable limit
13.73 MPa
140 kgf/cm2
1991 psi
■ NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you must contact a Kubota-authorized pump
service shop.
(1) Injection Nozzle
(2) Injection Pump Pressure Tester
(3) Protection Cover for Jetted Fuel
W1017430
Fuel Tightness of Delivery Valve
2. Remove the injection pipes and glow plugs.
3. Install a pressure tester to the fuel injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by the hand and raise the pressure to
approx. 13.73 MPa (140 kgf/cm2, 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 13.73 to 12.75 MPa (from 140
to 130 kgf/cm2, from 1991 to 1849 psi).
8. Measure the time lapse for fuel pressure to drop to: 12.75 MPa
(130 kgf/cm2, 1849 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
Factory spec.
10 seconds
13.73 → 12.75 MPa
140 → 130 kgf/cm2
1991 → 1849 psi
Allowable limit
5 seconds
13.73 → 12.75 MPa
140 → 130 kgf/cm2
1991 → 1849 psi
Fuel tightness of
delivery valve
■ NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you must contact a Kubota-authorized pump
service shop.
(1) Injection Pump Pressure Tester
(2) Injection Nozzle
(3) Protection Cover for Jetted Fuel
W1017786
1-S16
ENGINE
CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the
direction of the fuel spray. If the spray from the nozzle directly contacts the human body, cells may be
destroyed and blood poisoning may be caused.
Nozzle Pattern
1. Set the injection nozzle to a nozzle tester, and check the nozzle
pattern.
2. If the pattern is defective, replace the nozzle piece.
(a) Good
(b) Bad
W10181310
Fuel Injection Pressure
1. Install the injection nozzle to a nozzle tester.
2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
replace the adjusting washer (1) in the nozzle holder to adjust it.
Fuel injection pressure
Factory spec.
13.73 to 14.71 MPa
140 to 150 kgf/cm2
1991 to 2134 psi
(Reference)
• Pressure variation with 0.01 mm (0.0004 in.) difference of
adjusting washer thickness.
Approx. 235 kPa (2.4 kgf/cm2, 34 psi)
(1) Adjusting Washer
W10182100
Valve Seat Tightness
1. Set the injection nozzle to a nozzle tester.
2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm2,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
Valve seat tightness
Factory spec.
No fuel leak at
12.75 MPa
130 kgf/cm2
1849 psi
W10183690
1-S17
ENGINE
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
• Assemble the nozzle in clean fuel.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
Tightening torque
(1)
(2)
(3)
(4)
Nozzle Holder
Adjusting Washer
Nozzle Spring
Push Rod
Nozzle holder
34.3 to 39.2 N·m
3.5 to 4.0 kgf·m
25.3 to 28.9 ft-lbs
Overflow pipe retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut
W1018491
1-S18
ENGINE
[2] PREPARATION
(1) Separating Engine
Draining Coolant
•
1.
2.
3.
4.
CAUTION
Never open the radiator cap while operating or immediately
after stopping the engine. Otherwise, hot water will spout
out from the radiator. Wait for more than ten minutes to cool
the radiator, before opening the cap.
Stop the engine and let it cool down.
Remove the drain plug (1) to drain the coolant.
Remove the radiator cap to completely drain the coolant.
After all coolant is drained, close the drain plug.
Coolant
Capacity (without
recovery tank)
4.6 L
4.9 U.S.qts.
4.0 lmp.qts.
(1) Drain Plug
W1019510
Draining Engine Oil
1. Park the machine on level ground.
2. Place an oil pan underneath the engine.
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plugs and tighten.
(When refilling)
• Fill the engine oil up to the upper line on the dipstick (3).
Engine oil
D1105
3.8 L
4.0 U.S.qts.
3.3 Imp.qts.
V1505
5.3 L
5.6 U.S.qts.
4.7 Imp.qts.
Capacity
■ IMPORTANT
• Never mix two different type of oil.
• Use the proper SAE Engine Oil according to ambient
temperatures.
(See page G-7)
(1) Drain Plug
(2) Oil Inlet Plug
(3) Dipstick
range.
W1019220
1-S19
ENGINE
Draining Transmission Fluid
1. Place oil pans underneath the transmission case.
2. Remove the drain plugs (1).
3. Drain the transmission fluid.
4. After draining, reinstall in the three drain plugs and tighten.
(When reassembling)
• Fill the transmission fluid from oil inlet (3) up to the upper line on
the dipstick (2).
• After running the engine for few minutes, stop it and check the
fluid level again, add the fluid to prescribed level if it is not correct
level.
Transmission fluid
Capacity
14.0 L
14.8 U.S.qts
12.3 Imp.qts
■ IMPORTANT
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.).
(1) Drain Plug
(2) Dipstick
(3) Oil Inlet
A : Upper Level
B : Lower Level
W1041483
Hydraulic Front Suction Pipe
1. Place oil pans underneath the rubber hose (4) and oil strainer (2).
2. Remove the rubber hose (4) from the front suction pipe (3).
3. Unscrew the front suction pipe mounting screw (1).
4. Unscrew the oil strainer (2), and remove the oil strainer and front
suction pipe (3).
(When reassembling)
Tightening torque
Oil strainer
(1) Front Suction Pipe Mounting Screw
(2) Oil Strainer
98.1 to 137.2 N·m
10.0 to 14.0 kgf·m
72.4 to 101.2 ft-lbs
(4) Rubber Hose
W1041888
Battery
CAUTION
• When disassembling the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Disconnect the negative cable (2) from the battery.
2. Disconnect the positive cable (1) from the battery.
(1) Positive Cable
(2) Negative Cable
W1042092
1-S20
ENGINE
Bonnet
1. Unscrew the bonnet mounting screws (2) and nuts.
2. Remove the bonnet (1) from the frame (3).
(1) Bonnet
(2) Bonnet Mounting Screw
(2) Frame
W1042247
Air Cleaner
1. Remove the air cleaner (1) with hoses from the intake manifold.
(1) Air Cleaner
W1043401
Wiring, Accelerator Wire and Hose
1. Disconnect the wiring (1) from the glow plug.
2. Disconnect 1P connectors (3), (10) from the coolant temperature
sensors.
3. Disconnect 2P connector (8) from the engine stop solenoid.
4. Disconnect the accelerator wire (6).
5. Disconnect the delivery hoses (9) from the flow priority valve.
6. Remove the fuse box (4).
7. Disconnect the radiator upper hose (2) from the thermostat
cover.
8. Disconnect the fuel hose (5) and fuel return hose (7).
(1)
(2)
(3)
(4)
(5)
Wiring
Radiator Upper Hose
1P Connector
Fuse Box
Fuel Hose
(6)
(7)
(8)
(9)
(10)
Accelerator Wire
Fuel Return Hose
2P Connector
Delivery Hose
1P Connector
W1033679
Wiring and Hose
1. Disconnect the wiring (2) and 2P connector (3) from the
alternator.
2. Disconnect the wiring (4) and 1P connectors (5) from the starter.
3. Disconnect the 1P connector (7) from the oil pressure switch.
4. Disconnect the ground cable (9).
5. Disconnect the radiator lower hose (1).
6. Remove the drain hoses (6), (8) from the drain plug.
(1)
(2)
(3)
(4)
(5)
Radiator Lower Hose
Wiring
2P Connector
Wiring
1P Connector
(6)
(7)
(8)
(9)
Drain Hose
1P Connector
Drain Hose
Ground Cable
W1046215
1-S21
ENGINE
Seat
1. Disconnect 2P connector from the seat switch.
2. Remove the seat (1) with the seat base.
Tightening torque
(1) Seat
17.7 to 20.5 N·m
1.8 to 2.1 kgf·m
13.1 to 15.1 ft-lbs
(2) Seat Base Mounting Screw
W1046944
Panel
1. Separate the front panel (1) from the rear panel (4).
2. Disconnect the connectors from the easy checker, fuel gauge,
coolant temperature gauge and hour meter in front panel (1).
3. Disconnect the connectors (2), (3) from the main switch and head
light switch.
4. Remove the horn (5).
5. Remove the rear panel (4).
(1) Front Panel
(2) 4P Connector
(3) 3P Connector
(4) Rear Panel
(5) Horn
W1040859
Fender
1. Remove the differential lock pedal (1) and brake lock lever (3).
2. Remove the main brake pedal (2), speed control pedal (4).
3. Remove the lever grips from hydraulic lift lever (5) and PTO lever
(7).
4. Remove the lever grip from high-low gear shift lever (6).
5. Remove the lever grip from 4WD lock lever (9).
6. Remove the fender (8).
(1)
(2)
(3)
(4)
(5)
Differential Lock Pedal
Main Brake Pedal
Brake Lock Lever
Speed Control Pedal
Hydraulic Lift Lever
(6)
(7)
(8)
(9)
High-Low Gear Shift Lever
PTO Lever
Fender
4WD Lock Lever
W1047430
1-S22
ENGINE
Fuel Tank
1. Disconnect the fuel hose and return hose from the fuel tank (1).
2. Disconnect the 1P connector from the fuel sensor.
3. Remove the fuel tank (1).
4. Remove the dust under plate (2).
5. Remove the fuel tank rear support (3).
(1) Fuel Tank
(2) Dust Under Plate
(3) Fuel Tank Rear Support
W1047809
Pipe Holder
1. Remove the pipe holder (1).
(1) Pipe Holder
W1048005
Radiator
1. Unscrew the dust plate mounting screws (3).
2. Remove the radiator assembly (1) with the dust plate (4).
(1) Radiator Assembly
(2) Dust Plate Stay
(3) Dust Plate Mounting Screw
(4) Dust Plate
W1049330
Drive Shaft
1. Unscrew the drive shaft mounting screws (2), and disconnect the
drive shaft (3) from the fan drive pulley (1).
(When reassembling)
• Apply grease to the all splines on the drive shaft.
Tightening torque
Drive shaft mounting
screw
(1) Fan Drive Pulley
(2) Drive Shaft Mounting Screw
19.6 to 29.4 N·m
2.0 to 3.0 kgf·m
14.5 to 21.7 ft-lbs
(3) Drive Shaft
W1059348
1-S23
ENGINE
Separating Engine
1. Unscrew the engine mounting nuts, and support the engine with
an engine lift hook and hoist.
2. Separate the engine from the frame.
W1059769
[3] DISASSEMBLING AND ASSEMBLING
(1) External Components
External Components
1. Remove the alternator (2) and the fan belt (6).
2. Remove the cooling fan (1).
3. Remove the muffler (3) and the starter (4).
4. Remove the air cleaner stay (8).
5. Remove the engine stop solenoid (7).
6. Remove the flow priority valve (9).
7. Remove the hydraulic pump (12) with the rear suction pipe (11).
8. Remove the engine support LH (5) and RH (10).
(1)
(2)
(3)
(4)
(5)
(6)
Cooling Fan
Alternator
Muffler
Starter
Engine Support LH
Fan Belt
(7)
(8)
(9)
(10)
(11)
(12)
Engine Stop Solenoid
Air Cleaner Stay
Flow Priority Valve
Engine Support RH
Rear Suction Pipe
Hydraulic Pump
W1052233
(2) Cylinder Head and Valve
Cylinder Head Cover
1. Disconnect the breather hose.
2. Remove the head cover nut.
3. Remove the cylinder head cover (1).
(When reassembling)
• Check to see if the cylinder head cover gasket is not defective.
Tightening torque
Cylinder head cover nut
6.9 to 8.8 N·m
0.7 to 0.9 kgf·m
5.1 to 6.5 ft-lbs
(1) Cylinder Head Cover
W1028468
1-S24
ENGINE
Injection Pipes
1. Loosen the screws to the pipe clamp (1).
2. Detach the injection pipes (2).
(When reassembling)
• By using compressed air, clean out the injector pipes (2). Then,
reassemble the pipes in the reverse order.
Tightening torque
Injection pipe retaining nut
(1) Pipe Clamp
24.5 to 34.3 N·m
2.5 to 3.5 kgf·m
18.1 to 25.3 ft-lbs
(2) Injection Pipe
W1028640
Nozzle Holder Assembly and Glow Plug
1. Remove the overflow pipe assembly (5).
2. Remove the nozzle holder assemblies (2) using a 21 mm deep
socket wrench.
3. Remove the copper gasket and heat seal (3).
4. Remove the lead (4) from the glow plugs.
5. Remove the glow plugs (1).
(When reassembling)
• Replace the copper gasket and heat seal with new one.
Tightening torque
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
Overflow pipe assembly
retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Glow plug
7.8 to 14.7 N·m
0.8 to 1.5 kgf·m
5.8 to 10.8 ft-lbs
(1) Glow Plug
(2) Nozzle Holder Assembly
(3) Heat Seal
(4) Lead
(5) Overflow Pipe Assembly
W10259700
Nozzle Heat Seal Service Removal Procedure
■ IMPORTANT
• Use a plus (phillips head) screw driver (1) that has a
diameter which is bigger than the heat seal hole (Approx. 6
mm (1/4 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat seal (4) out
together with the injection nozzle gasket (3).
4. If the heat seal drops, repeat the above procedure.
(When reassembling)
• Heat seal and injection nozzle gasket must be changed when the
injection nozzle is removed for cleaning or for service.
(1) Plus Screw Driver
(2) Nozzle Holder
(3) Injection Nozzle Gasket
(4) Heat Seal
W1021255
1-S25
ENGINE
Rocker Arm and Push Rod
1. Remove the rocker arm bracket nut.
2. Detach the rocker arm assembly (1).
3. Remove the push rods (2).
(When reassembling)
• When refitting the push rods (2) into the tappets (3), make sure
the push rod locates correctly into the tappet seat.
■ IMPORTANT
• After installing the rocker arm, be sure to adjust the valve
clearance.
Tightening torque
Rocker arm bracket nut
(1) Rocker Arm Assembly
(2) Push Rod
21.6 to 26.5 N·m
2.2 to 2.7 kgf·m
15.9 to 19.5 ft-lbs
(3) Tappet
W1021437
1-S26
ENGINE
Cylinder Head and Cylinder Head Gasket
1. Loosen the pipe clamps (1), and remove the water return hose
(2).
2. Remove the cylinder head screw in the order of (n or r) to (a) and
remove the cylinder head.
3. Remove the cylinder head gasket.
(When reassembling)
• Replace the cylinder head gasket with a new one.
• Tighten the cylinder head screws after applying sufficient oil.
• Tighten the cylinder head screws in several steps and specified
sequence (a) to (n or r).
• Retighten the cylinder head screws after running the engine for
30 minutes.
• By using a torque wrench, correctly tighten the cylinder head
screws to correct torque figure.
• The different type of screw (4) is used for the positions (j) and (n)
in illust. (A), and (n) and (r) in the illust (B). (If mounted)
Tightening torque
(1)
(2)
(3)
(4)
Cylinder head screw
Clamp
Return Hose
Cylinder Head Screw
Cylinder Head Screw
63.7 to 68.6 N·m
6.5 to 7.0 kgf·m
47.0 to 50.6 ft-lbs
(A) D1105
(B) V1505
n or r to a : To Loosen
a to n or r : To Tighten
W10205250
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
• Visually check the contact between tappets and cams for proper
rotation. If defect is found, replace tappets.
• Before installing the tappets, apply engine oil thinly around them.
■ IMPORTANT
• Replace the tappets (1) in the same order they were removed
from.
(1) Tappet
W1025896
1-S27
ENGINE
Valves
1. Remove the valve caps (2).
2. Remove the valve spring collet (3) by pushing the valve spring
retainer (4) with valve spring replacer (1).
3. Remove the valve spring retainer (4), valve spring (5) and valve
stem seal (6).
4. Remove the valve (7).
(When reassembling)
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
■ IMPORTANT
• Don’t change the combination of valve and valve guide.
(1)
(2)
(3)
(4)
Valve Spring Replacer
Valve Cap
Valve Spring Collet
Valve Spring Retainer
(5) Valve Spring
(6) Valve Stem Seal
(7) Valve
W1234567
Thermostat Assembly
1. Remove the thermostat cover mounting screws (1), and remove
the thermostat cover (2).
2. Remove the thermostat assembly (4).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the
thermostat cover side of the gasket (3).
(1) Thermostat Cover Mounting Screw
(2) Thermostat Cover
(3) Thermostat Cover Gasket
(4) Thermostat Assembly
W1472583
(3) Oil Pan, Timing Gears, Camshaft and Fuel Camshaft
Fan Drive Pulley
1. Secure the flywheel to keep it from turning.
2. Remove the fan drive pulley screw.
3. Draw out the fan drive pulley with a puller.
(When reassembling)
• Install the pulley to crankshaft, aligning the marks (1) on them.
[Only D1105]
• Apply engine oil to the fan drive pulley retaining screw. And
tighten it.
Tightening torque
Fan drive pulley screw
235.4 to 245.2 N·m
24.0 to 25.0 kgf·m
173.6 to 180.8 ft-lbs
(1) Aligning Mark
W10181950
1-S28
ENGINE
Gear Case
1. Remove the gear case.
(When reassembling)
• Apply a thin coat of grease to the oil seal, and install it, ensuring
the lip does not get cut or rolled.
• Measure (L) when the gear case mounting bolt is inserted in the
gear case bolt hole and judge the installation position of the
mounting bolt when you do not understand the installation
position of the mounting bolt.
A : L = 18 mm (0.71 in.) (Pipe Pin Position)
B : L = 13 mm (0.51 in.) (Water Pipe Mounting)
C : L = 10 mm (0.39 in.)
D : Nut
(1) Gear Case
W1030917
Speed Control Plate
2. Remove the speed control plate (1).
3. Remove the governor spring (2). Be careful not to drop spring
into crankcase.
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) to both
sides of the solenoid cover gasket and control plate gasket.
• Be careful not to drop the governor spring (2) into the crankcase.
(1) Speed Control Plate
(2) Governor Spring
W1031942
1-S29
ENGINE
Injection Pump
1. Disconnect the start spring (4) on the thrust lever side (5).
2. Align the control rack pin (2) with the notch (1) on the crankcase,
and remove the injection pump (3).
3. Remove the injection pump shims.
4. The injection pump should not be disassembled.
(When reassembling)
• When installing the injection pump, insert the control rack pin (2)
firmly into the groove (7) of the thrust lever of fork lever.
■ NOTE
• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or
advances the injection timing by approx. 0.0087 rad (0.5 °).
• In disassembling and replacing, be sure to use the same
number or new gasket shims with the same thickness.
(1) Notch
(2) Control Rack Pin
(3) Injection Pump
(4) Start Spring
(5) Thrust Lever
(6) Groove
W1033441
1-S30
ENGINE
Cam Gear, Idle Gear 1 and Governor Gear
1. Remove the idle gear 1 (4).
2. Remove the fuel camshaft stopper (6).
3. Draw out the fuel cam gear (1) with fuel camshaft (7).
4. Remove the camshaft stopper bolt.
5. Remove the cam gear (5) with camshaft.
6. Remove the external snap ring (8) from the governor shaft (9).
7. Remove the governor gear (2) with governor shaft (9).
■ NOTE
• Three-lever type fork lever
To remove the governor shaft (9), follow the procedures in 5,
6 above and never remove fork lever and the max torque
limiter.
(When reassembling)
• Apply engine oil thinly to the fuel camshaft (7) before installation.
• Make sure to assemble the external snap ring (8) of the governor
shaft (9).
• Check the governor shaft (9) for smooth rotation.
■ IMPORTANT
• When replacing the ball bearing of governor shaft, securely
fit the ball bearing (10) to the crankcase, apply an adhesive
(Three Bond 1324B or equivalent) to the set screw (11), and
tighten the screw until its tapered part contacts the
circumferential end of the ball bearing.
• When installing the idle gear, be sure to align the alignment
marks (12) on each gears.
(1)
(2)
(3)
(4)
(5)
(6)
Fuel Cam Gear
Governor Gear
Crank Gear
Idle Gear 1
Cam Gear
Fuel Camshaft Stopper
(7)
(8)
(9)
(10)
(11)
(12)
Fuel Camshaft
External Snap Ring
Governor Shaft
Ball Bearing
Set Screw
Alignment Mark
W1033942
1-S31
ENGINE
Oil Pan and Oil Strainer
1. Remove the oil pan mounting screws.
2. Remove the oil pan (4) by lightly tapping the rim of the pan with
a wooden hammer.
3. Remove the oil strainer (3).
(When reassembling)
• After cleaning the oil strainer, check to see that the filter mesh is
clean, then reinstall.
• Visually check the O-ring (2), apply engine oil, and install it.
• Securely fit the O-ring to the oil strainer.
• Apply a liquid gasket (Three Bond 1215 or equivalent) to the oil
pan side of the oil pan gasket (1).
• To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the center.
(1) Oil Pan Gasket
(2) O-ring
(3) Oil Strainer
(4) Oil Pan
W1074670
(4) Piston and Connecting Rod
Connecting Rod
1. Remove the connecting rod cap.
(When reassembling)
• Align the marks (a) with each other. (Face the marks toward the
injection pump.)
• Apply engine oil to the connecting rod screws and lightly screw it
in by hand, then tighten it to the specified torque.
If the connecting rod screw is difficult to turn, clean the threads.
If the connecting rod screw is still hard to turn or screw in, replace
it.
Tightening torque
Connecting rod screw
41.2 to 46.1 N·m
4.2 to 4.7 kgf·m
30.4 to 34.0 ft-lbs
(a) Mark
W10242740
1-S32
ENGINE
Pistons
1. Turn the flywheel and bring the piston to top dead center.
2. Draw out the piston upward by lightly tapping it from the bottom
of the crankcase with the handle of a hammer.
3. Draw out the other pistons in the same method as above.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough engine
oil to the piston.
• When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.
■ IMPORTANT
• Do not change the combination of cylinder and piston. Make
sure of the position of each piston by marking. For example,
mark “1” on the No.1 piston.
• When installing the piston into the cylinder, place the gaps
of all the piston rings as shown in the figure.
• Carefully insert the pistons using a piston ring compressor
(1).
Otherwise, their chrome-plated section may be
scratched, causing problem inside the cylinder.
(1)
(A)
(B)
(C)
(D)
Piston Ring Compressor
Top Ring Gap
Second Ring Gap
Oil Ring Gap
Piston Pin Hole
(a) 0.785 rad (45 °)
(b) 0.785 rad (45 °)
(c) 1.57 rad (90 °)
W10277450
1-S33
ENGINE
Piston Ring and Connecting Rod
1. Remove the piston rings using a piston ring tool.
2. Remove the piston pin (7), and separate the connecting rod (6)
from the piston (5).
(When reassembling)
• When installing the ring, assemble the rings so that the
manufacturer’s mark (12) near the gap faces the top of the piston.
• When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin.
• When installing the connecting rod to the piston, immerse the
piston in 80 °C (176 °F) oil for 10 to 15 minutes and insert the
piston pin to the piston.
• When installing the connecting rod to the piston, align the mark
(8) on the connecting rod to the fan-shaped concave (9).
■ NOTE
• Mark the same number on the connecting rod and the piston
so as not to change the combination.
(1)
(2)
(3)
(4)
(5)
(6)
Top Ring
Second Ring
Oil Ring
Piston Pin Snap Ring
Piston
Connecting Rod
(7)
(8)
(9)
(10)
(11)
(12)
Piston Pin
Mark
Fan-shaped Concave
Expander Joint
Oil Ring Gap
Manufacturer’s Mark
W10281670
1-S34
ENGINE
(5) Crankshaft
Flywheel
1. Secure the flywheel to keep it from turning, using a flywheel
stopper.
2. Remove all flywheel screws (1) and then remove the flywheel (2).
(When reassembling)
• With No. 1 piston at TDC, align the “1TC” mark (a) on the outer
surface of the flywheel horizontally with the alignment mark (b)
on the rear end plate. Now fit the flywheel in position.
• Apply engine oil to the threads and the undercut surface of the
flywheel screw and fit the screw.
Tightening torque
(1) Flywheel
(2) Flywheel Screw
53.9 to 58.8 N·m
5.5 to 6.0 kgf·m
39.8 to 43.4 ft-lbs
Flywheel screw
(a) 1TC Mark
(b) Alignment Mark
W10290240
Bearing Case Cover
1. Remove the bearing case cover mounting screws.
2. Remove the bearing case cover (6).
(When reassembling)
• Fit the bearing case gasket (3) and the bearing case cover gasket
(4) in the correct location.
• Install the bearing case cover (6) to position the casting mark
“UP” on it upward.
• Apply engine oil to the oil seal (5) lip and take care that it is not
rolled when installing.
• Tighten the bearing case cover mounting screws with even force
on the diagonal line.
Tightening torque
Bearing case cover screw
9.8 to 11.3 N·m
1.00 to 1.15 kgf·m
7.2 to 8.3 ft-lbs
(1) Bearing Case Cover Mounting Screw (5) Oil Seal
(Inside)
(6) Bearing Case Cover
(2) Bearing Case Cover Mounting Screw
(Outside)
(a) Upside
(3) Bearing Case Gasket
(4) Bearing Case Cover Gasket
W10292140
1-S35
ENGINE
Crankshaft Assembly
1. Remove the main bearing case screw 2 (1).
2. Pull out the crankshaft assembly.
■ IMPORTANT
• Take care to protect crankshaft bearing 1 from scratches,
caused by the crank gear, etc.. (Wrap the gear in vinyl tape,
etc.)
(When reassembling)
• Clean the oil passage of the crankshaft with compressed air.
• Apply oil to the main bearing case screw 2 (1).
• Install the crankshaft assembly, aligning the screw hole of main
bearing case with the screw hole of crankcase.
• Clean the oil passage of the crankshaft with compressed air.
Tightening torque
Main bearing case screw 2
49.0 to 53.9 N·m
5.0 to 5.5 kgf·m
36.2 to 39.8 ft-lbs
(1) Main Bearing Case Screw 2
W10295750
Main Bearing Case Assembly
1. Remove the two main bearing case screws 1 (2) of each main
bearing cases.
2. Remove the main bearing case from crankshaft.
(When reassembling)
• Clean the oil passage in the main bearing cases.
• Apply clean engine oil on the bearings.
• Install the main bearing case assemblies in the original positions.
Since diameters of main bearing cases vary, install them in order
of makings (b) from the gear case side.
• Match the alignment numbers (a) on the main bearing case
assembly 1.
• When installing the main bearing case 1 and 2, face the mark
“FLYWHEEL” to the flywheel.
• Install the thrust bearing (3) with its oil groove facing outward.
• Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 to the specified torque.
Tightening torque
Main bearing case screw 1
(1) Main Bearing Case Assembly 1
(2) Main Bearing Case Screw 1
(3) Thrust Bearing
29.4 to 34.3 N·m
3.0 to 3.5 kgf·m
21.7 to 25.3 ft-lbs
(a) Alignment Number
(b) Marking (A, B, C) (D1105)
(b) Marking (A, B, C, D) (V1505)
W1037295
1-S36
ENGINE
[4] SERVICING
(1) Cylinder Head and Valves
Top Clearance
1. Remove the cylinder head. (Do not attempt to remove the
cylinder head gasket.)
2. Move the piston up and stick a strip of fuse [1.5 mm dia. (0.059
in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston
head at three positions with grease so as to avoid the intake and
exhaust valves and the combustion chamber ports.
3. Lower the piston, and install the cylinder head and tighten the
cylinder head screws to the specified torque.
4. Turn the flywheel until the piston passes top dead center.
5. Remove the cylinder head, and measure the thickness of the
squeezed fuses.
6. If the measurement is not within the factory specifications, check
the oil clearance between the crankpin and crankpin bearing and
between the piston pin and small end bushing.
■ NOTE
• After checking the top clearance, be sure to assemble the
cylinder head with a new cylinder head gasket.
Top clearance
Tightening torque
(1) Fuse
Factory spec.
Cylinder head screws
0.55 to 0.70 mm
0.0217 to 0.0276 in.
63.7 to 68.6 N·m
6.5 to 7.0 kgf·m
47.0 to 50.6 ft-lbs
(2) Fuse
W1020190
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head’s four sides and two
diagonal as shown in the figure.
3. Measure the clearance with a thickness gauge.
4. If the measurement exceeds the allowable limit, correct it with a
surface grinder.
■ IMPORTANT
• Do not place the straightedge on the combustion chamber.
• Be sure to check the valve recessing after correcting.
Cylinder head surface
flatness
Allowable limit
0.05 mm
0.0020 in.
W1027737
1-S37
ENGINE
Cylinder Head Flaw
1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the read permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid
(2) Detergent
(3) White Developer
W1076542
Valve Recess
1. Clean the cylinder head surface, valve face and valve seat.
2. Insert the valve into the valve guide.
3. Measure the valve recess with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
5. If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
Factory spec.
0.05 (protrusion) to
0.25 (recessing) mm
0.0020 (protrusion) to
0.0098 (recessing) in.
Allowable limit
0.40 (recessing) mm
0.0157 (recessing) in.
Valve recess
(1) Cylinder Head Surface
(A) Recess
(B) Protrusion
W10768800
Clearance between Valve Stem and Valve Guide
1. Remove carbon from the valve stem.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. with a small hole gauge, and
calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
Clearance between
valve stem and valve
guide
Factory spec.
0.035 to 0.065 mm
0.0014 to 0.0025 in.
Allowable limit
0.10 mm
0.0039 in.
Valve stem O.D.
Factory spec.
6.960 to 6.975 mm
0.2741 to 0.2746 in.
Valve guide I.D.
Factory spec.
7.010 to 7.025 mm
0.2760 to 0.2765 in.
W10774950
1-S38
ENGINE
Replacing Valve Guide
(When removing)
1. Press out the used valve guide using a valve guide replacing tool.
(See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new valve guide and valve guide bore, and apply engine
oil to them.
2. Press in a new valve guide using a valve guide replacing tool.
3. Ream the I.D. of the valve guide to the specified dimension.
Valve guide I.D.
(Intake and exhaust)
Factory spec.
7.010 to 7.025 mm
0.2760 to 0.2765 in.
■ IMPORTANT
• Do not hit the valve guide with a hammer during
replacement.
(A) When Removing
(B) When Installing
W10278890
Valve Seat
1. Coat the valve face lightly with prussian blue and put the valve on
its seat to check the contact.
2. If the valve does not seat all the way around the valve seat or the
valve contact is less than 70 %, correct the valve seating as
follows.
3. If the valve contact does not comply with the reference value,
replace the valve or correct the contact of valve seat.
Valve seat width
(1) Correct
(2) Incorrect
Factory spec.
2.12 mm
0.0835 in.
(3) Incorrect
W10282190
1-S39
ENGINE
Correcting Valve and Valve Seat
■ NOTE
• Before correcting the valve and seat, check the valve stem
and the I.D. of valve guide section, and repair them if
necessary.
• After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
Valve face angle
Factory
spec.
IN.
1.047 rad
60 °
EX.
0.785 rad
45 °
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 1.047 rad (60 °) (intake
valve) or 0.785 rad (45 °) (exhaust valve) valve seat cutter.
2. Resurface the seat surface with a 0.523 rad (30 °) valve seat
cutter to intake valve seat and with a 0.262 rad (15 °) valve seat
cutter to exhaust valve seat so that the width is close to specified
valve seat width (2.12 mm, 0.0835 in.).
3. After resurfacing the seat, inspect for even valve seating, apply a
thin film of lapping compound between the valve face and valve
seat, and fit them with valve lapping tool.
4. Check the valve seat with prussian blue. The valve seating
surface should show good contact all the way around.
Valve seat angle
(1) Valve Seat Width
(2) Identical Dimensions
Factory
spec.
IN.
1.047 rad
60 °
EX.
0.785 rad
45 °
(A)
(B)
(C)
(a)
(b)
(c)
Check Contact
Correct Seat Width
Check Contact
0.262 rad (15 °) or 0.523 rad (30 °)
0.785 rad (45 °) or 1.047 rad (60 °)
0.523 rad (30 °) or 0.262 rad (15 °)
W10283500
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
■ IMPORTANT
• When valve lapping is performed, be sure to check the valve
recess and adjust the valve clearance after assembling the
valve.
W10288140
1-S40
ENGINE
Free Length and Tilt of Valve Spring
1. Measure the free length (B) of valve spring with vernier calipers.
If the measurement is less than the allowable limit, replace it.
2. Put the valve spring on a surface plate, place a square on the
side of the valve spring.
3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (A).
If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
Tilt (A)
Allowable limit
1.0 mm
0.039 in.
Factory spec.
37.0 to 37.5 mm
1.457 to 1.476 in.
Allowable limit
36.5 mm
1.437 in.
Free length (B)
(A) Tilt
(B) Free Length
W10289350
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
Factory spec.
117.4 N / 31.0 mm
11.97 kgf / 31.0 mm
26.4 lbs / 1.22 in.
Allowable limit
100.0 N / 31.0 mm
10.2 kgf / 31.0 mm
22.5 lbs / 1.22 in.
Setting load /
Setting length
W10784360
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and then
calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the rocker
arm and measure the oil clearance again. If it still exceeds the
allowable limit, replace also the rocker arm shaft.
Oil clearance between
rocker arm and rocker
arm shaft
Factory spec.
0.016 to 0.045 mm
0.00063 to 0.00177 in.
Allowable limit
0.10 mm
0.0039 in.
Rocker arm shaft O.D.
Factory spec.
11.973 to 11.984 mm
0.4714 to 0.4718 in.
Rocker arm I.D.
Factory spec.
12.000 to 12.018 mm
0.4724 to 0.4731 in.
W10291500
1-S41
ENGINE
Push Rod Alignment
1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push
rod.
Push rod alignment
Allowable limit
0.25 mm
0.0098 in.
W10292900
Oil Clearance between Tappet and Tappet Guide Bore
1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder gauge,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
Oil Clearance between
tappet and tappet guide
bore
Factory spec.
0.020 to 0.062 mm
0.0008 to 0.0024 in.
Allowable limit
0.07 mm
0.0028 in.
Tappet O.D.
Factory spec.
19.959 to 19.980 mm
0.7858 to 0.7866 in.
Tappet guide bore I.D.
Factory spec.
20.000 to 20.021 mm
0.7874 to 0.7882 in.
W10293660
1-S42
ENGINE
(2) Timing Gears, Camshaft and Governor Gear
Timing Gear Backlash and Governor Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance is not correct, replace the gear.
Factory spec.
0.032 to 0.115 mm
0.0013 to 0.0045 in.
Allowable limit
0.15 mm
0.0059 in.
Factory spec.
0.036 to 0.114 mm
0.0014 to 0.0045 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between idle
gear 1 and injection
pump gear
Factory spec.
0.034 to 0.116 mm
0.0013 to 0.0046 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between
injection pump gear and
governor gear
Factory spec.
0.030 to 0.117 mm
0.0012 to 0.0046 in.
Allowable limit
0.15 mm
0.0059 in.
gear 1 and crank gear
gear 1 and cam gear
W10280630
Idle Gear 1 Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear from the
front and rear.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
Idle gear 1 side
clearance
Factory spec.
0.20 to 0.51 mm
0.0079 to 0.0201 in.
Allowable limit
0.8 mm
0.0315 in.
W10285590
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. measure the side clearance by moving the cam gear from the
front to rear.
camshaft stopper.
Camshaft side
clearance
Factory spec.
0.07 to 0.22 mm
0.0028 to 0.0087 in.
Allowable limit
0.30 mm
0.0118 in.
W10295630
1-S43
ENGINE
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
camshaft.
Camshaft alignment
Allowable limit
0.01 mm
0.0004 in.
W10296710
Cam Lobe Height
1. Measure the height of the cam lobe at its highest point with an
outside micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
Cam lobe height of
intake
Cam lobe height of
exhaust
Factory spec.
28.80 mm
1.1339 in.
Allowable limit
28.75 mm
1.1319 in.
Factory spec.
29.00 mm
1.1417 in.
Allowable limit
28.95 mm
1.1398 in.
W10297880
Oil Clearance of Camshaft Journal
1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a cylinder
gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
Factory spec.
0.050 to 0.091 mm
0.00197 to 0.00358 in.
Allowable limit
0.15 mm
0.0059 in.
Camshaft journal O.D.
Factory spec.
35.934 to 35.950 mm
1.4147 to 1.4153 in.
Camshaft bearing I.D.
(Cylinder block bore
I.D.)
Factory spec.
36.000 to 36.025 mm
1.4173 to 1.4183 in.
Oil clearance of
camshaft journal
W10299330
1-S44
ENGINE
Oil Clearance between Idle Gear 1 Shaft and Idle Gear Bushing
1. Measure the idle gear shaft 1 O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
bushing.
If it still exceeds the allowable limit, replace the idle gear shaft 1.
idle gear shaft 1 and idle
gear bushing
Factory spec.
0.020 to 0.054 mm
0.0008 to 0.0021 in.
Allowable limit
0.10 mm
0.0039 in.
Idle gear shaft 1 O.D.
Factory spec.
25.967 to 25.980 mm
1.0223 to 1.0228 in.
Idle gear bush I.D.
Factory spec.
26.000 to 26.021 mm
1.0236 to 1.0244 in.
W10301050
Replacing Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing using an idle gear bushing
replacing tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing tool,
until it is flush with the end of the idle gear.
(A) When Removing
(B) When Installing
W10302410
1-S45
ENGINE
(3) Piston and Connecting Rod
Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
piston.
Factory spec.
22.000 to 22.013 mm
0.8661 to 0.8667 in.
Allowable limit
22.03 mm
0.8673 in.
Piston pin bore I.D.
W10304770
Oil Clearance between Piston Pin and Small End Bushing
1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer,
bushing. If it still exceeds the allowable limit, replace the piston
pin.
piston pin and small end
bushing
Factory spec.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
Allowable limit
0.15 mm
0.0059 in.
Piston pin O.D.
Factory spec.
22.002 to 22.011 mm
0.8662 to 0.8666 in.
Small end bushing I.D.
Factory spec.
22.025 to 22.040 mm
0.8671 to 0.8677 in.
W10305740
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing replacing
tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to
them.
2. Using a small end bushing replacing tool, press in a new bushing
(service parts) taking care to see that the connecting rod oil hole
matches the bushing hole.
piston pin and small end
bushing (Spare parts)
Small end bushing I.D.
(Spare parts)
(1) Seam
(2) Oil Hole
Factory spec.
0.015 to 0.075 mm
0.00059 to 0.00295 in.
Allowable limit
0.15 mm
0.0059 in.
Factory spec.
22.026 to 22.077 mm
0.7885 to 0.7904 in.
(A) When Removing
(B) When Installing
(a) 0.785 rad (45 °)
W10307120
1-S46
ENGINE
Connecting Rod Alignment
■ NOTE
• Since the I.D. of the connecting rod small end bushing is the
basis of this check, check bushing for wear beforehand.
1. Install the piston pin into the connecting rod.
2. Install the connecting rod on the connecting rod alignment tool.
3. Put a gauge over the piston pin, and move it against the face
plate.
4. If the gauge does not fit squarely against the face plate, measure
the space between the pin of the gauge and the face plate.
connecting rod.
Connecting rod
alignment
Allowable limit
0.05 mm
0.0020 in.
W10314620
Piston Ring Gap
1. Insert the piston ring into the lower part of the cylinder (the least
worn out part) with a piston.
2. Measure the ring gap with a thickness gauge.
piston ring.
Top ring
Piston ring gap
Second ring
Oil ring
Factory
spec.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
Allowable
limit
1.25 mm
0.0492 in.
Factory
spec.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
Allowable
limit
1.25 mm
0.0492 in.
Factory
spec.
0.25 to 0.40 mm
0.0098 to 0.0157 in.
Allowable
limit
1.25 mm
0.0492 in.
W10310120
Clearance between Piston ring and Piston Ring Groove
1. Clean the rings and the ring grooves, and install each ring in its
groove.
2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
Second
ring
Clearance between
piston ring and piston
ring groove
Oil ring
Factory specification : a
(A) Top Ring (Key Stone Type)
Factory
spec.
0.085 to 0.112 mm
0.0033 to 0.0044 in.
Allowable
limit
0.20 mm
0.0079 in.
Factory
spec.
0.020 to 0.055 mm
0.0008 to 0.0021 in.
Allowable
limit
0.15 mm
0.0059 in.
More than 0.2 mm
0.0079 in.
(B) 2nd, Oil Ring
W10312390
1-S47
ENGINE
(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
thrust bearings.
4. If the same size bearing is still loose because of the crankshaft
journal wear, replace it with an oversize one referring to the table
and figure.
Crankshaft side
clearance
Factory spec.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Allowable limit
0.50 mm
0.0197 in.
(Reference)
• Oversize dimensions of crankshaft journal
Oversize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
51.5 to 51.7 mm
2.028 to 2.035 in.
51.6 to 51.8 mm
2.031 to 2.039 in.
Dimension B
28.20 to 28.25 mm
1.1102 to 1.1122 in.
28.40 to 28.45 mm
1.1181 to 1.1201 in.
Dimension C
2.3 to 2.7 mm radius
0.091 to 0.106 in. radius
0.091 to 0.106 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
W10317070
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
crankshaft.
Crankshaft alignment
Allowable limit
0.02 mm
0.0008 in.
W10330010
1-S48
ENGINE
Oil Clearance between Crankpin and Crankpin Bearing
1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the
oil clearance.
crankpin bearing.
6. If the same size bearing is still loose because of the crankpin
wear, replace it with an undersize one referring to the table and
figure.
■ NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod
screws are tightened.
crankpin and crankpin
bearing
Factory spec.
0.029 to 0.091 mm
0.0011 to 0.0036 in.
Allowable limit
0.20 mm
0.0079 in.
Crankpin O.D.
Factory spec.
39.959 to 39.975 mm
1.5732 to 1.5738 in.
Crankpin bearing I.D.
Factory spec.
40.004 to 40.050 mm
1.5750 to 1.5768 in.
(Reference)
• Undersize dimensions of crankpin
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
0.1102 to 0.1260 in. radius
0.1102 to 0.1260 in. radius
*Dimension B
1.0 to 1.5 mm relief
0.0394 to 0.0591 in. relief
0.0394 to 0.0591 in. relief
Dimension C
39.759 to 39.775 mm dia.
1.5653 to 1.5659 in. dia.
39.559 to 39.575 mm dia.
1.5574 to 1.5581 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.
W10331060
1-S49
ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 1
1. Measure the O.D. of the crankshaft front journal with an outside
micrometer.
2. Measure the I.D. of the crankshaft bearing 1 with an inside
micrometer, and calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 1.
journal wear, replace it with an undersize one referring to the
table and figure.
crankshaft journal and
crankshaft bearing 1
Factory spec.
0.034 to 0.114 mm
0.0013 to 0.0045 in.
Allowable limit
0.20 mm
0.0079 in.
Crankshaft journal O.D.
Factory spec.
47.934 to 47.950 mm
1.8872 to 1.8878 in.
Crankshaft bearing 1
I.D.
Factory spec.
47.984 to 48.048 mm
1.8891 to 1.8916 in.
(Reference)
• Undersize dimensions of crankshaft journal
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
0.0906 to 0.1063 in. radius
0.0906 to 0.1063 in. radius
*Dimension B
0.0394 to 0.0591 in. relief
0.0394 to 0.0591 in. relief
Dimension C
47.734 to 47.750 mm dia.
1.8793 to 1.8799 in. dia.
47.534 to 47.550 mm dia.
1.8714 to 1.8720 in. dia.
(0.8-S)
(0.0394 to 0.0591 in.) relief.
W10337170
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) is toward the exhaust manifold
side. (See figure.)
Dimension (A)
(1) Seam
(2) Crankshaft Bearing 1
Factory spec.
0 to 0.3 mm
0 to 0.0118 in.
(3) Cylinder Block
W10339460
1-S50
ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 (Crankshaft Bearing 3)
1. Put a strip of plastigage on the center of the journal.
2. Install the bearing case and tighten the bearing case screws 1 to
the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale and get the
oil clearance.
4. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 2 (1) and crankshaft bearing (3).
journal wear, replace it with an undersize one referring to the
table and figure.
■ NOTE
• Be sure not to move the crankshaft while the bearing case
screws are tightened.
Factory spec.
0.034 to 0.095 mm
0.0013 to 0.0037 in.
Allowable limit
0.20 mm
0.0079 in.
(Intermediate)
Factory spec.
47.934 to 47.950 mm
1.8872 to 1.8878 in.
I.D.
Factory spec.
47.984 to 48.029 mm
1.8891 to 1.8909 in.
Factory spec.
0.034 to 0.098 mm
0.0013 to 0.0039 in.
Allowable limit
0.20 mm
0.0079 in.
(Flywheel side)
Factory spec.
51.921 to 51.940 mm
2.0441 to 2.0449 in.
I.D.
Factory spec.
51.974 to 52.019 mm
2.0462 to 2.0480 in.
(Reference)
• Undersize dimensions of crankshaft journal
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
0.0906 to 0.1063 in. radius
0.0906 to 0.1063 in. radius
*Dimension B
0.0394 to 0.0591 in. relief
0.0394 to 0.0591 in. relief
Dimension C
47.734 to 47.750 mm dia.
1.8793 to 1.8799 in. dia.
47.534 to 47.550 mm dia.
1.8714 to 1.8720 in. dia.
Dimension D
51.721 to 51.740 mm dia.
2.0362 to 2.0370 in. dia.
51.521 to 51.540 mm dia.
2.0284 to 2.0291 in. dia.
(0.8-S)
(0.0394 to 0.0591 in.) relief.
W10340750
1-S51
ENGINE
Replacing Crankshaft Sleeve
1. Remove the used crankshaft sleeve.
2. Set the sleeve guide (2) to the crankshaft.
3. Heat a new sleeve to a temperature between 150 and 200 °C
(302 and 392 °F), and fix the sleeve to the crankshaft as shown
in figure.
4. Press fit the sleeve using the auxiliary socket for pushing (3).
■ NOTE
• Mount the sleeve with its largely chamfered surface facing
outward.
• If sleeve is not hot enough, it might stop halfway, so be
careful.
(1) Crankshaft Sleeve
(2) Sleeve Guide
(3) Auxiliary Socket for Pushing
(4) Crankshaft
W1045923
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “Correcting
Cylinder”.)
Factory spec.
78.000 to 78.019 mm
3.0709 to 3.0716 in.
Allowable limit
78.15 mm
3.0768 in.
Cylinder I.D.
(A) Top
(B) Middle
(C) Bottom (Skirt)
(a) Right-angled to Piston Pin
(b) Piston Pin Direction
W10343890
1-S52
ENGINE
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
Oversized cylinder liner
I.D.
Factory spec.
78.500 to 78.519 mm
3.0906 to 3.0913 in.
Allowable limit
78.65 mm
3.0965 in.
Finishing
Hone to 1.2 to 2.0 mm µR max.
∇∇∇
(0.000047 to 0.000079 in. µR max.)
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.5 mm (0.0197 in.)
■ NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction)
(2) Cylinder I.D. (Oversize)
W10344480
(6) Oil Pump
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.
2. If the clearance exceeds the factory specifications, replace the oil
pump rotor assembly.
Rotor lobe clearance
Factory spec.
0.06 to 0.18 mm
0.0024 to 0.0071 in.
W10355630
Clearance between Outer Rotor and Pump Body
1. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
Clearance between
outer rotor and pump
body
Factory spec.
0.100 to 0.180 mm
0.0039 to 0.0071 in.
W10356560
Clearance between Rotor and Cover
1. Put a strip of plastigage onto the rotor face with grease.
2. Install the cover and tighten the screws.
3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.
Clearance between rotor
and cover
Factory spec.
0.025 to 0.075 mm
0.0010 to 0.0030 in.
W10357320
1-S53
2
TRANSMISSION
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 2-M1
2. POWER TRAIN ............................................................................................. 2-M2
[1] HYDROSTATIC TRANSMISSION (HST) .............................................. 2-M2
(1) Structure ............................................................................................ 2-M2
(2) Oil Flow .............................................................................................. 2-M3
(3) Operation ........................................................................................... 2-M4
(4) Charge Relief Valve ........................................................................... 2-M7
(5) Check and High Pressure Relief Valve .............................................. 2-M8
(6) Control Linkage.................................................................................. 2-M9
3. RANGE GEAR SHIFT SECTION .............................................................. 2-M10
4. REAR WHEEL DRIVE SECTION.............................................................. 2-M11
[1] DUAL - ACTING OVERRUNNING FOUR WHEEL DRIVE................ 2-M11
(1) Basic Actions in Dual-Acting Overrunning 4WD Mode .................... 2-M13
(2) Basic Actions in Full-Time 4WD Mode............................................. 2-M15
5. PTO SECTION ............................................................................................ 2-M16
6. DIFFERENTIAL GEAR SECTION.............................................................. 2-M18
[1] DIFFERENTIAL FUNCTION ................................................................. 2-M18
[2] DIFFERENTIAL LOCK.......................................................................... 2-M19
TRANSMISSION
1. STRUCTURE
(1) Hydrostatic Transmission
(HST) Section
(2) Range Gear Shift Section
(3) PTO Section
(4) Differential Gear Section
(5) Rear Wheel Drive Section
(Dual Acting Overrunning
Clutch)
2-M1
TRANSMISSION
2. POWER TRAIN
[1] HYDROSTATIC TRANSMISSION (HST)
(1) Structure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Motor Shaft
Needle Bearing
Thrust Plate
Charge Relief Valve
Cylinder Block (Motor)
Valve Plate
Needle Bearing
(8)
(9)
(10)
(11)
(12)
(13)
Oil Seal
Needle Bearing
Valve Plate
Center Section
Cylinder Block (Pump)
Piston
(14)
(15)
(16)
(17)
(18)
(19)
Retainer Plate
Thrust Plate
Variable Swashplate
HST Housing
Pump Shaft
Valve Plug
(20) Check Valve Spring
(21) Relief Valve Spring
(22) Check and High Pressure
Relief Valve (Forward)
Relief Valve (Reverse)
The hydrostatic transmission (HST) consists of a variable displacement piston pump, a fixed displacement piston
motor, two check and high pressure relief valves and a charge relief valve.
The pump and motor have nine pistons in their cylinder blocks.
The discharge rate of the HST is 18.9 cm3/rev. (1.15 cu.in./rev.).
The speed control pedal permits simple operation of the machine, starting, stopping, increasing or decreasing
speed.
2-M2
TRANSMISSION
(2) Oil Flow
(1)
(2)
(3)
(4)
Pump
Charge Relief Valve
PTO Charge Relief Valve
(5) Oil Cooler
Relief Valve
(7) Motor
(8) Flow Priority Valve
(9) Hydraulic Pump
Relief Valve
A : To PTO Control Valve
B : From Power Steering
Controller
C : To Power Steering Controller
D : To Implement Control Valve
EF :EF Port
PF :PF Port
P : P Port
The closed hydraulic oil loop runs between the pump (1) and motor (7) in the hydrostatic transmission (11).
When the engine is started, the hydraulic pump (9) is rotated to drow oil from the transmission case through the
suction pipe.
The oil is forced out by the hydraulic pump (9) to the power steering controller through the flow priority valve (8).
When the control valve in the power steering controller is at “Neutral” position, the oil is delivered to the oil cooler
(5).
The oil from the oil cooler (5) is delivered to the PTO charge relief valve (4), oil filter cartridge (3) and charge relief
valve (2).
The oil is drained into the transmission case through the hydrostatic transmission housing.
2-M3
TRANSMISSION
(3) Operation
■ Neutral
(1)
(2)
(3)
(4)
Oil Cooler
Check and High Pressure
(6) Charge Relief Valve
(7)
(8)
(9)
(10)
(11)
(12)
Motor Shaft
Piston
Hydraulic Pump
Power Steering Controller
Flow Priority Valve
(13)
(14)
(15)
(16)
(17)
(18)
Pump Shaft
Swashplate
Oil Strainer
Transmission Case
Implement Control Valve
A:
B:
C:
D:
a:
b:
c:
Port A
Port B
Port C
Port D
High Pressure
Low Pressure
Charge Pressure
Engine revolution rotates the pump shaft (13) via the universal joint.
When the speed control pedal is in neutral, the swashplate (14) is at right angles to the pump piston and they only
rotate with pump cylinder block (15) without reciprocating.
Since the oil is not being pumped to the motor, the cylinder block (7) in the motor is stationary and the motor shaft
(8) does not rotate.
2-M4
TRANSMISSION
■ Forward
(1)
(2)
(3)
(4)
Oil Cooler
(7)
(8)
(9)
(10)
(11)
(12)
Motor Shaft
Piston
Hydraulic Pump
Flow Priority Valve
(13)
(14)
(15)
(16)
(17)
(18)
Pump Shaft
Swashplate
Oil Strainer
Transmission Case
A:
B:
C:
D:
a:
b:
c:
Port A
Port B
Port C
Port D
High Pressure
Low Pressure
Charge Pressure
When the speed control pedal is stepped on and in forward, the swashplate (14) is tilted as shown in the figure
above.
As the pump cylinder block (15) rotates with the pump shaft (13), oil is forced out of pump port B at high pressure.
As the pressure oil enters motor port D, the pistons, which align with port D, are pushed against the inclined thrust
plate slide down the inclined surface.
Then the motor shaft (8) rotates with the motor cylinder block (7). This drives the machine forward and the angle
of swashplate (14) determines the motor shaft speed.
2-M5
TRANSMISSION
■ Reverse
(1)
(2)
(3)
(4)
Oil Cooler
(7)
(8)
(9)
(10)
(11)
(12)
Motor Shaft
Piston
Hydraulic Pump
Flow Priority Valve
(13)
(14)
(15)
(16)
(17)
(18)
Pump Shaft
Swashplate
Oil Strainer
Transmission Case
A:
B:
C:
D:
a:
b:
c:
Port A
Port B
Port C
Port D
High Pressure
Low Pressure
Charge Pressure
When the speed control pedal is stepped on and in reverse, the swashplate (14) is tilted as shown in the figure
above.
As the pump cylinder block (15) rotates with the pump shaft (13), oil is forced out of pump port A at high pressure.
As the pressure oil enters motor port C, the pistons, which align with port C are pushed against the inclined thrust
plate and slide down the inclined surface.
Then the motor shaft (8) rotates with the motor cylinder block (7). This drives the machine backward and the angle
of swashplate (14) determines the motor shaft speed.
2-M6
TRANSMISSION
The oil from the oil filter cartridge is regulated the
setting pressure by the charge relief valve (0.40 to 0.58
MPa, 4.0 to 6.0 kgf/cm2, 57 to 85 psi). The regulated oil
is fed as charge oil to HST main circuit.
The oil that is relieved by charge relief valve passes
to HST housing (1) through the poppet (4).
(1)
(2)
(3)
(4)
HST Housing
Plug
Spring
Poppet
a : From Oil Filter Cartridge
W1014549
2-M7
TRANSMISSION
(5) Check and High Pressure Relief Valve
■ In Neutral
The cartridge-type check and high-pressure relief
valve consists of pressure poppet (2), check valve seat .
The check and high-pressure relief valves are laid out
facing each other as shown in the figure.
(1)
(2)
(3)
(4)
(5)
(6)
Check Valve Seat
Pressure Poppet
Relief Valve Spring
Spring Guide
Check Valve Spring
Valve Plug
P1 :P1 Port
P2 :P2 Port
P3 :P3 Port
■ When Check Valve Activating
The charge flow coming through the charge port
forces open the low-pressure-line check and highpressure relief valve and goes into the low-pressure-line.
Any excessive charge flow goes through the charge
relief valve into HST housing.
W1016420
■ When High Pressure Relief Valve Activating
The check and high-pressure relief valve in the highpressure line serves as a high-pressure relief valve. If
the pressure exceeds a high-pressure limit level, the
pressure poppet (2) opens itself against the relief valve
spring (3) force and opens the valve that is located
between the check valve seat (1) and the pressure
poppet (2). Now the flow goes to P2.
If the P3 pressure drops, the relief valve spring forces
the valve seat closed against the pressure. The highpressure oil at P3 does not flow to P2 any longer.
As discussed above, the check and high-pressure
relief valve protects engines, pumps, motors, gears and
even the machine itself from overload.
Oil temperature
High Pressure Relief Valve
operating pressure
50 to 60 °C
(122 to 140 °F)
33.3 to 35.2 MPa
340 to 359 kgf/cm2
4833 to 5116 psi
W1016728
2-M8
TRANSMISSION
(6) Control Linkage
(1)
(2)
(3)
(4)
Neutral Spring
Speed Control Rod
Brake Lock Lever
Main Brake Pedal
(5)
(6)
(7)
(8)
Speed Control Pedal
Speed Control Bracket
Damper Stay
Damper
(9) Brake Rod 1
(10) Brake Return Spring
(11) Neutral Arm
(12) Ball Bearing
(13) Speed Change Arm
(14) Trunion Shaft
The speed control pedal (5) and the trunnion shaft (14) of the variable swashplate are linked with the speed control
bracket (6), speed control rod (2), and speed change arm (13).
As the front footrest of the pedal is depressed, the swashplate rotates and forward traveling speed increases.
Depressing the rear footrest increase reverse speed.
Then, the swashplate is returned to neutral with the speed change arm (13), when the pedal is released.
The damper (8) is connected to the speed control pedal (5) linked with the speed control bracket (6) and damper
stay (7), restrict the movement of the linkage to prevent abrupt operation or reversing.
The ball bearing (12) on the neutral arm (11) seats the detent of the speed change arm (13) so that the speed
change arm (13) returns to neutral.
2-M9
TRANSMISSION
3. RANGE GEAR SHIFT SECTION
Two kinds of power flow are selected by operating the
range gear shift lever to shift the 15T - 26T gear (7) on
the bevel pinion shaft (6).
■ Low Range
Motor Shaft (1) → 28T Gear (2) → 15T Gear (5) →
(18T -) 17T Gear Shaft (3) → (15T -) 26T Gear (7) →
Bevel Pinion Shaft (6) → Differential Gear (4).
■ High Range
Motor Shaft (1) → 28T Gear (2) → 15T Gear (5) →
18T (- 17T) Gear Shaft (3) → 15T (- 26T) Gear (7) →
Bevel Pinion Shaft (6) → Differential Gear (4).
(1)
(2)
(3)
(4)
Motor Shaft
28T Gear
18T - 17T Gear Shaft
Differential Gear
(5) 15T Gear
(6) Bevel Pinion Shaft
(7) 15T - 26T Gear
W1015959
2-M10
TRANSMISSION
4. REAR WHEEL DRIVE SECTION
[1] DUAL - ACTING OVERRUNNING FOUR WHEEL DRIVE
(1) RWD Shaft 2
(2) Dual-acting Overrunning
Clutch
(3) RWD Shaft 1
(4) 11T Gear
(6) 16T-33T Gear
(7) 34T Gear
W1017791
This machine is equipped with the dual-acting overrunning 4WD system.
The dual -acting overrunning clutch (2) is mounted between the RWD shaft 2 (1) and RWD shaft 1 (2).
Driving power is transmitted to the dual-acting overrunning clutch (2) as follows ;
Bevel Pinion Shaft (4) → 11T Gear (4) → 16T-33T Gear (6) → 34T Gear (7) → RWD Shaft 1 (3) → Dual-acting
Overrunning Clutch (2).
2-M11
TRANSMISSION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
RWD Shaft 2
Thrust Collar
External Snap Ring
Washer
Brake Shoe
Garter Spring
Thrust Collar
Return Spring
Drive Cam
Shift Fork
RWD Shaft 1
External Snap Ring
Clutch Bracket
Internal Snap Ring
Pin
Center Cam
Driven Cam
Clutch Case
Brake Ring
[A] Dual-Acting Overrunning
4WD (2WD Mode)
[B] Full-Time 4WD
W1015160
The dual-acting overrunning 4WD system can be engaged by simply switching the control lever. There are two
mode to choose from : full-time 4WD mode and dual-acting overrunning 4WD mode.
If the later mode is selected, the 2WD and 4WD are automatically switched from each other in both the forward
and backward runs in response to the road condition and other factors.
The dual-acting overrunning 4WD system can minimize damage to the lawn. In this mode, the wheels drag
themselves much less on the ground with repetitious forward and backward runs, this also allows small-radius turns
and in other running styles.
On slopes, the full-time 4WD mode may be selected to ensure the best possible traction, stability and safety.
■ IMPORTANT
• Do not steer the rear wheels sharply when the Dual-acting overrunning 4WD clutch lock lever is in the
“Full-time 4WD” position.
■ 2WD mode
RWD Shaft 1 (11) → Drive Cam (9) → Center Cam (16)
■ Mode 4RM
RWD Shaft 1 (11) → Drive Cam (9) → Center Cam (16) → Driven Cam (17) → RWD Shaft 2 (1)
2-M12
TRANSMISSION
(1) Basic Actions in Dual-Acting Overrunning 4WD Mode
■ When the engine is not running or the speed
change gears are in neutral position
The center cam (5) is held against the drive cam (4)
by force of the return spring (6).
In this state, the power is not transmitted to the driven
cam (1) and the rear wheels are not driven either.
(1)
(2)
(3)
(4)
(5)
(6)
Driven Cam
Brake Ring
Brake Shoe
Drive Cam
Center Cam
Return Spring
F : Front Side
R : Rear Side
W1017048
■ When the machine is operated or the front wheels
are slipping
When the RWD shaft 1 starts turning, the drive cam
(4) is activated.
When the drive cam (4) is about to produce more
turns than the driven cam (1), the center cam (5) is
moved to the left by the drive cam (4) due to the friction
between the brake ring (2) and the brake shoe (3).
In this way the center cam (5) and the driven cam (1)
are activated by the driven cam (1), which drives all the
four wheels.
(1)
(2)
(3)
(4)
(5)
(6)
Driven Cam
Brake Ring
Brake Shoe
Drive Cam
Center Cam
Return Spring
F:
R:
a:
b:
Front Side
Rear Side
More Turns
Fewer Turns
W1017156
2-M13
TRANSMISSION
■ When the machine makes a turn
As the machine makes a turn, the driven cam (1)
produces more turns than the drive cam (4).
The center cam (5) is activated by the driven cam (1).
The center cam (5) is moved to the right by force of the
return spring (6), because the center cam (5) is
disengaged from the drive cam (4).
(1)
(2)
(3)
(4)
(5)
(6)
Driven Cam
Brake Ring
Brake Shoe
Drive Cam
Center Cam
Return Spring
F:
R:
a:
b:
Front Side
Rear Side
More Turns
Fewer Turns
W1017253
■ While the machine is turning
While the machine is turning, the center cam (3) is
pressed against the drive cam (4) by force of the return
spring (2).
In this state, the driven cam (1) is not activated.
(1)
(2)
(3)
(4)
(5)
(6)
Driven Cam
Brake Ring
Brake Shoe
Drive Cam
Center Cam
Return Spring
F:
R:
a:
b:
Front Side
Rear Side
More Turns
Fewer Turns
W1017376
2-M14
TRANSMISSION
(2) Basic Actions in Full-Time 4WD Mode
When the clutch lever of the dual-acting overrunning
4WD is set at the full-time 4WD position, the shift fork
starts turning to push the clutch bracket (5) to the left. By
this, the center cam (6) comes into contact with the
driven cam (4). Now the four wheels are driven.
(1)
(2)
(3)
(4)
(5)
(6)
Driven Cam
Brake Ring
Brake Shoe
Drive Cam
Center Cam
Return Spring
F : Front Side
R : Rear Side
W1017500
2-M15
TRANSMISSION
5. PTO SECTION
■ PTO “Engage”
(1)
(2)
(3)
(4)
28T Gear
Pump Shaft
Return Spring
PTO Brake Disc
(5)
(6)
(7)
(8)
PTO Shaft
Coupling
Clutch Shaft
PTO Brake Plate
(9)
(10)
(11)
(12)
Clutch Case
Piston
Steel Plate
Clutch Disc
(13)
(14)
(15)
(15)
Pressure Plate
33T Gear
PTO Control Valve
Valve Lever
The main components of the PTO section are shown in the figure above.
When the PTO lever is set to “ENGAGE” position, the PTO control rod is pulled and the PTO control valve (15)
rotates.
The oil is forced out by the hydraulic pump to the hydraulic PTO clutch through the steering controller, PTO control
valve (15) and clutch shaft (7).
The piston (10) is pushed against the steel plates (11), clutch discs (12) and pressure plate (13) by this movement.
The steel plates (11) and pressure plate (13) are held between the clutch discs (12) and piston (10), and the friction
between them cause the clutch discs (12) to rotate, thus transmitting the power from the engine to the implement as
follows ;
Pump Shaft (2) → 28T Gear (1) → 33T Gear (13) → Piston (10) → Clutch Case (9) → Clutch Shaft (7) → Coupling
(6) → PTO Shaft (5).
2-M16
TRANSMISSION
■ PTO “Disengage”
(1)
(2)
(3)
(4)
28T Gear
Pump Shaft
Return Spring
PTO Brake Disc
(5)
(6)
(7)
(8)
PTO Shaft
Coupling
Clutch Shaft
PTO Brake Plate
(9)
(10)
(11)
(12)
Piston
Steel Plate
Clutch Disc
Pressure Plate
(13) 33T Gear
(14) PTO Control Valve
(15) Valve Lever
When the PTO lever is set to “DISENGAGE” position, the oil passage is closed by the PTO control valve (14).
The piston (9) is pushed against the PTO brake plates (8) and PTO brake disc (4), which creates clearance between
the steel plates (10) and clutch discs (11), causing no friction. At the same time, the PTO brake disc (4) is held
between the PTO brake plates (8), causing friction. Therefore, the power to the implement is shut off and brake
engages to prevent the PTO shaft (5) from the free-spinning.
2-M17
TRANSMISSION
6. DIFFERENTIAL GEAR SECTION
[1] DIFFERENTIAL FUNCTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Bevel Pinion Shaft
Differential Case
Differential Side Gear
Differential Pinion Gear
Differential Pinion Shaft
Spiral Bevel Gear
Differential Case
W1017697
1. During Straight Running
Rotation of the bevel pinion shaft (1) is transmitted to the spiral bevel gear (6) and differential case (2).
When road resistance to the right and left wheels are equal, differential pinions (4), (8) and differential side gears
(3), (7) are all rotate as a unit. Both front axles received equal input, and both wheels turn at the same speed, allowing
the machine to go straight ahead.
At this time, differential pinions (4), (8) do not rotate around the differential pinion shaft (5).
2. During Turning
When the machine turns, the road resistance to the inside tire increases (as if braking is applied to that side only).
In other words, if one of tires slows down, revolution difference is generated in the differential side gears (3), (7). When
rotation of one differential side gear becomes lower than the other, differential pinions (4), (8) begin rotating around
differential pinion shaft (5). The other differential side gear is increased in speed by the speed increment of differential
pinion shaft (5). This means that rotation of one front axle is slowed down and that of the other front axle is increased.
Thus, the machine turns smoothly without power loss.
The combined number of revolutions of the right and left differential side gears (3), (7) is always twice that of the
spiral bevel gear (6). When spiral bevel gear revolution is 100 min-1 (rpm), and if one of the differential side gears
stops moving, the revolution of the other differential side gear becomes 200 min-1 (rpm) and if one rotates at
50 min-1 (rpm), the other rotates at 150 min-1 (rpm)
2-M18
TRANSMISSION
[2] DIFFERENTIAL LOCK
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Differential Pinion
Differential Lock Shift Fork
Differential Lock Gear
Differential Gear Shaft
Differential Lock Clutch
Differential Case
Spiral Bevel Gear
When resistance to the right and left tires are greatly different due to ground conditions or type of work, the tire with
less resistance slips and prevents the machine from moving ahead. To compensate for this drawback, the differential
lock restricts the differential action and causes both front axles to rotate as a unit.
When the differential lock pedal is stepped on, it causes the differential lock lever (3) to rotate, which will move the
differential lock shift fork (2) and the differential lock clutch (5) toward the spiral gear (8). The differential lock clutch
(5) engaged with the teeth of the differential case (6) to cause the differential case (6) and the differential lock clutch
(5) to rotate as a unit.
Therefore, differential pinions (1) are unable to rotate around differential pinion shaft (7) and identical revolutions
are transmitted to the right and left differential gear shaft (4), (9).
2-M19
SERVICING
CONTENTS
1.
2.
3.
4.
TIGHTENING TORQUES ..............................................................................2-S6
CHECKING, DISASSEMBLING AND SERVICING......................................2-S7
[1] CHECKING AND ADJUSTING ...............................................................2-S7
[2] PREPARATION ......................................................................................2-S10
(1) Separating Transmission Assembly..................................................2-S10
(2) Separating Hydrostatic Transmission (HST).....................................2-S19
(3) Separating Transmission Case.........................................................2-S20
(4) Separating Differential Gear Case ....................................................2-S20
(1) Hydrostatic Transmission..................................................................2-S22
(2) Hydraulic PTO Clutch Assembly .......................................................2-S24
(3) RWD Case ........................................................................................2-S25
(4) Transmission Case ...........................................................................2-S26
(5) Differential Gear Case ......................................................................2-S27
[4] SERVICING ............................................................................................2-S29
(1) Hydrostatic Transmission..................................................................2-S29
(2) Hydraulic PTO Clutch .......................................................................2-S31
(3) Transmission Case ...........................................................................2-S32
(4) Differential Gear Case ......................................................................2-S33
TRANSMISSION
1. TROUBLESHOOTING
HYDROSTATIC TRANSMISSION SECTION
Solution
Reference
Page
Oil level is low
Fill oil to proper level
G-7, 2-S10
Control linkage defective (Speed control pedal to
speed change arm)
Repair control
linkage
2-S12, S14,
S16
Charge pressure is too
low
• Charge relief valve
defective
Replace charge relief
valve
• Oil filter cartridge
clogged
Replace oil filter
cartridge
• PTO charge relief
valve defective
Replace PTO charge
relief valve
2-S9, S19
Check and high pressure relief valve defective
Replace check and
high pressure relief
valve
2-S9, S22
HST component parts defective
Replace HST
assembly
2-S19, S22
to S23
Oil level is low
G-7, 2-S10
speed change arm)
Repair control
linkage
2-S12, S14,
S16
low
defective
valve
clogged
Replace oil filter
cartridge
valve defective
Replace PTO charge
relief valve
2-S9, S19
Replace check and
valve
2-S9, S22
Replace HST
assembly
2-S19, S22
to S23
Oil level is low
G-7, 2-S10
speed change arm)
Repair control
linkage
2-S12, S14,
S16
low
defective
valve
clogged
Replace oil filter
cartridge
valve defective
Replace PTO charge
relief valve
2-S9, S19
Replace check and
valve
2-S9, S22
Replace HST
assembly
2-S19, S22
to S23
Symptom
System Will Not
Operate in Either
Direction
Vibration and Noise
Loss of Power
Probable Cause
2-S8, S23
G-18
2-S8, S23
G-18
2-S8, S23
G-18
W1022927
2-S1
TRANSMISSION
HYDROSTATIC TRANSMISSION SECTION (Continued)
Solution
Reference
Page
Oil level is low
G-7, 2-S10
Radiator net clogged
Clean or flush
radiator net
–
Excessive machine load
Reduce machine
load
–
Symptom
Transmission Oil
Runs Too Hot
Probable Cause
low
defective
valve
clogged
Replace oil filter
cartridge
valve defective
Replace PTO charge
relief valve
Machine Will not
Stop in Neutral
Position
speed change arm)
Repair control
linkage
Improper adjustment of neutral arm holder shaft
Adjust
System Operate in
One Direction Only
speed change arm)
Repair control
linkage
Replace check and
valve
2-S8, S23
G-18
2-S9, S19
2-S12, S14,
S16
2-S7
2-S12, S14,
S16
2-S9, S22
W1023989
RANGE GEAR SHIFT SECTION
Symptom
Noise from
Transmission
Gear Slip Out of
Mesh
Probable Cause
Solution
Reference
Page
Transmission oil insufficient
Refil
G-7, 2-S10
Gear worn or broken
Replace
2-S20
Bearing worn
Replace
–
Shift fork worn
Replace
2-S20, S32
Shift fork bent
Replace
2-S20, S32
W1021570
PTO SECTION
Symptom
Probable Cause
Solution
Reference
Page
Loss of PTO Power
Clutch disc worn
Replace
2-S24, S31
PTO Noisy
PTO bearing worn
Replace
2-S24
PTO Clutch Cannot
be Disengaged even
if Clutch Lever is
Pulled to Disengage
Clutch disc worn
Replace
2-S24, S31
Improper oil pressure
Check
G-7, 2-S10
W1023839
2-S2
TRANSMISSION
DIFFERENTIAL CASE SECTION
Symptom
Excessive or
Unusual Noise at All
Times
Gear Slip Out of
Mesh
Probable Cause
Reference
Page
Solution
Improper backlash between bevel pinion shaft
and spiral bevel gear
Adjust
2-S34
Improper backlash between differential case and
differential side gear
Adjust
2-S33
Bearing worn
Replace
Insufficient or improper type of transmission fluid
used
Replenish or Replace
Differential pinions or differential side gears worn
or damaged
Replace
2-S28
Differential lock binding (does not disengage)
Replace
3-S4
Bearing worn
Replace
–
–
G-7, 2-S10
W1025803
2-S3
TRANSMISSION
Item
Adjusting Screw Length
Check and High Relief Pressure
Charge Pressure
Allowable Limit
Approx. 15 mm
Approx. 0.59 in.
15 to 20 mm
0.59 to 0.79 in.
34.3 MPa
350 kgf/cm2
4975 psi
–
0.40 to 0.58 MPa
4.0 to 6.0 kgf/cm2
57 to 85 psi
–
Cylinder Block Bore to Piston
Clearance
0.02 mm
0.0008 in.
0.04 mm
0.0016 in.
Piston Slipper
Thickness
3.00 mm
0.118 in.
2.90 mm
0.114 in.
PTO Brake Plate
Thickness
4.35 to 4.65 mm
0.1713 to 0.1830 in.
4.25 mm
0.1673 in.
PTO Brake Disc
Thickness
3.65 to 3.95 mm
0.1437 to 0.1555 in.
3.30 mm
0.1299 in.
Pressure Plate
Thickness
1.95 to 2.05 mm
0.0768 to 0.0807 in.
1.80 mm
0.0709 in.
Clutch Disc
Thickness
1.90 to 2.10 mm
0.0748 to 0.0827 in.
1.60 mm
0.0630 in.
Steel Plate
Thickness
0.95 to 1.05 mm
0.0374 to 0.0413 in.
0.80 mm
0.0315 in.
Clutch Shaft to 16T - 33T Gear
Clearance
0.007 to 0.047 mm
0.0003 to 0.0018 in.
0.10 mm
0.0039 in.
16T-33T Gear
I.D.
26.007 to 26.028 mm
1.0239 to 1.0247 in.
–
Clutch Shaft
O.D.
21.987 to 22.000 mm
0.8657 to 0.8661 in.
–
Needle
O.D.
1.997 to 2.000 mm
0.0786 to 0.0787 in.
–
Shift Fork to 15T - 26T
Clearance
0.03 to 0.40 mm
0.0001 to 0.015 in.
0.5 mm
0.020 in.
Differential Case (Spiral Bevel Gear) to
Clearance
0.025 to 0.066 mm
0.0010 to 0.0025 in.
0.30 mm
0.0118 in.
Differential Case
I.D.
32.000 to 32.025 mm
1.2599 to 1.2608 in.
–
Spiral Bevel Gear
I.D.
32.000 to 32.025 mm
1.2599 to 1.2608 in.
–
O.D.
31.959 to 31.975 mm
1.2582 to 1.2588 in.
–
W1027349
2-S4
TRANSMISSION
(Continued)
Item
Differential Pinion Shaft to Differential
Pinion
Clearance
Allowable Limit
0.016 to 0.045 mm
0.0007 to 0.0018 in.
0.30 mm
0.0118 in.
Differential Pinion
I.D.
16.000 to 16.018 mm
0.6300 to 0.6306 in.
–
O.D.
15.973 to 15.984 mm
0.6289 to 0.6292 in.
–
0.1 to 0.3 mm
0.004 to 0.011 in.
0.4 mm
0.016 in.
Differential Pinion to Differential Side Gear
Backlash
Bevel Pinion Shaft
Side Clearance
Less than 0.15 mm
Less than 0.006 in.
–
Bevel Pinion Shaft to Spiral Bevel Gear
Backlash
0.10 to 0.30 mm
0.0040 to 0.0118 in.
–
W1027629
2-S5
TRANSMISSION
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8)
Item
N·m
kgf·m
ft-lbs
Holder shaft mounting screw
23.5 to 27.4
2.40 to 2.79
17.4 to 20.2
Oil strainer
98.1 to 137.2
10.0 to 14.0
72.4 to 101.2
ROPS mounting screw
123 to 147
12.6 to 14.9
90.8 to 108.4
17.7 to 20.5
1.8 to 2.1
13.1 to 15.1
Power steering hose mounting nut
24.6 to 29.4
2.5 to 3.0
18.1 to 21.6
Power steering pipe mounting nut
54.0 to 63.7
5.5 to 6.5
39.8 to 47.0
Delivery pipe mounting nut
39.3 to 47.0
4.0 to 5.0
28.9 to 36.1
Drive shaft mounting screw
27.5 to 29.4
2.8 to 3.0
20.3 to 21.6
Transmission mounting screw (M12)
62.8 to 72.5
6.4 to 7.4
46.3 to 53.5
Side frame mounting screw and nut
62.8 to 72.5
6.4 to 7.4
46.3 to 53.5
Front wheel mounting nut
39.3 to 44.1
4.0 to 4.5
29.0 to 32.5
PTO pipe mounting nut
54.0 to 63.7
5.5 to 6.5
39.8 to 47.0
HST mounting screw (M8)
23.6 to 27.4
2.4 to 2.8
17.4 to 20.2
39.3 to 44.1
4.0 to 4.5
29.0 to 32.5
Transmission case mounting screw and nut
39.3 to 44.1
4.0 to 4.5
29.0 to 32.5
Hydraulic cylinder mounting screw and nut
39.3 to 44.1
4.0 to 4.5
29.0 to 32.5
Front axle case mounting screw
39.3 to 44.1
4.0 to 4.5
29.0 to 32.5
Center section hex. socket screw
49.0 to 58.8
5.0 to 6.0
36.2 to 43.4
Valve plug
58.8 to 98.1
6.0 to 10.0
43.4 to 72.3
Differential bearing holder mounting screw
17.7 to 20.5
1.8 to 2.1
13.1 to 15.1
Spiral bevel gear UBS screw
29.5 to 34.3
3.0 to 3.5
21.7 to 25.3
W1012736
2-S6
TRANSMISSION
Adjustment of HST Neutral Position
1. Check the adjusting screw length (L). If measurement is not
within the factory specifications, adjust the adjusting screw (2).
2. Lift the front and rear of machine so that the front and rear wheels
are off the ground.
3. Remove the right front wheel.
4. Run the engine at low idle speed.
5. Loosen the holder shaft mounting screw (6).
6. Rotate the holder shaft (5) counterclockwise so that the front axle
shafts turn forward.
7. Then rotate it clockwise until the front axles stop completely.
8. Put a mark on the side frame (Position A).
9. Rotate the holder shaft (5) clockwise so that the front axle shafts
turn reverse.
10.Then rotate it counterclockwise until the front axles stop
completely.
11.Put a mark on the side frame (Position B).
12.Set the holder shaft (1) where it is right in the center between
position A and B, and tighten the holder shaft mounting screw (6)
firmly.
This means the hydrostatic transmission is fully in neutral.
(Position N)
Adjusting screw length
“L”
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Factory spec.
15.0 mm
0.59 in.
Allowable limit
15 to 20 mm
0.59 to 0.79 in.
Holder shaft mounting
screw
Adjusting Lock Nut
Adjusting Screw
Neutral Spring
Plate
Holder Shaft
Holder Shaft Mounting Screw
L:
A:
B:
N:
23.5 to 27.4 N·m
2.40 to 2.79 kgf·m
17.4 to 20.2 ft-lbs
Adjusting Screw Length
Position A
position B
Position N
W1011821
Adjusting Speed Control Rod
■ NOTE
• Before adjusting the neutral of HST, adjust the brake
system.
1. After adjusting the neutral of HST, pull the parking lock lever (3).
2. Check that the groove of brake lock (5) engages with the pin of
speed control bracket (6) smoothly.
3. If not, adjust the length of speed control rod (2) with the
turnbuckle (1).
■ NOTE
• After adjustment, secure the turnbuckle (1) with the lock
nuts (8).
(1)
(2)
(3)
(4)
Turnbuckle
Speed Control Rod
Parking Lock Lever
Main Brake Pedal
(5)
(6)
(7)
(8)
Groove of Brake Lock
Pin of Speed Control Bracket
Lock Nut
W1021165
2-S7
TRANSMISSION
Charge Pressure
CAUTION
• When checking, park the machine on flat ground, apply the
parking brake.
■ NOTE
• Use a new transmission oil filter cartridge.
1. Remove the seat assembly and plate (1).
2. Remove the plug (R 1/4) from P2 port (2).
3. Assemble the adaptor 58 (Code No. 07916-52391) and threaded
joint (Code No. 07916-50341).
4. Install the assembled adaptor 58 and threaded joint to P2 port
(2).
5. Then, connect the cable (Code No. 07916-50331), threaded joint
(Code No. 07916-51301) to threaded joint in order.
6. Reinstall the seat assembly.
7. Run the engine at maximum speed.
8. Place the high-low gear shift lever in neutral.
9. Release the speed control pedal to set in neutral, and measure
the charge pressure.
10.If the charge pressure is not within the factory specifications,
change the charge relief valve assembly in HST.
(When reassembling)
• Install the plug (R 1/4) to P2 port (2) with seal tape.
Charge pressure
(Oil temperature at 50 to
60 °C (122 to 140 °F))
(1) Plate
Factory spec.
0.40 to 0.58 MPa
4.0 to 6.0 kgf/cm2
57 to 85 psi
(2) P2 Port
W1031768
2-S8
TRANSMISSION
HST High Relief Pressure
CAUTION
parking brake.
2. Remove the plug (R 1/4) from P1 (1) or P3 (3) port. (P3 is for
forward and P1 is for reverse)
3. Assemble the adaptor 58 (Code No. 07916-52391) and threaded
joint (Code No. 07916-50341).
4. Install the assembled adaptor 58 and threaded joint to P3 (3) or
P1 (1) port.
5. Then, connect the cable (Code No. 07916-50331), threaded joint
(Code No. 07916-51301) and pressure gauge to threaded joint in
order.
7. Run the engine at maximum speed.
8. Place the high-low gear shift lever in high.
9. Depress the speed control pedal, and measure the high relief
pressure.
10.If the measurement is not factory specification, change the check
and high relief valve assembly.
■ IMPORTANT
• Measure quickly otherwise the relief valve may not be in
operation more than 10 seconds
(When reassembling)
• Install the plug (R 1/4) to P1 (1) or P3 (3) port with seal tape.
High relief pressure
60 °C (122 to 140 °F))
(1) P1 Port (Reverse)
(2) Plate
Factory spec.
34.3 MPa
350 kgf/cm2
4975 psi
(3) P3 Port (Forward)
W1033699
PTO Charge Pressure
CAUTION
parking brake.
■ NOTE
• Use a new transmission oil filter.
2. Unscrew the plug (1) from the oil filter bracket.
3. Install the adaptor D. Then connect the cable and pressure
gauge to adaptor D.
5. Start the engine and set at maximum speed.
6. PTO lever is set to “ENGAGE” position, and read the gauge.
7. If the pressure is not within the factory soecification, adjust with
the adjusting screw (3).
PTO charge pressure
60 °C (122 to 140 °F))
(1) Plug
(2) Plate
Factory spec.
785 to 1078 kPa
8.0 to 11.0 kgf/cm2
114 to 156 psi
(3) Adjusting Screw
W1056633
2-S9
TRANSMISSION
[2] PREPARATION
(1) Separating Transmission Assembly
Battery and Battery Support
•
•
1.
2.
3.
4.
5.
CAUTION
When disconnecting the battery cables, disconnect the
negative cable from the battery first.
When connecting, connect the positive cable to the battery
first.
Disconnect the negative cable (4) from the battery.
Disconnect the positive cable (1) from the battery.
Unscrew the battery mounting nuts (2), and remove the battery
(3).
Push out the wiring clip (6) with the wiring from the hole of the
battery support (5).
Unscrew the battery support mounting screws, and remove the
battery support (5).
(1) Positive Cable
(2) Battery Mounting Nut
(3) Battery
(4) Negative Cable
(5) Battery Support
(6) Wiring Clip
4. After draining, reinstall the three drain plug and tighten.
(When reassembling)
the dipstick (2).
level.
Transmission fluid
Capacity
14.0 L
14.8 U.S.qts
12.3 Imp.qts
■ IMPORTANT
G-7.).
(1) Drain Plug
(2) Dipstick
(3) Oil Inlet
A : Upper Level
B : Lower Level
W1012046
2-S10
TRANSMISSION
Hydraulic Front Suction Pipe
1. Place oil pans underneath the rubber hose (4) and oil strainer (2).
2. Remove the rubber hose (4) from the front suction pipe (3).
3. Unscrew the front suction pipe mounting screw (1).
4. Unscrew the oil strainer (2), and remove the oil strainer and front
suction pipe (3).
(When reassembling)
Tightening torque
98.1 to 137.2 N·m
10.0 to 14.0 kgf·m
72.4 to 101.2 ft-lbs
Oil strainer
(1) Front Suction Pipe Mounting Screw
(2) Oil Strainer
(4) Rubber Hose
W1012305
Seat
Tightening torque
(1) Seat
17.7 to 20.5 N·m
1.8 to 2.1 kgf·m
13.1 to 15.1 ft-lbs
W1040675
Panel
light switch.
(1) Front Panel
(2) 4P Connector
(3) 3P Connector
(4) Rear Panel
(5) Horn
W1040859
2-S11
TRANSMISSION
Fender
1. Remove the differential lock pedal (1) and brake lock lever (3).
2. Remove the main brake pedal (2), speed control pedal (4).
3. Remove the lever grips from hydraulic lift lever (5) and PTO lever
(7).
4. Remove the lever grip from high-low gear shift lever (6).
5. Remove the lever grip from 4WD lock lever (9).
6. Remove the fender (8).
(1)
(2)
(3)
(4)
(5)
Differential Lock Pedal
Main Brake Pedal
Brake Lock Lever
Speed Control Pedal
Hydraulic Lift Lever
(6)
(7)
(8)
(9)
High-Low Gear Shift Lever
PTO Lever
Fender
4WD Lock Lever
W1041101
Fuel Tank
1. Disconnect the fuel hose and return hose from the fuel tank (1).
2. Disconnect the 1P connector from the fuel sensor.
3. Remove the fuel tank (1).
4. Remove the dust under plate (2).
5. Remove the fuel tank rear support (3).
(1) Fuel Tank
(2) Dust Under Plate
(3) Fuel Tank Rear Support
W1041351
2-S12
TRANSMISSION
Wirings, Power Steering Hoses and Pipe
1. Remove the accelerator wire (1).
2. Disconnect the connectors (4) (5) (6), and remove the wire
harness (2) from the steering post (10).
3. Disconnect the power steering hoses and pipe (3) (7) (8) (9) from
the power steering controller (11).
4. Remove the return pipe (3).
(When reassembling)
• Apply grease to the O-ring on the return pipe (3)
■ IMPORTANT
• Be sure to connect the power steering hoses and pipes (3)
(7) (8) (9) to their original position, and tighten them to the
specified torque.
Power steering hose
mounting screw
24.6 to 29.4 N·m
2.5 to 3.0 kgf·m
18.1 to 21.6 ft-lbs
Power steering pipe
mounting screw
54.0 to 63.7 N·m
5.5 to 6.5 kgf·m
39.8 to 47.0 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Accelerator Wire
Wire Harness
Return Pipe 1
10P Connector
2P Connector
4P Connector
Cylinder Hose 2
Cylinder Hose 1
Delivery Hose
Steering Post
R : R Port
(Connect to Cylinder Hose 2)
L : L Port
P : P Port
(Connect to Delivery Hose)
T : T Port (Connect to Return Pipe 1)
(a) Front Side
W1041728
2-S13
TRANSMISSION
Speed Control Rod, Lowering Speed Adjusting Rod and
Hydraulic Pipes
1. Remove the speed control rod (1).
2. Remove the plate (5).
3. Remove the external snap ring (8) and straight pin (11), and pull
out the lowering speed adjusting rod (2).
4. Remove the external snap ring (6) and straight pin (10), and pull
out the joint (7).
5. Remove the bracket (9).
6. Remove the return pipe 2 (4) and delivery pipe (3).
(When reassembling)
• Apply grease to the O-ring on the return pipe 2 (4)
■ IMPORTANT
• Be sure to tighten the delivery pipe mounting nuts to
specified torque.
• Apply liquid lock (Three Band 1324 or its equivalent) to the
plate mounting screws.
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Delivery pipe mounting nut
Speed Control Rod
Lowering Speed Adjusting Rod
Delivery Pipe
Return Pipe 2
Plate
External Snap Ring
(7)
(8)
(9)
(10)
(11)
39.3 to 49.0 N·m
4.0 to 5.0 kgf·m
28.9 to 36.1 ft-lbs
Joint
External Snap Ring
Bracket
Straight Pin
Straight Pin
W1042155
Fuel Filter and Fuel Pump
1. Disconnect 2P connector (2) from the PTO switch.
2. Disconnect 2P connector (4) from the fuel pump (1).
3. Remove the fuel filter (3) and fuel pump (1).
4. Remove the negative cable (5).
(1) Fuel Pump
(2) 2P Connect (for PTO Switch)
(3) Fuel Filter
(4) 2P Connector (for Fuel Pump)
(5) Negative Cable
W1042801
2-S14
TRANSMISSION
Rear Wheel Drive Shaft
1. Slide the external snap ring (2) and coupling (1).
2. Remove the rear wheel drive shaft (3).
(When reassembling)
• Apply grease to the all splines.
■ IMPORTANT
• If the external snap ring is defective, replace it.
• Securely fit the external snap rings (2) of the rear drive shaft.
(1) Coupling
(2) External Snap Ring
W1015882
Drive Shaft
1. Unscrew the drive shaft mounting screws (2).
2. Remove the drive shaft (1) from HST pump shaft.
(When reassembling)
■ NOTE
• Apply grease to the splines on the drive shaft and HST pump
shaft.
■ IMPORTANT
• Be sure to tighten the drive shaft mounting screws (2) to the
specified torque.
Tightening torque
Drive shaft mounting
screw
(1) Drive Shaft
27.5 to 29.4 N·m
2.8 to 3.0 kgf·m
20.3 to 21.6 ft-lbs
(2) Drive Shaft Mounting Screw
W1016116
Separating Transmission Case and Engine Frame
1. Support the rear end of the transmission and frame.
2. Unscrew the transmission mounting screws (1) (2), and separate
the transmission case and engine frame.
(When reassembling)
■ NOTE
• Apply liquid lock (Three Bond 1324 or its equivalent) to the
transmission mounting screws (1), (2).
• Screw in the reamer screws (2), first.
Tightening torque
Transmission mounting
screw (M12)
(1) Transmission Mounting Screw
62.8 to 72.5 N·m
6.4 to 7.4 kgf·m
46.3 to 53.5 ft-lbs
(2) Transmission Mounting Screw
(Reamer)
W1043384
2-S15
TRANSMISSION
Fender Support and Connecting Plate
1. Remove the fender supports (1), (3).
2. Remove the connecting plate (2).
(1) Fender Support (LH)
(2) Connecting Plate
(3) Fender Support (RH)
W1043605
Lever and Rod
1. Remove the 4WD lever rod (2) and 4WD lever (1).
2. Remove the PTO control rod (3) and PTO lever (4).
(1) 4WD Lever
(2) 4WD Lever Rod
(3) PTO Control Rod
(4) PTO Lever
W1043870
Neutral Arm, Speed Change Arm and Side Frame
1. Remove the neutral spring (3).
2. Unscrew the holder shaft mounting screw (6) and remove the
neutral arm (5).
3. Remove the speed change arm (4).
4. Remove the brake return spring (8) and lift spring rod (7).
5. Remove the side frames (1), (2).
(When reassembling)
■ NOTE
side frame mounting screws and speed change arm
mounting screw.
• Adjust the length “A” of adjusting screw (10) with adjusting
nuts (9).
• Adjust the length “B” of lift spring rod (7) with adjusting nuts
(11).
Tightening torque
Side frame mounting
screw and nut
62.8 to 72.5 N·m
6.4 to 7.4 kgf·m
46.3 to 53.5 ft-lbs
(Reference)
• Length “A” : 15 to 20 mm (0.59 to 0.78 in.)
• Length “B” (LH) : 70 mm (2.8 in.)
• Length “B” (RH) : 50 mm (2.0 in.)
(1)
(2)
(3)
(4)
(5)
(6)
Side Frame (LH)
Side Frame (RH)
Neutral Spring
Speed Change Arm
Neutral Arm
Holder Shaft Mounting Screw
(7)
(8)
(9)
(10)
(11)
Lift Spring Rod
Brake Return Spring
Adjusting Nut
Adjusting Screw
Adjusting Nut
W1043994
2-S16
TRANSMISSION
Support Plate
1. Remove the support plate (1) from the front frame.
(1) Support Plate
W1044828
Brake Rod, Differential Lock Rod and Mower Lift Lever
1. Remove the brake rod 1 (2) and differential lock rod (1).
2. Remove the feedback rod (3).
3. Remove the hydraulic control lever assembly (4).
(When reassembling)
• Adjust the length “A” of the feedback rod (3).
(Reference)
(1) Differential Lock Rod
(2) Brake Rod 1
(3) Feedback Rod
(4) Hydraulic Control Lever Assembly
W1045187
Mower Lift Arm and Front Wheel
1. Remove the cotter pin and clevis pin, and disconnect the lift link
(1) and lift arm (2).
2. Remove the front wheel (3).
3. Unscrew the pin mounting screw and pull out the mower lift arm
pin (4), and remove the mower lift arm (5).
(When reassembling)
• Apply grease to the mower lift arm pin (4) and pivot of mower lift
arm.
■ IMPORTANT
• Be sure to tighten the front wheel mounting nuts to the
specification torque.
Tightening torque
(1) Lift Link
(2) Lift Arm
(3) Rear Wheel
Front wheel mounting nut
39.3 to 44.1N·m
4.0 to 4.5 kgf·m
29.0 to 32.5 ft-lbs
(4) Mower Lift Arm Pin
(5) Mower Lift Arm
W1045417
2-S17
TRANSMISSION
Brake Rod 2 and Front Frame
1. Remove the snap pin (5) and two clevis pins (3), and slide the
brake arm 2 (4).
2. Remove the brake rod 2 (1).
3. Remove the brake switch (2).
4. Remove the front frame (6).
(When reassembling)
■ NOTE
front frame mounting screws.
(1) Brake Rod 2
(2) Brake Switch
(3) Clevis Pin
(4) Brake Arm 2
(5) Snap Pin
(6) Front Frame
W1045685
2-S18
TRANSMISSION
(2) Separating Hydrostatic Transmission (HST)
PTO Pipe, Oil Filter Bracket and RWD Case
1. Unscrew PTO pipe mounting nut (1), and remove PTO pipe (2).
2. Remove the oil filter bracket (4).
3. Remove the RWD case (3) with the dual-acting overrunning
clutch and PTO clutch.
(When reassembling)
• When reassembling RWD case (3), apply grease to O-ring and
oil seal.
• Apply liquid gasket (Three Bond 1208D or its equivalent) to joint
surface of RWD case (3).
• When connecting PTO pipe (2) and RWD case (3), apply grease
to the O-ring and take care not to damage them.
• When assemble the oil filter bracket (4), apply grease to the Oring.
■ IMPORTANT
• Be sure to tighten PTO pipe mounting nut (1) to the specified
torque.
Tightening torque
PTO pipe mounting nut
(1) PTO Pipe Mounting Nut
(2) PTO Pipe
54.0 to 63.7 N·m
5.5 to 6.5 kgf·m
39.8 to 47.0 ft-lbs
(3) RWD Case
(4) Oil Filter Bracket
Separating Hydrostatic Transmission (HST)
1. Remove the external snap ring (3) from RWD shaft 1 (2). (Only
4WD Model)
2. Separate HST (1) from transmission case.
(When reassembling)
• Apply liquid gasket (Three Bond 1208D or its equivalent) to the
joint surface of transmission case.
■ NOTE
• Securely fit the external snap ring (3) to RWD shaft 1 (2).
■ IMPORTANT
• Be sure to tighten HST mounting screws to the specified
torque.
23.6 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
HST mounting screw
(M10)
39.3 to 44.1 N·m
4.0 to 4.5 kgf·m
29.0 to 32.5 ft-lbs
Tightening torque
(1) HST
(2) RWD Shaft 1
W1046998
2-S19
TRANSMISSION
(3) Separating Transmission Case
PTO Clutch Shaft Assembly
1. Remove the range gear shift lever (6).
2. Remove the PTO clutch shaft with hydraulic PTO clutch
assembly (5), 33T Gear (2) and 16T-33T gear, and remove the
RWD shaft 1 (3) with 34T gear (4).
(When reassembling)
• Insert the PTO brake disc into the stud bolt (1) as shown in the
figure.
(1) Stud Bolt
(2) 33T Gear
(3) RWD Shaft 1
(4) 34T Gear
(5) Hydraulic PTO Clutch Assembly
(6) Range Gear Shift Lever
W1047327
Separating Transmission Case
1. Remove the transmission case (1) from the differential gear case.
(When reassembling)
surface of transmission case (1).
■ IMPORTANT
• Be sure to tighten the transmission case mounting screws
and nut.
Tightening torque
Transmission case
mounting screw and nut
(1) Transmission Case
39.3 to 44.1 N·m
4.0 to 4.5 kgf·m
29.0 to 32.5 ft-lbs
(2) Differential Gear Case
W1047514
(4) Separating Differential Gear Case
Hydraulic Cylinder Assembly
1. Remove the hydraulic cylinder assembly (1) from the differential
gear case.
(When reassembling)
surface of the differential gear case and hydraulic cylinder
assembly (1).
• Check the face of stopper plate (2) as shown in the figure.
Tightening torque
Hydraulic cylinder
(1) Hydraulic Cylinder Assembly
39.3 to 44.1 N·m
4.0 to 4.5 kgf·m
29.0 to 32.5 ft-lbs
(2) Stopper Plate
W1047870
2-S20
TRANSMISSION
Front Axle Case
1. Remove the front axle case (1) from the differential gear case (2).
(When reassembling)
surface of the differential gear case (2) and front axle cases (1).
Tightening torque
(1) Front Axle Case
Front axle case mounting
screw
39.3 to 44.1 N·m
4.0 to 4.5 kgf·m
29.0 to 32.5 ft-lbs
W1048133
2-S21
TRANSMISSION
Gears
1. Remove the ball bearing (4) and 28T gear (5).
2. Remove the external snap ring (3) and 30T gear (2).
(1) Center Section
(2) 30T Gear
(4) Ball Bearing
(5) 28T Gear
W1034318
Center Section
1. Remove the center section mounting hex. socket head screws.
2. Separate the center section (2) from HST housing.
(When reassembling)
• Cover the splines of each shaft with thin tape to protect sealing
lip.
• Apply grease to the oil seals for the pump and motor shaft.
• Place a new gasket on the housing.
• Install center section with valve plates in place.
■ IMPORTANT
• Valve plates (1), (3) may stick to the center section but they
are not fixed. Take care not to drop them.
• Be sure to tighten the hex. socket head screws to the
specified torque.
Tightening torque
Center section hex. socket
screw
(1) Valve Plate of Pump
(2) Center Section
49.0 to 58.8 N·m
5.0 to 6.0 kgf·m
36.2 to 43.4 ft-lbs
(3) Valve Plate of Motor
W1034463
Check and High Pressure Relief Valve
1. Remove the valve plug (1), and remove the check valve spring
(2) and relief valve assembly (3).
(When reassembling)
• Take care not to damage the O-ring on the plug.
Tightening torque
Valve plug
(1) Valve Plug
(2) Check Valve Spring
58.8 to 98.1 N·m
6.0 to 10.0 kgf·m
43.4 to 72.3 ft-lbs
(3) Check and High Pressure Relief
Valve Assembly
W1034707
Motor Cylinder Block and Pump Cylinder Block
1. Pull out the output shaft (4) and motor cylinder block (3) with
pistons as a unit.
2. Slide out the pump cylinder block (2) with pistons.
(1) Input Shaft
(2) Pump Cylinder Block
(3) Motor Cylinder Block
(4) Output Shaft
W1034865
2-S22
TRANSMISSION
Input Shaft
1. Remove the internal snap ring (4) and remove the oil seal (3).
2. Remove the external snap ring (2).
3. Tap out the input shaft (1) to the cylinder block side.
(1) Input Shaft
(3) Oil Seal
(4) Internal Snap Ring
W1034986
Cover “A”, “B” and Trunnion Shaft
1. Remove the internal snap rings (1) (5) both side.
2. Tap the trunnion shaft (3) using a soft hammer to create a
clearance between the case and the cover “B” (4).
Then, pry the cover “B” (4) open with a screw-driver. Pry the
cover “A” (2) in the same way.
3. Take out the trunnion shaft (3).
(When reassembling)
■ NOTE
• Take care not to damage the O-rings.
(2) Cover “A”
(3) Trunnion Shaft
(3) Cover “B”
W1035205
Charge Relief Valve
1. Remove the internal snap ring (1) and remove the plug (2).
2. Remove the spring (3) and push out the charge relief poppet (4).
(When reassembling)
■ NOTE
• Take care not to damage the O-ring.
(2) Plug
(3) Spring
(4) Charge Relief Poppet
W1035400
2-S23
TRANSMISSION
(2) Hydraulic PTO Clutch Assembly
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Ball Bearing
Needle Bearing
16T-33T Gear
Needle Bearing
PTO Brake Disc
Clutch Case
D-ring
Piston
Return Spring
Collar
External Snap Ring
External Snap Ring
PTO Brake Plate
Steel Plate
Clutch Disc
Pressure Plate
Internal Snap Ring
Clutch Shaft
Ball Bearing
33T Gear
Internal Snap Ring
Thrust Collar
O-ring
Ball Bearing
Thrust Collar
Ball Bearing
Seal Ring
W1016737
1.
2.
3.
4.
5.
6.
Remove the ball bearing (1) and remove the 16T-33T gear (3) with the needle bearings (2), (4).
Remove the external snap ring (12), and remove PTO brake plate (13), PTO brake disc (5) and thrust collar.
Remove the ball bearing (26), and remove the 33T gear (20) with the ball bearings (19), (24).
Slide out the hydraulic PTO clutch assembly from the clutch shaft (18).
Remove the internal snap ring (17), and remove the pressure plate (16), clutch discs (15) and steel plates (14).
Press the collar and remove the external snap ring (11), and remove the piston (8).
CAUTION
• Return spring (9) is under pressure and retained by external snap ring (11). Carefully compress return
spring (9) before trying to remove external snap ring (11), then carefully release pressure after external
snap ring (11) is removed.
(When reassembling)
• Apply transmission fluid to O-ring (23), D-ring (7), seal ring (27) and take care not to damage it.
• Replace O-ring, D-ring and seal ring, if it is defective.
2-S24
TRANSMISSION
(3) RWD Case
RWD Case
1. Remove the external snap ring (6) and pull out the PTO control
valve (1).
2. Remove the external snap ring (15) and pull out the shift rod (8),
and remove the shift fork (13).
3. Remove the dual-acting overrunning clutch (11) and thrust collar
(10) from RWD shaft 2 (9).
4. Pull out RWD shaft 2 (9) from RWD case (3).
5. Remove the clutch bracket (12) from the dual-acting overrunning
clutch.
(When reassembling)
• Take care not to damage the O-rings (7) on the shift rod (8).
■ NOTE
• When inserting the shift rod (8), take care not to damage the
surface of shift rod.
• Apply transmission oil to the thrust collar (10).
• When assembling the dual-acting overrunning clutch (11)
into RWD shaft 2 (9), aligning the positions (A), (B) as shown
in the figure.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
PTO Control Valve
O-ring
RWD Case
Ball Bearing
Oil Seal
External Snap Ring
O-ring
Shift Rod
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
RWD Shaft 2
Thrust Collar
Dual-acting Overrunning Clutch
Clutch Bracket
Shift Fork
O-ring
External Snap Ring
Brake Ring
(Dual-acting Overrunning Clutch)
W1024639
2-S25
TRANSMISSION
Dual-acting Overrunning Clutch Assembly
1. Remove the internal snap ring (1), drive cam (2), pins (3), center
cam (4), return spring (5), driven cam (6) and thrust collar (7)
from the clutch case (13).
2. Remove the external snap ring (8), washer (9), brake ring (10),
garter spring (11) and brake shoe (12) from the clutch case (13).
(When reassembling)
• When assembling the washer (9) into the brake ring (10), apply
transmission oil to the washer (9).
• When assembling the driven cam (6), apply transmission oil to
the thrust collar (7) and driven cam (6).
• When installing the center cam (4), take care not to damage the
brake shoe (12).
• When installing the drive cam (2), be sure to align the gear of
center cam (4) and drive cam (2).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Internal Snap Ring
Drive Cam
Pin
Center Cam
Return Spring
Driven Cam
Thrust Collar
(8)
(9)
(10)
(11)
(12)
(13)
External Snap Ring
Washer
Brake Ring
Garter Spring
Brake Shoe
Clutch Case
W1024976
Bevel Pinion Shaft and 18T - 17T Gear Shaft
1. Remove the bevel pinion shaft (3) from the transmission case (1).
2. Remove the external snap ring (4) and 11T gear (5).
3. Remove the ball bearing (6) and 15T - 26T gear (7).
4. Remove the external snap ring (9) and two ball bearings (8).
5. Remove the 18T - 17T gear shaft (2) from the transmission case
(1).
(When reassembling)
■ NOTE
• When installing the bevel pinion shaft (3) in the transmission
case (1), be sure to install the shim.
(1)
(2)
(3)
(4)
(5)
Transmission Case
18T - 17T Gear Shaft
Bevel Pinion Shaft
External Snap Ring
11T Gear
(6)
(7)
(8)
(9)
Ball Bearing
15T - 26T Gear
Ball Bearing
External Snap Ring
W1050638
2-S26
TRANSMISSION
Front Cover
1. Remove the front cover (1) with the PTO shaft (2) from the
differential gear case (3).
(When reassembling)
surface of the differential gear case (3) and front cover (1).
(1) Front Cover
(2) PTO Shaft
W1051118
Removing Differential
1. Remove the bearing holder mounting screws, and remove the
differential bearing holder (1).
2. Remove the differential assembly.
3. Remove the internal snap ring (5) from the differential gear case
right side.
(When reassembling)
• Install the differential assembly (3), noting the number of shims
(2), (4).
Tightening torque
Differential bearing holder
mounting screw
(1) Differential Bearing Holder
(2) Shim
(3) Differential Assembly
17.7 to 20.5 N·m
1.8 to 2.1 kgf·m
13.1 to 15.1 ft-lbs
(4) Shim
W1027403
Bearings
1. Remove the right and left bearings from the differential case.
■ NOTE
• Be careful to note location of all shims when disassembling.
Shims will need to be reinstalled in the location they came
from.
W1027669
Spiral Bevel Gear
1. Remove the spiral bevel gear UBS screws (1).
2. Remove the spiral bevel gear (2) from differential case (3).
(When reassembling)
• Apply liquid lock (Three Bond 1324 or its equivalent) to the spiral
bevel gear UBS screws.
Tightening torque
Spiral bevel gear UBS
screw
(1) Spiral Bevel Gear UBS Screw
(2) Spiral Bevel Gear
29.5 to 34.3 N·m
3.0 to 3.5 kgf·m
21.7 to 25.3 ft-lbs
(3) Differential Case
W1027735
2-S27
TRANSMISSION
Differential Side Gear and Differential Pinion
1. Put parting marks on the differential pinion (2) and the differential
side gear (1).
2. Tap out the dowel pin (3).
3. Remove the differential pinion shaft.
4. Remove the differential pinion (4), differential side gear (1) and
shim (5).
(When reassembling)
• Install the differential pinion and differential side gear, aligning
the parting marks.
(1) Differential Side Gear
(2) Differential Pinion
(3) Dowel Pin
(4) Differential Pinion
(5) Shim
W1027910
2-S28
TRANSMISSION
[4] SERVICING
Pump Shaft and Motor Shaft
1. Check the seal surface (1) and the bearing surface (2).
2. If the shaft is rough or grooved, replace it.
(1) Seal Surface
(2) Bearing Surface
(3) Motor Shaft
(4) Pump Shaft
W1024186
Cylinder Block Bore and Pistons
1. Lift all the pistons gently with the retainer plate (1).
2. Check the pistons for their free movement in the cylinder block
bores.
3. If the piston or the cylinder block bore is scored, replace cylinder
block assembly.
■ IMPORTANT
• Do not interchange pistons between pump and motor
cylinder block. Pistons and cylinder blocks are matched.
Clearance between
piston and bore
(1) Retainer Plate
(2) Piston
Factory spec.
0.02 mm
0.0008 in.
Allowable limit
0.04 mm
0.0016 in.
(3) Cylinder Block
W1035703
Piston Slipper
1. Check the slipper (1) for flatness.
2. If rounded, replace it.
3. Measure the thickness of piston slipper.
4. If the measurement is less than the allowable limit, replace.
5. Check the lubricant hole (2) for clogging.
■ IMPORTANT
• Do not interchange pistons between pump and motor
cylinder block. Pistons and cylinder blocks are matched.
Factory spec.
3.00 mm
0.118 in.
Allowable limit
2.90 mm
0.114 in.
Thickness of slipper
(1) Piston Slipper
(2) Lubricant Hole
W1035895
Cylinder Block Face
1. Check the polished face (1) of cylinder block for scoring.
2. If scored, replace cylinder block assembly.
3. Check the spring (2) for breakage.
4. If broken, replace cylinder block assembly.
(1) Polished Face
(2) Spring
W1036188
2-S29
TRANSMISSION
Valve Plate
1. Check the engagement of the valve plate (1) and the anchor pin
(2).
2. Pushing the valve plate against the anchor pin, lift it to remove.
3. Check the valve plate for foreign particles.
4. Clean the valve plate and dry with compressed air.
5. Check the valve plate for scratches, wear and erosion. (Run a
finger nail across the valve plate surface. If worn, it will be felt.)
6. If worn or scored, replace it.
■ NOTE
• After checking, coat them with hydrostatic transmission oil.
(1) Valve Plates
(2) Anchor Pin
W1036339
Thrust Plate and Swashplate
1. Check the thrust plate (1) for scratches and excessive wear.
3. Check the bearing surface (2) of trunnion shaft (swashplate) for
scratches and excessive wear.
(1) Thrust Plate
(2) Bearing Surface
W1036630
Trunnion Shaft Cover
1. Check the bearing (2) for scratches and excessive wear.
3. Check the oil seal (3) and the O-rings (1) for damage.
■ NOTE
• After checking, coat the bearings with hydrostatic
transmission oil, and the oil seal lip and the O-rings (1) with
grease.
(1) O-ring
(2) Bearing
(3) Oil Seal
W1036765
Oil Seals and Bearings for Shaft
1. Check the oil seals (1) for damage.
2. Check the bearings (2) for wear.
3. If the bearings are worn, replace them.
■ NOTE
• After checking, coat the bearing with hydrostatic
transmission oil and the oil seal lip with grease.
(1) Oil Seal
(2) Needle Bearing
W1036910
Check and High Pressure Relief Valve
1. Check the valve plug (1) and valve (3) for scratches and damage.
2. Check the valve seat in the port block for damage.
3. Check the spring (2) for breakage and wear.
4. If anything unusual, replace the check and high pressure relief
valve assembly.
(1) Valve Plug
(2) Spring
(3) Valve
W1037053
2-S30
TRANSMISSION
Charge Relief Valve
1. Check the spring (2) for breakage and wear.
2. If it is unusual, replace it.
(1) Valve Plug
(2) Spring
(3) Valve Poppet
W1037317
(2) Hydraulic PTO Clutch
PTO Brake Plate and PTO Brake Disc Wear
1. Measure PTO brake plate thickness and PTO brake disc
thickness with an outside micrometer.
2. If the thickness is less than the allowable limit, replace it.
PTO brake plate
thickness
PTO brake disc
thickness
Factory spec.
4.35 to 4.65 mm
0.1713 to 0.1830 in.
Allowable limit
4.25 mm
0.1673 in.
Factory spec.
3.65 to 3.95 mm
0.1437 to 0.1555 in.
Allowable limit
3.30 mm
0.1299 in.
W1017239
Pressure Plate, Clutch Disc and Steel Plate Wear
1. Measure the thickness of the pressure plate, clutch disc and steel
plate with the outside micrometer.
Thickness of pressure
plate
Factory spec.
1.95 to 2.05 mm
0.0768 to 0.0807 in.
Allowable limit
1.80 mm
0.0709 in.
Factory spec.
1.90 to 2.10 mm
0.0748 to 0.0827 in.
Allowable limit
1.60 mm
0.0630 in.
Factory spec.
0.95 to 1.05 mm
0.0374 to 0.0413 in.
Allowable limit
0.80 mm
0.0315 in.
Thickness of clutch disc
Thickness of steel plate
W1017366
2-S31
TRANSMISSION
Clearance between Clutch Shaft and 16T-33T Gear
1. Measure 16T-33T gear I.D. with an inside micrometer, and then
the clutch shaft O.D. with an outside micrometer.
2. Measure O.D. of two needles in the needle bearing with an
outside micrometer.
3. Clearance is the difference between the gear I.D. and the sum of
shaft O.D. and two needle O.D..
4. If the clearance exceeds the allowable limit, replace it.
Clearance between
clutch shaft and 16T33T gear
Factory spec.
0.007 to 0.047 mm
0.0003 to 0.0018 in.
Allowable limit
0.10 mm
0.0039 in.
16T-33T gear I.D.
Factory spec.
26.007 to 26.028 mm
1.0239 to 1.0247 in.
Clutch shaft O.D.
Factory spec.
21.987 to 22.000 mm
0.8657 to 0.8661 in.
Needle O.D.
Factory spec.
1.997 to 2.000 mm
0.0786 to 0.0787 in.
(1) 16T-33T Gear
(2) Clutch Shaft
(3) Needle Bearing
W1026873
Checking Bearing
1. While holding the inner race, push and pull the outer race in all
directions to check for wear and roughness.
2. Apply transmission oil to the bearing, and hold the inner race.
Then, turn the outer race to check rotation.
3. For needle bearing, invert the needle rollers to check for any
damage and wear.
4. If defects are found, replace it.
W1024506
Clearance between Shift Fork and 15T-26T Gear Groove
1. Insert the shift fork into the 15T-26T gear groove, and measure
the clearance with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace it.
Clearance between shift
fork and 15T-26T gear
Factory spec.
0.03 to 0.40 mm
0.0001 to 0.015 in.
Allowable limit
0.5 mm
0.020 in.
W1026751
2-S32
TRANSMISSION
Clearance between Differential Case (Spiral Bevel Gear) and
1. Measure the differential side gear boss O.D. with an outside
micrometer.
2. Measure the differential case I.D. and the spiral bevel gear I.D.
with an inside micrometer, and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace faulty parts.
Clearance between
differential case (spiral
bevel gear) and
Factory spec.
0.025 to 0.066 mm
0.0010 to 0.0025 in.
Allowable limit
0.30 mm
0.0118 in.
Differential case I.D.
Factory spec.
32.000 to 32.025 mm
1.2599 to 1.2608 in.
Spiral bevel gear I.D.
Factory spec.
32.000 to 32.025 mm
1.2599 to 1.2608 in.
Differential side gear
O.D.
Factory spec.
31.959 to 31.975 mm
1.2582 to 1.2589 in.
W1028123
Clearance between Differential Pinion Shaft and Differential
Pinion
1. Measure the differential pinion shaft O.D. with an outside
micrometer.
2. Measure the differential pinion I.D. with an inside micrometer,
and calculate the clearance.
Clearance between
differential pinion shaft
and differential pinion
Factory spec.
0.016 to 0.045 mm
0.0007 to 0.0018 in.
Allowable limit
0.30 mm
0.0118 in.
Differential pinion I.D.
Factory spec.
16.000 to 16.018 mm
0.6300 to 0.6306 in.
Differential pinion shaft
O.D.
Factory spec.
15.973 to 15.984 mm
0.6289 to 0.6292 in.
W1028504
Backlash between Differential Pinion and Differential Side Gear
1. Secure the differential case with a vise.
2. Set the dial indicator (lever type) with its finger on the tooth of the
differential side gear.
3. Press differential pinion and side gear against the differential
case.
4. Hold the differential pinion and move the differential side gear to
measure the backlash.
5. If the backlash exceeds the allowable limit, adjust with differential
side gear shims.
Backlash between
differential pinion and
Factory spec.
0.1 to 0.3 mm
0.004 to 0.011 in.
Allowable limit
0.4 mm
0.016 in.
(Reference)
• Thickness of shims :
0.8 mm (0.0315 in.), 1.0 mm (0.0394 in.), 1.2 mm (0.0472 in.)
W1028708
2-S33
TRANSMISSION
Backlash between Bevel Pinion Shaft and Spiral Bevel Gear
(1)
(2)
(3)
(4)
(5)
(6)
Shim
Shim
Bevel Pinion Shaft
Shim
Bearing Holder
Spiral Bevel Gear
W1029105
1. Set the dial indicator (lever type) with its finger on the end of spiral bevel pinion shaft (3).
2. Move the spiral bevel pinion back and forth to each end and measure the side clearance.
3. If the side clearance exceeds the factory specification, adjust with the shims (2) at rear end of the bevel pinion shaft
(3).
4. Set the dial indicator (lever type) with its finger on the tooth surface of spiral bevel gear (6).
5. Measure the backlash by fixing the bevel pinion shaft (3) and moving spiral bevel gear (6) by hand.
6. If the backlash is not within the factory specifications, adjust with the shims (1), (4) at bearing holder (5) and
differential case.
7. Adjust the backlash properly by repeating the above procedures.
(When adjusting)
Side clearance of
bevel pinion shaft
Factory spec.
Less than 0.15 mm
Less than 0.006 in.
Backlash between
bevel pinion shaft
and spiral bevel
gear
Factory spec.
0.10 to 0.30 mm
0.0040 to 0.0118 in.
W1029368
(Reference)
• Thickness of shims (1), (4) :
0.2 mm (0.008 in.), 0.5 mm (0.020 in.)
• Thickness of shims (2)
0.2 mm (0.008 in.), 0.3 mm (0.012 in.), 0.5 mm (0.020 in.)
2-S34
3
FRONT AXLE
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 3-M1
FRONT AXLE
1. STRUCTURE
(1) Differential Gear Shaft
(2) Ball Bearing
(3) Front Axle Case
(4) Front Axle
(5) 57T Gear
(6) Ball Bearing
(7) Spiral Bevel Gear
(8) Differential Gear Assembly
The front axles are the semifloating type with ball bearings (2), (6) between the front axle (4) and the front axle case
(3) which supports the front wheel load as well as transmitting power to the front wheels.
The differential gear assembly (8) automatically controls the revolution of right and left wheels when the front
wheels encounter unequal road resistance during turning.
3-M1
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................3-S1
2. TIGHTENING TORQUES ..............................................................................3-S2
3. CEHCKING, DISASSEMBLING AND SERVICING......................................3-S3
[1] PREPARATION ........................................................................................3-S3
[2] DISASSEMBLING AND ASSEMBLING..................................................3-S4
FRONT AXLE
1. TROUBLESHOOTING
Symptom
Probable Cause
Solution
Reference
Page
Differential Lock can
not be Set
Differential lock shift fork damaged
Replace
3-S4
Differential lock clutch damaged
Replace
3-S4
Differential Lock
Pedal does not
Return
Differential lock pedal return spring weaken or
damaged
Replace
–
Differential lock fork shaft rusted
Repair
3-S4, 4-S8
W1011382
3-S1
FRONT AXLE
Item
Front axle case mounting screw and nut
N·m
kgf·m
ft-lbs
39.3 to 44.1
4.0 to 4.5
29.0 to 32.5
W1012736
3-S2
FRONT AXLE
3. CEHCKING, DISASSEMBLING AND SERVICING
[1] PREPARATION
(When reassembling)
the dipstick (2).
level.
Transmission fluid
Capacity
14.0 L
14.8 U.S.qts
12.3 Imp.qts
■ IMPORTANT
G-7.).
(1) Drain Plug
(2) Dipstick
(3) Oil Inlet
A : Upper Level
B : Lower Level
W1011852
3-S3
FRONT AXLE
Separating Front Axle Case
1. Support the differential gear case, and remove the front wheel.
2. Remove the support plate (2).
3. Remove the assist spring (3), mower lift arm (1) and brake return
spring (4).
4. Disconnect the brake rod 1 (5).
5. Disconnect the differential lock rod (6).
6. Remove the front axle case (7) from differential gear case.
(When reassembling)
• Apply grease to the oil seal of front axle case (7).
surface of the front axle case and differential gear case.
Tightening torque
(1)
(2)
(3)
(4)
screw
Mower Lift Arm
Support Plate
Assist Spring
Brake Return Spring
39.3 to 44.1 N·m
4.0 to 4.5 kgf·m
29.0 to 32.5 ft-lbs
(5) Brake Rod 1
(7) Front Axle Case
W1010993
Front Axle
1. Remove the spring (1).
2. Draw out the differential lock clutch (3) and differential lock shift
fork (2).
3. Remove the external snap ring (5), and remove the bearing (4).
4. Draw out the 57T gear (7) from the front axle (6).
5. Tap out the front axle to the outside of front axle case.
(When reassembling)
• Apply grease to the lip of oil seal.
(1)
(2)
(3)
(4)
Spring
Shift Fork
Bearing
(6) Front Axle
(7) 57T Gear
W1011413
3-S4
4
BRAKES
MECHANISM
CONTENTS
1. FEATURES .................................................................................................... 4-M1
2. OPERATION .................................................................................................. 4-M2
BRAKES
1. FEATURES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Return Spring
Brake Cam Lever
Brake Rod 1
Brake Rod 2
Parking Lock Lever
Main Brake Pedal
Brake Arm 1
Brake Arm 2
Turnbuckle
Front Axle Case
W1012646
Mechanical wet disc brakes are used for the right and left travelling brakes. They are operated by the main brake
pedal (6) through the mechanical linkages and provide stable braking and require little adjustment.
The parking brake is a mechanical type which is designed to actuate the travelling brakes through the linkage.
Pulling the parking lock lever (5) results in the same state as the obtained when the main brake pedal is pressed.
4-M1
BRAKES
2. OPERATION
(1) Front Axle Case
(2) Brake Cam Lever
(3) Brake Cam
(4) Friction Plate
(5) Steel Ball
(6) Actuator
(7) Brake Disc
(8) Bearing Holder
The brake body is incorporated in the front axle case (1) filled with transmission oil and is designed to brake when
the brake disc (7) splined with the differential gear shaft (9) is pressed against the actuator (6) by means of the cam
mechanism incorporating steel balls (5).
For greater braking force, three brake discs (7) are provided at the right and left sides respectively, and the friction
plates (4) fixed to the front axle case is arranged between the brake discs (7).
■ During Braking
When the main brake pedal is pressed, the linkage causes the brake cam lever (2) and brake cam (3) to turn into
the direction of arrow shown in the above figure.
Therefore, the actuator (6) also moves the direction of arrow. At this time, since the actuator (6) rides on the steel
balls (5) set in the grooves of the front axle case to press the brake discs (7), the differential gear shaft (9) is braked
by the frictional force generated by the actuator (6) and brake discs (7).
4-M2
SERVICING
CONTENTS
1.
2.
3.
4.
(1) Brake Pedal ........................................................................................4-S5
(2) Brake Assembly ..................................................................................4-S6
[3] SERVICING ..............................................................................................4-S9
BRAKES
1. TROUBLESHOOTING
Symptom
Uneven Braking
Force
Brake Drags
Poor Braking Force
Probable Cause
Solution
Reference
Page
Brake pedal free travel unevenly adjusted
Adjust
4-S4
Brake disc worn
Replace
4-S9
Actuator warped
Replace
4-S9
Brake pedal free travel too small
Adjust
4-S4
Ball hoses of actuator for uneven wear
Replace
4-S9
Brake pedal return spring weaken or broken
Replace
4-S5
Brake cam lever rusted
Repair
4-S9
Brake pedal free travel excessive
Adjust
4-S4
Brake disc worn
Replace
4-S9
Actuator warped
Replace
4-S9
Brake cam lever damaged
Replace
4-S9
Transmission fluid improper
Change
G-7, 4-S6
W1014322
4-S1
BRAKES
Item
Allowable Limit
20 mm
0.79 in.
20 to 30 mm
0.79 to 1.18 in.
373 to 411 N
38 to 42 kgf
84 to 92 lbs
–
–
0.30 mm
0.0118 in.
22.89 to 22.99 mm
0.9012 to 0.9051 in.
22.40 mm
0.8819 in.
Brake Pedal
Free Travel
Main Brake Pedal
Force
Actuator and Bearing Holder
Flatness
Actuator and Ball
Height
Brake Disc
Thickness
3.3 to 3.5 mm
0.130 to 0.137 in.
3.0 mm
0.118 in.
Friction Plate
Thickness
1.92 to 2.08 mm
0.0756 to 0.0818 in.
1.52 mm
0.0598 in.
W1013874
4-S2
BRAKES
Item
Front axle case mounting screw and nut
N·m
kgf·m
ft-lbs
39.3 to 44.1
4.0 to 4.5
29.0 to 32.5
W1012736
4-S3
BRAKES
Brake Pedal Free Travel
1. Press the main brake pedal five times with a force of 147 to 294
N (15 to 30 kgf, 33 to 66 lbs).
2. Press the center of the pedal (3) at a force of 39 to 58 N (4 to 6
kgf, 9 to 13 lbs), and measure the movement at the footrest of
pedal.
3. If the measurement is not within the allowable limits, turn the
turnbuckle (5) to adjust.
4. After adjustment, tighten the lock nut (4) firmly.
Factory spec.
20 mm
0.79 in.
Allowable limit
20 to 30 mm
0.79 to 1.18 in.
Brake pedal free travel
■ NOTE
• After checking brake pedal free travel, be sure to engage the
parking lock lever fully and check to see that the main brake
pedal is securely locked.
(1) Brake Rod 1
(2) Brake Rod 2
(3) Main Brake Pedal
(4) Adjusting Nut
(5) Turnbuckle
W1011243
Brake Rod 2
1. Measure the spring length “L” with vernier calipers.
2. If the measurement is not within the reference value, adjust the
brake rod 2 with the adjusting nuts (1).
3. Press the main brake pedal to lock the position of third notch, and
measure the force of main brake pedal.
4. If the measurement is not within the factory specifications, adjust
the spring length “L”.
Force of main brake
pedal
Factory spec.
373 to 411 MPa
38 to 42 kgf/cm2
84 to 92 psi
■ NOTE
• Apply grease to the rod as shown in the figure.
(Reference)
• Brake rod 2 spring length “L” : 123 to 125 mm (4.85 to 4.92 in.)
(1) Adjusting Nut
(A) Grease
(B) Third Notch
W1011467
4-S4
BRAKES
(1) Brake Pedal
Removing Brake Pedal and Links
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Brake Rod 2
Return Spring
Brake Rod 1
Brake Arm 1
Brake Arm 2
Brake Shaft
W1011962
1. Remove the seat, steering post cover, pedals and fender. (Refer to page 2-S11 to S12.)
2. Remove the return springs (2) and brake rod 1 (3).
3. Remove the differential lock rod.
4. Remove the brake rod 2 (1).
5. Remove the clevis pins, brake arm 1 (4) and brake arm 2 (5) and pull out the brake shaft (6).
(When reassembling)
• Apply grease to the brake rod 2 and moving parts.
• Take care not to damage the brake switch.
4-S5
BRAKES
(2) Brake Assembly
(When reassembling)
the dipstick (2).
level.
Transmission fluid
Capacity
14.0 L
14.8 U.S.qts
12.3 Imp.qts
■ IMPORTANT
G-7.).
(1) Drain Plug
(2) Dipstick
(3) Oil Inlet
A : Upper Level
B : Lower Level
W1014130
4-S6
BRAKES
Separating Front Axle Case
1. Support the differential gear case, and remove the front wheel.
2. Remove the support plate (2).
3. Remove the assist spring (3), mower lift arm (1) and brake return
spring (4).
4. Disconnect the brake rod 1 (5).
5. Disconnect the differential lock rod (6).
6. Remove the front axle case (7) from differential gear case.
(When reassembling)
• Apply grease to the oil seal of front axle case (7).
surface of the front axle case and differential gear case.
Tightening torque
(1)
(2)
(3)
(4)
screw
Mower Lift Arm
Support Plate
Assist Spring
Brake Return Spring
39.3 to 44.1 N·m
4.0 to 4.5 kgf·m
29.0 to 32.5 ft-lbs
(5) Brake Rod 1
(7) Front Axle Case
W1014366
Front Axle
1. Remove the spring (1).
2. Draw out the differential lock clutch (3) and differential lock shift
fork (2).
3. Remove the external snap ring (5), and remove the bearing (4).
4. Draw out the 57T gear (7) from the front axle (6).
5. Tap out the front axle to the outside of front axle case.
(When reassembling)
(1)
(2)
(3)
(4)
Spring
Shift Fork
Bearing
(6) Front Axle
(7) 57T Gear
W1014606
4-S7
BRAKES
Brake Assembly
1. Remove the internal snap ring (4).
2. Remove the differential gear shaft (2) with brake discs (5).
3. Remove the actuator (6) and steel balls (7).
(When reassembling)
• When installing the internal snap ring (4) to front axle case (3) as
shown in the figure.
• When installing the bearing holder (2) to the front axle case (3),
do not forget to install the straight pin (8).
(Refer to the figure)
(1)
(2)
(3)
(4)
Bearing Holder
Front Axle Case
Internal Snap Ring
(5)
(6)
(7)
(8)
Brake Disc
Actuator
Steel Ball
Straight Pin
W1012864
Brake Discs and Friction Plates
2. Remove the brake discs and friction plates (2).
3. Remove the bearing holder (3).
(When reassembling)
• Install the brake discs with their holes (5) offset at least 1/3 of the
total hole area.
(2) Brake Discs and Friction Plate
(3) Bearing Holder
(5) Hole
W1015294
4-S8
BRAKES
[3] SERVICING
Brake Cam Lever Movement
1. Move the brake cam lever by hand to check the side to side
movement.
2. If the movement is heavy, smooth the brake cam with emery
paper.
Actuator Flatness and Bearing Holder Wear
1. Place a straightedge of 150 mm (5.91 in.) or more in length on
the contacting surface of the actuator and the bearing holder.
2. Inspect the friction surface of the actuator and the bearing holder
with a straightedge, and determine if a 0.30 mm (0.0118 in.)
feeler gauge will fit on the worn area.
3. If it will fit, resurface.
Height of Actuator and Ball
1. Measure the dimensions of the actuator with the ball installed.
2. If the measurement is less than the allowable limit, replace the
actuator and balls.
3. Inspect the ball holes of cam plate for uneven wear.
4. If the uneven wear is found, replace it.
Height of actuator and
ball
Factory spec.
22.89 to 22.99 mm
0.9012 to 0.9051 in.
Allowable limit
22.40 mm
0.819 in.
Brake Disc and Friction Plate Wear
1. Measure the brake disc thickness and the friction plate thickness
with an outside micrometer.
Factory spec.
3.3 to 3.5 mm
0.130 to 0.137 in.
Allowable limit
3.0 mm
0.118 in.
Factory spec.
1.92 to 2.08 mm
0.0756 to 0.0818 in.
Allowable limit
1.52 mm
0.0598 in.
Brake disc thickness
Friction plate thickness
W1015877
4-S9
5
REAR AXLE
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 5-M1
REAR AXLE
1. STRUCTURE
(1)
(2)
(3)
(4)
(5)
(6)
Rear Wheel Hub
Rear Axle Cover
Bevel Gear
Rear Axle Gear Case
Bevel Gear
Knuckle Arm
(7)
(8)
(9)
(10)
(11)
(12)
Tie-Rod
Differential Gear Assembly
Rear Axle Bracket (Rear)
Thrust Collar
Bevel Gear
(13)
(14)
(15)
(16)
(17)
(18)
Differential Gear Case
Differential Yoke Shaft (Left)
Rear Axle Bracket (Front)
Bevel Pinion Shaft
Coupling
(19)
(20)
(21)
(22)
(23)
Differential Yoke Shaft (Right)
Bevel Gear
Bevel Gear Shaft
Bevel Gear
The rear axle of 4WD is constructed as shown above. Power is transmitted from the transmission through the rear
wheel drive shaft (17) to the bevel pinion shaft (16), then to the bevel gear (12) and to the differential gear assembly
(8).
The power through the differential side gear (19) is transmitted to the differential yoke shaft (20), and to the bevel
gear shaft (22) through the bevel gears (21), (5) in the rear axle gear case (4).
The revolution is greatly reduced by the bevel gears (23), (3), then the power is transmitted to the rear wheel hub
(1).
The differential system allows each wheel to rotate at a different speed to make turning easier.
5-M1
SERVICING
CONTENTS
1.
2.
3.
4.
[2] PREPARATION ........................................................................................5-S5
(1) Separating Rear Axle..........................................................................5-S5
[4] SERVICING ............................................................................................5-S12
REAR AXLE
1. TROUBLESHOOTING
Symptom
Rear Wheels Wander
to Right of Left
Rear Wheels Can Not
Be Driven
Noise
Probable Cause
Solution
Reference
Page
Tire pressure uneven
Adjust
G-43
Improper toe-in adjustment (improper alignment)
Adjust
5-S4
Clearance between rear axle case boss and rear
axle bracket (front, rear) excessive
Replace
5-S15
Rear axle rocking force too small
Adjust
5-S4
Rear wheel sway excessive
Replace
–
Tie-rod end loose
Tighten
5-S7
Air sucked in power steering circuit
Bleed
Rear wheel driving gears in rear axle gear case
broken
Replace
5-S9
Rear wheel drive shaft broken
Replace
5-S6
Rear wheel drive gears in transmission broken
Replace
2-S20
Rear differential gear broken
Replace
5-S10 to
S11
Coupling displaced
Reassemble
5-S6
Gear backlash excessive
Adjust or replace
5-S11
Oil insufficient
Replenish
Bearings damaged or broken
Replace
5-S8 to S11
Gears damaged or broken
Replace
5-S8 to S11
Bevel pinion shaft turning force improper
Adjust
–
G-7, 5-S5
5-S13
W1014322
5-S1
REAR AXLE
Item
Allowable Limit
Rear Wheel Alignment
Toe-in
0 to 10 mm
0.00 to 0.39 in.
–
Rear Axle
Rocking Force
49.1 to 117.6 N
5.0 to 12.0 kgf
11.1 to 26.4 lbs
–
Knuckle Arm Support to Knuckle Arm
Clearance
0.1 to 0.3 mm
0.0040 to 0.0118 in.
–
Knuckle Arm Support to Knuckle Arm
Bushing
Clearance
0.02 to 0.11 mm
0.0008 to 0.0118 in.
0.40 mm
0.0157 in.
Knuckle Arm Support
O.D.
20.00 to 20.03 mm
0.7874 to 0.7886 in.
–
Knuckle Arm Bushing
I.D.
20.05 to 20.11 mm
0.7894 to 0.7917 in.
–
Clearance
0.020 to 0.054 mm
0.00080 to 0.00211 in.
0.20 mm
0.0079 in.
Differential Case Bore
I.D.
20.000 to 20.021 mm
0.78741 to 0.78822 in.
–
Differential Yoke Shaft
O.D.
19.967 to 19.980 mm
0.78611 to 0.78661 in.
–
Clearance
0.032 to 0.068 mm
0.00127 to 0.00266 in.
0.20 mm
0.0079 in.
Differential Pinion Gear Boss
O.D.
14.950 to 14.968 mm
0.58859 to 0.58929 in.
–
Differential Case
I.D.
15.000 to 15.018 mm
0.59056 to 0.59125 in.
–
58.7 to 79.0 N
6.1 to 8.1 kgf
13.2 to 17.8 lbs
–
Differential Caseto Differential Yoke Shaft
Differential Pinion Gear to Differential
Case
Pinion Shaft
Turning Force
Bevel Pinion Shaft to Bevel Gear
Backlash
0.20 to 0.25 mm
0.008 to 0.010 in.
–
12T Bevel Gear to 12T Bevel Gear
Backlash
0.10 to 0.30 mm
0.0040 to 0.0118 in.
–
Rear Axle Case Boss (Front)
O.D.
64.910 to 64.940 mm
2.55551 to 2.55669 in.
–
I.D.
65.000 to 65.020 mm
2.55906 to 2.56024 in.
–
Rear Axle Case Boss (Rear)
O.D.
44.950 to 44.975 mm
1.76970 to 1.77067 in.
–
I.D.
45.000 to 45.099 mm
1.77166 to 1.77555 in.
–
W1013874
5-S2
REAR AXLE
Item
N·m
kgf·m
ft-lbs
Lock nut of rocking force adjusting screw
23.6 to 27.4
2.4 to 2.8
17.4 to 20.2
Slotted nut of drag link end
17.7 to 34.3
1.8 to 3.5
13.0 to 25.3
Rear axle bracket mounting screw and nut
124 to 147
12.6 to 15.0
91.1 to 108.4
Rear wheel mounting nut
81.8
9.0
65.1
Slotted nut of tie-end end
17.7 to 34.3
1.8 to 3.5
13.0 to 25.3
Bevel gear case mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Knuckle arm mounting screw
M10 screw
39.3 to 64.7
4.0 to 6.6
29.0 to 47.7
Knuckle arm mounting screw
M12 screw
80 to 110
8.2 to 11.2
59.1 to 81.1
Knuckle arm support mounting screw
23.6 to 27.4
2.4 to 2.8
17.4 to 20.2
Bevel support cover mounting screw
18.7 to 32.3
1.9 to 3.3
13.8 to 23.8
Axle flange mounting screw
44.2 to 63.7
4.5 to 6.5
32.6 to 47.0
W1016410
5-S3
REAR AXLE
Toe-in
1. Inflate the tires to the specified pressure.
2. Turn the rear wheels straight ahead.
3. Measure the toe-in (B-A).
replace the tie-rod.
Tie-rod (B-A)
Factory spec.
A : Wheel to Wheel Distance at Front
B : Wheel to Wheel Distance at Rear
0 to 10 mm
0 to 0.39 in.
C : Front
W1011383
Rear Axle Rocking Force
1. Jack up or lift up the rear side of frame.
2. Set a spring balance to the rear axle flange.
3. Measure the rear axle rocking force.
with the adjusting screw (1).
5. Tighten the lock nut (2) firmly.
Rear axle rocking force
Tightening torque
(1) Adjusting Screw
Factory spec.
Lock nut
49.1 to 117.6 N
5.0 to 12.0 kgf
11.1 to 26.4 lbs
23.6 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
(2) Lock Nut
W1011523
5-S4
REAR AXLE
[2] PREPARATION
(1) Separating Rear Axle
Draining Rear Axle Gear Case Oil
1. Place oil pans underneath the rear axle gear case.
2. Remove the drain plug (3) with hexagonal wrench (2), and
remove the oil filler plug (1).
3. Screw in the drain plug.
(When reassembling)
• Fill new oil up to the level of the oil filter plug.
• Apply liquid gasket (Three Bond 1208D or its equivalent) to the
drain plug (3).
Rear axle gear case oil
Capacity
0.5 L
0.53 U.S.qts.
0.44 Imp.qts.
■ IMPORTANT
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
(1) Oil Filler Plug
(2) Hexagonal Wrench
(3) Drain Plug
W1011744
Draining Rear Axle Differential Case Oil
1. Place oil pans underneath the rear axle differential case.
2. Remove the drain plug (2) and oil filler plug (1) to drain oil.
3. Screw in the drain plug.
(When reassembling)
• Fill new oil up to the upper level on the oil filler plug.
Rear axle differential
case oil
Capacity
1.5 L
1.59 U.S.qts.
1.32 Imp.qts.
■ IMPORTANT
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
(1) Oil Filler Plug
(2) Drain Plug
range.
W1011954
5-S5
REAR AXLE
Drag Link
1. Remove the slotted nut and disconnect the drag link (2) from the
knuckle arm (1).
(When reassembling)
■ IMPORTANT
• After tightening the slotted nut to the specified torque,
install the cotter pin as shown in the figure.
Tightening torque
(1) Knuckle Arm
Slotted nut
17.7 to 34.3 N·m
1.8 to 3.5 kgf·m
13.0 to 25.3 ft-lbs
(2) Drag Link
W1012134
1. Slide the external snap rings (2) and couplings (1).
2. Remove the rear wheel drive shaft (3).
(When reassembling)
• Apply grease to the all splines.
■ IMPORTANT
• If the external snap rings are defective, replace them.
• Securely fit the external snap rings (2) of the rear wheel drive
shaft.
(1) Coupling
W1012268
5-S6
REAR AXLE
Rear Axle
1. Place the jacks under the rear axle, and lift up the rear axle frame.
2. Remove the rear axle bracket mounting screws and nuts.
3. Separate the rear axle from the rear axle frame.
4. Remove the rear wheels.
5. Remove the slotted nut, and disconnect the tie-rod (2) from the
knuckle arm (1).
6. Remove the rear axle brackets (2), (4).
(When reassembling)
• Apply grease to the oil seal of rear axle bracket (Front) (4).
• Apply grease to the O-rings.
• Apply grease to the inside of rear axle brackets (3), (4) and
bosses of rear axle differential case (5).
• Apply liquid lock (Three Bond 1324 or its equivalent) to the rear
axle bracket mounting screws.
■ IMPORTANT
• Be sure to tighten the rear wheel mounting nuts to the
specified torque.
• Be sure to tighten the slotted nuts to the specified torque.
Tightening torque
(1)
(2)
(3)
(4)
Rear axle bracket
124 to 147 N·m
12.6 to 15.0 kgf·m
91.1 to 108.4 ft-lbs
Rear wheel mounting nut
81.8 N·m
9.0 kgf·m
65.1 ft-lbs
Slotted nut
17.7 to 34.3 N·m
1.8 to 3.5 kgf·m
13.1 to 25.3 ft-lbs
Rear Axle Gear Case
Tie-rod
(5) Rear Axle Differential Case
A : Grease
W1012615
5-S7
REAR AXLE
Separation of Rear Axle Differential Case and Bevel Gear Case
1. Remove the bevel gear case (2) and rear axle gear case (3) as a
unit from the rear axle differential case (1).
(When reassembling)
• Apply grease to the O-ring.
Tightening torque
Bevel gear case mounting
screw
(1) Rear Axle Differential Case
(2) Bevel Gear Case
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 ft-lbs
(3) Rear Axle Gear Case
W1018806
Knuckle Arm and Knuckle Arm Support
1. Remove the knuckle arm (1).
2. Remove the knuckle arm support (3).
(When reassembling)
• Apply grease to the bushing.
• Install the knuckle arm (1) to the rear axle case (4), noting the
number of shims (2) between them.
Tightening
torque
M10
39.3 to 64.7 N·m
4.0 to 6.6 kgf·m
29.0 to 47.7 ft-lbs
M12
80 to 110 N·m
8.2 to 11.2 kgf·m
59.1 to 81.1 ft-lbs
Knuckle arm mounting
screw
Knuckle arm support mounting
screw
(1) Knuckle Arm
(2) Shim
23.6 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
(3) Knuckle Arm Support
(4) Rear Axle Gear Case
W1019003
5-S8
REAR AXLE
Separation of Bevel Gear Case and Rear Axle Gear Case
1. Remove the internal snap ring (7) and shims (6), and remove the
bevel gear (5) with the bearing.
2. Shift the external snap ring (8).
3. Remove the bevel support cover (1).
4. Tap out the bevel gear shaft (9) upward, and separate the bevel
gear case (4) from the rear axle gear case (3).
(When reassembling)
• Apply grease to the lip of oil seals (10).
• Apply liquid gasket (Three Bond 1208D or its equivalent) to both
side of a new gasket.
• Install the bevel gear (5) with the bearing, noting the number of
shims.
Tightening torque
(1)
(2)
(3)
(4)
(5)
Bevel support cover
mounting screw
Bevel Support Cover
Bevel Gear
Rear Axle Gear Case
Bevel Gear Case
Bevel Gear
(6)
(7)
(8)
(9)
(10)
18.7 to 32.3 N·m
1.9 to 3.3 kgf·m
13.8 to 23.8 ft-lbs
Shim
Internal Snap Ring
External Snap Ring
Bevel Gear Shaft
Oil Seal
W1019233
5-S9
REAR AXLE
Axle Flange and Rear Wheel Hub
1. Unscrew the axle flange mounting screw (8).
2. Separate the axle flange (7) from the rear axle gear case (1).
3. Remove the bearing (2), bevel gear (3) and collars (4).
4. Tap out the rear wheel hub (10).
(When reassembling)
• Install the oil seal (9) of axle flange (7), noting its direction as
shown in the figure.
• Apply liquid gasket (Three Bond 1208D or its equivalent) to both
sides of a new gasket.
Tightening torque
(1)
(2)
(3)
(4)
(5)
44.2 to 63.7 N·m
4.5 to 6.5 kgf·m
32.6 to 47.0 ft-lbs
Axle flange mounting
screw
Rear Axle Gear Case
Bearing
Bevel Gear
Collar
Bearing
(6)
(7)
(8)
(9)
(10)
Gasket
Axle Flange
Axle Flange Mounting Screw
Oil Seal
Rear Wheel Hub
W1019601
Bevel Pinion and Differential Gear Assembly
1. Remove the internal snap ring (1) and adjusting collar (2).
2. Remove the bevel pinion shaft (3).
3. Draw out the differential gear assembly (7) with left and right
differential yoke shaft (6), (8) from the differential gear case (5).
(1)
(2)
(3)
(4)
Internal Snap Ring
Adjusting Collar
Bevel Pinion Shaft
Adjusting Collar
(5)
(6)
(7)
(8)
Differential Gear Case
W1019873
5-S10
REAR AXLE
1. Tap out the spring pins (2), and remove the left and right
differential yoke shafts (1), (3) from differential assembly.
2. Remove the thrust collars (4), (8) and differential side gears (5),
(7) from the differential case (12).
3. Remove the differential pinion gears (6), (9) from the differential
case (12).
4. Remove the external snap ring (10), and remove the bevel gear
(11) with the ball bearing.
5. Remove the ball bearing (13) from the differential case (12)
(When reassembling)
• Apply molybdenum disulfide (Three Bond 1901 or its equivalent)
to inner circumferential surface of differential side gears (5), (7)
and the differential pinion gears (6), (9).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Spring Pin
Thrust Collar
Differential SIde Gear
(8)
(9)
(10)
(11)
(12)
(13)
Thrust Collar
External Snap Ring
Bevel Gear
Differential Case
Ball Bearing
W1020050
5-S11
REAR AXLE
[4] SERVICING
Clearance between Knuckle Arm Support and Knuckle Arm
1. Tighten the knuckle arm mounting screws to the specified torque.
2. Measure the clearance between the knuckle arm support and
knuckle arm with a feeler gauge.
with shims between the knuckle arm and rear axle case.
Clearance between
knuckle arm support and
knuckle arm
Factory spec.
0.1 to 0.3 mm
0.0040 to 0.0118 in.
(Reference)
• Thickness of shims :
0.5 mm (0.020 in.), 0.3 mm (0.012 in.), 0.2 mm (0.008 in.)
W1020280
Clearance between Knuckle Arm Support and Knuckle Arm
Bushing
1. Measure the knuckle arm support O.D. with an outside
micrometer.
2. Measure the knuckle arm bushing I.D. with an inside micrometer,
and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace the bushing.
Factory spec.
0.02 to 0.11 mm
0.0008 to 0.0043 in.
Allowable limit
0.4 mm
0.0157 in.
Knuckle arm support
O.D.
Factory spec.
20.00 to 20.03 mm
0.7874 to 0.7886 in.
Knuckle arm bushing
I.D.
Factory spec.
20.05 to 20.11 mm
0.7894 to 0.7917 in.
Clearance between
knuckle arm support and
knuckle arm bushing
W1020423
Clearance between Differential Case and Differential Yoke Shaft
1. Measure the differential yoke shaft O.D..
2. Measure the differential case bore I.D., and calculate the
clearance.
Factory spec.
0.020 to 0.054 mm
0.00080 to 0.00211 in.
Allowable limit
0.20 mm
0.0079 in.
Differential case bore
I.D.
Factory spec.
20.000 to 20.021 mm
0.78741 to 0.78822 in.
Differential yoke shaft
O.D.
Factory spec.
19.967 to 19.980 mm
0.78611 to 0.78661 in.
Clearance between
differential case and
differential yoke shaft
W1020615
5-S12
REAR AXLE
Clearance between Differential Pinion Gear and Differential
Case
1. Measure the differential pinion gear boss O.D..
2. Measure the differential case bore I.D., and calculate the
clearance.
Factory spec.
0.032 to 0.068 mm
0.00127 to 0.00266 in.
Allowable limit
0.20 mm
0.0079 in.
Differential pinion gear
boss O.D.
Factory spec.
14.950 to 14.968 mm
0.58859 to 0.58929 in.
Differential case bore
I.D.
Factory spec.
15.000 to 15.018 mm
0.59056 to 0.59125 in.
Clearance between
differential pinion gear
and differential case
W1020802
Turning Force of Bevel Pinion Shaft
1. Install the bevel pinion shaft assembly to the rear axle case.
2. Wind a string around the spiral bevel pinion shaft, and attach
spring balance to the tip of the string.
3. Slowly pull the spring balance in a direction at right angle to the
bevel pinion shaft to measure the turning force.
4. If the turning force is not within the factory specifications, adjust
with the lock nut.
Turning force of bevel
pinion shaft
Factory spec.
58.7 to 79.0 N
6.1 to 8.1 kgf
13.2 to 17.8 lbs
■ NOTE
• The turning torque is figured by multiplying the radius
(distance from the center of the spiral bevel pinion shaft to a
point on the circumference from which the string is pulled)
by the reading on the spring balance.
• After turning force adjustment, be sure to stake the lock nut.
W1020967
5-S13
REAR AXLE
Backlash between Bevel Pinion Shaft and Bevel Gear
1. Set a dial gauge (lever type) with its finger on the spline of bevel
pinion shaft.
2. Measure the backlash by moving the bevel pinion shaft by hand
lightly.
3. If the backlash is not within the factory specifications, change the
adjusting collars (3), (4). For example, change the adjusting
collar (4) to 0.1 mm (0.0039 in.) smaller size, and change the
adjusting collar (3) to 0.1 mm (0.0039 in.) larger size.
4. Adjust the backlash properly by repeating the above procedures.
Backlash between bevel
pinion shaft and bevel
gear
Factory spec.
0.20 to 0.25 mm
0.008 to 0.010 in.
(Reference)
• Above factory specification should be measured on the tooth of
bevel pinion. When measuring the backlash on the spline of its
shaft, factory specification will be 0.0571 to 0.1714 mm (0.00225
to 0.00675 in.).
• Thickness of adjusting collars (3), (4) :
3.4 mm (0.134 in.), 3.6 mm (0.142 in.), 3.8 mm (0.150 in.)
4.0 mm (0.157 in.), 4.1 mm (0.161 in.), 4.2 mm (0.165 in.)
4.4 mm (0.173 in.), 4.6 mm (0.181 in.)
(1) Bevel Gear
(3) Adjusting Collar
(4) Adjusting Collar
W1021136
Backlash between 12T Bevel Gear and 12T Bevel Gear
1. Place three trips of fuse wire around the 12T bevel gear (1) with
grease.
2. Fix the rear axle case, bevel gear case and front gear case.
3. Turn the axle.
4. Remove the bevel gear case from rear axle case, and measure
the thickness of the fuse wires with an outside micrometer.
5. If the backlash is not within the factory specifications, adjust with
shim (3).
Backlash between 12T
bevel gear and 12T
bevel gear
Factory spec.
0.10 to 0.30 mm
0.0040 to 0.0118 in.
(Reference)
• Thickness of adjusting shims :
0.8 mm (0.031 in.), 1.0mm (0.039 in.), 1.2mm (0.047 in.)
• Tooth contact : More than 35 %.
(1) 12T Bevel Gear
(2) 12T Bevel Gear
(3) Shim
W1021372
5-S14
REAR AXLE
Outside Diameter of Rear Axle Case Bosses and Inside
Diameter of Rear Axle Bracket
1. Measure the rear axle case bosses O.D. with an outside
micrometer.
2. Measure the rear axle bracket I.D. with a cylinder gauge.
(Reference)
Rear axle case boss
(front) O.D.
Factory spec.
64.910 to 64.940 mm
2.55551 to 2.55669 in.
Rear axle case bracket
(front) I.D.
Factory spec.
65.000 to 65.020 mm
2.55906 to 2.56024 in.
Rear axle case boss
(rear) O.D.
Factory spec.
44.950 to 44.975 mm
1.76970 to 1.77067 in.
Rear axle case bracket
(rear) I.D.
Factory spec.
45.000 to 45.099 mm
1.77166 to 1.77555 in.
W1017939
5-S15
6
STEERING
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 6-M1
2. STEERING CONTROLLER .......................................................................... 6-M2
STEERING
1. STRUCTURE
(1) Steering Cylinder
(2) Steering Controller
(3) Oil Cooler
(4) PTO Relief Valve
(5) Oil Filter Cartridge
(HST)
(7) Oil Strainer
(8) Hydraulic Pump
(9) Flow Priority Valve
A : To Implement Control Valve
B : To PTO Control Valve
EF :EF Port
PF :PF Port
P : P Port
T : T Port
L : L Port
R : R Port
This machine is provided with hydrostatic power steering.
In the full hydrostatic power steering, the steering controller (2) is connected to the steering cylinder (1) by
hydraulic piping. Accordingly, it does not have mechanical transmitting parts such as steering gear, pitman arm, drag
link, etc.. Therefore, it is simple in construction. This steering system consists of the oil strainer (7), hydraulic pump
(8), flow priority valve (9), steering controller (2) and steering cylinder (1) etc..
Flow priority valve divides the oil into two direction. One is the control flow to power steering (constantly 10 L/min.,
2.64 U.S.GPM, 2.20 Imp.GMP), and the other is excessive flow to control valve of implement lift control.
By operating the power steering body, the required amount of oil is fed to the steering cylinder (1).
6-M1
STEERING
2. STEERING CONTROLLER
The steering controller (2) consists of a control valve
(6) and a metering device (5)
■ Control Valve
The control valve is a rotating spool type. When the
steering wheel is not turned, the position of the spool (7)
and sleeve (9) is kept neutral by the centering spring (8).
This causes the forming of a "Neutral" oil circuit. When
the steering wheel is turned either clockwise or
counterclockwise, the position of the spool and sleeve
changes in relation to the centering spring. This allows
the forming of a "Right Turning" or "Left Turning" oil
circuit. At the same time, the metering device rotates
with the spool and sends the oil to the cylinder
corresponding to the rotation of the steering wheel.
■ Metering Device
The oil, sent from the hydraulic pump to the steering
cylinder, passes through the metering device (3).
Namely, when the rotor is driven, two chambers suck in
oil due to volumetric change in the pump chambers
formed between the rotor (12) and the stator (13), while
oil is discharged from other two chambers. On the other
hand, rotation of the steering wheel is directly transmitted
to the rotor through the spool (7), drive shaft (10), etc.
Accordingly, the metering device serves to supply the
steering cylinder with oil, amount of which corresponds to
the rotation of the steering wheel. The wheels are thus
turned by the angle corresponding to the rotation of the
steering wheel. When the engine stops or the hydraulic
pump malfunctions, the metering device functions as a
manual trochoid pump, which makes manual steering
possible
■ Relief Valve
The relief valve (1) is located in the steering
controller. It controls the maximum pressure of the
power steering system.
Its setting pressure is as follows.
10.8 to 11.3 MPa
110.2 to 115.2 kgf/cm2
1567 to 1638 psi
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Steering Cylinder
Steering Controller
Check Valve
Relief Valve
Metering Device
Control Valve
Spool
Centering Spring
Sleeve
Drive Shaft
Distributor Plate
Rotor
Startor
A : Control Valve
B : Metering Device
P : P Port (From Hydraulic
Pump)
T : T Port (To Independent PTO
Clutch Valve and HST
Circuit)
L : L Port
R : R Port
W1012850
6-M2
SERVICING
CONTENTS
1.
2.
3.
4.
(1) Relief Valve.........................................................................................6-S4
[2] PREPARATION ........................................................................................6-S5
(1) Separating Power Steering Controller ................................................6-S5
(2) Separating Steering Support...............................................................6-S6
(1) Steering Support .................................................................................6-S7
[4] SERVICING ..............................................................................................6-S8
(1) Steering Cylinder ................................................................................6-S8
STEERING
1. TROUBLESHOOTING
Symptom
Cannot Be Steered
Probable Cause
Solution
Reference
Page
Steering controller malfunctioning
Replace
6-S6
Hose broken
Replace
6-S6
Power steering oil improper
Change with
specified oil
G-7
Hydraulic pump malfunctioning
Replace
7-S6
Priority valve malfunctioning
Repair or replace
7-S6
Replace
6-S6
Replace
6-S6
Priority valve malfunctioning
Repair or replace
7-S6
Air sucked in pump due to lack of oil
Replenish
G-7
Air sucked in pump from suction circuit
Repair
Steering Wheel Turns
Spontaneously When
Released
Repair or replace
6-S6
Rear Wheels Wander
to Right and Left
Replace
6-S6
Replenish
G-7
Repair
–
Insufficient bleeding
Bleed
–
Steering cylinder malfunctioning
Replace
6-S8
Improper toe-in adjustment
Adjust
5-S5
Tire pressure uneven
Inflate
G-43
Wheels Are Turned
to a Direction
Opposite to Steering
Direction
Steering cylinder piping connected in reverse
Repair
6-S8
Steering Wheel Turns
Idle in Manual
Steering
Insufficient bleeding
Bleed
–
Replenish
G-7
Noise
Replenish
G-7
Repair
Steering controller (relief valve) malfunctioning
Replace
Hard Steering
Steering Force
Fluctuates
Oil Temperature
Increases Rapidly
–
–
6-S6
W1014322
6-S1
STEERING
POWER STEERING BODY
Item
Relief Valve
Setting Pressure
Allowable Limit
10.8 to 11.3 MPa
110.2 to 115.2 kgf/cm2
1567 to 1638 psi
–
W1013874
STEERING CYLINDER
Cylinder Length (Rod End to Rod End)
Rod End Length
439 to 441 mm
17.29 to 17.36 in.
–
15 mm
0.59 in.
–
Set Angle C
Angle
0.175 rad
10 °
–
Set Angle D
Angle
0.314 rad
18 °
–
Set Angle E
Angle
0.349 rad
20 °
–
W1013973
6-S2
STEERING
Item
N·m
kgf·m
ft-lbs
Power steering hose mounting nut
24.6 to 29.4
2.5 to 3.0
18.1 to 21.6
Power steering pipe mounting nut
54.0 to 63.7
5.5 to 6.5
39.8 to 47.0
W1012736
6-S3
STEERING
(1) Relief Valve
Relief Valve Setting Pressure
1. Disconnect the power steering hose 1 (or 2) from cylinder joint,
and set a pressure gauge (Code No. : 07916-50321) between
them using power steering adaptor (1) (Code No. : 07916-54021)
and cable (Code No. : 07916-50331).
3. Fully turn the steering wheel to the left (or right) and read the
pressure gauge when the relief valve operates.
■ NOTE
• After set a pressure gauge, be sure to bleed air from the
system.
Relief valve setting
pressure
Factory spec.
10.8 to 11.3 MPa
110.2 to 115.2 kgf/cm2
1567 to 1638 psi
(1) Power Steering Adaptor
W1011368
6-S4
STEERING
[2] PREPARATION
(1) Separating Power Steering Controller
Battery
CAUTION
• When disassembling the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
(1) Positive Cable
(2) Negative Cable
Seat
Tightening torque
(1) Seat
17.7 to 20.5 N·m
1.8 to 2.1 kgf·m
13.1 to 15.1 ft-lbs
W1040675
Panel
light switch.
(1) Front Panel
(2) 4P Connector
(3) 3P Connector
(4) Rear Panel
(5) Horn
W1013706
6-S5
STEERING
Power Steering Hose, Pipe and Controller
1. Disconnect the power steering hoses and pipe (3), (4), (5), (6).
2. Unscrew the power steering controller mounting screws (2), and
remove the power steering controller (1).
(When reassembling)
• Be sure to connect the power steering hoses and pipe (3), (4),
(5), (6) to their original position, and tight them to the specified
torque.
Power steering hose
mounting nut
24.6 to 29.4 N·m
2.5 to 3.0 kgf·m
18.1 to 21.6 ft-lbs
Power steering pipe
mounting nut
54.0 to 63.7 N·m
5.5 to 6.5 kgf·m
39.8 to 47.0 ft-lbs
Tightening torque
(1) Power Steering Controller
(2) Power Steering Controller Mounting
Screw
(3) Return Pipe 1
(4) Delivery Hose
(5) Cylinder Hose 1
(6) Cylinder Hose 2
R : R Port
L : L Port
P : P Port
(Connect to Delivery Hose 1)
T : T Port (Connect to Return Pipe)
(a) Front Side
(2) Separating Steering Support
Steering Support
1. Removing the seat and panels. (Refer to 6-S5.)
2. Disconnect the power steering hoses and pipe. (Refer to 6-S6.)
3. Remove the steering post covers.
4. Disconnect the accelerator wire (5).
5. Remove the OPC controller (1) and head lamp (2).
6. Unscrew the steering support mounting screw (3), and remove
the steering support (4).
(1) OPC Controller
(2) Head Lamp
(3) Steering Support Mounting Screw
(4) Steering Support
(5) Accelerator Wire
W1014193
6-S6
STEERING
(1) Steering Support
Steering Shaft
1. Remove the power steering controller (2).
2. Unscrew the universal joint mounting screw (3), and remove the
universal joint (1).
3. Remove the external snap rings (4), (10) and washers (5), (9)
from the steering shaft (7).
4. Remove the steering shaft (7).
5. Remove the bushes (6), (8).
(When reassembling)
• Apply grease to the inside of bushes (6), (8).
(1)
(2)
(3)
(4)
(5)
Universal Joint
Universal Joint Mounting Screw
External Snap Ring
Washer
(6)
(8)
(8)
(9)
(10)
Bush
steering Shaft
Bush
Washer
External Snap Ring
W1012459
6-S7
STEERING
[4] SERVICING
(1) Steering Cylinder
Cylinder Length
1. The length between rod ends is important.
When reassembling the rod ends, set the cylinder to the shortest
position and adjust the length “A”.
Length “A”
Factory spec.
439 to 441 mm
17.29 to 17.36 in.
Length “B”
Factory spec.
15 mm
0.59 in.
Set angle “C”
Factory spec.
0.175 rad
10 °
■ IMPORTANT
• When adjusting the cylinder length “A”, be sure to set the
direction of the rod ends (1), (4) with joint boss of cylinder
(1) as shown in figure.
Set angle “D”
Factory spec.
0.314 rad
18 °
Set angle “E”
Factory spec.
0.349 rad
20 °
(1) Rod End (Knuckle Arm)
(2) Lock Nut
(3) Lock Nut
(4) Rod End (Main Frame)
(5) Main Frame
(a) Front View
W1011546
6-S8
7
HYDRAULIC SYSTEM
MECHANISM
CONTENTS
1.
2.
3.
4.
5.
6.
7.
HYDRAULIC CIRCUIT .................................................................................. 7-M1
HYDRAULIC PUMP ...................................................................................... 7-M2
FLOW PRIORITY VALVE ............................................................................ 7-M3
RELIEF VALVE ............................................................................................. 7-M4
IMPLEMENT CONTROL VALVE ................................................................. 7-M5
FEEDBACK LINKAGE .................................................................................. 7-M6
HYDRAULIC CYLINDER .............................................................................. 7-M7
HYDRAULIC SYSTEM
1. HYDRAULIC CIRCUIT
(1)
(2)
(3)
(4)
Steering Cylinder
Steering Controller
Hydraulic Block Type Outlet
Lowering Speed Adjusting
Valve
(5) Hydraulic Cylinder
(6) Implement Control Valve
(7)
(8)
(9)
(10)
(11)
(12)
Orifice
Relief Valve
Hydraulic Pump
Oil Strainer
Flow Priority Valve
Hydraulic Transmission
(13)
(14)
(15)
(16)
(17)
Filter Cartridge
Oil Cooler
PTO Control Valve
Hydraulic PTO Clutch
EF :EF Port
PF :PF Port
P : P Port
T : T Port
L : L Port
R : R Port
The hydraulic system of these machines are composed of a hydraulic pump (9), hydraulic block type outlet (3),
implement control valve (6), hydraulic cylinder (5) and other components.
This system has the following functions.
Position control of the front implement connected to the lift arm.
Hydraulic power take off from the hydraulic block type outlet (3) to operate the implements such as a grass collector
and, etc..
Oil is supplied by a hydraulic pump (9) connected to the engine. When an engine is started, hydraulic pump (9)
starts running, sucks oil from a transmission case. The hydraulic pump (9) forces out the oil to the hydraulic block
type outlet (3), implement control valve (6), hydraulic cylinder (5), steering controller (2), PTO control valve (16),
hydraulic PTO clutch (17) and hydrostatic transmission (12).
7-M1
HYDRAULIC SYSTEM
2. HYDRAULIC PUMP
The hydraulic pump is composed of the case (1),
cover (3), side plate (5), and two spur gears (drive gear
(4) and driven gear (2)).
Hydraulic pump is driven by the governor shaft.
Displacement
24.0 L/min.
6.3 U.S.gals./min.
5.2 Imp.gals./min.
(1) Case
(2) Driven Gear
(3) Cover
Engine speed
At 2700 min-1
(rpm)
Condition
9.8 MPa
100 kgf/cm2
1422 psi
(4) Drive Gear
(5) Side Plate
W1013860
7-M2
HYDRAULIC SYSTEM
3. FLOW PRIORITY VALVE
The flow priority valve is a flow divider that divides the
flow from single hydraulic source (hydraulic pump) to
actuates two circuits (position control circuit and power
steering circuit) simultaneously.
This valve feeds fixedly controlled flow (10 L/min, 2.6
U.S.GPM, 2.2 Imp.GPM) to the PF port with priority and
excessive flow to the EF port.
(1) Spring
(2) Spool
(3) Valve Body
EF : EF Port
PF : PF Port
P : P Port
W1013500
7-M3
HYDRAULIC SYSTEM
4. RELIEF VALVE
The implement control system circuit has a relief
valve to restrict the maximum pressure in the circuit. The
relief valve is located top of the hydraulic cylinder body.
The relief valve is of the guide piston type with
damping effect.
Among direct acting relief valves, this type is suited to
higher pressure and has large capacity. Furthermore,
this type is free from unstable operation, such as
chattering, which occurs often in direct acting relief
valves.
As shown in the figure, the guide is attached to the
poppet (5) and a valve chamber D.C. (called the damping
chamber) is formed at the bottom of the guide piston.
The inlet of the valve leads to the chamber via a
clearance between the sliding portion of the guide and
the seat (6), minimizing valve vibration with the damping
effect of the chamber.
When the oil pressure in the circuit is lower that the
setting pressure of the relief valve, the relief valve is not
operated and the oil fed to the relief valve from the
hydraulic pump flows into the implement control valve.
As the oil pressure in the circuit increases, so does
the pressure in the damping chamber D.C.. When the
pressure rises above the valve setting and overcomes
the spring force, the valve opens. Oil then flows out to
the transmission case through T port, preventing any
further rise in pressure. The valve closes again when
enough oil is released to drop pressure below the valve
setting.
(Reference)
• Relief valve setting pressure :
13.8 to 14.2 MPa
140 to 145 kgf/cm2
1992 to 2062 psi
• Engine speed : Maximum
• Oil temperature : 40 to 50 °C
104 to 122 °F
(1)
(2)
(3)
(4)
(5)
(6)
Plug
Washer
Shim
Hydraulic Cylinder BOdy
Poppet
Seat
D.C. : Damping Chamber
P : Pump Port
T : Tank Port (To
Transmission Case)
a : To Implement Control
Valve
W1013612
7-M4
HYDRAULIC SYSTEM
5. IMPLEMENT CONTROL VALVE
This implement control valve is located under the hydraulic cylinder block.
■ Neutral
Oil forced into the implement control valve (1) through
P port and returns to the transmission case through T2
port.
Also, C port is closed by spool (2), oil in the hydraulic
cylinder does not flow to the transmission case.
Thus, the implement remains at its fixed position.
(2) Spool
P : Pump Port
C : Cylinder Port
T1, T2 : Tank Port
W1013463
■ Lift
When the hydraulic control lever is set to the “LIFT”
position, the spool (2) is move to the left.
The oil forced into the implement control valve (1)
through P port flows to C port.
The oil pushes and flows into the hydraulic cylinder
through the C port to lift the implement.
(2) Spool
P : Pump Port
C : Cylinder Port
T1, T2 : Tank Port
W1013558
■ Down
When the hydraulic control lever is moved to
“DOWN” position, the spool (2) is moved to the right.
Oil in the hydraulic cylinder is forced out to the
transmission case through the T1 port by the weight of
the implement, causing the implement to lower.
Oil forced into the implement control valve (1) through
the P port and returns to the transmission case through
the T2 port.
(2) Spool
P : Pump Port
C : Cylinder Port
T1, T2 : Tank Port
W1013658
7-M5
HYDRAULIC SYSTEM
6. FEEDBACK LINKAGE
When the hydraulic control lever 1 (1) is moved to
rearward to lift the implement, the spool of the implement
control valve (7) is pulled out to form a raising circuit.
Then the lift arm (9) begins to rise.
After the lift arm (9) gets to the uppermost position,
the spool is pushed in and returned to form a neutral
circuit by the motions of the feedback pin (8), feedback
rod (3), hydraulic control lever 2 (2), control lever arm (5)
and control lever shaft (6).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Hydraulic Control Lever 1
Hydraulic Control Lever 2
Feedback Rod
Interlocker
Control Lever Arm
Control Lever Shaft
Feedback Pin
Lift Arm
A : When the hydraulic control
lever is moved to rearward
B : When the lift arm gets to the
uppermost position
W1014224
7-M6
HYDRAULIC SYSTEM
7. HYDRAULIC CYLINDER
(1) Lowering Speed Adjusting
Shaft
(2) Lowering Speed Adjusting
Valve
(3) Orifice
(4) Hydraulic Cylinder Case
(5) Relief Valve
(6) Hydraulic Arm
(7) Lift Arm
(9) Hydraulic Rod
(10) Back-up Ring
(11) O-ring
(12) Piston
The main components of the hydraulic cylinder are shown in the figure above.
While the lift arm (7) is rising, oil from the hydraulic pump flows into the hydraulic cylinder through the implement
control valve (8). Then oil pushes out the piston (12).
While the lift arm (7) is lowering, oil in the hydraulic cylinder is discharged to the transmission case through the
implement control valve (8) by the weight of the implement. At this time, the lowering speed of the implement can be
controlled by the lowering speed adjusting valve (2) attached to the hydraulic cylinder case (4). Turning the lowering
speed adjusting knob clockwise decreases the lowering speed, and counterclockwise increases lowering speed.
When the lowering speed adjusting valve (2) is completely closed, the lift arm (7) is held at its position since oil in the
hydraulic cylinder is sealed between the piston (12) and lowering speed adjusting valve (2).
7-M7
SERVICING
CONTENTS
1.
2.
3.
4.
(1) Hydraulic Pump and Flow Priority Valve.............................................7-S4
(2) Hydraulic Cylinder Assembly ..............................................................7-S5
(1) Hydraulic Pump and Flow Priority Valve.............................................7-S6
(2) Hydraulic Cylinder Assembly ..............................................................7-S7
[3] SERVICING ............................................................................................7-S11
(1) Hydraulic Pump.................................................................................7-S11
(2) Hydraulic Cylinder .............................................................................7-S12
HYDRAULIC SYSTEM
1. TROUBLESHOOTING
Symptom
Implement Does Not
Rise (No Noise)
Probable Cause
Solution
Reference
Page
Control valve broken
Replace
7-S8
Control valve improperly assembled
Assemble
7-S8
Relief valve spring damaged
Replace
7-S10
Spool sticks
Repair
7-S8
Piston O-ring or cylinder damaged
Replace
7-S9
Lowering speed adjusting valve closed
Open
Oil strainer clogged
Clean or replace
G-26
Suction pipe loosen or broken
Repair or replace
2-S11
Suction pipe connecting hose loosen or broken
Repair or replace
2-S11
Suction pipe O-ring broken
Replace
7-S6
Insufficient transmission oil
Refill
G-7
Relief valve setting pressure too low
Adjust or replace
Hydraulic pump broken
Replace
7-S6
Implement Does Not
Lower
Control valve malfunctioning
Repair or replace
7-S8
Implement Drops by
Its Weight
Hydraulic cylinder worn or damaged
Replace
7-S12
Piston O-ring worn or damaged
Replace
7-S9
Control valve malfunctioning
Replace
7-S8
(Noise)
–
7-S5, S10
W1017660
7-S1
HYDRAULIC SYSTEM
HYDRAULIC PUMP
Item
Hydraulic Pump
Allowable Limit
29.0 L/min.
Above 7.6 U.S.GPM
6.3 Imp.GPM
–
24.0 L/min.
Above 6.3 U.S.GPM
5.2 Imp.GPM
21.0 L/min.
5.5 U.S.GPM
4.6 Imp.GPM
Delivery
(At No Pressure)
10.0 L/min.
Above 2.6 U.S.GPM
2.2 Imp.GPM
–
Delivery
(At 7.8 MPa
80 kgf/cm2
1138 psi)
10.0 L/min.
Above 2.6 U.S.GPM
2.2 Imp.GPM
9.5 L/min.
2.5 U.S.GPM
2.1 Imp.GPM
13.8 to 14.2 MPa
140 to 145 kgf/cm2
1992 to 2062 psi
–
Delivery
(At No Pressure)
Delivery
(At 9.8 MPa
100 kgf/cm2
1422 psi)
Flow Priority Valve
Relief Valve (Hydraulic Pump)
Setting Pressure
Tip of Gear to Casing (Hydraulic Pump)
Clearance
–
0.15 mm
0.0059 in.
Bushing to Gear Shaft (Hydraulic Pump)
Clearance
0.025 to 0.111 mm
0.0010 to 0.0044 in.
0.12 mm
0.0047 in.
Gear Shaft
O.D.
14.970 to 14.980 mm
0.5894 to 0.5898
–
Bush
I.D.
15.005 to 15.081
0.5908 to 0.5938
–
Side Plate (Hydraulic Pump)
Thickness
2.48 to 2.50 mm
0.0976 to 0.0984 in.
2.40 mm
0.0945 in.
Hydraulic Cylinder
I.D.
70.05 to 70.10 mm
2.7579 to 0.7598 in.
70.15 mm
2.7618 in.
Hydraulic Arm Shaft to Bush
Left and Right
Clearance
0.020 to0.110 mm
0.0008 to 0.0043 in.
0.30 mm
0.0118 in.
Hydraulic Arm Shaft (Left)
O.D.
37.925 to 37.950 mm
1.4931 to 1.4941 in.
–
Hydraulic Arm Shaft (Right)
O.D.
33.925 to 33.950 mm
1.3356 to 1.3366 in.
–
Bush (Left)
I.D.
37.970 to 38.035 mm
1.4949 to 1.4974 in.
–
Bush (Right)
I.D.
33.970 to 34.035 mm
1.3374 to 1.3400 in.
–
W1013874
7-S2
HYDRAULIC SYSTEM
Item
N·m
kgf·m
ft-lbs
Engine stop solenoid mounting screw
9.80 to 11.2
1.00 to 1.15
7.24 to 8.32
Flow priority valve mounting screw
17.7 to 20.6
1.8 to 2.1
13.0 to 15.2
Delivery hose mounting nut
24.6 to 29.4
2.5 to 3.0
14.5 to 21.6
Hydraulic pump mounting screw and nut
23.6 to 27.4
2.4 to 2.8
17.4 to 20.2
Cover mounting screw
39.2 to 44.1
4.0 to 4.5
28.9 to 32.5
Hydraulic cylinder assembly mounting screw and nut
39.2 to 44.1
4.0 to 4.5
28.9 to 32.5
Control valve mounting screw
23.6 to 27.4
2.4 to 2.8
17.4 to 20.2
Relief valve plug
49.0 to 68.6
5.0 to 7.0
36.2 to 50.6
W1018416
7-S3
HYDRAULIC SYSTEM
(1) Hydraulic Pump and Flow Priority Valve
Flowmeter Connecting and Test Preparation
■ IMPORTANT
• When using a flowmeter other than KUBOTA specified
flowmeter (Code No. 07916-52791), be sure to use the
instructions with that flowmeter.
• In this hook-up, there is no relief valve.
Therefore while testing, do not close the flowmeter loading
valve completely.
1. Disconnect the delivery hose (4), and install the plug to the flow
priority valve body (EF port).
2. Install the adaptor 51 to the flow priority valve body (PF port).
3. Connect the hydraulic test hose (Code No. 07916-52651) to the
flowmeter (Code No. 07916-52791) inlet port.
4. Connect the another hydraulic test hose to flowmeter outlet port
and transmission oil filling port, firmly.
5. Open the flowmeter loading valve completely.
(Turn
counterclockwise).
(1) Delivery Hose (EF Port)
(2) Flow Priority Valve Body
(3) Hydraulic Pump
(4) Delivery Hose (PF Port)
W1017826
Hydraulic Pump Test
■ NOTE
• Before pump testing, perform the “Flowmeter Connecting
and Test Preparation”. (See page 7-S4.)
1. Remove the plug (1), and pull out the spool (3) and spring (2).
2. Open the loading valve completely.
3. Start the engine and set at approx. 2700 min-1 (rpm).
4. Read and note the pump delivery at no pressure.
5. Slowly close the loading valve to increase pressure approx. 9.8
MPa (100 kgf/cm2, 1422 psi).
6. Read and note the pump delivery at rated pressure.
7. Open the loading valve and stop the engine.
8. If the pump delivery does not reach the allowable limit, check the
pump suction line, oil filter or hydraulic pump.
Hydraulic pump delivery
at no pressure
(Oil temperature at 50
°C (122 °F))
Hydraulic pump delivery
at rated pressure
°C (122 °F))
Factory spec.
29.0 L/min.
Above 7.6 U.S.GPM
6.3 Imp.GPM
Factory spec.
24.0 L/min.
Above 6.3 U.S.GPM
5.2 Imp.GPM
Allowable limit
21.0 L/min.
5.5 U.S.GPM
4.6 Imp.GPM
(Condition)
• Engine speed ..... Approx. 2700 min-1 (rpm)
• Rated pressure ..... 9.8 MPa (100 kgf/cm2, 1422 psi)
(1) Plug
(2) Spring
(3) Spool
(4) Flow Priority Valve Body
W1010923
7-S4
HYDRAULIC SYSTEM
Flow Priority Valve Test
■ NOTE
• Before flow priority valve testing, perform the “Flowmeter
Connecting and Test Preparation”. (See page 7-S4.)
1. Open the loading valve completely.
2. Start the engine and set at approx. 2700 min-1 (rpm).
3. Read and note the flow priority valve delivery at no pressure.
4. Slowly close the loading valve to increase pressure approx. 7.8
MPa (80 kgf/cm2, 1138 psi).
5. Read and note the flow priority valve delivery at rated pressure.
6. Open the loading valve and stop the engine.
7. If the flow priority valve delivery does not reach the allowable
limit, check the pump suction line, oil filter or hydraulic pump.
Flow priority valve
delivery (PF port) at no
pressure
°C (122 °F))
Flow priority valve
delivery (PF port) at
rated pressure
°C (122 °F))
Factory spec.
10.0 L/min.
Above 2.6 U.S.GPM
2.2 Imp.GPM
Factory spec.
10.0 L/min.
Above 2.6 U.S.GPM
2.2 Imp.GPM
Allowable limit
9.5 L/min.
2.5 U.S.GPM
2.1 Imp.GPM
(Condition)
• Engine speed ..... Approx. 2700 min-1 (rpm)
• Rated pressure ..... 7.8 MPa (80 kgf/cm2, 1138 psi)
W1012525
Relief Valve Setting Pressure
1. Remove the seat assembly and plate.
2. Remove the plug (1) from rear of hydraulic cylinder block.
3. Install the adaptor 58. Then connect the cable and pressure
gauge to adaptor 58.
5. Start the engine and set a maximum speed.
6. Move the mower lift lever all way up to operate the relief valve
and read the gauge.
7. If the pressure is not within the factory specifications, adjust with
the adjusting shims (3).
Relief valve setting
pressure
Factory spec.
13.8 to 14.2 MPa
140 to 145 kgf/cm2
1992 to 2062 psi
(Reference)
• Thickness of shims (3) : 0.1 mm (0.0039 in.), 0.2 mm (0.0079 in.)
(1) Plug
(2) Lowering Speed Adjusting Rod
(3) Shim
W1012745
7-S5
HYDRAULIC SYSTEM
(1) Hydraulic Pump and Flow Priority Valve
Removing Hydraulic Pump and Flow Priority Valve
1. Remove the engine stop solenoid (2).
2. Remove the delivery hoses (1), (8).
3. Remove the flow priority valve (4).
4. Disconnect the suction pipe (7) and remove the hydraulic pump
(5).
(When reassembling)
• Apply grease to O-ring and take care not to damage it.
• Apply liquid gasket (Three Bond 1208D or equivalent) to the
engine stop solenoid gasket.
Engine stop solenoid
mounting screw
9.80 to 11.2 N·m
1.00 to 1.15 kgf·m
7.24 to 8.32 ft-lbs
Flow priority valve
mounting screw
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
Delivery hose mounting
nut
24.6 to 29.4 N·m
2.5 to 3.0 kgf·m
14.5 to 21.6 ft-lbs
Hydraulic pump mounting
screw and nut
23.6 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
Delivery Hose (EF Port)
Flow Priority Valve Mounting Screw
Flow Priority Valve
(5)
(6)
(7)
(8)
Hydraulic Pump
Hydraulic Pump Mounting Screw
Suction Pipe
Delivery Hose (PF Port)
W1011203
Hydraulic Pump
1. Secure the hydraulic pump with a vise, and remove the cover (7).
2. Remove the side plate (5), driven gear (4) and drive gear (9).
3. Remove the internal snap ring (1), and remove the oil seal (2).
(When reassembling)
• Be careful not to damage the gasket (6).
• Align the holes on the cover (7) and casing (3).
• If the oil seal is defective, worn or scratched, replace it.
• Install the side plate, noting its location and direction.
• Install the gears, noting its direction.
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Internal Snap Ring
Oil Seal
Casing
Driven Gear
Side Plate
Gasket
Cover mounting screw
(7)
(8)
(9)
(10)
(11)
34.3 to 39.2 N·m
3.5 to 4.0 kgf·m
25.3 to 28.9 ft-lbs
Cover
Bush
Drive Gear
Bush
Cover Mounting Screw
W1011445
7-S6
HYDRAULIC SYSTEM
Battery
CAUTION
• When disconnecting the battery cables, disconnect the
negative cable from the battery first.
When connecting, connect the positive cable to the battery
first.
3. Unscrew the battery mounting nuts (2), and remove the battery
(3).
(1) Positive Cable
(2) Battery Mounting Nut
(3) Battery
(4) Negative Cable
W1021027
Seat
Refer to “TRANSMISSION” Section. (See page 2-S11.)
W1021463
Panel
W1021499
Fender
W1021535
Speed Control Rod, Lowering Speed Adjusting Rod and
Hydraulic Pipes
W1021571
Feedback Rod and Mower Lift Lever
1. Remove the feedback rod (2).
2. Remove the hydraulic control lever assembly (1).
(When reassembling)
• Adjust the length “A” of the feedback rod (2).
(Reference)
(1) Mower Lift Lever Assembly
(2) Feedback Rod
W1021616
7-S7
HYDRAULIC SYSTEM
Separating Hydraulic Cylinder Assembly
1. Remove the hydraulic cylinder assembly mounting screws and
nuts, and separate the hydraulic cylinder assembly (1).
(When reassembling)
Tightening torque
Hydraulic cylinder
assembly mounting screw
and nut
39.2 to 44.1 N·m
4.0 to 4.5 kgf·m
28.9 to 32.5 ft-lbs
W1013253
Control Valve
1. Remove the control valve mounting screws, and remove the
control valve (2).
(When reassembling)
• Take care not to damage the O-rings (1).
Tightening torque
(1) O-ring
Control valve mounting
screw
23.6 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
(2) Control Valve
W1013474
Disassembling Control Valve
1. Remove the spring pin (6) and snap ring (5).
2. Draw out the spool (4) with the spring (2).
(1) Snap Ring
(2) Spring
(3) Control Valve Body
(4) Spool
(5) Snap Ring
(6) Spring Pin
W1013678
7-S8
HYDRAULIC SYSTEM
Lift Arm, Hydraulic Arm Shaft and Hydraulic Arm
1. Remove the external snap ring, and remove the lift arm LH (1).
2. Pull out the hydraulic arm shaft (4) and lift arm RH (2) as a unit.
(When reassembling)
• Align the alignment marks (5) of the hydraulic arm (6) and
hydraulic arm shaft (4).
• Align the alignment marks (3) of the lift arm LH (1) and hydraulic
arm shaft (4).
• Apply grease to the right and left bushings and O-rings.
(1) Lift Arm LH
(2) Lift Arm RH
(3) Alignment Mark
(4) Hydraulic Arm Shaft
(5) Alignment Mark
(6) Hydraulic Arm
W1013495
Hydraulic Piston
1. Use compressed air through the hydraulic cylinder oil gallery to
take out the hydraulic piston (1).
(When reassembling)
• Take care not to damage the O-ring (3) and backup ring (2).
• Apply transmission fluid to the O-ring.
• Replace the O-ring if it is defective, worn or scratched, which may
cause oil leakage.
(1) Hydraulic Piston
(2) Backup Ring
(3) O-ring
W1013522
Lowering Speed Adjusting Valve
1. Remove the lowering speed adjusting valve body (4) with the
lowering speed adjusting shaft (6).
2. Remove the poppet (2) and spring (1).
(When reassembling)
■ NOTE
• *The orifice is added to reduce the lifting speed of mower.
(1)
(2)
(3)
(4)
Spring
Poppet
O-ring
Lowering Speed Adjusting Valve
Body
(5) O-ring
(6)
(7)
(8)
(9)
(10)
Lowering Speed Adjusting Shaft
Stopper
Collar
Internal Snap Ring
Orifice*
W1013618
7-S9
HYDRAULIC SYSTEM
Relief Valve
1. Remove the plug (1), and remove the shims (2), (3), spring (4),
poppet (5) and the valve seat (6).
(When reassembling)
• Take care not to damage the O-ring.
Tightening torque
Relief valve plug
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
■ IMPORTANT
• After disassembling and assembling the relief valve, be sure
to adjust the relief valve setting pressure.
(1) Plug
(2) Shim
(3) Shim
(4) Spring
(5) Poppet
(6) Valve Seat
W1013647
7-S10
HYDRAULIC SYSTEM
[3] SERVICING
(1) Hydraulic Pump
Clearance between Tip of Gear Tooth and Casing
1. Measure the gear shaft O.D. with an outside micrometer.
2. Measure the bush I.D. with a cylinder gauge, and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace the pump
assembly.
Clearance between tip
of gear tooth and casing
(a) I.D.
Allowable limit
0.15 mm
0.0059 in.
(b) O.D.
W1011837
Clearance between Bush and Gear Shaft
1. Measure the gear shaft O.D. with an outside micrometer.
2. Measure the bush I.D. with a cylinder gauge, and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace the bush.
Factory spec.
0.025 to 0.111 mm
0.0010 to 0.0044 in.
Allowable limit
0.12 mm
0.0047 in.
Gear shaft O.D.
Factory spec.
14.970 to 14.980 mm
0.5894 to 0.5898 in.
Bush I.D.
Factory spec.
15.005 to 15.081 mm
0.5908 to 0.5938 in.
Clearance between
bushing and gear shaft
(a) I.D.
(b) O.D.
W1011967
Side Plate Thickness
1. Measure the side plate thickness with an outside micrometer.
Factory spec.
2.48 to 2.50 mm
0.0976 to 0.0984 in.
Allowable limit
2.40 mm
0.0945 in.
Side plate thickness
W1012143
7-S11
HYDRAULIC SYSTEM
(2) Hydraulic Cylinder
Hydraulic Cylinder Bore
1. Check the cylinder internal surface for scoring or damage.
2. Measure the cylinder I.D. with a cylinder gauge.
hydraulic cylinder block.
Factory spec.
70.05 to 70.10 mm
2.7579 to 2.7598 in.
Allowable limit
70.15 mm
2.7618 in.
Cylinder I.D.
W1013716
Clearance between hydraulic Arm Shaft and Bush
1. Measure the hydraulic arm shaft O.D. with an outside
micrometer.
2. Measure the bushing I.D. with a cylinder gauge, and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace the bushing.
Factory spec.
0.020 to 0.110 mm
0.0008 to 0.0043 in.
Allowable limit
0.30 mm
0.0118 in.
Factory spec.
0.020 to 0.110 mm
0.0008 to 0.0043 in.
Allowable limit
0.30 mm
0.0118 in.
Left
Factory spec.
37.925 to 37.950 mm
1.4931 to 1.4941 in.
Right
Factory spec.
33.925 to 33.950 mm
1.3356 to 1.3366 in.
Left
Factory spec.
37.970 to 38.035 mm
1.4949 to 1.4974 in.
Right
Factory spec.
33.970 to 34.035 mm
1.3374 to 1.3400 in.
Left
Clearance
between hydraulic
arm shaft and
bushing
Right
Hydraulic arm
shaft O.D.
Bushing I.D. (after
press fitted)
W1013775
7-S12
8
ELECTRICAL SYSTEM
MECHANISM
CONTENTS
1. WIRING DIAGRAM ....................................................................................... 8-M1
2. STARTING SYSTEM .................................................................................... 8-M3
[1] OPERATOR PRESENCE CONTROL (OPC) SYSTEM....................... 8-M3
(1) Related Switches and Controller........................................................ 8-M4
(2) Operation ........................................................................................... 8-M5
F2880, F3680, RCK72-F36, RCK72R-F36, RCK60-F36, RCK60R-F36 WSM
ELECTRICAL SYSTEM
1. WIRING DIAGRAM
Fuel
Sensor
0.5 YG
0.5 B
PTO Switch
0.5 RY
0.5 O
0.5 RY
0.5 YR
0.5 Br
0.5 B
0.5 RY
0.5 WB
3B
0.5 B
2 RG
0.85 RL
0.5 RY
0.85 RL
0.5 B
Y
R
Seat Switch
M8
0.5 WB
0.5 RG
0.5 LW
0.5 RG
20A
10A
5A
Fuel Pomp
Frame Earth
2 RG
12 V
55 W
Fuse Box
2 RW
Work
Light
Head Lamp
0.5 BrW
0.5 WB
0.5 O
0.5 RY
3 BY
0.5 WL
0.5 BR
0.5 YR
0.5 B
3 BW
Brake
Switch
Horn Relay
Horn
0.5 LW
Glow Plug Indicator
Brake Switch
PTO Switch
AC
Starting Switch
Solenoid
Grow Plug
Seat Switch
GND
Starter
Controller
Main Switch
AC
G
B
2 RW
3R
3 BR
3 BY
ST
Head Lamp Switch
OFF ON
3B
0.5 RL
0.5 Br
M8
Frame Earth
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
0.5 RY
Joint
Connector
3 BR
0.5 WB
Water Temperature
Switch
3B
0.5 B
0.5 B
0.5 B
0.5 B
3B
0.5 B
0.5 B
0.5 B
0.5 B
Resistance
Welding
Glow Plug
0.5 WG
Water Temperature
Sensor
2W
0.5 WL
2W
0.5 L
3 BW
0.5 RY
0.5 B
0.5 B
0.5 Br
0.5 WG
0.5 RY
0.5 BrW
0.5 RY
0.5 RY
R
Br
0.5 B
0.5 Br
RW
Engine Stop
Solenoid
0.5 YG
0.5 RY
0.5 L
0.5 WR
0.5 RY
12
3.4
OIL
12
3.4
RL
L
W
GLOW
12
3.4
CHG
Monitor Lamp
3R
S
B
+
3R
3R
0.5 RY
0.5 WR
3R
20 BR
HOUR METER
-
12 V
+ U E
E
Fuel Meter
3GFACAB9P001A
8-M1
C
50A
Hour Meter
+ U E
F
H
Starter
Alternator
Battery
Oil Switch
Slow Blow
Fuse
Water Temperature
Meter
Color of wiring
W.....White
ELECTRICAL SYSTEM
O.....Orange
RW.....Red / White
BY.....Black / Yellow
R.....Red
WB.....White / Black
RG.....Red / Green
YR.....Yellow / Red
L.....Blue
WR.....White / Red
RY.....Red / Yellow
YG.....Yellow / Green
Y.....Yellow
WG.....White / Green
BW.....Black / White
LW.....Blue / White
B.....Black
WL.....White / Blue
BR.....Black / Red
BrW.....Brown / White
Br.....Brown
RL.....Red / Blue
W1012663
8-M2
ELECTRICAL SYSTEM
2. STARTING SYSTEM
[1] OPERATOR PRESENCE CONTROL (OPC) SYSTEM
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Battery
Starter
Slow Blow Fuse (50A)
Main Switch
Fuse (5A)
Glow Plug
Glow Plug Lamp
Seat Switch
PTO Switch
Brake Switch
Controller
Frame Earth
1 to 10 :Controller Terminals
AC :AC Terminal
G : G Terminal
ST :ST Terminal
S : S Terminal
B : B Terminal
W1013395
This machine is equipped with the operator presence control (OPC) system.
This system is controlled by three safety switch (seat switch (8), PTO switch (9) and brake switch (10)) and
controller (11).
8-M3
ELECTRICAL SYSTEM
(1) Related Switches and Controller
■ Seat Switch
The seat switch is located in the bottom of seat (2).
This switch is the open type. In normal operating
condition, the switch is open circuit. When sitting on the
seat, the seat switch (1) is turned “ON”. When the seat
is vacant, the seat switch (1) is turned “OFF”.
(1) Seat Switch
(2) Seat
W1013834
■ PTO Switch
The PTO switch (1) is located at the side frame (RH).
This switch is the open type. In normal operating
condition, the switch is open circuit.
When the PTO lever (2) is set at the “DISENGAGE”
position, the PTO switch (2) is pushed by the PTO lever
and is turned “ON”. When the PTO lever (2) is set at the
“ENGAGE” position, the PTO switch (1) is not pushed by
the PTO lever (2), and is turned “OFF”.
(1) PTO Switch
(2) PTO Lever
W1013949
■ Brake Switch
The brake switch (1) is located on the front frame.
This switch is the close type. In normal operating
condition, the switch is close circuit.
When depressing the brake pedal, the brake switch
(1) is not pushed by the brake arm (2), and is turned
“ON”. When the brake pedal is free, the brake switch (1)
is pushed by the brake arm (2), and is turned “OFF”.
(1) Brake Switch
(2) Brake Arm
W1014147
■ Controller
The controller (1) is located at inside the panel.
(1) Controller
W1014349
8-M4
ELECTRICAL SYSTEM
(2) Operation
■ Starting the Engine
(1)
(2)
(3)
(4)
(5)
Battery
Starter
Main Switch
Fuse (5A)
(6)
(7)
(8)
(9)
(10)
Glow Plug
Glow Plug Lamp
Seat Switch
PTO Switch
Brake Switch
(11)
(12)
(13)
(14)
(15)
Controller
Frame Earth
Holding Coil
Pulling-in Coil
[A] When the main switch is
turned to the “ON” position
(AC terminal)
[B] When the main switch is
turned to the “START”
position (ST terminal)
When the main switch (4) is turned to the “ON” position (AC terminal) under the following condition, the electrical
current flows to the holding coil (14) of the engine stop solenoid (13). (Figure [A])
When the main switch (4) is turned to the “START” position (ST terminal), the electrical current flows to the starter
(2). Then, the electrical current flows to the pulling-in coil (15) of the engine stop solenoid (13) through the starter (2).
(Figure [B]) The engine can be started.
Seat Switch (8)
(Occupied : ON)
(Vacant : OFF)
PTO Switch (9)
(Disengaged : ON)
(Engaged : OFF)
Brake Switch (10)
(Pedal depressed : ON)
(Pedal free : OFF)
ON
ON
ON
W1014766
8-M5
ELECTRICAL SYSTEM
■ Stopping the Engine, Automatically
(1)
(2)
(3)
(4)
(5)
Battery
Starter
Main Switch
Fuse (5A)
(6)
(7)
(8)
(9)
(10)
Glow Plug
Glow Plug Lamp
Seat Switch
PTO Switch
Brake Switch
(11)
(12)
(13)
(14)
(15)
Controller
Frame Earth
Holding Coil
Pulling-in Coil
[A] Condition 1
[B] Condition 2
[C] Condition 3
When the following conditions become complete, the electrical current does not flow to the holding coil (14) of the
engine stop solenoid (13) from the controller (11). Then, the engine will stop in 0.6 to 1.4 seconds.
Condition
Seat Switch (8)
(Occupied : ON)
(Vacant : OFF)
PTO Switch (9)
(Disengaged : ON)
(Engaged : OFF)
Brake Switch (10)
(Pedal depressed : ON)
(Pedal free : OFF)
1
OFF
ON
OFF
2
OFF
OFF
ON
3
OFF
OFF
OFF
W1015064
8-M6
SERVICING
CONTENTS
1.
2.
3.
4.
(1) Battery.................................................................................................8-S6
(2) Main Switch.........................................................................................8-S6
(3) Starter .................................................................................................8-S8
(4) Glow Plug............................................................................................8-S9
(5) Safety Switch ......................................................................................8-S9
(6) Fuel Pump.........................................................................................8-S10
(7) Engine Stop Solenoid .......................................................................8-S11
(8) Charging System ..............................................................................8-S11
(9) Lighting System ................................................................................8-S13
(10)Cooling System.................................................................................8-S14
(11)Gauges .............................................................................................8-S14
(1) Starter ...............................................................................................8-S16
(2) Alternator ..........................................................................................8-S17
[3] SERVICING ............................................................................................8-S19
(1) Starter ...............................................................................................8-S19
(2) Alternator ..........................................................................................8-S22
ELECTRICAL SYSTEM
1. TROUBLESHOOTING
Solution
Reference
Page
Battery discharged or defective
Recharge or replace
8-S4
Battery positive cable disconnected or
improperly connected
Repair or replace
8-S4
Battery negative cable disconnected or
improperly connected
Repair or replace
8-S4
Slow blow fuse blown
Replace
G-34
Short-circuited
Repair or replace
Symptom
All Electrical
Equipment Does Not
Operate
Fuse Blows
Frequently
Probable Cause
–
W1014322
BATTERY
Battery Discharges
Too Quickly
Battery defective
Recharge or replace
8-S4
Alternator defective
Repair or replace
8-S11 to S12
Wiring harness disconnected or improperly
connected
Repair or replace
–
Cooling fan belt slipping
Adjust tension
G-25
W1013718
STARTING SYSTEM
Starter Does Not Work Battery discharged or defective
Glow Plug Does Not
Glow
Recharge or replace
8-S4
Replace
G-34
Replace
8-S10
Replace
8-S10
Replace
8-S9
Controller defective
Replace
G-19, 6-S6
connected
Repair or replace
–
Starter defective
Repair or replace
8-S19 to S21
Main switch defective
Replace
Battery discharged or defective
Recharge or replace
8-S4
Replace
G-34
connected
Repair or replace
Glow plug defective
Replace
8-S9
Replace
8-S6 to S7
Replace
G-34
Engine Does Not Stop Fuse blown
When Main Switch Is Wiring harness disconnected or improperly
Turned “OFF”
connected
Position
Engine Does Not
Restart
Repair or replace
8-S6 to S7
–
–
Replace
8-S6 to S7
Engine stop solenoid defective
Replace
8-S11
Replace
G-19, 6-S6
Replace
8-S11
Replace
G-19, 6-S6
W1013718
8-S1
ELECTRICAL SYSTEM
CHARGING SYSTEM
Symptom
Probable Cause
Solution
Reference
Page
Charging Lamp Does
Not Light When Main
Switch Is Turned
“ON” Position
Fuse blown
Replace
G-34
Bulb blown
Replace
G-34
connected
Repair or replace
–
Charging Lamp Does
Not Go Off When
Engine Is Running
Short circuit between alternator L terminal lead
and chassis
Repair or replace
–
Alternator defective
Repair or replace
8-S11 to
S12
W1014322
LIGHTING SYSTEM
Head Light Does Not
Light
Oil Pressure
Indicator Lamp
Lights Up When
Engine Is Running
Oil Pressure
Indicator Lamp Does
Not Light When Main
Switch Is Turned
“ON” Position and
Engine Is Not
Running
Fuse blown
Replace
G-34
Bulb blown
Replace
G-34
Head light switch defective
Replace
8-S13
connected
Repair or replace
–
Engine oil pressure too low
Check and repair
G-7
Replenish
G-7
Oil pressure switch defective
Replace
Short circuit between oil pressure switch lead
(1P connector) and chassis
Repair
Fuse blown
Replace
G-34
Bulb blown
Replace
G-34
Oil pressure switch defective
Replace
8-S13
connected
Repair or replace
Replace
8-S13
–
–
8-S6 to S7
W1013718
8-S2
ELECTRICAL SYSTEM
OPERATOR PRESENCE CONTROL
Symptom
Probable Cause
Solution
Reference
Page
Engine Does Not
Stop When Operator
Leaves Seat (PTO
Lever Is Set at
“ENGAGE” Position /
Parking Lock Lever
Is at Parking
Position)
Replace
8-S9
Replace
8-S10
Replace
G-19, 6-S6
Replace
8-S11
Engine Stop When
PTO Lever Is Set at
“ENGAGE” Position
(Operator Is Seated /
Parking Lock Lever
Is at Parking
Position)
Replace
8-S9
Replace
G-19, 6-S6
Engine Stop When
Operator Leaves
Seat (PTO Lever Is
Set at “DISENGAGE”
Position / Parking
Lock Lever Is at
Parking Position)
Replace
8-S10
Replace
8-S10
Replace
G-19, 6-S6
W1011794
GAUGES
Fuel Gauge Does Not
Function
Coolant Temperature
Gauge Does Not
Function
Fuel gauge defective
Replace
8-S15
Fuel level sensor defective
Replace
8-S14
connected
Repair or replace
Coolant temperature gauge defective
Replace
8-S15
Coolant temperature sensor defective
Replace
8-S15
connected
Repair or replace
–
–
W1011939
8-S3
ELECTRICAL SYSTEM
STARTER
Item
Commutator
O.D.
Difference of
O.D.’s
Mica
Undercut
Brush
Length
Allowable Limit
28.0 mm
1.10 in.
27.0 mm
1.06 in.
Less than 0.05 mm
0.0020 in.
0.40 mm
0.0157 in.
0.50 to 0.80 mm
0.020 to 0.031 in.
0.20 mm
0.0079 in.
16.0 mm
0.630 in.
10.5 mm
0.413 in.
W1013874
ALTERNATOR
Slip Ring
Brush
O.D.
14.4 mm
0.567 in.
14.0 mm
0.551 in.
Length
10.5 mm
0.413 in.
8.4 mm
0.331 in.
W1013973
8-S4
ELECTRICAL SYSTEM
(For general use screws, bolts and nuts : See page G-8)
Item
N·m
kgf·m
ft-lbs
Starter
B terminal nut
7.8 to 9.8
0.8 to 1.0
5.8 to 7.2
Starter
C terminal nut
7.9 to 11.8
0.8 to 1.2
5.8 to 8.7
Starter
Magnetic switch mounting nut
5.9 to 10.8
0.6 to 1.1
4.4 to 7.9
Starter
Through bolt
4.42 to 7.35
0.45 to 0.75
3.23 to 5.42
Alternator
Pulley nut
58.3 to 78.9
5.95 to 8.05
43.0 to 58.2
W1012736
8-S5
ELECTRICAL SYSTEM
•
•
•
•
■
•
CAUTION
To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
Never remove the battery cap while the engine is running.
Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.
Keep sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen becomes
very explosive.
IMPORTANT
If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (Lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
(1) Battery
Battery Voltage
1. Stop the engine and turn the main switch off.
2. Connect the COM (−) lead of the voltmeter to the battery’s
negative terminal post (2) and the (+) lead to the positive terminal
post (1), and measure the battery voltage.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
Battery voltage
(1) Positive Terminal Post
Factory spec.
More than 12 V
(2) Negative Terminal Post
W1012467
Battery Terminal Connection
1. Turn the main switch on, and turn on the head light.
2. Measure the voltage with a voltmeter across the battery’s positive
terminal post and the cable terminal, and the voltage across the
battery’s negative terminal post and the chassis.
3. If the measurement exceeds the factory specification, clean the
battery terminal posts and cable clamps, and tighten them firmly.
Potential difference
Factory spec.
Less than 0.1 V
W1012569
(2) Main Switch
Connector Voltage
1. Remove the front panel.
2. Disconnect the 4P connector from the main switch.
3. Measure the voltage with a voltmeter between the connector
terminal and the chassis.
4. If the voltage differs from the battery voltage, the wiring harness
is faulty.
Voltage (Connector
terminal - Chassis)
Factory spec.
Approx. battery voltage
W1013261
8-S6
ELECTRICAL SYSTEM
Main Switch Continuity
1) Main Switch Key at OFF Position
1. Set the main switch OFF position.
2. Measure the resistance with an ohmmeter across the B terminal
and the AC terminal, B terminal and ST terminal, B terminal and
G terminal.
3. If infinity is not indicated, the contacts of the main switch are
faulty.
B terminal - AC terminal
Resistance
B terminal - ST terminal
Infinity
B terminal - G terminal
2) Main Switch Key at ON Position
1. Set the main switch ON position.
and the AC terminal.
3. If 0 ohm is not indicated, the B - AC contact of the main switch
are faulty.
Resistance
0Ω
3) Main Switch Key at PREHEAT Position
1. Set and hold the main switch key at the PREHEAT position.
and the G terminal, and measure the resistance across the B
terminal and the AC terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance
0Ω
4) Main Switch Key at START Position
1. Set and hold the main switch key at the START position.
and the G terminal, across the B terminal and the ST terminal,
and across the B terminal and the AC terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance
B terminal - ST terminal
Infinity
(1) G Terminal
(2) AC Terminal
(3) ST Terminal
(4) B Terminal
W1013384
8-S7
ELECTRICAL SYSTEM
(3) Starter
M Terminal Voltage
1. Measure the voltage with a voltmeter between the M terminal and
the chassis.
2. If the voltage differs from the battery voltage, the battery’s
positive cable or the battery negative cable is faulty.
Voltage
Factory spec.
W1014220
Motor Test
CAUTION
• Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the motor does not run, starter is faulty.
Repair or replace the starter.
■ NOTE
• B terminal : It is the terminal which connect the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the motor to the magnet switch.
(1) C Terminal
W1014468
Magnetic Switch Test
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the pinion gear does not pop out, the magnetic switch has
failed.
Repair or replace the starter.
■ NOTE
• B terminal : It is the terminal which connect the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the starter to the magnet switch.
(1) S Terminal
W1014652
8-S8
ELECTRICAL SYSTEM
(4) Glow Plug
Lead Terminal Voltage
1. Disconnect the 1P connector (1) from the glow plug (2) after
turning the main switch off.
2. Turn the main switch key to the “PREHEAT” position, and
measure the voltage between the lead terminal and the chassis.
3. Make sure that the PTO lever is in the “DISENGAGE” position
and apply the parking brake.
4. Turn the main switch key to the “START” position, and measure
the voltage with a voltmeter between the lead terminal and the
chassis.
5. If the voltage at either position differs from the battery voltage, the
wiring harness or main switch is faulty.
Voltage (Lead terminal Chassis)
(1) 1P Connector
Main switch key at
“PREHEAT”
Main switch key at
“START”
(2) Glow Plug
W1014836
Glow Plug Continuity
1. Disconnect the lead from the glow plugs.
2. Measure the resistance with an ohmmeter between the glow plug
3. If 0 ohm is indicated, the screw at the tip of the glow plug and the
housing are short-circuited.
4. If the factory specification is not indicated, the glow plug is faulty.
Glow plug resistance
Factory spec.
Approx. 0.9 ohms
W1015086
(5) Safety Switch
Seat Switch Continuity
1. Disconnect the 2P connector for the seat switch (1).
2. Remove the seat switch (1) from the seat.
3. Using an ohmmeter, check for continuity between the switch
terminals.
There should be continuity when the seat switch (1) is pushed,
and no continuity when the seat switch (1) is released.
4. If the seat switch (1) is faulty, replace it.
(1) Seat Switch
(2) Seat
W1021913
8-S9
ELECTRICAL SYSTEM
PTO Switch Continuity
1. Disconnect the 2P connector for the PTO switch (1).
terminals when the PTO lever is set at “ENGAGE” position.
3. If there is continuity, the PTO switch (1) is faulty.
terminals when the PTO lever is set at “DISENGAGE” position.
5. If there is no continuity, the PTO switch (1) is faulty.
6. If the PTO switch (1) is faulty, replace it.
(1) PTO Switch
W1021741
Brake Switch Continuity
1. Disconnect the 2P connector from the brake switch (1).
terminals while depressing the brake pedal.
3. If there is no continuity, the brake switch (1) is faulty.
terminals while the brake pedal is released.
5. If there is continuity, the brake switch (1) is faulty.
6. If the brake switch (1) is faulty, replace it.
(1) Brake Switch
W1021608
(6) Fuel Pump
Connector Voltage
1. Disconnect the 2P connector from the fuel pump.
2. Turn the main switch key to the “ON” position, and measure the
voltage with a voltmeter between the connector terminal.
or main switch is faulty.
Connector voltage
Factory spec.
W1019481
Fuel Pump Continuity
1. Disconnect the 2P connector from the fuel pump.
2. Check the continuity between the connector terminals with an
ohmmeter.
3. If it does not conduct, the fuel pump is faulty.
4. If the fuel pump is faulty, replace it.
W1019816
8-S10
ELECTRICAL SYSTEM
(7) Engine Stop Solenoid
Connector Voltage
1. Disconnect the 2P connector from the engine stop solenoid.
voltage with a voltmeter between the connector terminal (White/
Blue) and the chassis.
Voltage
(Connector terminal Chassis)
Factory spec.
W1020004
Engine Stop Solenoid Test
2. Remove the engine stop solenoid from the engine.
3. Connect the jumper leads from the battery positive terminal to the
connector terminal (White), and from the battery negative
terminal to the chassis.
4. If the solenoid plunger is not retracted, the engine stop solenoid
is faulty.
5. Connect the jumper leads from the battery positive terminal to the
connector terminal (Red), and from the battery negative terminal
to the chassis.
Push the solenoid plunger in by your finger, and then release it.
6. If the solenoid plunger is not held, the engine stop solenoid is
faulty.
7. If the engine stop solenoid is faulty, replace it.
W1020102
Engine Stop Solenoid Continuity
2. Measure the resistance with an ohmmeter between the
connector terminal and the chassis.
3. If the factory specifications are not indicated, the engine stop
solenoid is faulty.
4. If the engine stop solenoid is faulty, replace it.
Resistance
[Connector terminal
(White) - Chassis]
Factory spec.
Approx. 0.4 ohms
Resistance
[Connector terminal
(Red) - Chassis]
Factory spec.
Approx. 1.5 ohms
W1020224
(8) Charging System
Alternator
1. Disconnect the 2P connector (3) from alternator after turning the
main switch OFF.
2. Perform the following checkings.
(1) B Terminal
(2) Alternator
(3) 2P Connector
W1016691
8-S11
ELECTRICAL SYSTEM
Connector Voltage
1. Turn the main switch OFF. Measure the voltage between the B
terminal (1) and the chassis.
2. Turn the main switch ON. Measure the voltage between the IG
terminal (3) and the chassis.
Voltage
(Main switch at OFF)
B Terminal - Chassis
Voltage
(Main switch at ON)
IG Terminal - Chassis
(1) B Terminal
(2) Alternator
(3) IG Terminal
(4) L Terminal
W1016886
No-Load Test
1. Connect the 2P connector (6) to previous positions of the
alternator after turning the main switch OFF.
2. Connect the jumper lead (3) between IG terminal (4) and B
terminal (2).
3. Start the engine and then set the idling speed.
4. Disconnect the negative cable from the battery.
5. Measure the voltage between the B terminal (2) and the chassis.
6. If the measurement is less than the factory specification,
disassemble the alternator and check the IC regulator.
Voltage
Factory spec.
Plus de 14 V
(Reference)
• Once the engine has started, the alternator temperature rises
quickly up to an ambient temperature of 70 to 90 °C (158 to 194
°F). As the temperature goes higher than 50 °C (122 °F), the
alternator voltage slowly drops ; at higher than 100 °C (212 °F),
it drops by about 1 V.
(1) Voltmeter
(2) B Terminal
(3) Connecting Lead
(4) IG Terminal
(5) L Terminal
(6) 2P Connector
W1017026
8-S12
ELECTRICAL SYSTEM
(9) Lighting System
Head Light Switch Connector Voltage
2. Disconnect the connector from the head light switch (1).
voltage with a voltmeter between the connector terminal (Red/
Blue) and the chassis.
Voltage (Connector
terminal - Chassis)
Factory spec.
(1) Head Light Switch
W1020458
Head Light Switch Continuity
2. Disconnect the connector from the head light switch (1).
3. Using an ohmmeter, check for continuity between the connector
terminals.
There should be no continuity when the head light switch is set at
“OFF” position, and continuity when the head light switch is set
at “ON” position.
(1) Head Light Switch
W1020683
Oil Pressure Indicator Lamp
1. Disconnect the 1P connector from the oil pressure switch (1).
2. Turn the main switch key to the “ON” position, and connect a
jumper lead from the 1P connector terminal to the chassis.
3. If the oil pressure indicator lamp does not light, the bulb or wiring
harness is faulty.
(1) Oil Pressure Switch
(a) From Oil Pressure Indicator Lamp
W10259540
Oil Pressure Switch Continuity
1. Disconnect the 1P connector from the oil pressure switch (1).
2. Measure the resistance with an ohmmeter between the switch
3. If 0 ohm is not indicated in the normal state, the switch is faulty.
4. If infinity is not indicated at pressure over 4.9 kPa (0.5 kgf/cm2, 7
psi), the switch is faulty.
Resistance
(Switch terminal Chassis)
In normal state
0Ω
At pressure over
approx. 4.9 kPa (0.5
kgf/cm2, 7 psi)
Infinity
(1) Oil Pressure Switch
W10260840
8-S13
ELECTRICAL SYSTEM
(10) Cooling System
Coolant Temperature Switch Connector Voltage
1. Disconnect the 1P connector from the thermo switch (1).
2. Turn the main switch key to the "ON" position, and measure the
voltage with a voltmeter between the connector terminal and the
chassis.
3. If no voltage is indicated, the wiring harness is faulty.
Voltage (Connector
terminal - Chassis)
Factory spec.
Positive voltage
(1) Thermo Switch
W1019979
Thermo Switch Continuity
1. Disconnect the 1P connector, and remove the thermo switch.
3. If infinity is indicated at temperature over factory specifications,
the switch is faulty.
Working temperature
Factory spec.
120 to 126 °C
248.0 to 258.8 °F
(C) 120 to 126 °C (248.0 to 258.8 °F)
(D) 116 °C (240.8 °F) or more
(A) ON
(B) OFF
W1020328
(11) Gauges
Fuel Level Sensor
1. Remove the fuel level sensor from the fuel tank.
2. Measure the resistance with an ohmmeter across the sensor
terminal and its body.
3. If the reference value are not indicated, the sensor is faulty
Resistance
(Sensor terminal Chassis)
(1) Fuel Level Sensor
Reference
value
Float at
upper-most
position
1 to 5 Ω
Float at
lower-most
position
103 to 117 Ω
E : Empty
F : Full
W1020613
8-S14
ELECTRICAL SYSTEM
Coolant Temperature Sensor
1) Lead Terminal Voltage
1. Disconnect the lead from the coolant temperature sensor after
turning the main switch OFF.
2. Turn the main switch ON and measure the voltage with a
voltmeter across the lead terminal and the chassis.
If the voltage differs from the battery voltage, the wiring harness,
fuse or coolant temperature gauge is faulty.
Lead terminal Chassis
Voltage
Approx. battery charge
2) Sensor Continuity
1. Measure the resistances with an ohmmeter across the sensor
2. If the reference value is not indicated, the sensor is faulty.
Resistance
(Sensor terminal Chassis)
Reference value
(1) Coolant Temperature Sensor
Approx. 16.1 Ω at 120 °C (248 °F)
Approx. 27.4 Ω at 100 °C (212 °F)
Approx. 51.9 Ω at 80 °C (176 °F)
Approx. 153.9 Ω at 50 °C (122 °F)
(a) From Temperature Gauge
W1020851
Fuel Gauge and Coolant Temperature Gauge Operation
2. Turn the main switch to ON position. Measure the voltage with a
voltmeter across the B terminal (4) and G terminal (2) of the
gauge.
3. If approx. battery voltage is indicated, the ignition and ground
lead connections are good.
4. Turn the main switch to OFF position. Connect a jumper lead
between S terminal (3) and G terminal (2) of the gauge.
5. Turn the main switch to ON position. If the gauge registers a full
scale reading under those conditions, the gauge is good. If less
than full scale reading is indicated, the gauge is defective and
should be replaced.
(1) Illumination Terminal
(2) G (Ground) Terminal
(3) S (Signal) Terminal
(4) B (Battery) Terminal
W1021720
8-S15
ELECTRICAL SYSTEM
(1) Starter
Disassembling Starter
(1) Solenoid Switch Mounting Nut
(2) Starter Drive Housing
(3) Drive Lever
(4) Gasket
(5) Solenoid Switch
(6) B Terminal Nut
(7) C Terminal Nut
(8) Snap RIng
(9) Overrunning Clutch
(10) Armature
(11) Brush Spring
(12) Connecting Lead
(13) Rear End Frame
(14) Gasket
(15) Brake Spring
(16) Brake Shoe
(17) End Frame Cap
(18) Screw
(19) Yoke
(20) Brush
(21) Brush Holder
(22) Through Bolt
W1222714
1. Unscrew the C terminal nut (7), and disconnect the connecting lead (12).
2. Unscrew the solenoid switch mounting nuts (1), and remove the solenoid switch (5).
3. Remove the end frame cap (17).
4. Remove the brake shoe (16), brake spring (15) and gasket (14).
5. Unscrew the through bolts (22), and remove the rear end frame (13).
6. Remove the brush from the brush holder while holding the spring up.
7. Remove the brush holder (21).
8. Draw out the yoke (19) from the starter drive housing (2).
9. Draw out the armature (10) with the drive lever (3).
■ NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease (DENSO.CO.LTD. No. 50 or equivalent) to the parts indicated in the figure.
- Joint of solenoid switch (a)
- Bushing (b)
- Drive lever (c)
- Collar (d)
- Teeth of pinion gear (e)
- Armature shaft (f)
Tightening torque
B terminal nut
7.8 to 9.8 N·m
0.8 to 1.0 kgf·m
5.8 to 7.2 ft-lbs
W1012736
8-S16
ELECTRICAL SYSTEM
(2) Alternator
Pulley
1. Secure the hexagonal end of the pulley shaft with a doubleended ratchet wrench as shown in the figure, loosen the pulley
nut with a socket wrench and remove it.
(When reassembling)
Tightening torque
Pulley nut
58.3 to 78.9 N·m
5.95 to 8.05 kgf·m
43.0 to 58.2 ft-lbs
W1017282
Rear End Cover
1. Unscrew the three rear end cover screws and the B terminal nut,
and remove the rear end cover.
W1017367
Brush Holder
1. Unscrew the two screws holding the brush holder, and remove
the brush holder (1).
(1) Brush Holder
W1017462
IC Regulator
1. Unscrew the three screws holding the IC regulator, and remove
the IC regulator.
(1) IC Regulator
W1017539
Rectifier
1. Remove the four screws holding the rectifier and the stator lead
wires.
2. Remove the rectifier (1).
(1) Rectifier
W1017612
8-S17
ELECTRICAL SYSTEM
Rear End Frame
1. Unscrew the two nuts and two screws holding the drive end
frame and the rear end frame.
2. Remove the rear end frame (1).
(1) Rear End Frame
W10192740
Rotor
1. Press out the rotor (1) from drive end frame (3).
■ IMPORTANT
• Take special care not to drop the rotor and damage the slip
ring or fan, etc.
(1) Rotor
(2) Block
(3) Drive End Frame
W10194380
Retainer Plate
1. Unscrew the four screws holding the retainer plate, and remove
the retainer plate (1).
(1) Retainer Plate
W10195420
Bearing on Drive End Side
1. Press out the bearing from drive end frame (3) with a press and
jig (1).
(1) Jig
(2) Block
(3) Drive End Frame
W10196110
Bearing at Slip Ring Side
1. Lightly secure the rotor (1) with a vise to prevent damage, and
remove the bearing (2) with a puller (3).
(1) Rotor
(2) Bearing
(3) Puller
W10197010
8-S18
ELECTRICAL SYSTEM
[3] SERVICING
(1) Starter
Overrunning Clutch
1. Check the pinion and if worn or damage, replace the clutch
assembly.
2. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
3. If the pinion slips or does not turn in both directions, replace the
overrunning clutch assembly.
■ NOTE
• Do not wash off the grease in the overrunning clutch with
the chemicals or oils.
W1156799
8-S19
ELECTRICAL SYSTEM
Commutator and Mica
1. Check the contact of the commutator for wear, and highly clean
the commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a saw
blade and chamfer the segment edges.
Factory
spec.
Commutator
O.D.
Allowable
limit
Factory
spec.
Difference of
O.D.’s
Allowable
limit
Electromagnetic
drive type
28.0 mm
1.102 in.
Planetary gear
reduction type
30.0 mm
1.181 in.
Electromagnetic
drive type
27.0 mm
1.063 in.
Planetary gear
reduction type
29.0 mm
1.142 in.
Electromagnetic
drive type
Less than 0.05 mm
0.002 in.
Planetary gear
reduction type
Less than 0.02 mm
0.0008 in.
Electromagnetic
drive type
0.4 mm
0.016 in.
Planetary gear
reduction type
0.05 mm
0.0020 in.
Factory spec.
0.50 to 0.80 mm
0.0197 to 0.0315 in.
Allowable limit
0.20 mm
0.0079 in.
Mica under cut
(1) Segment
(2) Depth of Mica
(3) Mica
(a) Correct
(b) Incorrect
W1155802
Brush Wear
1. If the face of the brush is dirty or dusty, clean it with emery paper.
2. Measure the brush length (A) with vernier caliper.
3. If the length is than the allowable limit, replace the yoke assembly
and brush holder.
Factory spec.
16.0 mm
0.630 in.
Allowable limit
10.5 mm
0.413 in.
Brush length A
W1156360
8-S20
ELECTRICAL SYSTEM
Brush Holder
1. Check the continuity across the brush holder and the holder
support with a circuit tester.
2. If it conducts, replace the brush holder.
W1156895
Armature Coil
1. Check the continuity across the commutator and armature coil
core with resistance range of circuit tester.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
resistance range of circuit tester.
4. If it does not conduct, replace the armature.
W1156507
Field Coil
1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with a
circuit tester.
4. If it conducts, replace the yoke assembly.
(1) Lead
(2) Bush
(3) Yoke
W1156968
8-S21
ELECTRICAL SYSTEM
(2) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
W1019790
Stator
1. Measure the resistance across each lead of the stator coil with
2. If the measurement is not within factory specification, replace it.
3. Check the continuity across each stator coil lead and core with
4. If infinity is not indicated, replace it.
Resistance
Factory spec.
Less than 1.0 Ω
W1019964
Rotor
1. Measure the resistance across the slip rings.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with resistance
range of circuit tester.
4. If infinity is not indicated, replace it.
Resistance
Factory spec.
2.9 Ω
W1020094
Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
Factory spec.
14.4 mm
0.567 in.
Allowable limit
14.0 mm
0.551 in.
Slip ring O.D.
W1020208
Brush Wear
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
Factory spec.
10.0 mm
0.3937 in.
Allowable limit
8.4 mm
0.331 in.
Brush length
W1020329
8-S22
ELECTRICAL SYSTEM
Rectifier
1. Check the continuity across each diode of rectifier with resistance
range of circuit tester.
2. The rectifier is normal if the diode in the rectifier conducts in one
direction and does not conduct in the reverse direction.
W1020452
IC Regulator
1. Check the continuity across the B terminal (2) and the F terminal
(1) of IC regulator with resistance range of circuit tester.
2. The IC regulator is normal if the conducts in one direction and
does not conduct in the reverse direction.
(1) F Terminal
(2) B Terminal
W1020645
8-S23
9
MOWER
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY DECALS
The following safety decals are installed on the mower.
If a decal becomes damaged, illegible or is not on the mower, replace it. The decal part number is listed in
the parts list.
9-1
SAFETY INSTRUCTIONS
9-2
TERMINOLOGY
TERMINOLOGY
[RCK72-F36]
(1) Mower Deck
(2) Front Roller
(3) Gear Box
(4) Center Frame
(5) Front Gauge Wheel
(6) Gauge Wheel Arm RH
(7) Discharge Deflector
(8) Anti-Scalp Roller
(9) Universal Joint
(10)Shield
(11)Gauge Wheel Arm LH
(12) Blade
(4) Center Frame
(8) Universal Joint
(9) Shield
(10) Gauge Wheel Arm LH
(11) Blade
[RCK72R-F36]
(1) Mower Deck
(2) Front Roller
(3) Gear Box
9-3
TERMINOLOGY
[RCK60-F36]
(1) Mower Deck
(2) Front Roller
(3) Gear Box
(4) Center Frame
(7) Discharge Deflector
(9) Universal Joint
(10)Shield
(11)Gauge Wheel Arm LH
(12) Blade
(4) Center Frame
(8) Universal Joint
(9) Shield
(10) Gauge Wheel Arm LH
(11) Blade
[RCK60R-F36]
(1) Mower Deck
(2) Front Roller
(3) Gear Box
9-4
SPECIFICATIONS
SPECIFICATIONS
Model
RCK72-F36
RCK72R-F36
RCK60-F36
Suitable front mower
F2880, F3680
Mounting method
2 point linkage
Adjustment of cutting height
Gauge wheel
Cutting width
1826 mm (71.9 in.)
Cutting height
RCK60R-F36
1524 mm (60 in.)
25 to 129 mm (1.0 to 5.0 in.)
Discharge sirection
Weight (Approx.)
Side
214 kg (472 lbs)
Rear
Side
210 kg (463 lbs)
180 kg (397 lbs)
-1
Rear
170 kg (375 lbs)
-1
Blade spindle speed
2405 min (2405 rpm)
2695 min (2695 rpm)
Blade tip velocity
78.7 m/s (15490 fpm)
73.8 m/s (14520 fpm)
Blade length
625 mm (24.6 in.)
523 mm (20.6 in.)
Number of blades
Total length
Dimensions
Total width
Total height
3
1160 mm (45.7 in.)
2250 mm
(88.6 in.)
1090 mm (42.9 in.)
1910 mm
(75.2 in.)
1850 mm
(72.8 in.)
1610 mm
(63.4 in.)
450 mm (17.7 in.)
W1028770
9-5
MECHANISM
CONTENTS
1. POWER TRANSMISSION ............................................................................ 9-M1
MOWER
1. POWER TRANSMISSION
(1)
(2)
(3)
(4)
(5)
Center Pulley
Bevel Gear
Collar
Bevel Gear
Bevel Gear Case
(6)
(7)
(8)
(9)
(10)
Pinion Shaft
Feather Key
Side Pulley
Side Pulley Holder
Blade Shaft
(11)
(12)
(13)
(14)
(15)
Dust Cover
Blade (Side)
Blade Boss
Feather Key
Bevel Gear Shaft
(16)
(17)
(18)
(19)
Blade Boss
Dust Cover
Center Pulley Holder
Blade (Center)
The power is transmitted from front PTO to blade as follows.
■ Blade (Center)
Front PTO Shaft → Universal Joint → Pinion Shaft (6) → Bevel Gear (4) → Bevel Gear (2) → Bevel Gear Shaft
(15) → Blade (Center) (19)
■ Blade (Side)
Front PTO Shaft → Universal Joint → Pinion Shaft (6) → Bevel Gear (4) → Bevel Gear (2) → Bevel Gear Shaft
(15) → Center Pulley (1) → Mower Belt → Side Pulley (8) → Blade Shaft (10) → Blade (Side) (12)
9-M1
SERVICING
CONTENTS
1. GENERAL .......................................................................................................9-S1
[1] MOWER IDENTIFICATION .....................................................................9-S1
[2] GENERAL PRECAUTION .......................................................................9-S1
[3] LUBRICANTS ...........................................................................................9-S2
[4] TIGHTENING TORQUES ........................................................................9-S2
(1) General Use Screws, Bolt and Nuts ...................................................9-S2
(2) Metric Screws, Bolts and Nuts ............................................................9-S3
(3) American Standard Screws, Bolts and Nuts with UNC or UNF
Threads ...............................................................................................9-S3
(4) Plugs ...................................................................................................9-S3
[5] MAINTENANCE CHECK LIST................................................................9-S4
[6] CHECK AND MAINTENANCE................................................................9-S5
(1) Check Points of Daily of Each Use .....................................................9-S5
(2) Check Point of Initial 50 Hours............................................................9-S7
(3) Check Point of every 50 Hours ...........................................................9-S7
(4) Check Point of Every 150 Hours.........................................................9-S8
(5) Check Point of Every 2 Years .............................................................9-S8
2. TROUBLESHOOTING ....................................................................................9-S9
3. SERVICING SPECIFICATIONS ..................................................................9-S10
4. TIGHTENING TORQUES ............................................................................9-S11
5. CHECKING, DISASSEMBLING AND ASSEMBLING ................................9-S12
[1] CHECKING AND ADJUSTING .............................................................9-S12
[2] PREPARATION ......................................................................................9-S16
(1) Mower Tilt Up....................................................................................9-S16
(2) Dismounting Mower ..........................................................................9-S17
[3] DISASSEMBLING...................................................................................9-S18
[4] SERVICING ............................................................................................9-S22
MOWER
1. GENERAL
[1] MOWER IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
mower serial number.
(1) Mower Serial Number
W1010628
[2] GENERAL PRECAUTION
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
installed in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Use KUBOTA genuine parts or KUBOTA-recommended parts
and lubricants or their equivalents.
• Gaskets and O-rings must be replaced during assembly.
• Apply grease to new O-rings or oil seals before assembling. See
the figure.
• When reassembling external snap rings or internal snap rings,
they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure.
• Metric screws, bolts and nuts are not interchangeable with
nonmetric fasteners
• Remove oil and dirt from parts before measuring.
(1) Grease
(2) Force
(3) Sharp Edge
(A) Oil Seal
(B) External Snap Ring
(C) Internal Snap Ring
W1010749
9-S1
MOWER
[3] LUBRICANTS
Capacity
Place
Lubricants
RCK72-F36 / RCK72R-F36
RCK60-F36 / RCK60R-F36
0.4 L
0.43 U.S.qts.
0.35 lmp.qts.
Gear box
SAE 90 gear oil
(API Service GL-5 gear oil)
Greasing
Universal joint
Bevel gear shaft and blade shafts
Belt tension pulley
Until grease overflows
Belt tension pivot
SAE multi-purpose type grease
Front gauge wheels
Front roller
[4] TIGHTENING TORQUES
(1) General Use Screws, Bolt and Nuts
Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened
according to the table below.
Indication on top of
bolt
No-grade or 4T
Material of bolt
Material of opponent
part
Unit
Diameter
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
7T
SS400, S20C
Ordinariness
N·m
7.85
to
9.31
17.7
to
20.5
39.3
to
45.1
62.8
to
72.5
108
to
125
167
to
191
246
to
284
334
to
392
kgf·m ft-lbs
0.80
to
0.95
1.8
to
2.1
4.0
to
4.6
6.4
to
7.4
11.0
to
12.8
17.0
to
19.5
25.0
to
29.0
34.0
to
40.0
5.79
to
6.87
13.1
to
15.1
29.0
to
33.2
46.3
to
53.5
79.6
to
92.5
123
to
141
181
to
209
246
to
289
9T
SCr435,
SCM435
S43C, S48C
Aluminum
Ordinariness
Aluminum
Ordinariness
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
N·m
kgf·m ft-lbs
7.85
to
8.82
16.7
to
19.6
31.4
to
34.3
0.80
to
0.90
1.7
to
2.0
3.2
to
3.5
5.79
to
6.50
12.3
to
14.4
23.2
to
25.3
–
–
–
5.79
to
6.50
13.1
to
15.1
29.0
to
32.5
46.3
to
53.5
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
7.24
to
8.31
17.4
to
20.2
35.5
to
41.2
57.2
to
66.5
91.2
to
108
145
to
166
203
to
235
272
to
318
0.80
to
0.90
1.8
to
2.1
4.0
to
4.5
6.4
to
7.4
–
1.00
to
1.15
2.4
to
2.8
4.9
to
5.7
7.9
to
9.2
12.6
to
15.0
20.0
to
23.0
28.0
to
32.5
37.5
to
44.0
7.85
to
8.82
17.7
to
20.5
39.3
to
44.1
62.8
to
72.5
–
9.81
to
11.2
23.6
to
27.4
48.1
to
55.8
77.5
to
90.2
124
to
147
197
to
225
275
to
318
368
to
431
–
–
–
N·m
kgf·m
ft-lbs
12.3
to
14.2
29.5
to
34.3
60.9
to
70.6
103
to
117
167
to
196
260
to
304
344
to
402
491
to
568
1.25
to
1.45
3.0
to
3.5
6.2
to
7.2
10.5
to
12.0
17.0
to
20.0
26.5
to
31.0
35.0
to
41.0
50.0
to
58.0
9.05
to
10.4
21.7
to
25.3
44.9
to
52.0
76.0
to
86.7
123
to
144
192
to
224
254
to
296
362
to
419
W1034542
9-S2
MOWER
(2) Metric Screws, Bolts and Nuts
Property class 8.8
Property class 10.9
Grade
Unit
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
M8
23.6 to 27.4
2.40 to 2.80
17.4 to 20.2
29.4 to 34.3
3.00 to 3.50
21.7 to 25.3
M10
48.1 to 55.8
4.90 to 5.70
35.5 to 41.2
60.8 to 70.5
6.20 to 7.20
44.9 to 52.1
Nominal Diameter
M12
77.5 to 90.1
7.90 to 9.20
57.2 to 66.5
103.0 to 117.0
10.50 to 12.00
76.0 to 86.8
M14
124.0 to 147.0
12.60 to 15.00
91.2 to 108.0
167.0 to 196.0
17.00 to 20.00
123.0 to 144.0
M16
196.0 to 255.0
20.0 to 23.0
145.0 to 166.0
260.0 to 303.0
26.50 to 31.00
192.0 to 224.0
W1013689
(3) American Standard Screws, Bolts and Nuts with UNC or UNF Threads
SAE GR.5
SAE GR.8
Grade
Unit
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
5/16
23.1 to 27.8
2.35 to 2.84
17.0 to 20.5
32.5 to 39.3
3.31 to 4.01
24.0 to 29.0
3/8
47.5 to 57.0
4.84 to 5.82
35.0 to 42.0
61.0 to 73.2
6.22 to 7.47
45.0 to 54.0
1/2
108.5 to 130.2
11.07 to 13.29
80.0 to 96.0
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
9/16
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
217.0 to 260.4
22.14 to 26.57
160.0 to 192.0
5/8
203.4 to 244.1
20.75 to 24.91
150.0 to 180.0
298.3 to 358.0
30.44 to 36.53
220.0 to 264.0
Nominal Diameter
W1022485
(4) Plugs
Material of opponent part
Shape
Tapered
screw
Straight
screw
Size
Ordinariness
Aluminum
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
R1/8
13 to 22
1.3 to 2.2
9.6 to 16.2
10 to 12
1.0 to 1.2
7.4 to 8.9
R1/4
29 to 44
3.0 to 4.5
21.4 to 32.5
20 to 29
2.0 to 3.0
14.8 to 21.4
G1/4
29 to 39
3.0 to 4.0
21.4 to 28.8
–
–
–
G3/8
49 to 59
5.0 to 6.0
36.1 to 43.5
–
–
–
G1/2
59 to 78
6.0 to 8.0
43.5 to 57.5
–
–
–
0000001666E
9-S3
MOWER
[5] MAINTENANCE CHECK LIST
To keep the mower working in good condition as well as to avoid any accident and trouble, carry out periodic
inspection and maintenance. Check the following points before use.
Service interval
Daily (Each use)
Check Points
Reference
Page
Make sure mower blade screws are tightened
9-S5
Check mower blades for wear or damage
9-S5
Check oil leaks
–
Check all hardware
–
Make sure all pins are in place
–
Clean mower deck
–
Apply grease to universal joint
9-S5
Apply grease to spindle shafts (Bevel gear shaft and blade shafts)
9-S6
Apply grease to belt tension pulley
9-S6
Apply grease to belt tension pivot
9-S6
Initial 50 hours
Change gear box oil
9-S7
Every 50 hours
Apply grease to front gauge wheels
9-S7
Apply grease to front roller
9-S7
Check gear box oil
9-S7
Check mower belt
9-S8
Every 150 hours
Change gear box oil
9-S8
Every 2 years (After
purchase)
Replace gear box oil seal
9-S8
W1013580
9-S4
MOWER
[6] CHECK AND MAINTENANCE
(1) Check Points of Daily of Each Use
Retightening Mower Blade Screw
•
1.
2.
3.
4.
CAUTION
To avoid injury, always handle the mower blade with care.
Dismount the mower and turn it over to expose the mower
blades.
Wedge a wooden block securely between the mower blade and
mower deck.
Retighten the mower blade screw to the specified torque.
If the mower blade screw is worn or broken, replace it.
Tightening torque
Mower blade screw
98.1 to 117.7 N·m
10.0 to 12.0 kgf·m
72.3 to 86.8 ft-lbs
(1) Mower Blade Screw
W1014611
Checking Mower Blade
1. Checking the cutting edge of mower blade.
2. Sharpen the cutting edges, if the mower blades are as shown in
figure (2).
3. Replace the mower blades, if they are as shown in figure (3).
■ IMPORTANT
• Never forget to set the two cup washers between mower
blade and spline boss, when reassembling the mower
blades.
■ NOTE
• To sharpen the mower blades by yourself, clamp the mower
blade securely in a vise and use a large mill file along the
original bevel.
• To balance the mower blade, place a small rod through the
center hole and check to see if the blade balances evenly.
File heavy side of the blade until it balances out even.
(1) New Blade
(2) Worn Blade
(3) Cracked Blade
W1017946
Greasing Universal Joint
1. Greasing the internal splines (1) and grease nipples (2) of the
universal joint if the amount of grease is insufficient.
(1) Spline
(2) Grease Nipple
W1015107
9-S5
MOWER
Greasing Spindle Shafts
1. Grease the grease nipples (1), (2) of the spindle shafts if the
amount of grease is insufficient.
(1) Grease Nipple (Bevel Gear Shaft)
(2) Grease Nipple (Blade Shaft)
W1015209
Greasing Belt Tension Pulley and Greasing Belt Tension Pivot
1. Grease the grease nipple (1) of the belt tension pulley if the
2. Grease the grease nipple (1) of the belt tension pivot if the
(1) Grease Nipple
(2) Grease Nipple
W1015312
9-S6
MOWER
(2) Check Point of Initial 50 Hours
Changing Gear Box Oil
1. Remove the mower from the machine, and place the mower on
level ground.
2. Remove the check plug (2) or oil filler plug (1).
3. Remove the drain plug (3), and drain the used oil completely.
4. After draining the used oil, reinstall the drain plug (3).
5. Fill with new oil up to the check plug level.
■ IMPORTANT
• Use the specified gear oil.
Refer to “LUBRICANTS”. (See page 9-S2.)
(1) Oil Filler Plug
(2) Check Plug
(3) Drain Plug
W1015494
(3) Check Point of every 50 Hours
Greasing Front Gauge Wheels
1. Grease the grease nipples (1), (2) of the front gauge wheels if the
(1) Grease Nipple
(Front Gauge Wheel Bracket)
(2) Grease Nipple
(Front Gauge Wheel)
W1015754
Greasing Front Roller
1. Grease the grease nipples (1) of the front roller if the amount of
grease is insufficient.
(1) Grease Nipple
W1015909
Checking Gear Box Oil
1. Place the mower on level ground.
2. Remove the oil filler plug (1) or check plug (2), and check to see
that the oil level is just below the check plug (2) port.
3. If the level is too low, add new oil to the prescribed level at the oil
filler plug (1).
■ IMPORTANT
• Use the specified gear oil.
Refer to “LUBRICATING” (See page 9-S2.)
(1) Oil Filler Plug
(2) Check Plug
W1018110
9-S7
MOWER
Checking Mower Belt
1. Inspect the mower belt.
2. Replace the mower belt, if there is any damage found. (See page
9-S19.)
W1018143
(4) Check Point of Every 150 Hours
Checking Gear Box Oil
See page 9-S7.
W1018524
(5) Check Point of Every 2 Years
Replacing Gear Box Oil Seal
1. Replace the gear box oil seals (1), (2) with new ones. (See page
9-S20).
(1) Oil Seal
(2) Oil Seal
W1016076
9-S8
MOWER
2. TROUBLESHOOTING
Symptom
Probable Cause
Reference
Page
Solution
Blade Does Not
Rotate
Mower belt broken
Replace mower belt
PTO clutch broken
Repair
Blade Speed Is Slow
Mower belt loosen
Replace mower belt
or tension spring
Grass clogged
Remove grass
Cup washer flattened out or worn
Replace cup washer
9-S18
Blade worn or broken
Sharpen or replace
blade
9-S5,S18
Mower blade mounting screw loosen
Retighten mounting
screw
9-S5,S18
Improper cutting height
Adjusting cutting
height
9-S13 to
S15
Trouble of hydraulic system (lift cylinder and
control valve)
Check hydraulic
system
7-S8 to S10
Lowering speed adjusting valve closed
Open
–
Linkage system broken
Replace linkage
system
–
Cutting Is Poor
Mower Is Not Lifted
9-S19
2-S21, S25
9-S19
–
W1014322
9-S9
MOWER
Item
Allowable Limit
Maximum Front Gauge Wheel Tire
Pressure
343 kPa
3.5 kgf/cm2
49.7 psi
–
Recommended Front Gauge Wheel Tire
Pressure
196 kPa
2.0 kgf/cm2
28.4 psi
–
Pinion Shaft
Turning Force
Turning Torque
Bevel Gears in Gear Box
Backlash
490 N
Less than 50 kgf
110 lbs
–
5.9 N·m
Less than 0.6 kgf·m
4.3 ft-lbs
–
0.13 to 0.25 mm
0.0052 to 0.0098 in.
–
W1013874
9-S10
MOWER
(For general use screws, bolts and nuts: See page 9-S2.)
Item
Mower blade mounting screw
N·m
kgf·m
ft-lbs
98.1 to 117.7
10.0 to 12.0
72.3 to 86.8
W1012736
9-S11
MOWER
5. CHECKING, DISASSEMBLING AND ASSEMBLING
Checking Front Gauge Wheel Tire Pressure
WARNING
• Never exceed the tire pressure shown below (maximum
limit) when attempting to seat the bead. If bead does not
seat by the time the pressure reaches maximum limit, deflate
the assembly reposition the tire on the rim, relubricate, and
reinflate. After seating the bead, adjust inflation pressure as
recommended in the inflation pressure chart.
1. The tire pressure naturally drops slowly in the course of time.
Thus, check it every day and inflate as necessary.
Maximum front gauge
wheel tire pressure
Factory spec.
343 kPa
3.5 kgf/cm2
49.7 psi
Recommend front
gauge wheel tire
pressure
Factory spec.
196 kPa
2.0 kgf/cm2
28.4 psi
CAUTION
• Do not attempt to mount a tire unless qualified. Use proper
equipment.
W1018550
9-S12
MOWER
Adjusting Cutting Height and Assist Spring
(1)
(2)
(3)
(4)
(5)
(6)
Front Gauge Wheel
Lift Rod
Front Roller
Anti-Scapl Roller
Adjusting Nut
Lift Spring Rod
[S] Side discharge mower
[R] Rear discharge mower
W1014160
(1)
(2)
(3)
(4)
(1)
(2)
(3)
(4)
RCK72-F36
RCK72R-F36
RCK60-F36
RCK60R-F36
W1019807
9-S13
MOWER
Adjusting Height and Assist Spring (Continued)
■ NOTE
• Before adjusting the cutting height, check the tire-pressure
of the front gauge wheels.
1. The cutting height can be adjusted from 25 mm to 129 mm (from
1.0 in. to 5.0 in.).
2. To adjust the cutting height, set the front gauge wheels (1), front
roller (5), anti-scalp rollers (4) and lift rods (2) as shown in the
table below. The recommended cutting height is approx. 51 to 77
mm (2.0 to 3.0 in.).
3. Check the length “L” of the lift spring rod (6). (without the grass
catcher)
(Reference)
• Length “L” (LH) : 70 mm (2.8 in.)
• Length “L” (RH) : 50 mm (2.0 in.)
Cutting Height
Front Gauge
Wheel
25 mm (1.0 in.)
32 mm (1.25 in.)
D - XII
D - YII
129 mm (5.0 in.)
II
D - YII
C-X
B - XII
C - XII
C-Y
B - YII
C - YII
B-X
A - XII
116 mm
(4.50 in.)
123 mm
(4.75 in.)
b
D - XII
C - YII
103 mm (4.0 in.)
110 mm
(4.25 in.)
I
D-Y
90 mm (3.5 in.)
97 mm (3.75 in.)
a
D-X
77 mm (3.0 in.)
84 mm (3.25 in.)
Anti-Scalp
Roller
E - YII
C - XII
64 mm (2.50 in.)
71 mm (2.75 in.)
E - XII
E-Y
51 mm (2.0 in.)
58 mm (2.25 in.)
Front Roller
E-X
38 mm (1.50 in.)
45 mm (1.75 in.)
Lift Rod
B - XII
B-Y
A - YII
Y - XII
A-X
W1019983
9-S14
MOWER
Adjusting Cutting Height and Assist Spring (Continued)
1. When setting the lift rod, insert the set pin as shown in the figure.
(1) Lift Rod (RH)
(2) Lift Rod (LH)
A, B, C, D :Direction where the set pin
is inserted
W1020910
Adjusting Lift Rod Spacers
1. Park the machine and mower deck on level ground and set the
desired cutting height.
2. Check the level of mower deck.
3. If not, adjust the level by the lift rod spacers (2).
(1) Lift Rod Spacer
(2) Lift Arm
9-S15
MOWER
[2] PREPARATION
(1) Mower Tilt Up
Mower Tilt Up
1. Place PTO lever in “DISENGAGE” position.
2. Stop the engine, set the parking brake.
3. Place High-Low gear shift lever in “NEUTRAL” position.
4. Disconnect the universal joint from the machine.
5. [RCK72-F36 / RCK72R-F36]
Detach the tilt pipe (3) set in the mower deck, and insert the tilt
lever (4) in the tilt pipe (3).
Pull the tilt pipe (3) in the direction of the arrow, and hook the tilt
lever (4).
CAUTION
• Securely insert the tilt lever (4) in the tilt pipe (3).
• Never release the tilt pipe (3) until the tilt lever (4) is locked
to the hook securely.
6. Start the engine and raise the mower deck fully.
7. Lock the lowering speed adjusting valve.
8. Stop the engine and remove the key.
9. Pull on the lock pins (6) of the anti-scalp roller (5) and push them
upward.
10.Pull on the lock pins (7) of the lift rods (8) and lock them in the
open position.
11.Disengage the lock of the tilting pin (9).
(1)
(2)
(3)
(4)
(5)
Gas Spring
Hook
Tilt Pipe
Tilt Lever
Anti-Scalp Roller
(6)
(7)
(8)
(9)
Lock Pin
Lock Pin
Lift Rod
Lock Pin
W1016339
9-S16
MOWER
Mower Tilt Up (Continued)
1. Pull up the mower deck as shown in the figure.
2. Lock the tilting pin (1) to the mower lift arm (2).
(1) Tilting Pin
(2) Mower Lift Arm
W1021734
(2) Dismounting Mower
Dismounting Mower Deck
CAUTION
• Before dismounting or mounting the mower deck, read and
understand how to use of the lowering speed adjusting
knob.
• The mower links (left hand, right hand) are spring-loaded.
Have an assistant hold the lift arm in position when
mounting and dismounting mower deck.
1. Place the PTO lever in the “DISENGAGE” position.
2. Place the High-Low gear shift lever in the “NEUTRAL” position.
3. Disconnect the universal joint from the machine.
4. Start the engine and raise the mower deck fully.
5. [RCK72-F36 / RCK72R-F36]
Unlock the tilt lever (1) with the tilt pipe.
Remove the clevis pin (3), and disconnect the gas spring (2) from
the mower lift arm (6).
6. Shut off the engine, pull the lock pins (4) of the lift rods (4) and
lock them in the open position.
7. Start the engine and down the mower deck fully, and shut off the
engine.
8. Remove the clevis pins (7), and disconnect the mower lift arms
(6) from mower deck.
(1)
(2)
(3)
(4)
Tilt Lever
Gas Spring
Clevis Pin
Lift Rod
(5) Lock Pin
(6) Mower Lift Arm
(7) Clevis Pin
W1016795
9-S17
MOWER
[3] DISASSEMBLING
Universal Joint and Covers
1. Remove the screw (1), and remove the universal joint (2).
2. Remove the left and right covers.
(1) Screw
(2) Universal Joint
W1021193
Mower Blade and Blade Boss
1. Turn over the mower.
2. Unscrew the mower blade mounting screw (1), and remove the
spline boss (2), two cup washers (3), mower blade (4) and dust
cover (5).
4. Remove the blade boss (7).
■ NOTE
• Wedge a block of wood between the mower blade and
mower deck that it will hold the mower blade safely while
loosing or tightening the mower blade mounting screw (1).
(When reassembling)
• Be sure to assemble two cup washers between the mower blade
(4) and spline boss (2).
■ IMPORTANT
• Make sure the cup washers (3) are not flattened out or worn,
causing mower blade to slip easily.
Replace the cup washer (3) if it is damaged.
Tightening torque
(1)
(2)
(3)
(4)
(5)
Mower blade mounting
screw
Mower Blade Mounting Screw
Spline Boss
Cup Washer
Mower Blade
Dust Cover
98.1 to 117.7 N·m
10.0 to 12.0 kgf·m
72.2 to 86.8 ft-lbs
(6) External Snap RIng
(7) Blades Boss
A : Loosen
W1021356
9-S18
MOWER
Gear Box, Mower Belt and Center Pulley Holder
1. Turn over the mower deck.
2. Unscrew the frame mounting nuts, and remove the center frame
(1).
3. Remove the tension spring (5).
4. Remove the gear box stays (3), (6).
5. Remove the mower belt (6).
6. Remove the gear box (2) and the center pulley holder (12).
7. Remove the oil seals (7), (10) and internal snap ring (9) from the
center pulley holder (12). And remove the shim (11) and ball
bearing (8).
(When reassembling)
• Replace the oil seals (7), (10) with new one.
■ NOTE
• Be sure to install the shim (11).
(1)
(2)
(3)
(4)
(5)
(6)
Center Frame
Gear Box
Gear Box Stay (RH)
Tension Pulley
Tension Spring
Gear Box Stay (LH)
(7)
(8)
(9)
(10)
(11)
(12)
Oil Seal
Ball Bearing
Internal Snap Ring
Oil Seal
Shim
Center Pulley Holder
W1021831
9-S19
MOWER
Disassembling Gear Box
1. Unscrew the drain plug (18), and drain the gear oil.
2. Remove the center pulley (20) with a puller, and remove the
feather key (21) on the bevel gear shaft (19).
3. Remove the gear box caps (1), (10).
4. Remove the oil seal (13) and the internal snap ring (14).
5. Unscrew the pinion shaft mounting screw (2) and tap out the
pinion shaft (17) with the ball bearing (16).
6. Remove the ball bearing (5), bevel gear (11) and collar (6).
7. Remove the external snap ring (9) and bevel gear (8) and draw
out the bevel gear shaft (19).
8. Remove the oil seal (22), ball bearing (7) and shim (12).
(When reassembling)
• Replace the oil seals (13), (22) and gear box caps (1), (10) with
the new ones.
• Check the backlash and turning torque.
If not correct, adjust with the shims (4), (12), (15).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Gear Box Cap
Pinion Shaft Mounting Screw
Internal Snap Ring
Shim
Ball Bearing
Collar
Ball Bearing
Bevel Gear
External Snap Ring
Gear Box Cap
Bevel Gear
Shim
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Oil Seal
Internal Snap Ring
Shim
Ball Bearing
Pinion Shaft
Drain Plug
Bevel Gear Shaft
Center Pulley
Feather Key
Oil Seal
Bevel Gear Case
W1023056
9-S20
MOWER
Side Pulley and Blade Shaft
1. Unscrew the pulley mounting nut (2) and remove the pulley (1)
and feather key (3).
2. Unscrew the pulley holder mounting screws and remove the side
pulley holder (6) from the mower deck.
3. Remove the oil seal (4), (9) and internal snap ring (5), (8), and tap
out the blade shaft (10) with ball bearing (7), (12).
(When reassembling)
• Replace the oil seals (4) and (9) with new ones.
■ NOTE
• Be sure to install the shim (11).
(1)
(2)
(3)
(4)
(5)
(6)
Side Pulley
Pulley Mounting Nut
Feather Key
Oil Seal
Internal Snap Ring
Side Pulley Holder
(7)
(8)
(9)
(10)
(11)
(12)
Ball Bearing
Internal Snap Ring
Oil Seal
Blade Shaft
Shim
Ball Bearing
W1024102
9-S21
MOWER
[4] SERVICING
Checking Torque of Pinion Shaft
■ NOTE
• Do not remove the mower belt.
1. Wind a string around the pinion shaft and set a push-pull gauge
to the end of the string, and then slowly pull the push-pull gauge
horizontally to measure the turning force.
2. If the measurement exceeds the factory specification, check the
bearing and gears and adjust the adjusting shims (1), (2), (3).
Turning force
Factory spec.
490 N
Less than 50 kgf
110 lbs
Turning torque
Factory spec.
5.9 N·m
Less than 0.6 kgf·m
4.3 ft-lbs
(Reference)
• Thickness of adjusting shims (1), (2) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
• Thickness of adjusting shims (3) : 0.1 mm (0.0039 in.)
0.2 mm (0.0079 in.)
(1) Shim
(2) Shim
(3) Shim
W1024471
Backlash between Bevel Gears
1. Remove the gear box cap.
2. Place fuses the bevel gear on the pinion shaft.
3. Turn the pinion shaft.
4. Take out the fuses, and measure the thickness of fuses with an
outside micrometer. (Backlash equal thickness of fuse)
5. If the backlash is not within the factory specifications, adjust with
shims (1), (2), (3).
6. Apply red lead lightly over several teeth at three positions equally
spaced on the bevel gear.
7. Turn the pinion shaft.
8. Check the tooth contact. If not correct, adjust with shim (1), (2),
(3).
■ NOTE
• After checking the tooth contact, checking the backlash
between pinion shaft and bevel gear again.
Backlash between bevel
gears
Factory spec.
0.13 to 0.25 mm
0.0052 to 0.0098 in.
(Reference)
• Thickness of adjusting shims (1), (2) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
• Thickness of adjusting shims (3) : 0.1 mm (0.0039 in.)
0.2 mm (0.0079 in.)
(1) Shim
(2) Shim
(3) Shim
[A] Correct Contact :
More than 35 % red lead contact
area on the gear tooth surface.
The center of tooth contact at 1/3
of the entire width from the small
end.
W1024912
9-S22
EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX
: (81)72-245-2484
E-mail : [email protected]
KUBOTA Corporation
Printed in Japan 2006. 04, S, EI, EI, e Code No.9Y011-15521
2006. 01, S, EI, EI, e

workshop manual f2880,f3680,rck72-f36, rck72r-f36

Transcription

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