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Service manual RC-750

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1. 40 7 7 HYDRAULICS DIAGRAM A et eee td 41 SPR VO PNN 42 8 1 REPLACING THE 70000000 42 8 2 REPLACING THE POTENTIOMETER 2 20 0 00000000000000 45 8 3 SETTING THE ZERO POSITION OF THE SERVO ENGINE 46 Page 2 57 HIT EN OR 10 MOWING MECHANISM SAFETY 5 5 2 2 0000 000000000000 48 11 RENIOTECONTROD u 49 11 1 ZERO POSITION PROGRAMMING 65 10000000000 000000000000 49 11 2 FREQUENCY CHANGE 49 12 DESCRIPTION OF THE ELECTRICAL BOX 50 A ELECIRICALDIAGOGRAM u llan aa Zn la an 51 13 TROUBLESHOOTING Sete oe ede ttu ves 52 14 HONDA IGX AAO e 54 14 1 MODIFICATION OF HONDA IGX440 ENGINE ccccccccecescececcececcececescecscscesescesescucaeees 54 14 2 VDPIAGNOSTICCONNECTION Q uuu mun uD 55 LL REPLACING THE MO TORO up Sut eet ved see opted burden tubas 55 14 4 FUEL SYSTEM 56 14 5 HONDA ENGINE SERVICE MANUAL ccccecescececcececcsceccececcececccscestscecescecescscescscusescecaeces 57 Page 3 57 1 REMOVING GUARDS 1 1 Removing the branches protective gua
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3. 218 322 o S S S SISIS SISIS SISISISISISI S 9 5 5 IB lt BIC Cable Mw 1 2 2 3 1 2 314 4 Ma Wire no x _ 1233124 4 13 7 8 9 14119 _ 2015 no du 27 Tiya v v v lsdyuila2aslaa asyiobi ermino srip 4175176 77178179 10211 12713 714 15216 717 2181219220 Termino strip no a 1 B B T Cable no 4 DIUE 10 7 8 7_ Wire no 2 X1 3X1 9 5 6 H8 Pin 2l ooo 0 0 22 0 rm gt gt 1 amp gIO ps 0 gt 1 je 12V Relais Wire no Cable no 3 680 1002 100 2 _ A5 x D 978 1 i c 12 X1 1 CD Plug and socket connection and cable Part no _ 3 300 2002 Casing with cover Inset 3 210 2004 24 pol male Cable loop 1_ 3 400 7040 34 x 0 75 1 Cable loop2 ___ A KAB1920 2x 15mm Cableloop3 7 3 4007018 12 ATM c Cable loop 4 3 400 7020 9 x0 75mm M UU H M HM Tl YES T NO CabletoopS 1 ______________ Face Blade Cable loop 6 cum Se Colou Upper part POTTED gt lt Cable loop
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5. aes Se So SA I EET app a y CCC 0 DR 26 _ i 2 lt 22 T THROTTLE CONTROL Gray i wer 4 8 WHITE 7 IGNITION COIL 5 PC 4P CONNECTOR 10 CARBURETOR 9 MAIN WIRE HARNESS 18P HARNESS Blue INSULATOR CONNECTOR Black INSIDE OF THE FAN COVER 3 HARNESS CLIP BRACKET 4 CRANKSHAFT POSITION 2 To the ECM CKP SENSOR 1 HARNESS me 17 v CRANKSHAFT POSITION 2 4 5 POWER COIL CHARGE jj COIL FUEL CUT 7 SOLENOID COIL SENSOR TERMINAL 16 GROUND TERMINAL 6 15 HARNESS Jor j 14 the fuel cut NY 7 solenoid w UN E CHARGE COIL 13 FUEL CUT NS WIRE SOLENOID 2P CONNECTOR Black To the rectifier 9 CORD CLAMP 12 FUEL x SOLENOID RECTIFIER ead 10 OIL LEVEL SWITCH TERMINAL 4P CONNECTOR SOLENOID COIL Green 2 CONNECTOR White 2 20 iGX440U e LOWER PART OF THE CYLINDER 3 MAIN WIRE HARNESS 18P CONNECTOR 2 POWER COIL CRANKSHAFT POSITION CKP Black SENSOR 4P CONNECTOR Black 1 SPARK PLUG CAP IGNITION COIL 16 IGNITION COIL 2P CONNECTOR Black M j oS 4 15 FUEL CUT Ao f CRANKSHAFT POSITION CKP SOLENOID d SENSOR TERMINAL 14 ENGINE gt GEES TEMPERATURE SAN SSR SENSOR kiy 2P CONNECTOR RR SY 5 CRANKSHAFT 13 27 4 POS
6. 1 5 iIGX440U With starter motor and charge coil 20A type YOLOW H24IMS AB315178 BUYYLS 1102 NOILINDI WAT 10 Url 25 91 eil 1 uec s 00 7310 B v 02 102 3DuvH2 109 1303 TERI L 15 1 102 i 01083105 119 1303 30 3 zz 52 32713 u 07 81 d e i8 ee T o s T O J 1 313112936 eee aub 92 i _ 01043105 An I2 FUSE 30 mirna Ww i e gt gt 5 8599 208888 segase a 1l 6 un ts A OW 010 TOH1N02 HILHAS NOLILYNIAWOJ HOSN3S 330H2 TULOHH 31871 ALINNELNOS H21IAS NOLLYNIBIWO2 12 p 31LLOH 3univu3dN 011 ILL 3NIDN3 m 1 7 2 SERVICE INFORMATION iGxaaou 1 THE IMPORTANCE OF PROPER SERVICING 7 TORQUE VALUES 2 IMPORTANT SAFETY PRECAUTIONS 8 SPECIAL TOOLS 3 SERVICE RULES 9 TROUBLESHOOTING 4 SYMBOLS USED IN THIS MANUAL 10 HARNESS ROUTING 5 SERIAL NUMBER LOCATION 11 TUBE ROUTING 6 MAINTENANCE STANDARDS 1 THE IMPORTANCE OF PROPER SERVICING Proper servicing Is essential to the safety of the operator and the reliability of the engine Any error or oversight made by the technician while servicin
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8. Good Check the spark arrester P 3 5 Restricted Clean the spark arrester P 3 5 Good Carbon Check for carbon deposits in the muffler deposited Remove the carbon deposit from inside of the P 5 1 muffler P 5 1 Good Check the Engine Temperature sensor No good Replace the Engine Temperature sensor Equipped type only P 11 10 P 11 9 Good Go to page 2 11 2 10 iGX440U From page 2 10 Check the wire harness connecting the Engine Temperature sensor and ECM for open or short circuit Equipped type only No good Repair or replace the wire harness Good Perform the FUEL SYSTEM troubleshoot ing P 2 14 Good Perform the IGNITION SYSTEM trouble shooting P 2 16 Good Perform the cylinder compression check 2 19 High Check for carbon deposits the combustion E chamber Low compression Check the valve clearance P 3 6 Check the valve timing P 2 19 Check the cylinder head P 12 5 Check for defective cylinder head gasket valves or valve seat Check for worn piston piston rings or cylin der Good Check the parts the control box P 6 2 3 No good Replace any damaged or faulty parts P 6 2 3 Good No good Repair or replace the wire harness Check the wire harness for open or short cir cuit Good Replace the P 6 2 2
9. Inside red 1mm blue 0 75mm rd P N 0 5mm Lower part b ack 12 DESCRIPTION OF THE ELECTRICAL BOX The box on the right side of the machine is a Timan control box The box includes an emergency stop hour counter circuit breakers and relays ignition indicator light and the supply of the NBB control box See the electrical diagram in section 12 1 IMPORTANT Never replace the fuses with fuses of a higher ampere value Before fitting a new fuse first always find out the cause and remove the problem The upper fuse 1s F1 and the lower fuse 1 F4 Timan F1 box 10 A NBB F2 control 15 A Honda engine F3 control 3 Chargi F4 charging socket 7 5 A e KI K2 utton relay K3 Relays Negative battery terminal relay 12V 70A K2 Fuel ignition IGN ignition coils relay Hour counter and ignition indicator light relay Emergency stop double relay which stops the power supply to K1 K2 K3 The electrical box also has a charging socket for charging the battery of the machine without removing the hydraulics guard Page 50 57 m 0104 01 61 gt gt J p u ewu ew 1 3 aben Stuha OSE OEE 16 GH 09 OEE 16 SH 191 S33A84 S V c V 3smavm RDS NIAN Uni UBS 0869 ET fe sxyuq eJ ION WOS HITE 91901 NODING OUEN
10. ELEMENT 6 2 CLEANER 4 FOAM ELEIVIENT 5 AIR CLEANER ELBOW PACKING 3 3 iGXdaou 3 Foam element Clean the element in warm soapy water rinse and allow to dry thoroughly or clean with a high flash point solvent and allow to dry thoroughly Dip the eiement in clean engine oil and squeeze out the excess oil Excess oil will restrict air flow through the form element and may cause the engine to smoke at startup 4 Paper element Tap the element lightly several times on a hard surface to remove excess dirt or blow compressed air lightly 207 kPa 2 1 kgf cm 30 psi or less through the filter from the inside out Never try to brush the dirt off brushing will force dirt into the fibers 5 Wipe dirt from the inside of the air cleaner elbow and air cleaner cover using a rag Be careful to prevent dirt from entering the air duct that leads to the carburetor 6 Install the foam element to the paper element Install the air cleaner elbow packing and air cleaner ele ments and tighten the wing nut securely Install the air cleaner cover and tighten the air cleaner cover nut securely NOTICE Operating the engine without the air cleaner element or with the element installed loosely will allow dirt to enter the engine causing rapid engine wear Install the air cleaner ele ment securely 4 SPARK PLUG Inspection cleaning If the engine has been running the engin
11. Turn the potentiometer 90 clockwise Remove the potentiometer Do not forget the O ring pli Assemble in the reverse order from above Please note 1 Grease the O ring before mounting it on the potentiometer so that it stays In place when assembling the potentiometer 2 When assembling the potentiometer see picture 2 make sure that the screws are located in the middle of the lengthwise holes in the potentiometer Page 45 57 8 3 Setting the zero position of the servo engine When the arms of the servo engine are being remounted make sure that they are aligned correctly otherwise the machine will not go straight Set as follows 4 5 Before mounting arms servo engine supply electricity to machine by pressing the emergency button on the remote control and on the machine Press the horn Put the left joystick in the maximum position to start the servo engine shaft rotating When the handle 15 released 577 the will automatically A find the zero position Press emergency button on the machine and on remote control Push the servo engine arm above the shaft Make sure that the arm is perpendicular in the bend of the servo engine support Use an angle iron Tighten the engine nut When tightening the nut make sure that the shaft and the arm do not rotate around each other Always check after assembling the arm Then supply electricity to the machine a
12. asn4 D z S4 euibu3 epuoH r 102 53 Ot O 2 1 is 5 S ose OT dwy esnj ww 1 dwy oe snd gt N dwy ST esnj p O EC MOJ 9 UAH JU OT esnj OTE pt CE I NdN OSZ T1 G 7 7 JU PII g A T JU HM IV ev IV ev 98 S8 n gieeq vc TT 8 TA 0 0 e MEE L AU AM w 002 1 90 09 09 A T Eo 491unoo Jn oH Zo 0061 7 9 V anuo v exeg 13 Troubleshooting Problem Possible cause Possible solution Starter works but the engine Spark plug 1 Check the gap or replace the plug won t start Damaged wiring Replace or repair wiring Fuel filter is blocked 1 Clean the filter in the carburettor No fuel Refill Vacuum valve under the fuel tank Replace the valve Flash of the engine control unit 1 See section 14 4 Set the mowing mechanism to the working Mowing mechanism is in the service position position Defective NPN sensor Replace the sensor Keep adjusting the sensor until the diode To
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14. extension 3 Loosen the belt see section 4 1 Lift up the belt and pull out the clutch from the machine at the same time 4 Fix the clutch in a vice loosen the screw holding the flange bearing and remove the bearing Page 16 57 5 Remove clutch 6 Remove the driving pulley and claw clutch 7 When assembling the driving pulley the screw must be treated with Loctite thread securing 8 When assembling the screw holding the flange bearing treat the screw with Loctite thread securing 9 Remove the groove and distance ring 10 Remove the guard bearing case Page 17 57 11 Loosen the setscrews on the flange bearing and remove the bearing Assemble in the reverse order from removing Please note the following 12 When installing the clutch on the machine make sure that the force arm of the clutch 1s in the lock of the machine 13 The setscrews of the bearing can be tightened after the screws holding the flange bearings are tightened Page 18 57 2 9 Replacing the guard bearing The guard bearing is replaced as follows Follow the instructions for replacing the belts between the clutch and engine up to and including point 6 See section 2 7 1 Remove the four guard screws and the distance ring and groove 2 Pull out the guard above the shaft and place the mowing mechanism in the service position 3 Pull out the bearing sleeve from the shaft using the shaft clamp 4 Remove the lock ring
15. ECM failure Engine temperature sensor failure Wire harness connecting engine tem perature sensor and ECM failure failure Power coil failure Wire harness connecting power coil and failure failure LED does not light up Battery failure 3A or 30A fuse blown Combination switch failure Wire harness failure failure While engine is running The engine continues to run 3 At start up Engine does not start While engine is running Engine stops At engine start up Engine does not start While engine is running Engine stops At start up Engine does not start While engine is running Engine stops At start up Engine does not start 7 The engine may or may not stop depending on the program in the 2 Rewriting of the program is needed Contact your Honda engine distributor 3 If the faulty engine temperature sensor is detected while engine is running the engine does not stop and the LED does not flash After the engine is stopped the engine does not start until the faulty engine temperature sensor is solved 2 6 iGXdadou a ENGINE DOES NOT START Starter motor equipped type Check whether the LED is on when the combi nation switch is turned on Turn the combination switch to the START position and check whether the LED flashes when cranking the engine On Perform the LED IS LIT BUT ENG
16. No good Install the diaphragm joint properly and if Check whether the diaphragm joint is installed necessary replace it P 7 1 properly and not damaged P 7 1 Good Check the auto fuel valve P 7 3 or fuel cock Replace the auto fuel valve 7 2 or fuel on the carburetor 6 9 good cock P 6 9 Good Check the fuel cut solenoid Equipped type No good Replace the fuel cut solenoid P 6 10 only P 6 13 Good Check the fuel cut solenoid rectifier Equipped type only P 11 10 No good Replace the fuel cut solenoid rectifier P 11 9 Good to page 2 15 2 14 iG2 140OUJ From 2 14 Check the fuel cut solenoid coil Equipped type only P 2 18 Good Check the wire harness for open or short cir cuit Good Check for a good seal between the breather cover and the crankcase Good Check the breather valve and breather valve stopper P 13 1 Good Fuel system is OK No good No good No good No good Replace the fuel cut solenoid coil P 11 1 Repair or replace the wire harness Install the breather cover properly If the cover is deformed replace it P 13 1 Replace any damaged or faulty parts P 13 1 2 15 iGX440U f IGNITION SYSTEM Check the spark plug 3 4 No good Replace the spark plug
17. gloves or safety shoes Handling hot or sharp parts can cause severe burns or cuts Before you grab something that looks like it can hurt you stop and put on gloves Make sure the engine is off before you begin any servicing procedures unless the instruction tells you to do otherwise This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Burns from hot parts Let the engine and exhaust system cool before working in those areas Injury from moving parts If the instruction tells you to run the engine be sure your hands fingers and clothing are out of the way Gasoline vapors are explosive To reduce the possibility of a fire or explosion be careful when working around gasoline or batteries Useonly a nonflammable solvent not gasoline to clean parts Never drain or store gasoline in an open container Keep all cigarettes sparks and flames away from all fuel related parts 2 1 3 SERVICE RULES 1 4 C N OQ Ol Use genuine Honda or Honda recommended parts and lubricants or their equivalents Parts that do not meet Honda s design specifications may damage to the unit Use the special tools designed for the product Install new gaskets O rings etc when reassembling When torquing bolts or nuts begin with larger diameter or inner bolts first and tighten to the
18. gt 2 4 3 5 2 1 8 EN 82 1 Cam _ _____ Engine temperature sensor EM a 1 4 723 10 Connecting rodot mos w adjusting serewiocent meos 88 Cowolpamesrew 20 mm selftapoing screw 17 017 Control box brake MexMmmseteppingssew 17 017 3 9 35 12 14 5 23 168 _ 8 09 2 7 17 17 7 122 1 3 3 6 Throtlechoke control motors screw Mx6mmscewwase 088 006 Motor piate screw Mex2ommpanssew 49 05 coverserew Maxi mmerewwehe 21 02 CT Cutting Thread indicates a self tapping bolt Use standard torque values for fasteners that are not listed in this table Thread Dia mm STANDARD TORQUE VALUES Torque valves 0 e 3 3 p 3 3 3 3 BIN QI Bolt and nut RO 3 ul Flange bolt and nut CT flange bolt Retightening AR QI 2 4 iGXdaou 8 SPECIAL TOOLS Toolmame Toolnumber Application 07401 0010000 07908 KE90000 07746 0010100 Float level gauge adjust wrench 3 x 4 mm Attachment 32 x 35 mm 07746 0010400 07746 0020200 07746 004030
19. hoses on the left and right engine Remove the counter valve at the T shaped connection on the tank Remove the belt tension adjusting screw on the pump 1 3 4 Page 38 57 5 Remove hanger screw 6 Remove the hanger screw 7 Loosen and remove the suction hose 8 Remove the reverse hose on the filter 9 Lift up the pump from the machine 10 Remove the ball joint of the arm servo engine support and the ventilator and driving pulley When replacing the pump do not remove the arms of the servo engine otherwise the zero position of the servo engine must be recalibrated See section 8 3 on setting the zero position of the servo engine Assemble in the reverse order from above Important treat all screws screwed into the pump and the pump shaft with Loctite thread securing Page 39 57 7 6 Cleaning the oil cooler The cooler is cleaned as follows First remove the branches protective guard see section 1 1 1 Loosen the eight screws of the mesh and remove the two screws completely on the top 1n the middle 2 Tilt the mesh backward and remove it by lifting 1t sideways up Loosen the four screws holding the cooler 4 Clean the cooler with compressed air from the rear part of the cooler UJ Mount the cooler in the reverse order than stated above Page 40 57 0000804 T 8 Servo engine 8 1 Replacing the Servo engine First remove the branches protective guard the hydr
20. that the engine is cool before muffler removal installation 1 Remove the spark arrester from the muffler P 5 1 2 Clean the carbon deposits from the spark arrester screen with a brush 3 Check the spark arrester screen for damage If the spark arrester is damaged replace it 4 Reinstall the spark arrester to the muffler P 5 1 3 5 6 VALVE CLEARANCE Inspection adjustment Valve cl arance inspection and adjustment must be per formed with the engine cold 1 2 3 Remove the cylinder head cover with recoil starter type Set the piston at top dead center of the compression stroke both valves fully closed by pulling the recoil starter slowly The A mark on the starter pulley will align with the projection on the fan cover when the piston is at top dead center of the compression stroke without recoil starter type Set the piston at top dead center of the compression stroke both valves fully closed by turning the cooling fan setting plate The projection of the cooling fan will align with the projection on the fan cover when the piston is at top dead center of the compression stroke Insert a feeler gauge between the rocker arm and valve to measure valve clearance 0 12 0 02 mm 0 15 0 02 mm Valve clearance 1 CYLINDER 2 HEAD COVER 6 x 25 CT bolt 2 1 WITH RECOIL STARTER TYPE S 2 N N PROJECTION t NN i AS ALY A
21. 0 07746 0040400 Attachment 52 x 55 mm Inner bearing driver attachment 15 mm Pilot 15 mm Pilot 17 mm 07749 0010000 07746 0030100 07936 KC10200 07936 KC10100 07936 3710300 07936 37 10100 07741 0010201 07725 0030000 07780 0010400 07780 0010500 07780 0012300 07780 0012400 07780 0014100 07781 0010101 07942 8230000 07984 2000001 driver handle 40 Bearing head 15 Bearing remover shaft 15 Bearing remover shaft set 17 Bearing remover shaft handle Remover weight Universal holder Valve seat cutter 45 35 mm Valve seat cutter 45 840 mm Valve seat cutter 32 935 mm Valve seat cutter 32 38 5 mm Valve seat cutter 60 937 5 mm Cutter holder 5 5 mm Valve guide driver 6 7 x 9 8 mm Valve guide reamer 5 510 mm 9 e 2 0 90 OVO 00 2 8 49 00 Carburetor float height inspection Valve clearance adjustment Balancer bearing installation camshaft bearing removal installation 35 x 52 x 8 mm oil seal installation Camshaft bearing removal Balancer bearing Bearing holder side installation Balancer bearing Crankcase side installation camshaft bearing removal installation Handle for 3 Crankshaft bearing installation Balancer bearing Bearing holder side removal Balancer bearing Bearing holder side removal Balancer bearing Crankcase side remov
22. 11 iGxX440U d ENGINE SPEED DOES NOT INCREASE OR ENGINE LACKS POWER Turn the combination switch to the OFF posi Insufficient Add fuel and then start the engine tion and check the fuel level in the tank Sufficient Check the spark arrester P 3 5 Restricted Clean the spark arrester P 3 5 Good Carbon a Check for carbon deposits in the muffler deposited Remove the carbon deposit from inside of the P 5 1 muffler P 5 1 Good Check whether the air cleaner element is No good Install the air cleaner element properly installed properly P 4 1 P 4 1 Good Check the air cleaner P 3 3 Restricted Clean the air cleaner element P 3 3 Good Tighten the air cleaner elbow nuts to the specified torque P 4 1 Replace the carburetor packing or insulator packing P 6 1 Check for loose air cleaner elbow nuts Check No good for air leakage through a damaged carburetor packing or insulator packing Perform the FUEL SYSTEM troubleshooting P 2 14 Good Go to page 2 13 2 12 2 12 Perform the IGNITION SYSTEM trouble shooting P 2 16 Check the throttle control Equipped type only 2 17 Good Perform the cylinder compression check P 2 19 No good Replace the throttle control P 9 3 4 High Check carbon deposits the combustion charnber Low cornpres
23. 3 a ai 0 25 274 444 12811 T n i E 85 Ws me 21 82 554 0 859 2000 3 8 24 UNF 2 2 105 5 4 15 622 161 oc 60 8725 76 5 3 01 5 4 2 21 4 TAPER ON DIA NSN TAPER 3 16 4 PLANS COTES DE LA PRISE 4 ABTRIEB MARZEICHNUNGEN 4 PLANOS DE DIMENSIONES DE Unit mm Type S gt Type Q gt 2 TARAUDAGE 3 8 24 UNF 2B LA TOMA DE FUERZA 1 Einheit mm S Typ 1 Unidad mm Tipo S gt Q Typ 2 28 24 UNF 28 BOHRUNG Tipo Q gt 2 MACHO DE ROSCAR 3 8 24 UNF 2B V Typ Type V 5 16 24 UNF2B BOHRUNG Tipo V 3 TARAUDAGE 5 16 24 UNF2B 4 21 4 KONIZITAT PRO FUR AUF DURCHM 3 MACHO DE ROSCAR 5 16 24 UNF2B 4 CONICITE DE 2 1 4 PAR PIED SUR LE KONUS 3 16 4 CONICIDAD DE 2 1 4 POR PIE EN EL DIAMETRE CONICITE 3 16 DI METRO CONICIDAD DE 3 16 1 4 iGXdadaou 5 ENGINE MOUNT DIMENSIONAL DRAWING 11 Unit mrn in 195 5 7 70 105 4 1 2 2 811 80 4 86 3 4 103 4 1 lt a 2 UI J 1 H gt 3 2 11 x 28 0 4 x 1 1 SLOT 17 0 7 5 PLAN COTE DE MONTAGE 5 MOTORLAGERUNG MA Q3ZE 5 PLANO DE DIMENSIONES DU MOTEUR ICHNUNG DE LA MONTURA DEL MOTOR 1 Unit mm 1 Einheit mm 2 2 9 11 2 2 811 1 Unidad mm ORIFICE LOCH 212 611 3 2 11 x 28 3 2 11 x 28 D en RANURA
24. 4 ring n x We Auto fuel valve located under the petrol tank Hose between the petrol pump and carburettor ES n x a L gt i Page 54 57 14 2 Diagnostic connection The Honda engine has a diagnostic connection to connect to a computer With the computer connected the following engine data can be read Throttle valve opening Engine revolutions Number of engine hours Sensor fault Previous error codes of the engine The diagnostic connection can only be used by authorized Honda dealers See the connection location below msi m 14 3 Replacing the motor oil Loosen the oil drain plug drain the oil tighten the plug and fill with approximately one litre of 10 40 motor oil DIPSTICK OIL FILLER CAP DIPSTICK UPPER LIMIT Page 55 57 Important Check the oil level every four hours during operation The engine does not have an alarm sensor to indicate when the oil level 1s too low In the factory the engine is filled with Texaco Havoline Extra SAE 10W 40 classification API SJ semi synthetic slightly flowing oil If another product is used first find out whether it can be mixed with this brand If oil which 1 not mixable with this brand is used the old oil must be completely drained before filling with new oil 14 4 Fuel system troubleshooting If the engine runs out of petrol problems can occur with getting fuel to
25. 587 0 120 0 0047 21 040 0 8283 20 970 0 8256 0 050 0 0020 Piston ring 0 150 0 0059 Ring end gap 1 00 0 0394 Second 0 35 0 50 0 014 0 020 7 1 00 0 0394 1 250 0 0492 Small end 1 0 21 070 0 8295 Big end I D 40 025 40 039 1 5758 1 5763 40 070 1 5776 Big end oil clearance 0 120 0 0047 Big end side clearance 1 0 0 039 Crank pin O D 39 930 1 5720 EX 5 400 0 2126 EX 5 300 0 2087 N EX 5 560 0 2189 Valve Valve clearance Stem O D Guide 0 Stem to guide clearance EX 0 050 0 077 0 0020 0 0030 0 130 0 0051 Seat width EX 1 200 1 400 0 0472 0 0551 2 300 0 0906 Valve sprina free lenath 46 3 1 82 44 8 1 76 Connecting 0 010 0 034 0 0004 0 0013 0 110 0 0043 0 900 1 100 0 0354 0 04 33 2 000 0 0787 Camshaft Camheight 3119830736 2258 1210 _ 30 586 1 2042 uu LE Piletscrewopening t 5tumsout ____ Flottheight o o 2332052 __ Sparkplug __ Gap 01 08 0 028 0 09 _ gniioncol Resistance 0160219 _ Secondary 374 458kQ 1 Miadeph 0 24000 This figure is caused by basic program in the The engine speed is different depending on the program in the ECM iGX440U 7 TORQUE VALUES EM 7 8 1 1 Oil drain bolt B M20 x 1 5 Cylinder head bolt M10 x 1 25 D
26. 7 57 2 2 Tightening the belts between the engine and clutch First remove the branches protective guard the hydraulics guard and the guard on the right side of the engine See sections 1 1 1 2 and 1 3 Belt tension Location of the engine screws Lock nut adjusting nut Tighten the belts as follows 1 Loosen the four screws holding the engine 2 Loosen the lock nuts on the setting fitting 3 Continue adjusting the lock nuts until the belt tension 1s 375 N for a new belt and 300 N for a used belt 4 Using the horizontal batten check whether the driving pulley of the engine 1 parallel to the clutch If not adjust the lock nuts Check the belt tension afterwards 5 Tighten the screws of the engine and lock nuts Important After tightening turn the transmission several times to spread the belt tension evenly Page 8 57 23 Tightening the belts between the engine and hydraulic pump First remove the branches protective guard the hydraulics guard and the guard on the right side of the engine 5ee sections 1 1 1 2 and 1 3 Pump screws Adjusting screw Tighten the belts as follows 1 Loosen the two screws holding the pump 2 Loosen the lock nut of the adjusting screw 3 Continue adjusting the adjusting screw until the belt tension is 250N for a new belt and 200N for a used belt 4 Tighten the screws of the pump and lock nuts Important After tightening turn the transmission several times to spread the b
27. 90 degrees to unlock the cap and remove the oil level gauge from the oil filler neck Wipe the oil level gauge clean Insert the oil level gauge without screwing it into the oil filler neck Remove the oil filler cap and check the oil level shown on the oil level gauge If the oil level is near or below the lower level mark on the oil level gauge fill with the recommended oil to the upper level mark SAE 10W 30 Recommended oil API Service classification SE SF or SG Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other vis cosities shown in the chart may be used when the aver age temperature in your area is within the recommended range Insert the oil level gauge into the oil filler neck and turn the oil filler cap clockwise 90 degrees to lock the cap 2 OIL FILLER CAP 1 OIL LEVEL Sut s 1 5 AE 10 20 30 40 2 Ambient Temperature 3 2 iGXaadgou Oil change 1 2 3 4 6 3 Check the engine on a level surface and remove the oil filler cap 3 2 Remove the oil drain bolt and sealing washer and drain the oil into a suitable container Please dispose of used motor oil in a manner that is com patible with the environment We suggest you take used oil in a sealed container to your locai recycling center or service station for r
28. AD DEL MOTOR rpm iGXaaou 3 DIMENSIONAL DRAWINGS 516 20 3 1 Unit mm in 1770 0 315 12 4 156 6 1 9 168 6 6 S type 371 5 14 63 Q type 397 15 6 V type 414 16 3 2 S type 407 16 0 Q type 432 5 17 03 V type 449 5 17 70 i d 442 17 4 446 17 6 454 17 9 222 8 7 8 EXHAUST GAS QUT eui 70 2 8 133 5 5 26 7 8 5 0 0 PILOT 9146 05 0 025 PILOT at 10 e g 5 748 x 0 0010 6 4 3 T DEPTH 4 0 2 DEPTH 4 5 0 18 018 q 176 6 9 P D 165 1 6 50 4 5 type M8 x 1 25 DEPTH 18 0 7 N type 6 5 16 24 UNC 2BTAP 6 V type 6 5 16 24 UNC 2BTAP 0 4 0 02 S type 98 51 o 9 0 335 5 Stype MB x 1 25 DEPTH 18 0 7 O type 4 3 8 16 UNC 2BTAP V type 4 3 8 16 UNC 2BTAP type 6 5 16 24 UNC 2BTAP APLCS V type 6 5 16 24 UNC 2BT AP 5 3 PLANS COTES 3 MAGZEICHNUNGEN 3 PLANOS DIMENSIONES 1 Uni 1 Einh 1 Unidad mm H Ty is 5 407 Type Q V 419 5 2 S yp 407 432 5 y Typ 449 5 2 Tipo 5 407 Tipo Q 432 5 po v V 449 5 3 AVANT TROU n 110 0 0 F HRUNG 8110 0 05 0 431 PILOTO DE 110 0 05 0 Tyne S MB x 112581 4 Ti Tipo S MB 105 A PROFUNDIDAD 4 Type 5 MS x 125 PROFONDEUR 18 41 S Typ ME 1 25 TIEFE 18 Type Q TARAUDAGE 6 5 16 24 UNC 2B gt O Typ 6 5 16 24 UNC 2B BOHRUNG Tipo Q MA
29. BKR7E E NGK K22PR UR DENSO DI Forced splash type Oil capacity 1 10 1 16 US qt 0 97 Imp qt Cooling system Starting system Recoil and starter motor Stopping system Ignition primary circuit open 1 1 iGxX440U 2 PERFORMANCE CURVES 2 TORQUE N m 12 1 OUTPUT kW 6 MAXIMUM TORQUE ENNII N ON 7 MAXIMUM HORSEPOWER LL d N 3 RECOMMENDED OPERATING SPEED RANGE 4 2 5 2 3 0 9 25 5 i 15 16 14 12 9 A 10 m 8 6 2 000 2 500 3 000 3 600 2 COURBES DE PERFORMANCES I PUISSANCE kW 2 COUPLE N m 3 COUPLE Ibf pi 4 COUPLE kgf m 5 PUISSANCE PS 6 COUPLE MAXIMUM 7 PUISSANCE MAXIMALE 8 PLAGE DES REGIMES DE SERVICE RECOMMANDES 9 REGIME MOTEUR min tr mn 9 ENGINE SPEED min rpm 2 LEISTUNGSKURVEN 1 LEISTUNG kW 2 DREHMOMENT N m 31 DREHMOMENT Ibf ft 4 DREHMOMENT kp m LEISTUNG PS 5 MAX DREHMOMENT 7 HOCHSTLEISTUNG 8 EMPFOHLENER BETRIEBSDREHZA HLBEREICH 9 MOTORDREHZAHL U min 2 CURVAS DE RENDIMIENTO 1 SALIDA kW 2 TORSION 3 TORSION Ib pie 4 TORSI N kgf m 5 SALIDA CV 6 TORSI N M XIMA 7 POTENCIA M XIMA EN CABALLOS 8 MARGEN DE VELOCIDADES DE OPERA CI N RECOMENDADAS 9 VELOCID
30. CHO DE ROSCAR 6 5 16 24 UNC 2B Type TARAUDAGE 6 5 16 24 UNC 2Tt V Typ 6 5 16 24 UNC 28 BOHRUNG Tipo V MACHO DE ROSCAR 6 5 16 24 28 5 Type S M8 x 1 25 PROFONDEUR 18 5 S Typ MB x 1 25 TIEFE 18 5 Tipo S 1 25 18 DE PROFUNDIDAD Q TARAUDAGE 6 5 16 24 UNC 2L Q Typ 6 5 16 24 UNC 2B BOHRUNG DE ROSCAR 6 5 16 24 UNC 2B V TARAUDAGE 6 5 16 24 UNC 2D 4PI CS V Typ 6 5 16 24 UNC 2B BOHRUNG 421 5 MACHO DE ROSCAR 6 5 16 24 UNC 2B 4PLCS 6 Type S 8 51 0 4 0 6 S Typ p 8 51 0 4 0 e Ti 5 8 51 40 3 0 Q TARAUDAGE 4 3 8 16 2 i Q Typ 4 3 8 16 UNC 2B BOHRUNG Q MACHO DE ROSCAR 4 3 8 16 UNC 2B gt TARAUDAGE 4 78 16 UNC 2B 4PLCS 4 3 8 16 UNC 2B BOHRUNG 4PLCS Taa y MACHO DE 4 3 8 16 UNC 2B 4PLCS m AVANT TROU 146 05 0 025 71 F HRUNG 0146 05 x 0 025 7 PILOTO de 0146 05 0 PROFONDEUR TIEFE 4 PROFUNDIDAD DE 4 8 SORTIE DES GAZ D ECHAPPEMENT 8 IABGASAUSLASSJ 8 SALIDA DE GASES DE ESCAPE 9 ouf 9 5 371 5 uo zn T 97 Q T 7 Type V 414 V Typ 397 414 1 3 iGxXadadou 4 PTO DIMENSIONAL DRAWINGS S type Q type V type DE FORCE 63 2 5 1 Unit In 28 y d 0 02 944 5 LO 5 of x of 5 re e N gt 60 2 4 88 5 3 48 72 2 2 84 PN 56 2 2 6
31. CUP Cleaning E FUEL CUP FILTER WARNING 2 O RING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 3 FUEL STRAINER CUP After installing the fuel strainer cup clieck for any sign of fuel leakage 1 Remove the fuel strainer 2 Remove the fuel cup filter and clean it 3 Install the fuel cup filter and tighten the fuel strainer cup to the specified torque TORQUE 3 9 N m 0 4 kgf m 2 9 Ibf ft 3 8
32. Good Perform the spark test P 2 19 Good Ignition system is OK No spark or weak spark Perform the spark test again using a new Good Replace the spark plug spark plug P 2 19 No spark or weak spark No good Replace the spark plug cap ignition coil P 11 9 Check the ignition coil P 11 11 Good No good Replace the combination switch or engine stop switch P 9 3 4 Check the combination switch or engine stop switch P 2 17 Good Check the crankshaft position CKP sensor P 2 17 No good Replace the crankshaft position CKP sensor P 10 1 11 1 Good Check the power coil P 2 17 _ Good No good Replace the power coil P 11 1 Check the wire harness for open or short cir cuit No good Repair or replace the wire harness Good Ignition system is OK iGX440U COILS AND IGNITION SWITCHES CHECK 3 THROTTLE CONTROL INSPECTION Measure the resistance between the ter minals when rotating the throttle con trol knob fully in the clockwise direction and when rotating it fully in the coun terclockwise direction 1 2 CRANKSHAFT POSITION POWER COIL INSPECTION SENSOR INSPECTION Measure the resistance between the terminal and engine ground Lg G R Specified resistance 3 7 Clockwise direction Measure the resistance between the terrninals fan cover bolt BI G 0 500 Coun
33. INE DOES NOT START troubleshooting P 2 10 flashes Perform the ENGINE DOES NOT START WITH LED FLASHING troubleshooting P 2 8 Starter motor does not operate or LED does not flashes Good Check the 3A fuse P 9 7 No good Replace the fuse P 9 3 Check the 30A fuse P 9 7 No good Replace the 30A fuse 9 3 Good Check the combination switch P 2 17 Good No good Replace the combination switch P 9 3 Check the wire harness for open or short cir cuit No good Repair or replace the wire harness Good Replace the ECM P 6 2 iGXadaou b ENGINE DOES NOT START WITH LED FLASHING LED flashing pattern 2 flashes per cycle Insufficient Add engine oil P 3 2 Turn the combination switch to the OFF posi tion and check the oil level P 3 2 Good No good Replace the oil level switch P 13 5 Check the oil level switch P 13 12 Good Check the wire harness connecting the oil No good Repair or replace the wire harness level switch and ECM for open or short circuit Good Replace the ECM 6 2 LED flashing pattern 4 flashes per cycle No good Replace the Engine Temperature sensor P 11 9 Check the Engine Temperature sensor P 11 10 Good Check the wire harness connecting the Engine Temperature sensor and ECM for open or short circuit No good Re
34. ITION ENGINE 0 SENSOR TEMPERATURE 6 yon SENSOR f 12 GROUND 7 IA S 11 7 TERMINAL P RG 11 FUEL jd SOLENOID 24 7 FUELCUT 2P CONNECTOR lt lt lt SOLENOID COIL Black ZI 2 2 White o 3 b 15 FUEL CUT SOLENOID _ 11 FUEL CUT E gt 6 HARNESS CLIP 10 FUEL CUT SOLENOID RECTIFIER 4 CONNECTOR Green SOLENOID 2 9 FUEL CUT Eu ck SOLENOID RECTIFIER SSK IS FUEL CUT SOLENOID RECTIFIER 12 8 LEVEL SWITCH TERMINAL a pea 6 ae gt HARNESS S CLIP EET ME 8 7 FUEL CUT OIL LEVEL SWITCH SOLENOID COIL TERMINAL 2P CONNECTOR White 2 21 iGXdadou i 4 STARTER STARTER MOTOR Equipped type MOTOR 2 FUSE 131 FUSE 30A TERMINAL 11 HARNESS BAND CLIP 1 1 HARNESS BAND CLIP x R QV D 11 2 FASTENER TUBE D COMBINATION SWITCH CABLE White 2 CHARGE COIL CABLE 3A Black 20A Gray 3 CHARGE COIL CABLE Gray 4 FUSE CABLE 30A 5 STARTER MOTOR CABLE cU MA 10 2 LE VZ Make sure that the cable does not touch the harness DN bracket A bracket installing 6 HARNESS bolts or cylinder barrel BRACKET A 7 RECTIFIER 9 RECTIFIER 4P CONNECTOR 8 GROUND TERMI
35. LES 2221050 4 SYMBOLS USED IN THIS MANUAL 2 2 5 SERIAL NUMBER LOCATION 2 2 6 MAINTENANCE STANDARDS 2 3 7 TORQUE 2 8 SPECIAL TOOLS eee 2 5 9 5 1 2 6 10 HARNESS ROUTING 2 20 11 TUBE 2 22 3 MAINTENANCE 2 087 1 MAINTENANCE SCHEDULE saves 2 ENGINE OlL eerte 3 2 3 AIR 3 4 SPARK PLUG uuu ua 3 4 5 SPARK 5 3 5 6 VALVE CLEARANCE entes 3 8 7 FUEL cart cett bee 3 7 8 FUEL TUBE MANU ate 928 9 FUEL STRAINER 13 8 m 1 SPECIFICATIONS iGX44OU 1 SPECIFICATIONS 4 PTO DIMENSIONAL DRAWINGS 2 PERFORMANCE CURVES 5 ENGINE MOUNT DIMENSIONAL 3 DIMENSIONAL DRAWINGS DRAWING 6 WIRING DIAGRAMS 1 SPECIFICATIONS DIMENSIONS AND WEIGHT P Tos J v 454 mm 17 9 in Maximum angie ofineination ENGINE __ GMO Minimum fuel consumption 328 g kW h 241 g PS h 0 53 Ib PS h RECEN 10 B T D C 1 400 rpm Ignition timing at no load 13 B T D C 3 600 min rpm Spark plug
36. N Cy Kun S Aon 3 4 STARTER COVER PULLEY 5 A MARK 6 WITHOUT RECOIL STARTER TYPE 2 PROJECTION 7 COOLING FAN SETTING PLATE TAPPET ADJUST WRENCH 3x4mm 07908 KE90000 2 FEELER GAUGE 3 6 iGxX440U 4 If adjustment is necessary proceed as follows a Hold the tappet adjusting screw using the special tool and loosen the tappet adjusting screw lock nut b Turn the tappet adjusting screw to obtain the specified clearance c Retighten the tappet adjusting screw lock nut while holding the rocker arm pivot TORQUE 7 5 N m 0 75 kgf m 5 5 Recheck valve clearance after tightening the tappet adjusting screw lock nut 5 Install the cylinder head cover 1 FUEL TANK Cleaning WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately After connecting the fuel tube check for any sign of fuel leakage 1 Drain the fuel from the fuel tank into a suitable container Manual fuel valve type Drain the fuel from the carburetor before removing the fuel tank proceed as follows a Turn the fuel valve lever to the OFF position b Loosen the drain screw of the carburetor and drain the fuel into a suitable container 2 Remove the fuel tank tank stay and auto fuel valve P 7 1 2 and disconnect t
37. NAL 11 TUBE ROUTING 1 BREATHER TUBE h Q p JJ her amp gt E UT Ww A 41 To air cleaner elbow 3 BREATHER 2 FUEL 6 CARBURETOR 5 FUEL COVER GROMMET 2 22 3 MAINTENANCE iGxa4OU 1 MAINTENANCE SCHEDULE 6 VALVE CLEARANCE 2 ENGINE OIL 7 FUEL TANK 3 AIRCLEANER 8 FUEL TUBE 4 SPARK PLUG 9 FUEL STRAINER CUP 5 SPARK ARRESTER 1 MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 1 Every Every _ Every ITEM Perform at every indicated month or 6 months year 2 years operating hour interval whichever or or Or comes first 100 Hrs 300 Hrs Engine oil Air cleaner E Spark plug Check adjust Replace ee NE 01 After every 500 Hrs Replace if necessary 3 F Combustion chamber Clean Fueltankandfilter 37 cheek Every 2 year Replace 38 _ Emission related items 1 For commercial use log hours of operation to determine proper maintenance intervals 2 Service more frequently when used in dusty areas 3 Check the belt for cracks or abnormal wear replace if necessary 3 1 iGX440U 2 ENGINE OIL Oil level check 1 2 3 4 5 Place the engine on a level surface Turn the oil filler cap counterclockwise
38. Service manual Valid for RC 750 type and serial number 410100 01 TIMAN Page 1 57 1 REMOVING GUARDS dos E D STU UO 4 1 1 REMOVING THE BRANCHES PROTECTIVE 4 1 2 REMOVING THE HYDRAULICS GUARD 4 1 3 REMOVING THE GUARD ON THE RIGHT SIDE OF THE ENGINE 5 1 4 REMOVING THE BLACK GUARD IN FRONT OF THE CLUTCH 5 1 5 REMOVING THE ENGINE COMPARTMENT GUARD 6 1 6 REMOVING THE MOWING MECHANISM GUARD ccccccececececececscscscscecsecceccccsccceceuececseecececs 6 PROPULSION SYSTEM teni 7 2 1 TIGHTENING AND MAINTENANCE OF DRIVING BELTS p 2 2 TIGHTENING THE BELTS BETWEEN THE ENGINE AND CLUTCH 8 2 3 TIGHTENING THE BELTS BETWEEN THE ENGINE AND HYDRAULIC PUMP 9 2 4 TIGHTENING THE BELTS BETWEEN THE CLUTCH AND MOWING MECHANISM 10 2 5 REPLACING THE BELT BETWEEN THE ENGINE AND HYDRAULIC PUMP 11 2 6 REPLACING THE BELTS BETWEEN THE CLUTCH AND MOWING MECHANISM 12 2 7 REPLACING THE BELTS BETWEEN THE ENGINE AND CLUTCH 13 2 8 REPLACING THE CLUTCH AND FLANGE BEARINGS cccecscecececccccccccscsc
39. aced as follows First remove the mowing mechanism guard See section 1 6 1 Remove the belt shaft 2 Lift up the mowing mechanism to the service position and remove the belt 3 Lift up the machine so that the mowing mechanism 1 in the lowest position 4 Remove the mowing mechanism belts Assemble in the reverse order from removing Tighten as in section 2 4 Page 12 57 2 7 Replacing the belts between the engine and clutch The belts are replaced as follows First remove the branches protective guard the hydraulic pump guard the guard on the right side of the engine the guard in front of the clutch and the mowing mechanism guard see sections 1 1 1 2 1 3 1 4 and 1 6 Remove the belt shaft N Lift up the mowing mechanism to the service position and remove the belt from the driveshaft 3 Remove the driving pulley screw Use the impact wrench 4 Loosen the two hexagon screws in the Taper Lock case Page 13 57 Screw the hexagon screw to the free thread Tighten the screw to remove the V belt driving pulley and the Taper Lock case Remove the V belt driving pulley and the Taper Lock case ao 4 i 3 4 p f Unscrew the four belt guard screws and remove the guard from the shaft Lift up the mowing mechanism to the service position Remove the hydraulic pump belt See section 2 5 Loosen the engine and set it to the adjusting screws so that the belts are loose See secti
40. al Handle for 2 Balancer bearing removal Cam pulley removal installation EX valve seat reconditioning IN valve seat reconditioning EX valve seat reconditioning IN valve seat reconditioning IN EX valve seat reconditioning Valve seat reconditioning Weight center pin of the camshaft installation Valve guide reaming sa ul Ne 1 01 E 2 5 9 TROUBLESHOOTING Self diagnosis as indicated the LED For details about self diagnosis please refer to P 2 7 When the battery is disconnected self diagnosis with the LED is not possible For diagnosis when the engine is not equipped with the starter motor or when the battery is disconnected refer to P 2 10 ECM COVER LED The LED for a failure flashes periodically as shown in the following figure Example In the case of 2 flashes the sequence of 0 3 sec on 0 3 sec off 0 3 sec on 1 5 sec off is repeated as a cycle 0 3sec 0 3 sec 0 3 sec 1 5 sec x 1 cycle ON OFF Possible problems Engine behavior LED illuminates None Electrical system is normal 2 flashes Insufficient oil While engine is running Engine stops 1 Oil level switch failure At start up Engine may or may not start 1 4 flashes Wire harness connecting oil level switch 6 flashes and ECM Engine Control Module failure
41. and Nilos ring then remove the bearings from the bearing sleeve and mount the new bearings Page 19 57 Assemble in the reverse order from removing Please note the following 5 The screws holding the guard must be treated with Loctite thread securing the assembly of the Nilos ring and distance ring 1s shown in the picture 6 The central screw holding the Taper Lock case must be tightened before tightening the hexagon screws in the driving pulley The screw holds the internal bearing ring of the guard in place The screw must be treated with Loctite thread securing The hexagon screws are tightened to 20 NM 7 Tighten the belt according to section 2 4 Page 20 57 3 MOWING MECHANISM 3 1 Removing the axis The flail axis 1s removed as follows First remove the mowing mechanism protective guard see section 1 6 and follow the instructions for removing the belt described in section 2 6 1 Remove the two screws of the inner guard note the distance ring between the two washers of the screw 2 Mount two approved lifting hangers to the lifting eyes on the mowing mechanism 3 Loosen and remove the two setscrews of the mowing mechanism and also the four screws holding the mowing mechanism 4 The mowing mechanism can now be unfastened from the arms and inner guard Page 21 57 Remove the vertical positioning shaft Remove the chain pulley holder Loosen the three screws holding the closing plate and remo
42. aulics guard and the guard on the right side of the engine See sections 1 1 1 2 and 1 3 Remove the hydrostatic pump belt see section 2 5 Remove the pressure hoses to the left and right engine Remove the counter valve at the T shaped connection on the hydraulic tank 3 Remove the belt tension adjusting screw on the pump 4 Remove the hanger screw 1 2 42 57 7 8 9 10 Loosen the servo engine arm Remove the hanger screw Loosen the rotating device on the suction hose approx one turn Remove the reverse hose on the filter Lift the pump up 20 cm by fastening the lifting lugs around the pump When lifting check if the suction hose rotates Remove the reverse filter Page 43 57 11 Remove the arm of the servo engine with screwdriver 12 Loosen the three screws holding the servo engine 13 Remove the electrical connection of the servo engine 14 Remove the servo engine Assemble in the reverse order from above Please note 1 Assemble the servo engine arm according to section 8 3 2 The screws holding the servo engine see picture 12 must be treated with Loctite thread securing Page 44 57 8 2 Replacing the Potentiometer First remove the branches protective guard the hydraulic pump guard and the engine compartment guard See sections 1 1 1 2 and 1 5 Remove the electrical connection of the potentiometer Loosen the two screws holding the potentiometer
43. e belts are set and maintained correctly a belt tightening tester is supplied with the machine Driving with belts that are too loose will considerably reduce the lifetime and efficiency of the belts and the driving pulleys will wear very quickly If the belts are too tight it will increase wear and tear on the machine bearings The belt tightening tester is used as follows 1 Before you start measuring turn the transmission several times to spread the tension across the entire belt 2 Place the belt tightening tester between the driving pulleys and push the pointer to the scale 3 Only use one finger to control the belt tightening tester 4 Activate the tester slowly by increasing the pressure until you hear feel a click after which do not exert pressure 5 Remove the tester from the belt and read the tension in the intersection of the scale and the front part of the pointer 6 Continue setting the belt tension until the value measured and the value in the table below are equal After each adjustment turn the transmission several times to make sure that the belt tension near the driving pulley 1s the same as in the rest of the belt Static belt tension N Used belt Belts between the engine and clutch 375 Belts between the engine and pump Belts between the clutch and mowing mechanism 375 300 Important After tightening turn transmission several times to spread the tension of the belt evenly Page
44. e will be very hot Allow it to cool before proceeding 1 Remove the spark plug cap P 2 19 and remove the spark plug using a spark plug wrench 1 SOLVENT 2 ENGINE OIL 26 gt 3 usd THOROUGHLY e 1 SPARK PLUG WRENCH 3 4 2 Visually inspect the spark plug Discard the plug if the insulator is cracked or chipped 1 SEALING 3 Remove carbon and other deposits with a plug cleaner or WASHER stiff wire brush Check the sealing washer for damage BKR7E E NGK Spark plug K22PR UR DENSO 4 Measure the plug gap with a wire type feeler gauge if the measurement is outside the specification adjust by bend ing the side electrode 0 7 0 8 mm Plug 0 7 0 8 mm 0 028 0 031 in 0 028 0 031 in 5 Install the spark plug fingertight to seat the washer then tighten with a plug wrench If reinstalling the used spark plug tighten 1 8 1 4 turn after the spark plug seats if installing a new spark plug tighten 1 2 turn after the spark plug seats TORQUE 18 N m 1 8 kgf m 13 ibf ft NOTICE A loose spark plug can become very hot and can damage the engine Overtightening can damage the threads in the cylinder block 6 install the spark plug cap securely P 2 19 5 SPARK ARRESTER Cleaning 1 SPARK ARRESTER CAUTION The engine and muffler become very hot during operation and they remain hot for a while after operation Be sure
45. ecececececescscececes 16 2 9 REPLACING THE GUARD 000000000000000000 19 MOWING MECHANISM 21 3 1 REMOVING THE FLAIL 58 200000000000 21 3 2 REPLACING THE BEARINGS IN THE FLAIL AXIS 23 3 3 FLAIL CUTTERS HANGERS AND 5 5 0000 25 3 4 REPLACING THE CASES OF SUPPORTING ARMS 26 THEE 27 4 1 BELTS PIE NSIDNZ Zuna yaaa d akal 27 4 2 REPLACING u aula yc aa luna yaykusaq 28 4 3 REPLACING THE BEARINGS IN THE RETURN PULLEY 20 4 4 REPLACING THE BEARINGS IN THE BEARING PULLEY 30 4 5 REPLACING THE HYDRAULIC WHEELS 2 2 02000080000000000 31 4 6 DI aaa b 32 RUBBER BELI HANGERS 33 AIR TRAP RUBBER BUMPS 33 cetera MR EEUU 34 7 1 CHECKING THE HYDRAULIC OIL 34 7 2 REPLACING THE GEAR OIL AND 35 7 3 MACHINE TOWING scade anis et 36 7 4 CHECKING HYDRAULIC 0 37 7 5 REPLACING THE PUMP yu T ease 38 7 6 CLEANING THE OIEPCOOLBE
46. eclamation Do not throw it in the trash pour it into the ground or down a drain CAUTION Used engine oil contains substances that have been identified as carcinogenic If repeatedly left in contact with the skin for prolonged periods it may cause skin cancer Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oll Tighten the oil drain bolt and a new sealing washer to the specified torque TORQUE 45 N m 4 5 kgf m 33 Ibf ft Refill with the recommended oil P 3 2 Engine oil capacity 1 10 1 16 US qt 0 97 Imp at Check the oil level and if the oil level is near or below the lower limit mark on the oil level gauge fill with the rec ommended oil to the upper level mark P 3 2 Install the oil filler cap P 3 2 AIR CLEANER Cleaning A dirty air cleaner will restrict air flow to the carburetor reducing engine performance If the engine is operated in dusty areas clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE 1 2 Remove the air cleaner cover nut and air cleaner cover Remove the wing nut air cleaner elements paper ele ment and foam element and air cleaner elbow packing and separate them Carefully check both elements for holes or tears and replace if damaged Check the air cleaner elbow packing for deterioration or damage 1 SEALING WASHER 2 OIL DRAIN BOLT 1 AIR CLEANER COVER NUT 7 PAPER
47. elt tension evenly Page 9 57 2 4 Tightening the belts between the clutch and mowing mechanism First remove the mowing mechanism guard See section 1 6 Adjusting screw Lock nut Mowing mechanism screws Horizontal batten Tighten the belts as follows 1 2 o Loosen the four screws holding the mowing mechanism two screws on each side Loosen the lock nuts on the adjusting screws Continue adjusting the nut on the adjusting screw until the belt tension is 375N for a new belt and 300N for a used belt Using the horizontal batten check whether the mowing mechanism driving pulley 1s parallel to the clutch If not adjust the nuts Check the belt tension afterwards Tighten the screws of the mowing mechanism and also the nuts Important After tightening turn the transmission several times to spread the belt tension evenly Page 10 57 2 5 Replacing the belt between the engine and hydraulic pump The belt is replaced as follows First remove the branches protective guard the hydraulic pump guard and the guard on the right side of the engine See sections 1 1 1 2 and 1 3 1 Loosen the two screws holding the pump 2 Loosen the adjusting screw nut and tilt the pump towards the engine 3 Now the belt can be removed Assemble in the reverse order from removing See section 2 3 for the correct belt tension Page 11 57 2 6 Replacing the belts between the clutch and mowing mechanism The belts are repl
48. equipment backwards Remove the hydraulics guard Replace the oil filter Before mounting a new filter do not forget to lubricate the gasket with oil Drain the oil off by loosening the oil drain plug After draining tighten the plug again with approx 6 litres of 10W40 Page 35 57 7 3 Machine towing If the machine hydraulics fail or if the motor won t start the machine can be towed First remove the hydraulics guard then turn each of the towing screws twice with a wrench Now the machine can be towed After towing tighten the towing screws to 14 Nm Towing screw right pump Towing screw left pump Note There are two screws on the right side of each pump The lower gold coloured screw is used for towing Warning Towing screws must only be loosened when the machine is on a flat surface If the screws are loosened when the machine 1 on a slope the machine might start moving AN Warning Do not loosen the towing screws until the engine is completely cold because the engine exhaust pipe which is near the screws may burn you Page 36 57 7 4 Checking hydraulic pressure The pumps have a safety relief valve which takes the oil to oil consuming machine components when the pressure exceeds 160 bar Important Before checking the pressure make sure the towing screws are tightened When testing the hydraulic pressure start by measuring the pressure of the hydraulic pump Remove the hydraulic hos
49. eral times and mea sure the cylinder compression 0 39 0 68 MPa 4 7 kgf cm Cylinder compression 57 100 psi at 600 min rpm Without recoil starter type Turn the combination switch to the START position until stable compression is obtained 0 39 0 68 MPa 4 7 Cylinder compression 57 100 psi at 600 min rpm VALVE TIMING CHECK Set the piston at top dead center of the compression stroke P 3 6 Remove the cylinder head side cover P 12 1 Check whether the alignment mark of the cylinder head and alignment mark of the cam pulley are aligned If not proceed as follows a Remove the timing belt from the cam pulley b Turn the cam pulley to align the alignment mark of the cam pulley with the alignment mark of the cylinder head c Set the timing belt to the cam pulley while holding the cam pulley 1 SPARK PLUG CAP Q lt i AS 4 t 1 CYLINDER COMPRESSION GAUGE Commercially available 2 This projection 1 CAM PULLEY is not used for this check 3 ALIGNMENT MARK 3 ALIGNMENT MARK 4 CYLINDER HEAD 2 19 iGX4400UP 10 HARNESS ROUTING INSIDE OF THE ELECTRIC PARTS COVER 2 POWER COIL CRANK 31 SHAFT POSITION COMBINATION 1 SPARK PLUG CAP SENSOR SWITCH ENGINE IGNITION COIL 4P CONNECTOR Black STOP SWITCH 6P 4 COMBINATION SWITCH CONNECTOR White ENGINE STOP SWITCH HARNESS a pm
50. es between the engine and the measured pump Block the reverse hose and insert the T shaped connection and the testing lubricator to the forward circuit when the pressure Is measured See the picture below The pressure is measured with the Honda engine idling and with the forward travel speed set to 50 If the pump is all right the pressure will measure between 160 and 180 bar Pressure Forward circuit when the machine moves forward wes o EE gt l Backward circuit when the Ux machine moves forward The direction indicated in the picture for forward and backward circuits applies to both pumps After checking the pressures of the pump measure the engine pressure First insert the T shaped connection and the testing Engine blocked lubricator to the forward circutt Block the engine by inserting the iron rod or a piece of wood in the gap between the drive wheel and the belt Pump Pressure Measure the pressure with the Honda engine idling and with a forward travel speed set to 50 If the engine is all right Pump the pressure will measure 160 bar When testing the oil must be between 40 and 50 C Page 37 57 7 5 Replacing the Pump First remove the branches protective guard the pump guard and the guard on the right side of the engine see sections 1 1 1 2 and 1 3 Remove the hydraulic pump belt see section 2 5 Drain the oil by loosening the oil drain plug Remove the pressure
51. g Bad mowing Set the mowing mechanism to the working Horn does not work Mowing mechanism is in the service position position Defective 10 A 15 A fuses Replace the fuses Replace the fuses fuses Horn is activated automatically Tilt sensor is active Drive to a flatter surface Emergency button on the remote control is Activate the emergency button on the activated machine Emergency button on the machine is not activated 1 See section 14 4 Page 53 57 14 HONDA iGX 440 To find and remove defects and to service the engine refer to the service manual of the Honda engine in section 13 4 Normally the Honda engine works on a gradient of up to 20 degrees so before it 1s supplied to Timan it is modified The engine can therefore work on a gradient up to 58 degrees The changes are described below 14 1 Modification of Honda iGX440 engine The engine is changed as follows 1 Different gasoline pump 2 Different modified gasoline swimmer and distance ring to extend the carburettor 3 Modified crank shaft so that the lubrication capabilities of the engine are significantly improved 4 Shortened crank shaft 5 Different suction hose to the gasoline tank to avoid the suction branch of the tank leaking gasoline when driving on slopes 6 Oillevel alarm removed Vacuum hose Hose between the fuel pump and the auto fuel valve Modified swimmer 5 w ES Carburettor extra
52. g can easily result in faulty operation damage to the engine or injury to the operator WARNING Improper servicing can cause an unsafe conditon that can lead to serious injury or death Follow the procedures and precautions in this shop manual carefully Some of the most important precautions are given below However we cannot warn you of every conceivable hazard that WARNING can arise in performing maintenance or repairs Only you can Failure to follow properly follow maintenance decide whether or not you should perform a given task instructions and precautions can cause you to be seriously hurt or killed Follow procedures and precautions in this shop manual carefully 2 IMPORTANT SAFETY PRECAUTIONS Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate cloth ing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields any time you hammer drill grind or work around pressurized air or or liquids and springs or other stored energy components If there is any doubt put on eye protection Use other protective wear when necessary for example
53. he fuel tube from the auto fuel valve 3 Disconnect the fuel tube and remove the fuel filter and O ring from the fuel tank Wash the fuel filter in nonflam mable or high flash point solvent Inspect the fuel filter screen to be sure it is undamaged 4 Clean the fuel tank with nonflammable or high flash point solvent and allow to dry thoroughly 5 Install the fuel filter O ring fuel valve fuel tube and fuel tank cap Connect the fuel tube to the fuel valve and install the fuel tank P 7 1 2 3 6 After reassembly check for fuel leaks 1 ROCKER ARM 2 TAPPET ADJUSTING SCREW 3 Dj 4 TAPPET ADJUSTING VALVE SCREW LOCK NUT 5 To increase valve clearance screw out 6 To decrease valve clearance screw in gt 1 FUEL 2 FUEL TANK a 3 TANK STAY 3 TUBE 2 FUELFILTER CLIP 1 O RING lt cS 4 AUTO i FUEL VALVE 5 FUEL TUBE 8 FUEL TUBE 1 FUEL Inspection uu WARNING Gasoline is highly flammable and explosive You can be burned seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately After connecting the fuel tube check for any sign of fuel leakage Check the fuel line for deterioration damage or leakage Replace the fuel line if necessary 3 FUEL STRAINER
54. luding point 4 see section 4 2 1 Remove the hydraulic hoses of the pump Block the hoses and fittings 2 Remove the nut of the rubber shock absorber 3 Remove the central screw on the lower side of the chassis 4 Loosen the driving wheel screw Lift up the belt hanger from the machine 5 Remove the driving wheel using the clamp and then remove the wheels motor Assemble in the reverse order from removing but make sure the belt hanger 1 parallel to the chassis before tightening the screws 3 and 4 When removing the belt hangers it 1s recommended to replace the cases in the tipping section When mounting the new wheels motor the screws holding the engine must be treated with Loctite thread securing Page 31 57 4 6 Spikes assembly e D Spikes are mounted between every fourth pattern on the belt see the picture See the picture Push the fitting inside and tighten the screw A set of spikes includes the following 14 inner spikes with fittings 14 outer spikes with fittings 14 10 25 screws 28 MIO washers 14 MIO closing nuts Page 32 57 5 RUBBER BELT HANGERS When servicing carefully check the rubber shock absorbers for cracks and other damage The rubber hangers of the triangle are replaced as follows Remove the nut on the upper side of the triangle 2 Turn the belt downwards then the rubber shock absorber can be replaced 6 AIR TRAP RUBBER BUMPS When servici
55. nce 3 1 4 7 6 1 FUEL CUT SOLENOID COIL 2P CONNECTOR White 2 18 SPARK TEST WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately NOTICE Do not operate the starter motor for more than 5 seconds at one try If stable compression is not obtained within 5 sec onds stop the starter motor and wait 10 20 seconds to allow the starter motor to cool and repeat the operation again 1 2 3 4 5 6 Loosen the carburetor drain screw to drain the carburetor througly Remove the spark plug cap from the spark plug Remove the spark plug from the cylinder P 3 4 Crank the engine several times to expel unburnt gas Attach the spark plug cap to the spark plug Ground negative electrode i e threaded part of the spark plug against the cylinder side head cover bolt With recoil starter type Pull the recoil starter to check whether sparks jump across the electrodes With starter motor type Turn the combination switch to the START position to check whether sparks jump across the electrodes CYLINDER COMPRESSION CHECK 1 2 3 1 2 3 Remove the spark plug cap and spark plug Turn the throttle control to the HIGH position With recoil starter type Pull the recoil starter forcefully sev
56. nd tilt it to the maximum using the remote control Page 46 57 gt gt 9 TILT SENSOR This sensor does two things 1 Engine protection The engine 15 approved and tested to drive on slopes with a maximum angle of 58 degrees When driving on more than 58 degree slopes the engine loses its lubricating capability which can result in an accident 2 Protection against the machine turning over The sensor works so that the pendulum activates the contact When the contact 1 for more than 1 second the machine starts beeping and the mowing mechanism stops Warning If the machine drives into a hole or if it skids on a slope the sensor cannot react before the machine turns over Pendulum Contact When checking the tilt sensor swing the pendulum to its maximum with the engine running The machine should start beeping Page 47 57 10 MOWING MECHANISM SAFETY SENSOR To avoid starting setting the machine in motion with the mowing mechanism in the service position the machine has an NPN safety sensor which 15 activated when the arms of the mowing mechanism are lifted The sensors located according to the picture 1 Once the handle 15 activated and the mowing mechanism 1 lifted from the supporting arms influenced by the springs 2 the NPN sensor must be deactivated which stops the engine When the sensor 15 not active the NPN diode 1s not lit The sensor is set by loosening the
57. ng carefully check the rubber shock absorbers for cracks and other damage The simplest way to remove the two rear rubber shock absorbers is by using the long extension of the socket wrench 1 Page 33 57 7 Hydraulics The hydraulic system consists of two variable hydraulic pumps each driving its hydraulic motor To avoid dirtying the oil the dipstick has a 3 mm air filter The dipstick has an embedded 0 2 bar counter valve which Keeps the oil in the tank when driving on slopes Prevents condensation in the tank See the hydraulic diagram in section 7 7 7 1 Checking the hydraulic oil level The hydraulic oil must always reach the cut out in the dipstick If the oil level 1s too low refill The oil must not contain water or impurities Before unscrewing the dipstick first always clean the surrounding area When refilling pour the oil slowly and carefully Remove spilt oil immediately In the factory the hydraulic tank is filled with Texaco Havoline Extra SAE 10W 40 classification API SJ semi synthetic slightly flowing oil Only use this oil Before using another brand contact Texaco for information on compatibility Page 34 57 7 2 Replacing gear oil and filter The gear oil and filter are replaced as follows 4 Start machine and let it run for about two minutes then top up the oil Remove the branches protective guard loosen the two screws indicated by the arrow and tilt the
58. nut see picture 3 Make sure that the sensor is set so that the mowing mechanism does not deactivate the sensor when it is in a working position The sensor has a working range of 5 mm Page 48 57 11 REMOTE CONTROL 11 1 Zero position programming The machine is set by the manufacturer in the factory so when the joysticks are released the machine idles This can change over time and the zero position can be found again by programming the remote control Before using this function lift up both belts approx 5 cm above ground with a fork lift truck or a Jack using the lifting lug Start the machine and set the revolutions to 20 The find the zero position as follows l Activate the PR button 1 for 3 seconds the display will show PR To set the left belt move the Joystick 2 to the left and release 1t Then activate the joystick 3 in several phases If the belt reverses move the Joystick from the zero position completely forward and then release it If the belt moves forward move the joystick backwards Repeat this until the left belt is idling Now press the button 4 to save the setting To set the right belt move the joystick 2 to the right and release it Then activate the joystick 3 in several phases If the belt reverses move the Joystick from the zero position completely forward and then release it If the belt moves forward move the joystick backwards Repeat this until the right belt i
59. o great a working range of NPN sensor lights Defective K2 relay Replace the relay Engine starter does not work Discharged battery Recharge the battery LT insi FUN not light up 1 Check 3 A fuse Detesives Ate engine Defective 30 A fuse engine Gas potentiometer is not in zero position Turn the potentiometer to the zero position Activate the horn Defective 10 A 15 A 3 A fuses Replace the fuses Clean replace the air filter Mowing mechanism does not turn on Defective K3 relay Replace the relay Replace wiring or plug Machine does not go mechanism Defective bearings mechanism Replace the axis Worn out flail cutter Mount new flail cutters Machine does not have sufficient thrust hydraulic pump oan the pump Loose Loose driving belt belt Tightenthebelt the belt Defective hydraulic motor Replace the hydraulic motor Overheated oil Clean the cooler the rear mesh and the mesh on the guard above the hydraulic pump No contact between the remote control and Change frequency Emergency button on the machine is the receiver activated Deactivate the emergency button Defective 15A fuse Replace the fuse Emergency button on the remote control is activated Deactivate the emergency button Page 52 57 Machine makes noise Defective flange bearing at the clutch Replace the bearing Defective guard bearing Replace the bearing Defective guard bearing Replace the bearin
60. on 2 2 on tightening belts between the clutch and engine Loosen the two screws holding the most rearward flange bearing Pull out the belt from the clutch driving pulley and lay it towards the chassis Turn the flange bearing approximately 25 degrees using a wrench Turn the shaft upwards and remove the belts If the belt is too tight it is better to loosen it before you lift up the shaft See section 4 1 Page 14 57 Assemble in the reverse order from removing Please note the following 15 Tighten the belt as shown in section 2 2 16 The screws holding the guard must be treated with Loctite thread securing 17 The central screw holding the Taper Lock case must be tightened before tightening the hexagon screws in the driving pulley The screw holds the internal bearing ring of the guard in place The screw must be treated with Loctite thread securing The hexagon screws are tightened to 20 NM Page 15 57 2 8 Replacing the clutch and flange bearings The clutch and bearings are replaced as follows Follow the instructions for replacing the belts between the clutch and engine up to and including point 11 See section 2 7 Follow the instructions for replacing the servo engine up to and including point 8 See section 9 1 1 Remove the electric connection of clutch and the lubricating hose of the flange bearing 2 Loosen the two screws holding the inner flange bearing use a socket wrench with a long
61. oving Please note the following When mounting the flail axis the eight screws holding the bearing sleeve must be treated with Loctite thread securing Page 24 57 3 3 Flail cutters hangers and screws The machine can have two types ot cutters Y shaped cutters or hammer cutters When servicing check the following The number of Y shaped cutters is 32 and the number of hammer flail cutters 1 16 The flail axes hangers must rotate freely Ifthe cutters show signs of wear tear replace them Case The picture shows a new and used Y shaped flail cutter When replacing check the wear and tear of the hanger where the cutter is suspended If the hanger is worn replace it When replacing the flail cutter always replace the screw and nuts on which the hanger is suspended Where the hanger will wear The picture shows a new and used hammer flail cutter When replacing check the hangers Replace the screws and nuts Replace the flail cutters before they are completely worn out new flail cutters mow better Adjust the mowing height according to the conditions and never allow the flail cutters to touch the ground Important When replacing flail cutters all cutters must be replaced otherwise the flail axis will be unbalanced When replacing the flail cutters always replace the screw and nuts Worn out screw which must be replaced 3 4 Replacing the cases of supporting arms Cases are re
62. pair or replace the wire harness Good Replace the 6 2 IGX440U LED flashing pattern 6 flashes per cycle Check the power coil P 2 17 No good Replace the power coil 11 1 Good Replace the ECM 6 2 LED flashing pattern 8 flashes per cycle Program failure 2 6 iGXdadaou c LED IS LIT BUT ENGINE DOES NOT START Starter motor equipped type ENGINE DOES NOT START Starter motor not equipped type Check continuity between the ST and BAT ter minals of the combination switch P 2 17 If necessary replace the combination switch P 9 3 Turn the combination switch to the START No good position and check whether the engine 1 cranks Good Check the starter solenoid P 11 6 If necessary replace it P 11 5 Good Good Disassemble the starter motor and check each part P 11 5 through 8 if necessary replace the faulty part P 11 5 Turn the combination switch to the OFF posi Insufficient Add fuel and then start the engine tion and check the fuel level in the tank Sufficient Check the oil level P 3 2 Good Check the oil level switch P 13 12 No good Replace the oil level switch P 13 5 Good Insufficient Add engine oil P 3 2 Check the air cleaner P 3 3 Restricted Clean the air cleaner element P 3 3 and install it properly P 4 1
63. placed as follows 1 Putthe mowing mechanism into the service position 2 Remove the springs of the supporting arms 3 Replace the cases Page 26 57 4 Belts 4 1 Belts tension To measure if the belts of the machine are adjusted correctly use a tape measure placed in front of the central chain pulley and measure approx 210 mm Push the upper side of the belt above the central chain pulley and measure the value on the tape The value of a correctly tightened belt is 180 mm If the belt 1s too loose adjust it as follows 1 Loosen the lock nuts 2 Loosen the rear closing screw 3 Tighten the belt by screwing the adjusting screw inside After adjusting and checking the belt tension tighten the closing screw and lock nuts Adjusting Lock nut screw Closing screw Page 27 577 4 2 Replacing Belts Belts are replaced as follows To replace the belts on the right side follow the instructions for replacing the belt between the engine and clutch up to and including point 8 See section 2 7 4 Assemble in the reverse order from removing T K P When assembling pull the belt backwards and push the return pulley over the shaft at the same time Remove the guard Loosen the two lock nuts and unscrew the adjusting screws to remove tension from the belt Loosen the nut and remove the return pulley using the clamp Now the belt can be removed Page 28 57 4 3 Replacing the bearing
64. rd The protective guard 1 removed as follows 1 Loosen the screws holding the protective guard in the front part of the machine 2 Tilt the protective guard backwards 3 Tilt the protective guard around the centre of rotation on the rear part of the machine and lay it on the floor 1 2 Removing the hydraulics guard 1 Loosen the six screws holding the guard 2 Lift the guard directly up and remove it from the machine Page 4 57 1 3 Removing the guard on right side of the engine First remove the branches protective guard and the hydraulics guard see sections 1 1 1 2 1 Loosen the rear screw 2 Press the belt with the left hand and lift off the guard sideways 14 Removing the black guard in front of the clutch First remove the branches protective guard the hydraulics guard and the guard on the right side of the engine See sections 1 1 1 3 1 Loosen the three screws and then lift up the guard Page 5 57 1 5 Removing the engine compartment guard First remove the branches protective guard and also the hydraulics guard See sections 1 1 1 2 The guard on the right side Loosen the two screws between the belts Then lift up the guard 1 Loosen the six screws holding the guard three on the upper side and three on the lower side 2 Then remove the guard Page 6 57 2 Propulsion system 2 1 Tightening and maintenance of driving belts To ensure that th
65. s idling Now press the button 5 to save the setting Activate the emergency button on the remote control 11 2 Frequency change If the remote control signal 15 interrupted the machine stops automatically To continue operating change the channel on the remote control Do this by holding the button 1 down and activating the button 2 at the same time This will change the channel number When the channel is changed the horn beeps briefly to indicate the change The number of the channel in shown on the display 3 Page 49 57 y JO YORS no 5196 eui 511990 Buiqunisip e Jr sdois eu punoj si en eA 195 5 eui yy udi 0061 yono ueuM 2 Jo SI Ajayes Ji Wes ULD epuoH Jo els 01 U09 eq ue 1J9 SI 1 JOU SI dois pue 1110 uo e oqe ue s 5 Teu duJe 01 AQ 196 901 y
66. s in the return Remove the return pulley according to section 4 2 1 When replacing the bearings it 15 also important to replace the Nilos rings 2 Now the bearings can be replaced When mounting be careful that the Nilos ring does not lay on the edge of the lock ring groove After the pulley is mounted on the machine do not forget to mount the distance ring otherwise the washer will damage the Nilos ring The picture shows a cross section of the bearing structure with the pulley mounted on the machine qr m Bearings lt Outside Nilos Distance ring Washer Page 29 57 4 4 Replacing the bearings in the bearing pulley The bearings are replaced as follows Remove the guard Loosen the bearing pulley nut Pull out the bearing pulley from the shaft using the clamp Now the bearings can be replaced When mounting be careful that the Nilos ring does not lay on the edge of the lock ring groove After the pulley is mounted on the machine do not forget to mount the distance ring otherwise the washer will damage the Nilos ring See the picture of the bearing structure on the previous page x d cm Page 30 57 4 5 Replacing the hydraulic wheels motor The hydraulic wheels motor 1s replaced as follows First remove the branches protective guard the hydraulics guard and the mowing mechanism guard see sections 1 1 1 2 1 6 Follow the instructions for replacing belts up to and inc
67. sion Check the valve clearance P 3 6 Check the valve timing 2 19 Check the cylinder head 12 5 Check for defective cylinder head gasket valves or valve seat Check for worn piston piston rings or cylin der No good Replace any darnaged or faulty parts P 6 2 3 Good Check the parts in the control box P 6 2 3 Good Check the wire harness for open or short cir No good Repair or replace the wire harness cuit Good Replace the ECM P 6 2 _ FUEL SYSTEM Good Remove the spark plug and check for wet or fouled electrode Disassemble and clean the carburetor P 6 9 10 Clean and dry the electrode and restart f flooding is severe check the carburetor float valve P 6 12 Check whether the fuel is reaching the carbu retor by loosening the drain screw Fuel not reaching carburetor Clogged Clean the fuel cup filter and fuel strainer cup P 3 8 necessary check and clean the fuel Check for a clogged fuel cup filter P 3 8 Good tank P 3 7 Check for a restricted fuel tube P 3 8 Clogged Clean the fuel tube P 3 8 If necessary check and clean the fuel tank Good i P 3 7 Clean the fuel filter P 3 7 If necessary check and clean the fuel tank P 3 7 Clogged Check clogged fuel filter P 3 7 Good
68. specified torque diagonally unless a particular sequence is specified Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation Many screws used in this machine are self tapping Be aware that cross threading or overtightening these screws will strip the threads and ruin the hole Use only metric tools when servicing this unit Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit 4 SYMBOLS USED IN THIS MANUAL As you read this manual you may find the following symbols with the instructions special tool is required to perform the procedure Apply grease M Apply oil O x O O Indicates the diarneter length and quantity of metric flange bolts used PO Indicates the reference page 5 SERIAL NUMBER LOCATION The engine serial number is stamped on the cylinder barrel Refer to this when ordering parts or making technical Inquiries ENGINE SERIAL NUMBER 6 STANDARDS Unit mm in Part Maximum speed load 8600mim rpm Idespeed 1400 ___ NN at 600 min rpm 88 120 3 4693 Cylinderhead Warpage 1 90 10 0 004 Piston 87 850 3 4
69. terclockwise direction Specified resistance Bu Ground 3 4 5 3 Q Lg W R Specified resistance 3 7 Clockwise direction 216 264 Q AL 3 7 Counterclockwise direction 1 1 2 2 TERMINAL COVER ge POWER cou Sei 3 1 gt CRANKSHAFT THROTTLE 11 2 POSITION G CONTROL POWER COIL CRANKSHAFT SENSOR BI 6P CONNECTOR POSITION CKP SENSOR 4P CONNECTOR Black 4P CONNECTOR Black FAN COVER BOLT GROUND 4 COMBINATION SWITCH ENGINE STOP SWITCH CHECK api 1412 43 141 6 ENGINE STOP SWITCH CONTINUITY TABLE 4 8 COMBINATION SWITCH pci2v FS COIL IGN With fuel cut solenoid type 6P CONNECTOR White position BIR Br A n EIo FS 4 5 4 7 ENGINE STOP SWITCH 41 10 ENGINE STOP SWITCH 6 CONTINUITY TABLE COMBINATION SWITCH CONTINUITY TABLE CONNECTOR White Without fuel cut solenoid type Switch DC12V position BIR 2 7 iIiGX440U 2 COMBINATION 1 SWITCH COMBINATION SWITCH ST TERMINAL BAT TERMINAL W 4 CHARGE COIL TERMINAL Gr CHARGE COIL TERMINAL BI 20A Gr 5 CHARGE COIL INSPECTION Measure the resistance between the terminals BI Gr 20A Gr Gr Specified resistance 1 8 2 8 0 1 0 3 0 20 6 FUEL CUT SOLENOID COIL INSPECTION Measure the resistance between the terminals Specified resista
70. the carburettor Check this by removing hose 1 and then pressing the button on the remote control If petrol is supplied by the petrol pump the problem is elsewhere If petrol is not supplied remove hose no 2 and blow pressure of about 1 bar into the hose This will open the vacuum valve under the tank Mount hose no 2 on the pump and try to start the engine again If petrol 1s supplied to hose no 1 refit it If not replace the vacuum valve under the tank n 4 Page 56 57 iGX440U PREFACE This manual covers the construction function and service procedures for the Honda iGX440U engine All information contained this manual is based the latest product information available at the time of printing We reserve the right to make changes at anytime without notice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without prior written permission of the publisher This Includes text figures and tables As you read this manual you will find information that is preceded by a symbol The purpose of this message is to help prevent damage to the engine other property or the environment MESSAGES Your safety and safety of others are very important To help you make informed decisions we have provided safety messages and other safet
71. ve the plate Remove the lubricator on the left side of the mowing mechanism Remove the bearing sleeves screws on the right and left side of the mowing mechanism 0 Lift up the flail axis from the shield of the mowing mechanism Page 22 57 3 2 Replacing the bearings in the axis The bearings on the left side are replaced as follows 1 Note the O ring on the left side of the bearing sleeve which keeps water outside the bearings 2 Loosen the nut holding the bearing 3 Remove the bearing sleeve using the clamp 4 Replace the bearings and mount them according to the pictures start with the bearing on the right 5 Make sure that the oil seal ring 1 turned according to the pictures When mounting use a special jack because otherwise the oil seal ring might be damaged 6 When mounting make sure the screw 15 treated with Loctite thread securing Page 23 57 The bearings on the right side of the axis are replaced as follows pulis j Remove the nut self locking washer and driving pulley Remove the distance tube note that the oil hole faces towards the bearings Remove the bearing sleeve using the clamp Replace the bearings and mount them according to the pictures start with the bearing exactly on the right The oil seal ring must be oriented according to the picture on the previous page Turn the bearing sleeve and mount the oil sleeve ring Assemble in the reverse order from rem
72. y information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing these engine You must use your own good judgement You will find important safety information in a variety of forms including Safety Labels on the engine Safety Messages Preceded a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean DANGER You WILL be KILLED SERIOUSLY HURT if you don t follow instructions WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions A CAUTION You CAN be HURT if you don t follow Instructions Instructions how to service these engines correct ly and safely Honda Motor Co Ltd Service Publications Office CONTENTS SPECIFICATIONS _ SERVICE INFORMATION MAINTENANCE Date of Issue December 2005 Honda Motor Co Ltd INDEX iGXddou 1 SPECIFICATIONS 1 1 SPECIFICATIONS DONNE 2 PERFORMANCE CURVES 1 2 3 DIMENSIONAL DRAWINGS 1 3 4 PTO DIMENSIONAL DRAWINGS 1 4 ENGINE MOUNT DIMENSIONAL DRAWING 2 llasan 1 5 6 WIRING 1 1 6 2 SERVICE INFORMATION 24 1 THE IMPORTANCE OF PROPER SERVICING 2 1 2 IMPORTANT SAFETY PRECAUTIONS 2 1 3 SERVICE RU

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